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Hydraulic Operated Lubrication Pump HTL 101

1. s esee 17 Components and Parts List Mini BE 18 Mc EMILE 20 Versio P serseri M 22 MCI e mE 24 Accessories Hydraulic TUDES cerunt nml enenatis 26 EC Declaration of incorporation ss 27 For further information refer to Installation Instructions for kit of seals 542 34079 1 2 0 30008 B08 Installation Instructions for hose stud 2 0 39000 A08 Page 3 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ERE 2 1EN 39001 E09 Introduction Explanation of Symbols Used The following description standards are used in this manual Safety Instructions Structure of safety instructions Pictogram Signal word Danger text Danger note How to avoid danger The following pictograms are used in this manual and are combined with the corresponding signal words 1013A94 4273200 600 1202 ATTENTION ATTENTION NOTE CAUTION CAUTION IMPORTANT WARNING WARNING The signal words give the seriousness of danger if the follow ing text is not observed ATTENTION refers to faults or damages on machines CAUTION refers to bad damages and possi ble injuries WARNING refers to possible dangerous inju ries NOTE indicates improved operation of the device IMPORTANT indicates special operating fea tures of the device Example ATTENTION When maki
2. tre install sur une machine etque sa mise en service est interdte tant qu il n aura pas t constat que la machine sur laquelle le produit men tionn ci dessus doit tre install est conforme aux r glementations r gissant toutes les exigences fonda mentales de s curit et celles relatives la sant y compris les amendements en vigueur au moment de la pr sente d claration Le fabricant s engage en cas de demande justifi e fournir sous forme crite aux organismes natio naux respectifs les documents techniques suivant Annexe VII Partie B relatifs au produit ci dessus Normes harmonis es no tamment Directive machines 2006 42 C E Parties 1 amp 2 S curit de machines Notions fondamentales directi ves g n rales d laboration Pompes et groupes de pompes pour liquides Exigences en mati re de s curit technique Walldorf Nov 30 2009 Dr Ing Z Paluncic Director Research amp Development LINCOLN N E Declaraci n CE de incorporaci n Por la presente declaramos que el modelo suministrado en la versi n suministrada es destinada a ser incorporada en una m quina y que su puesta en servicio est prohibida antes de que la m quina en la que vaya a ser incorporada haya sido declarada conforme a las disposiciones de los requisitos pertinentes y fundamentales de salud y seguridad en su redacci n vigente en el momento de instalaci n El fabrican
3. 666341705 DN6x650DKOS DKOS8 S 650 HD DN 6 2040 N 04V00 666 341706 DN6x700DKOS DKOS8 S 700 HDDN62040N 04VO0 666 34170 7 DN 6 x 750 DKOS DKOS 8 S 750 HD DN 6 2040 N 04V00 666 34170 8 DN 6 x 800 DKOS DKOS 8 S 800 HD DN 6 2040 N 04V00 666341709 DN 6x 850 DKOS DKOS8 5 850 HDDN6 2040 N 04V00 666340714 O DN6x900DKOS DKOS8 S To 900 HDDN62040N 04V00 6663407712 DN6x950DKOS DKOS8 S 950 HDDN62040N 04VO0 666 34171 3 DN 6 x1000 DKOS DKOS 8 S 1000 HD DN 6 2040 N 04V00 666 34171 4 DN 6 x 1250 DKOS DKOS 8 S 1250 HD DN 6 2040 N 04V00 666 34171 5 DN 6 x 1500 DKOS DKOS 8 S 1500 HD DN 6 2040 N 04V00 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions D EG Einbauerklarung Bauart von in der von uns gelieferten Ausf hrung zum Einbau in eine Maschine bestimmt ist und dass ihre Inbetriebnahme solange untersagt ist bis festgestellt wurde dass die Maschine in die das o g Produkt eingebaut werden soll den Bestimmungen aller einschl gigen grundlegenden Sicherheits und Gesund heitsanforderungen ent spricht einschlie lich deren zum Zeitpunkt der Erkl rung getenden Anderungen Der Hersteller verpflichtet sich technische Dokumente gem Anhang VII Teil B bei be grtindeter Anfrage zum o g Produkt einzelstaatlichen Stell
4. Closure plug Page 10 of 28 ATTENTION Before beginning with maintenance or repair work on the lubrication pump HTL 101 and before dismantling it ensure that the hydraulic system of the carrier is depressurized 1013A94 Capacity esses eee emn es 400Q I8 1 eT 4 7 a secs cm up to NLGI class 2 Chisel paste sca se ss ses veee t teere aene n eiecti DA 2 37608 1 EP2 grease ss e 042 87609 2 NOTE The cartridges are not available as single units They are only supplied in packages of 12 cartridges 6001202 Dispose of emptied cartridges according to the legal regulations pertaining to envi ronmental protection 1 Closure cap 2 Cartridge 3 Follower plate Lightly grease the inner o ring Remove the closure cap 1 Fig 7 from the cartridge Insertthe cartridge in the bore hole by lightly pressing and screw it into the housing presented as in Fig 8 hand tightly Vent housing Remove closure plug 15 Press red follower piston 3 Fig 7 into the cartridge until lubricant comes out of the open bore hole Close housing with closure plug again Operate the pump by switching on the hydraulic unit until lubricant flows out of the opened outlet 3 NOTE The pump delivers lubricant very slowly It may take a while before the lubricant flows out of the outlet without air bubbles 6001202 Connect the supply hose to the lubrication point to one of the pump outlets 3 amp 7 Thread G 1
5. by means of suitable hydraulic lines and connectors The flow of hydraulic oil from the carrier is restricted throttled and flows via the pressure connection 14 P fig 2 through the filter which is installed below the pressure connection to the integrated hydraulically operated stepper motor and backto the hydraulic system of the carrier via the return line connection 13 R A driving pin attached to the stepper motor activates the ec centric shaft 9 fig 1 via a one way clutch The pump ele ment is thereby actuated and delivers lubricant The flow quantity of the hydraulic oil can be adjusted via the regulating throttle valve 12 fig 2 thereby adjusting the output quantity of the pump accordingly The throttle valve is notched whereby 16 notches correspond to one complete rotation 12 Cover cap for throttle valve fine restrictor 13 Return connection R M 16 x 1 5 6133b03 14 Pressure connection P M 16 x 1 5 with integrated oil strainer Fig 2 Hydraulic oil connection of the pump HTL 101 Adjustment and Operation Basic Adjustment of the Throttle Valve NOTE The eccentric shaft is factory set to 4 rpm output 1 cm min 6001202 gt Adjust the required amount of lubricant by means of the output diagram fig 13 amp chapter Adjustment of output turning clockwise less lubricant turning anticlockwise more lubricant WARNING Risk of injury When adjusting the fine restric
6. dispositivi di pompaggio per liquidi Requisiti generali di sicurezza tecnica Lincoln GmbH Heinrich Hertz Str 2 8 D 69169 Walldorf Page 27 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions Lincoln s Global Distribution and Service Network The Best in Our Industry Whatever service is required selecting a lubricating system customised system installation or the supply of top quality prod ucts you will always be best advised by the staff of the Lincoln offices representatives and contract dealers Systems dealers Our systems dealers have the most extensive specialised knowledge in our industry They plan your installations to suit your specifications with exactly the combination of Lincoln components that you need They then build the installations at your op eration with experienced technicians or work closely with your personnel to ensure that everything goes smoothly All dealers have the complete range of pumps distributers monitoring devices and accessories in stock and meet our exacting demands with their specialised knowledge about products installations and service Whenever and wherever you need our experts from St Louis to Singapore Walldorf and worldwide Lincoln s first class systems dealers are at your service Find out where the nearest Lincoln distribution and service office to you is located Lincoln
7. 4 Fill the lubricant supply hose to the lubrication point via the lubrication hydraulic fitting by means of a manually operated grease gun until the lubricant flows out atthe lu brication point LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Maintenance continuation Cartridge Replacement Switch off the hydraulic unit Unscrew the old cartridge Remove the closure cap of the new cartridge Screw in the new cartridge hand tightly in the housing The pump is ready for operation again NOTE If afterwards the pump does not dispense lubricant immediately vent the housing see paragraph vent housing fig 8 0000 6001202 6136503 Fig 9 Cartridge Replacement Removal of Oil Strainer The oil strainer should be cleaned every 2000 operating hours To do this proceed as follows 2 Depressurize hose lines of the hydraulic system on the carrier device 2 Remove the pressure line to the lubrication pump HTL 101 gt Unscrew the oil strainer and clean it 6137b03 Fig 10 Cleaning the Oil Strainer 16 Oil strainer Page 11 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ERE 2 1EN 39001 E09 Technical Data Ratings Lubrication P
8. Industrial One Lincoln Way 1 314 679 4200 St Louis MO 63120 1578 1 800 424 5359 USA www lincolnindustrial co m Europe Africa Asia Lincoln GmbH Heinrich Hertz Stra e 2 8 49 6227 33 0 69190 Walldorf 49 6227 33 259 Germany lincoln lincolnind ustrial de Asia Australia Pa cific Lincoln Industrial 3 Tampines Central 1 65 6588 0188 Corporation 04 05 Abacus Plaza 65 6588 3438 Singapore 529540 sales lincolnindustrial com sg DIN EN ISO 9001 LINCOLN copyright 2009 furor pas EE Printed in Germany PINEN Gotan durch GUT
9. Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Hydraulic Operated Lubrication Pump HTL 101 6131b03 810 55289 1 LINCOLN GmbH e Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions This User Manual was compiled on behalf of the manufacturer by Lincoln GmbH EdiDoc GmbH Heinrich Hertz Str 2 8 Erzberger Str 8 D 69169 Walldorf D 68753 Waghausel All rights reserved Any duplication of this User Manual in its entirety or in part by whatever means is prohibited without the prior consent in writing of Lincoln GmbH Subject to modifications without prior notification LINCOLN Prone 49 6227 33 0 hy Fax 49 6227 33 259 E Mail Lincoln lincolnindustrial de 2009 by Page 2 of 28 2 1EN 39001 E09 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions LINCOLN ERE Table of Contents Page Introduction Explanation of Symbols Used seeses 4 User s Responsibility cessere 4 Environmental Protection sese 4 NI cM c 4 Safety Instructions Appropriate USO cii ce decd suicdesbecssceaeesiiiindecuemevereee 5 MISUSE ratos cased fecctashedsccsgacczastepaneceaseensec lt fitecatcivaekeertiae
10. anual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Technical Data continuation Dimensions 197 173 B HTL101 050a08 und 6138b03 Fig 12 Dimensions of the Hydraulic Lubrication Pump HTL 101 all dimensions in mm Page 13 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN a 2 1EN 39001 E09 Technical Data continuation Flow Rate Diagram WARNING Risk of injury Before adjusting the fine restrictor make sure to switch off the hydraulic drive 1013A94 IMPORTANT The throttle valve may still be pressurized for a long time after switching off the hy draulic unit Therefore first of all check whether the pressure connection P 14 fig 2 is de pressurized The eccentric shaft must not rotate anymore see fig 4 6001a02 Lubricant Output of the HTL 101 at 100 bar back pressure and 60 to 80 C operating temperature see version P pos 13 pages 22 and 23 25 Speed of the eccentric shaft rpm 15 20 5 10 25 30 35 close lt lt lt _ Throttling by means of notches 40 45 50 55 60 65 0pen Output cm3 min B HTL101 040a09 6011d07 Fig 13 Flow rate diagram Average output on medium sized hydraulic hammers From output diagram fig 13 the adjustment of the throttle valve can be determined in depen
11. bsolutely forbidden to carry out main tenance or repair work and to replace the cartridge while the hydraulic unit is in op eralion 1013A94 Repairs Repairs are only to be performed by authorized and qualified persons who are familiar with all applicable regulations Page 5 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ERE 2 1EN 39001 E09 Safety Instructions continuation Operation Maintenance and Repair continuation Operation Maintenance Hydraulic operated lubrication pumps HTL 101 shall be operated only with an installed pressure relief valve shall regularly be supplied with clean lubricant cartridges operate automatically However check at regular intervals approx every 2 days whether the pump effectively de livers lubricant visual check Disposal Dispose of used or contaminated lubricants as well as of parts that were in touch with lubricant e g emptied car tridges according to the legal regulations pertaining to envi ronmental protection Exclusion of Liability The manufacturer of the lubrication pump HTL 101 does not accept any liability for damages caused by tardy replacement of the cartridges lack of lubricant contaminated lubricants use of lubricants that are inappropriate or only condition ally appropriate for the unit or which are not pumpable inappropriate disposal of used or
12. connec tion 6001a02 7 Pressure relief valve 9 Eccentric shaft During the operation the piston 4 Fig 5 sucks in lubricant from the cartridge via the suction bore hole 2 and delivers it to the connected lubrication point through the bore hole 1 An integrated check valve prevents the lubricant from returning to the cartridge Piston diameter C7 sse CMM Lubricant output ssssssss s approx 0 22 cm stroke 1 Delivery bore hole 2 Suction bore hole 3 Return spring 4 Piston The pressure relief valve limits the pressure build up in the system opens when a pressure of 120 bar is reached NOTE If lubricant is expelled atthe pressure relief valve this indicates that there is a blockage to or at the lubrication point 6001a02 Page 9 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ERE 2 1EN 39001 E09 Maintenance ATTENTION Do not perform any maintenance or repair work or replace the cartridge while the hydraulic unit is in operation 1013A94 Lubricant Cartridge 7 6007b03 Fig 7 Cartridge with Lubricant First insertion of cartridge Beste r Seaver Part No 442346 6135b07 Fig 8 Insert cartridge into the lubrication pump HTL 101 3 Lubricant outlet G 1 4 7 Pressure relief valve 120 bar M 12 Nm 5 15
13. contaminated lubricants arbitrary modification of system parts use of unauthorized spare parts and lubricant cartridges including the usage of refilled cartridges with non ap proved or contaminated lubricants Page 6 of 28 Installation ATTENTION Before installing or disassembling the lubrication pump HTL 101 ensure that the hydraulic system of the carrier unit the supply to the lubrication pump is depres mem surized It is forbidden to manipulate the protection devices installed on the hydraulic unit If necessary these devices may be removed temporarily during the installation of the pump The devices must be properly put back in place after installa tion Use only original spare parts or spare parts and cartridges authorized by Lincoln see spare parts list page 18 ff IMPORTANT Observe the installation guidelines and instructions of the machine unit manufac turer when drilling and welding as well as the specified minimum distance on vehi cle chassis frames for holes between up per lower rim of the frame or between two bore holes 6001202 Installation and Maintenance of Hydraulic Hoses ATTENTION The operational safety of the lubrication pump HTL 101 is only guaranteed with a professional installation and maintenance of hydraulic hoses lines The following j 1013A94 points must be observed Hydraulic Hose lines may never be subjected to torsion must be installed twist free must
14. dency of the lubricant out put Max speed of the eccentric shaft e 20 rpm Max OUtpUl2 ierit ite cipere tnu etd ette te inse DrR ce Rees 4 4 cm3 min Notches per throttle revolution assesses sss 16 Factory setting Position of the throttle valve fig 13 20 notches Speed of eccentric shaft sess approx 4 rpm OUIDUT e approx 1 cm min The integrated pump element supplies 0 22 cm of lubricant per stroke It is driven by the eccentric shaft 1 stroke revolu tion The speed of the eccentric shaft is determined by the position of the throttle valve The throttle valve is notched whereby 16 notches correspond to one complete rotation Page 14 of 28 Adjusting the output gt Open the cover cap of the throttle valve 12 fig 2 gt Close the throttle by tuming it clockwise gt Determine the number of notches corresponding to the required output by means of the output diagram fig 13 gt Example required output esses 2 cm min Ed E approx 42 speed of eccentric shaft approx 9 rpm gt Open the throttle counterclockwise until you have reached the number of notches gt Check the output If necessary adapt the output proceeding from this throt tle position tuming clockwise 0c eeeeee eee eters less lubricant turning anticlockwise ssss
15. en in gedruckter Form zur Verf gung zu stellen Angewendete harmonisierte Normen insbesondre Maschinenrichtlinie 2006 42 EG GB EC Declaration of incorporation Herewith we declare that the model of Hydraulic Operated Lubrication Pump HTL101 in the supplied version is intended to be incorporated into machinery and must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the relevant fundamental requirements on health and safety including all modifications of this directive valid atthe time of the decla ralion The manufacturer undertakes to make available any technical documents in printed version following Annex VII Part B to subna tional authorities in the case of reasonable request regard ing the above mentioned product Applied harmonized stan dards in particular Machinery Directive 2006 42 EC DINEN ISO 12100 Teil 1 amp 2 Part 1 amp 2 Sicherheit von Maschinen Grundbegriffe allgemeine Gestaltungsleits atze Pumpen und Pumpen ger te f r Fl ssigkeiten Algemeine sicherungs technische Anforderungen Safety of machinery Basic terms general design guidelines Pumps and pump units for liquids General safety requirements hle F D claration CE d incorporation Par la pr sente nous d cla rons que le produit ci dessous dans la version dans laquelle nous le livrons est destin
16. itably qualified If required Lincoln GimbH offers you full service in the form of advice on site installation assistance training etc We will be pleased to inform you about our possibilities to support you purposefully In the event of inquiries pertaining to maintenance repairs and spare parts we require model specific data to enable us to clearly identify the components of your pump system Therefore always indicate the part model and series number of your pump system LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Safety Instructions Appropriate Use General Safety Instructions The hydraulic operated lubrication pump model HTL 101 is Hydraulic operated lubrication pumps model HTL 101 designed for initial or for subsequent retrofit installation It is are designed with state of the art technology designed for M can be assembled for safe operation 1 the automatic lubrication of hydraulic hammers Incorrect use may result in bearing damage caused by 2 the automatic lubrication of hydraulically driven units under or over lubrication MERE is to deliver lubricants and chisel pastes up to Modifications or alterations to an installed system by the class 2 customer are subject to prior consultation with the manu facturer of the l
17. ked parts are glued into the hous 8 3 Package ring 12x 30x 7 1 220 12229 8 ing for reasons of vibration If dismantled they may be destroyed If so replace 8 4 Bearing 1 250 14064 6 P pump item 9 completely 8 5 Sealing ring 122 7 x 2 5 1 442 70146 1 Tab 3 Parts list model N see identification plate Page 21 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual o c 2 Oo wx to E 2 wx a O 2 1EN 39001 E09 Components and Parts List continuation Exploded drawing model P suoneoyipoui oi 1oe qns Fig 17 Exploded drawing model P see identification plate Page 22 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications User Manual Operation Instructions Components and Parts List continuation Parts List model P LINCOLN ma 2 1EN 39001 E09 Item Description Qty Part Number Description Part Number 1 del mili CASE pante 12 642 37608 1 Pump housing assy 642 40950 1 Connection fitting Filter ass 528 32215 1 2 XGE 6 SG 4 AC 1 223 10055 5 y 1 Oil inlet fitting 3 Kit of seals I 542 34073 1 M16 x 1 5x M20 x 1 5A 8 S 304 19893 1 O ring 219 12451 3 a Pomp element te 1 Pap ene Oil outlet fitting XGE 85G A A3C 223 10055 4 4 1 O ring 19 2 x 3 1 219 13053 6 Thrott
18. le valve assy 542 34281 1 4 2 O ring 14 2 x 2 5 2 219 13053 5 1 5 Hydraulic fitting 1 251 14109 6 see IMPORTANT note IMPORTANT 6 Closure plug G 1 4 3 229 197021 Please use Loctite 403 to glue in flat pack 7 Valve body 120 bar 1 235 14343 5 mg item 3 8 Housing cover assy 1 542 34079 4 6001a02 8 1 Hex head screw M6 x 18 C 4 201 13668 1 see NOTE 8 2 Shim StA64C 4 209 13011 5 NOTE The marked parts are glued into the hous 8 3 Package ring 12x 30x 7 1 220 12229 8 ing for reasons of vibration If dismantled they may be destroyed If so replace 8 4 Bearing 1 250 14064 6 P pump item 9 completely 9 5 Sealing ring 122 7 x 2 5 1 442 70146 1 Tab 4 Parts list model P see identification plate Page 23 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Components and Parts List continuation Exploded drawing model R I A Fig 18 Exploded drawing model R see identification plate Page 24 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions Components and Parts List continuation Parts List model R LINCOLN ma 2 1EN 39001 E09 Description Qty Part Num ber Desc
19. lief valve 7 cartridge is equipped with an easy to exchange pump element 5 is equipped with a lubrication hydraulic fitting 4 for manual lubrication override e g if the hydraulic system fails to operate does not require supplementary directional valve has three different outlets 3 amp 7 for the individual grease 9 supply connection of the hammer unit 6132b03 NOTE Fig 1 Components of the Lubrication Pump HTL 101 If the lower lubricant outlet connection is 1 Follower piston cartridge full used 7 the outlet fitting and the pressure 2 Cartridge relief valve must be exchanged 3 Lubricant outlet G 1 4 E 4 Lubrication hydraulic fitting for manual lubrication 6001202 If the rear outlet is used the outlet fitting M 14 Nm 5 and closure plug must be exchanged 5 Pump element 6 Housing 7 Pressure relief valve 120 bar M 12 Nm 5 8 Housing cover 9 Eccentric cam shaft 10 Low level position window of the follower piston cartridge empty 11 Fastening holes for M 16 bolts 12 Cover cap for the regulating throttle valve 13 Oil return connection R M 30 Nm 5 14 Oil pressure connection P M 30 Nm 5 Page 7 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Working Method gt Connect the lubrication pump HTL 101 to the hydraulic system of the carrier
20. ng use of other than the tested spare parts serious damage may affect your device Therefore for the operation of your device always use original parts made by Lincoln 1013A94 GmbH Page 4 of 28 Furthermore you will find the following text symbols in this manual Listing of applicable statements Subpoint of applicable statements Determination of the number or sequence of contents gt Procedural instruction a User s Responsibility To ensure the safe operation of the unit the user is responsi ble for the following 1 The pump system shall be operated only for the in tended use see next chapter Safety Instructions and its design shall neither be modified nor transformed 2 The pump system shall be operated only if itis ina proper functioning condition and if it is operated in accor dance with the maintenance requirements 3 The operating personnel must be familiar with this Owner Manual and the safety instructions mentioned within and observe these carefully The correct installation and connection of tubes and hoses if not specified by Lincoln GmbH is the user s responsibility Lincoln GmbH will gladly assist you with any questions per taining to the installation Environmental Protection Waste e g used oil detergents lubricants must be dis posed of in accordance with relevant environmental regula tions Service The personnel responsible for the handling of the pump system must be su
21. not rub against metal components or edges are to undergo regular visual checks and exchanged in the case of wear or at the latest 2 years after installation Pay attention with non linear installations to allow for as large a bending radius as possible Kinks are to be avoided In constricted installation conditions use pipe elbow unions to avoid the danger of kinking behind the hose socket LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Description The Pump Model HTL 101 is a hydraulically driven grease pump for the lubrication of hydraulic hammers or other units with an available hy draulic circuit is compact and can therefore be fitted directly to the hammer or other units Together with the carrier it forms a complete assembly is driven by the hydraulic system of the carrier continuously delivers lubricant to the lubrication point while the hydraulic unit is in operation and stops when the hydraulic flow stops The lubricant quantity is adjustable via the regulating throttle valve see Fig 3 is equipped with a visual lubricant level indicator by means of the follower plate of the cartridge If the follower plate is located in the low level position of the car tridge 10 the cartridge must be replaced is protected by means of a 120 bar pressure re
22. plication as they would spoil within a short period of time 6001a02 Our accessories comprise special hoses DN 6 Type 2040N 04V00 with black outside coating in various lengths for the con nection of pump HTL 101 oil pressure and oil return to the hydraulic system of a hammer The connecting fittings are made of high tensile special steel and are provided with fittings DKOS 8 S M16 x 1 5 1 C9PX 8 048 The following hoses can be ordered Tab 6 Hydraulic tubes Page 26 of 28 Part no Kind of connection both sides Tube length in mm Material of tube 666 34169 1 DN 6 x 420 DKOS DKOS 8 S 420 HD DN 6 2040 N 04V00 666 34169 2 DN 6 x 430 DKOS DKOS 8 S 430 HD DN 6 2040 N 04V00 666341693 DN6x450DKOS DKOS8 S 450 HDDN62040N 04VO0 666340694 DN6x4 0DKOS DKOS8 S 470 HDDN62040N 04VOO 666034095 DN6x480DKOS DKOS8 S T 480 HDDN62040N 04VOO 666 34169 6 DN 6 x 490 DKOS DKOS 8 S 490 HD DN 6 2040 N 04V00 666 34169 7 DN 6 x 500 DKOS DKOS 8 S 500 HD DN 6 2040 N 04V00 66634198 DN6x540DKOS DKOS8 S 540 HDDN62040N 04VO0 666340099 DN6x550DKOS DKOS8 S 550 HDDN6 2040 N 04V00 6663407024 DN6x560DKOS DKOS8 S 560 HDDN62040N 04V00 6663417002 DN6x600DKOS DKOS8 S 600 HD DN 6 2040 N 04V00 666 34170 3 DN 6x 610 DKOS DKOS 8 S 610 HD DN 6 2040 N 04V00 666341704 DN6x620DKOS DKOS8 S 620 HDDN62040N 04VO0
23. ription Qty Part Number TT with chisel paste 12 642 37608 1 Pump assy 1 642 40950 1 Ec Tanger 1 Stepper motor SSV V6 K assy 619 29090 1 O ring 5 0x1 5 219 12222 2 Pump element C7 1 642 29086 1 Heavy duty dowel SG 5 0x16 215 10560 3 O ring 19 2x3 219 13053 6 je ated Miis 211 10213 2 O ring 14 2x2 5 1 219 130535 EN 201 10431 6 Screw 10 9 M6x50 A3C 200 10078 3 Spring DF50 3 DA 8x0 8 028 8 218 10141 7 Bracket assy with spring 542 34079 7 Screw hex socket M6x18 C 4 201 13668 1 Coupling nut M11x1x5 0 F 519 32307 1 Washer St A6 4 C 209 1301 1 5 Filter assy 528 32215 1 Paorageming Teo er eecneeese M b ouod 5 A 8S 304 19893 1 ORB epee AT fitting XGE o Sealing ring 122 7x2 5 442 70146 1 85 G A A3 C ee Throttle valve 542 34281 1 D see IMPORTANT note IMPORTANT Tab 5 Parts list model R See identification plate Please use Loctite 403 to glue in flat pack ing item 3 6001a02 see IMPORTANT note IMPORTANT Please use Loctite 274 to mount screw hex socket item 9 4 6001a02 Page 25 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ERE 2 1EN 39001 E09 Accessories Hydraulic tubes NOTE For applications of pump HTL 101 on hammers use hoses with special fittings that resist the high vibrations during the hammer s operation Standard hose fittings are not suitable for this type of ap
24. s and Parts List continuation Parts List model H LINCOLN ma 2 1EN 39001 E09 Item Description Qty Part Number Description Part Number 1 del wili nigel pante 12 642 37608 1 Pump housing assy 642 40950 1 Connection fitting Filter assy 528 32215 1 2 XGE6 SG 4 AC 1 223 10055 5 i 1 R il inlet fitting S uos jones M16 x 1 5x M20 x 1 5A 8 S 304 19893 1 O ring 219 12451 3 Pump element esr 1 642729086 Oil outlet fiting XGE 85 G4 A PM A3C i 4 1 O ring 19 2 x 3 1 219 13053 6 Throttle valve assy 542 34079 2 4 2 O ring 14 2 x2 5 2 219 13053 5 1 5 Hydraulic fitting 1 251 14109 6 see IMPORTANT note IMPORTANT 1 E 5 6 Closure plug G 1 4 3 229 197021 Please use Loctite 403 to glue in flat pack 7 Valve body 120 bar 1 235 14343 5 mg item 3 8 Housing cover assy 1 542 34079 4 6001202 8 1 Hex head screw M6 x 18 C 4 201 13668 1 see NOTE 8 2 Shim StA64C 4 209 13011 5 NOTE The marked parts are glued into the hous 8 3 Package ring 12x 30x 7 1 220 12229 8 ing for reasons of vibration If dismantled they may be destroyed If so replace 8 4 Bearing 1 250 14064 6 P pump item 9 completely 8 5 Sealing ring 122 7 x 2 5 1 442 70146 1 Tab 2 Parts list model H see identification plate Page 19 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual LINCOLN Opera
25. ssus more lubricant LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions 2 1EN 39001 E09 Technical Data continuation Hydraulic Circuit 4442a05 Fig 14 Hydraulic Circuit HTL 101 1 Screen 2 Filter 3 Stepper motor 4 Throttle adjustable 5 By pass for warming up Page 15 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 suomneoyipoui oi 1oe qns 2 1EN 39001 E09 Note Es OO SS Pieter eee EEE EE LL LL ET EEE EE TE LLLI 65 c o 0O G 2 gt c2 S o 5 o9 2o Page 16 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39001 E09 Troubleshooting Fault Pump does not deliver the lubricant Cause Remedy Cartridge empty 2 Replace the cartridge see page 11 Lubricant supply blocked gt Check the cartridge No oil pressure supply gt Check the hydraulic system and repair it gt Check the tube and hose lines and replace them Air entrapments in the suction area of the cartrigde gt Vent housing see page 10 Fir
26. st Instertion of cartridge Fault Lubricant quantity too low Cause Remedy Throttle not adjusted correctly 2 Turn the throttle anticlockwise by 1 to 2 notches more lubricant will flow out see Fig 3 Fault Lubricant quantity too high Cause Remedy Throttle not adjusted correctly 2 Turn the throttle clockwise by 1 to 2 notches less lubricant will flow out see Fig 3 Fault Lubricant leaking at the cartridge inlet Cause Remedy Leakage gt Check the sealing ring in the pump unit and replace it if necessary 2 Check wether the cartridge is threaded correctly hand tight seat Fault Lubricant leaking at the grease outlet Cause Remedy Leakage gt Check the fittings and retighten them if necessary Fault Oil pressure leaking at the hydraulic system Cause Remedy Leakage gt Check the fittings and retighten them if necessary Tab 1 Troubleshooting Page 17 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions 2 1EN 39001 E09 Components and Parts List Exploded drawing model H L A 4439c05 Fig 15 Exploded drawing model H see identification plate Page 18 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions Component
27. te se obliga a hacer disponible documentos t cnicos seg n anexo VII parte B en versi n imprimida a entes uniestatales a petici n fundada referente al producto arriba mencionado Normas armonizadas utilizadas particularmente Directiva de m quinas 2006 42 CE Parte 1 amp 2 Seguridad de maquinas T rminos b sicos axiomas generales de dse o Bombas y equipos de bombas para l quidos Prescripciones generales referente a la seguridad LINCOLN ma 2 1EN 39001 E09 Origind Language l Dichiarazione CE di incorporazione Si dchiara che il prodotto da roi fornito Hiermit erkl ren wir dass de nella versione da noi fornita destinato all installazione in una macchina e che la relati va messa in esercizio resta vietata fino all avvenuto accertamento della conformit della macchina nella quae il suddetto prodotto deve essere installato con tutti i requisiti basilari prescritti in termini di sicurezza e di salute incluse le relative modifiche vigenti al momento della dichiarazione Il costrut lore si impegna a mettere a disposizione la documenta zione tecnica ai sensi aell Allegato VII partel B in forma scritta relativa al sum menzionato prodotto dietro richiesta motivata presso le singole sedi nazional Norme armonizzate applicate in particolare Direttiva Macchine 2006 42 CE Parte1e2 Sicurezza delle macchine Concetti basilari principi guida generali DIN EN 908 Pompe e
28. teteees 5 General Safety Instructions 0 2 0 eeeee cesses eeseeeeceeneeeaeeeeeens 5 Accident Prevention Regulations esses 5 Operation Maintenance and Repair sess 5 Flepall 5 een et e REIR DH IEEE ied 5 Operation Maintenance sese 6 Disposal ida bate asco esee decades 6 Exclusion of Liability s 6 Installation s esses senem nnns 6 Installation and Maintenance of Hydraulic Hoses 6 Description The Pump Model HTL 101 see 7 Working Method seem 8 Adjustment and Operation Basic Adjustment of the Throttle Valve eee 8 Monitoring of Function eese 8 Pump Element prisiar tor be cR n Dres 9 Pressure Relief Valve sess 9 2 1EN 39001 E09 Page Maintenance sse eene emen 10 Lubricant Cartridge essen 10 First insertion of cartridge eee 10 Cartridge Replacement sse 11 Removal of Oil Strainer se esee 11 Technical Data puit 12 Pressure Diagram Ratio Comparison 12 DIMENSIONS ec REPRE RU ERR FIDE ah EA GRE 13 Flow Rate Diagram oo eee cece essen 14 Average output on medium sized hydraulic hammers seen 14 Hydraulic Circuit eese 15 Troubleshooting
29. tion Instructions EE 2 1EN 39001 E09 Components and Parts List continuation Exploded drawing model N S VS S Ny OP 4 Fig 16 Exploded drawing model N see identification plate Page 20 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions Components and Parts List continuation Parts List model N LINCOLN ma 2 1EN 39001 E09 Item Description Qty Part Number Description Part Number 1 del MIR nigel pante 12 642 37608 1 Pump housing assy 642 40950 1 Connection fitting Filter assy 528 32215 1 2 XGE6 SG 4 AC 1 223 10055 5 i 1 R il inlet fitting 3 Kit of seals I 542 34073 1 M16 x 1 5x M20 x 1 5A 8 S 304 19893 1 O ring 219 12451 3 a Pomp element te 1 Pap ene Oil outlet fitting XGE 85G A B A3C i 4 1 O ring 19 2 x 3 1 219 13053 6 Throttle valve assy 542 34079 9 4 2 O ring 14 2 x2 5 2 219 13053 5 1 5 Hydraulic fitting 1 251 14109 6 see IMPORTANT note IMPORTANT 1 E 5 6 Closure plug G 1 4 3 229 197021 Please use Loctite 403 to glue in flat pack 7 Valve body 120 bar 1 235 14343 5 mg item 3 8 Housing cover assy 1 542 34079 4 6001202 8 1 Hex head screw M6 x 18 C 4 201 13668 1 see NOTE 8 2 Shim StA64C 4 209 13011 5 NOTE The mar
30. tor make sure to switch off the hydraulic drive 1013A94 IMPORTANT The throttle valve may still be pressurized for a long time after switching off the hy draulic unit 600 1a02 Therefore first of all check whether the 6011c07 pressure connection P 14 fig 2 is de Fig 3 Throttle valve adjustment pressurized The eccentric shaft must not rotate anymore see fig 4 Page 8 of 28 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User Manual Operation Instructions ma 2 1EN 39001 E09 Adjustment and Operation continuation 6134b03 Fig 4 Monitoring of Function Pump Element 4349a02 Fig 5 Pump Element Pressure Relief Valve 4195a99 Fig 6 Pressure relief valve cartridge Monitoring of Function The eccentric shaft 9 Fig 4 located at the bottom of the pump housing cover serves for checking the function If it turns clockwise the pump elementis operating correctly NOTE Before switching on the hydraulic unit check whether there is sufficient lubricant in the cartridge If necessary replace the cartridge see chapter Maintenance page 10 IMPORTANT The lubrication pump must be protected with a pressure relief valve 7 NOTE If the lower outlet connection is used for lubricant delivery the pressure relief valve must be fitted to the upper outlet
31. ubrication system or with its appointed Misuse dealers Any use of the hydraulic operated lubrication pump HTL 101 Hydraulicoperatgd lubricati n pumps model b TE 101 that is not expressly mentioned in this user s manual will be are not to be installed in the lower area of the hammer regarded as misuse must be installed in such a way that the operator can If the hydraulic operated lubrication pump HTL 101 is used or always see the position of the low level indicator of the operated in a different manner other than specified any claim follower piston for warranty or liability will be null and void After each cartridge replacement be sure that the pump NOTE delivers lubricant If personal injury or material damage Accident Prevention Regulations occurs as a result of inappropriate opera tion e g if the safety instructions are To prevent accidents observe all city state or provincial and 6001202 ignored or resulting from incorrect installa federal safety regulations of the country in which the hydraulic tion of the hydraulic operated lubrication operated lubrication pump HTL 101 will be used pump HTL 101 no claims or legal actions may be taken against Lincoln GmbH Operation Maintenance and Repair ATTENTION Before beginning with maintenance or repair work to the lubrication pump HTL 101 ensure that the hydraulic system of the carrier unit the supply to the lubrica tion pump is depressurized 1013494 ATTENTION It is a
32. ump HTL 101 Lubrication output Max operating pressure lubricant Hydraulic hammer with metering device Ratio Factory Gutput Settir ings Speed revolutions eseeee max Hydraulic pressure seses min Hydraulic pressure sss sse Admissible operating temperature bebes 0 22 cm3 stroke 120 bar 2s 270 bar 25 C to 80 C 1 1 65 4 rpm 250 bar 40 bar Pressure Diagram Ratio Comparison Standard Fitting Connections Oil Pressure P sssssssssssssss M 16x 1 5 mm Oil Return R ssssssssssssssssss M 16x 1 5 mm Lubricant outlet seen Gi 1 4 NOTE The minimum operating temperature de pends on the pumpability of the lubricants For Lincoln chisel pastes itis 25 C Ob serve the manufacturer s specifications for 6001a02 standard greases The following pressure diagram depicts the relationship between the inlet pressure of the hydraulic system and the maximum outlet pressure of the lubrication pump with closed outlet or with a blockage The maximum outlet pressure was determined with an EP 2 grease at room temperature Fig 11 Pressure diagram A Oil pressure Hydraulic System Inlet B Delivery Pressure Lubricant Outlet Page 12 of 28 300 350 bar 4440202 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications Subject to modifications User M

Hydraulic Operated Lubrication Pump HTL 101

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