Hydraulically Operated Lubrication Pump HTL 201
Contents
1. Designation Part no 2 1 2 2 23 2 4 2 5 2 6 2 7 Reservoir for oil X xix x x x x 542 33134 1 Filling gt Untighten the screw top 2 7 from the reservoir 2 4 2 Fillin the lubricating oil through the filter 2 6 gt Close the reservoir 2 4 again with the screw top after filling 2 7 2 Reservoir for oil assy 2 7 Screw top 2 6 Strainer 2 5 Strainer insert 2 4 Reservoir 2 3 Hexagonal socket head screws M5x25 2 2 Adapter 2 1 O ring 6 Cartridge housing Page 13 of 24 LINCOLN GmbH e Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions ERE 2 1EN 39007 B11 Maintenance continuation First insertion of cartridge B HTL201 040d10 Fig 4 9 Insert cartridge into the lubrication pump HTL 201 3 Pump element 4 Lubrication fitting for manual lubrication 15 Cylinder head screw Cartridge Replacement B HTL201 040e 10 Fig 4 10 Cartridge Replacement Page 14 of 24 0020 Lightly grease the inner o ring Cut off tip of thread throat 1 2 Fig 4 1 of the new car tridge Insert the cartridge in the bore by lightly pressing and screw it into the housing presented as in Fig 4 9 hand tightly Vent housing Remove cylinder head screw 15 from front or rear side Press follower piston 1 1 Fig 4 1 into the cartridge un til lubricant comes out of the open bore hole 12. cesse Dimensions LINCOLN ERE 2 1EN 39007 B11 Technical Data 30 bar Factory Output Settings AOL aie cioe sete tetoe n tis completely opened max output ee depending on input pressure P Tightening Torques Hydraulic fitting 4 sese 14 Nm 5 96 Valve insert 7 iei eei 8 Nm 10 96 Cylinder head screws M4 x 12 15 3 Nm 1096 Cylinder head screws M8 x 80 9 15 Nm 10 96 Fixing screws M10x90 sese 70 Nm 10 IMPORTANT The specified admissible operating temperature refers to the pump and the components of the entire lubrication system but not to the lubricant to be supplied Therefore please observe that the transportation of the lubricant in a system depends on the lubricant s flow prop erties The admissible operating temperature of the lubri cant may differ from the system operating temperature and has to be verified separately For applicable lubricants also see User Manual 2 0 4000 1 chapter Approved lubricants 6001 a02 lb e oe Gite AW SS SSS SSS Ee 2x 910 5 A 194 B 286 80 Fig 5 1 all dimensions in mm Page 16 of 24 Dimensions of the Hydraulic Lubrication Pump HTL 201 with cartridge 6566 h08 A Height 194 mm with 150 g cartridge B Height 286 mm with 310 g cartridge LINCOLN GmbH
3. x x for 380 g lubricant cartridges see Installation Instructions 2 0L 30008 B08 part no 810 55488 1 5 for 500 g lubricant cartridges 2 7 Hexagonal socket head screws M5x35 2 6 Flat packing NBR 2 5 Sealing ring PU90 2 4 Adapter 2 3 O ring NBR 2 2 O ring NBR 2 1 Tubular support 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 39007 B11 Maintenance continuation Filling of Reservoir Operation with lubricant cartridge gt Replace the emptied lubricant cartridge 150 g 310 g as Soon as its follower piston has sunk down to the cartridge housing 6 NOTE Cartridges 150 g 310 g 380 g are not included in the scope of delivery but have to be ordered separately 6001a02 IMPORTANT Dispose of emptied cartridges according to the legal regulations pertaining to envi ronmental protection Operation with press container Fillthe press container with lubricant or with a 380 g lubricant cartridge as soon as the hand lever 1 1 has sunk as shown in Fig 4 3 B HTL20 1 040910 Fig 4 3 Filling level control of the press container 1 Press container 1 1 Hand lever 1 2 Closure cap 1 3 Spring 1 4 Follower piston 2 Adapter 3 Pump element lubricant outlet G 1 4 4 Hydraulic lubrica
4. see 19 Exploded Drawing and Parts List 20 EC Declaration of incorporation 23 Lincoln worldwide ese e 24 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 24 LINCOLN GmbH e Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ma 2 1EN 39007 B11 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 6001202 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 making use of other than the tested spare parts s
5. Einbauerklarung Hiermit eikl ren wir dass die 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 heisanforderungen ent spricht einschlie ich deren zum Zeitpunkt der Erkl rung getencen nderungen Der Hersteller verpflichtet sich technische Dokumente gem Anhang VII Teil B bei be gr ndeter Anfrage zum o g Produkt einzelstaatlichen Stellen in gediuckter Form zur Verf gung zu stellen Angewendete harmonisierte Normen insbesoncere Maschin enrichtlinie 2006 42 EG GB EC Declaration of incorporation Herewith we declare that the model of in the supplied version is intended to be incorporated into machinery and must not be put into service until the machinery irto 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 at the time of the decla ration The manufacturer undertakes to make available any technical documents in printed versian following Annex VII Part B to subra tional authorities in the case of reasonable request regard ing the above mentioned product Applied harmonized stan dards
6. 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 39007 B11 Technical Data continuation Flow Rate Diagram The lubricant flow rate as a function of the throttle setting at The output results from the throttle revolutions and the use of different pressures can be read from the following flow rate the use of a pump element with an output of 0 22 ccm stroke diagram The throttle valve is provided with notches whereby Max output seem 6 7 ccm min 16 notches correspond to one complete revolution of the at 200 bar and max opening of throttle throttle Lubricant Output HTL 201 at 80 bar and 40 C operating temperature 100 bar back pressure 30 Output ccm min 05 0 0 0 20 40 60 60B HTL201050b10 close lt lt lt _ Throttling by means of notches gt gt gt open Fig 6 1 Flowrate diagram at 80 bar averaged curve progression Lubricant Output HTL 201 at 140 bar and 40 C operating temperature 100 bar back pressure 43 Output ccm min 0 20 40 60 80B HTL201 050c10 close lt lt lt _ Throttling by means of notches gt gt gt open Fig 6 2 Flow rate diagram at 140 bar averaged curve progression Lubricant Output HTL 201 at 200 bar and 40 C operating temperature 100 bar back pressure 70 67 Output ccm m
7. ie de s curit technique 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 maquina y que su puesta en servicio est prohibida artes de que b m quina en la que vaya a ser incarporada haya sido dechrada 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 fabricante se cbliga a hacer disponible cbcumertos 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 particularmerte Directiva de m quinas 2006 42 CE Parte1 amp 2 Seguridad de m quinas T rminos b sicos axiomas generales de disefio Bombas y equipos de bombas para l quidos Prescripciones generales referente a la seguridad LINCOLN ma 2 1EN 39007 B11 Dichiarazione CE di in corporazione Si dichiara che il prodotto da noi fornito nella versione da noi fornita destinato all installazione in una macchina e che la relati va messa in esercizio resta vietata fino all avvenuto accertamerto della conformit della macchina nella quale 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 mamerto d
8. Check whether the standard pressure relief valve 120 bar is sufficient If necessary use the optional pressure relief valve with 270 bar Tab 1 Troubleshooting Page 19 of 24 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions EE 2 1EN 39007 B11 Exploded Drawing and Parts List B HTL20 1 070a10 Fig 8 1 Exploded Drawing and Parts List Page 20 of 24 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications User Manual Operation Instructions LINCOLN ERE 2 1EN 39007 B11 Exploded Drawing and Parts List continuation Subject to modifications Parts List Pos Description Qty Part Number Pos Description HTL 201 with pump element C7 1 642 41184 1 7 ras reler Valve 235 14343 5 Pressure relief valve HTL 201 with pump element K7 1 642 41 184 2 270 bar optionally 235 14343 2 1 um with chisel paste 12 642 37608 4 9 Oylinderhead screw M8 x 80 n 201 10431 7 3 Closure plug M20 x 1 5 Cartridge with EP 2 gease 150 g 12 642 37 609 3 12 for throttle 442 72445 1 T with 12 642 37636 2 14 Oil strainer assy 447 72394 1 Cartridge with EP 2 gease 310 g 12 642 37609 4 15 Cylinder head screw 8 8 M4 x 12 3 201 12015 9 a R 7 Threaded packing 1 1 Gasket for cartridge 1 219 10555 1 GM1000
9. in particular Machinery Directive 2006 42 EC DINEN ISO 12100 Teil 1 amp 2 Part1 amp 2 Sicherheit von Maschinen Grundbegriffe algemeine Gestaltungsleits tze 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 Gereral safety requrements F D claration CE d incorporation Par la pr sente nous d cla rons que le produit ci dessous HTL 201 dans la version dans laquelle nous le livrons est destin amp re install sur une machine et que sa mise en service est irterdite tant quil n aura pas t constat que la machine sur laquelle le produit men lionr ci dessus doi tre in stall est conforme aux r gle mertations r gissant toutes les exigences fondamertales s curit et celles relatives la sant y compris es amen dements en vigueur au mo mert de la pr sente d cla ration Le fabricant s engage en cas ce demande justifi e fourrir sous forme crite aux arganismes nationaux respec tifs les documerts techniques suvantAnnexe VII Partie B relatifs au produit ci dessus Normes harmonis es notam ment Directive machines 2006 42 CE Parties 1 amp 2 S curit de machines Notions fondamentales drecti ves g n rales d laboration DIN EN 908 Pompes et grou pes de pompes pour liquides Exigences en mati
10. lubrication hydraulic fitting 4 for manual lubrication override e g if the hydraulic system fails to operate does not require supplementary directional valve NOTE Connecting fittings 13 amp 14 and gease cartridges 1 are not included in the scope of delivery and have to be ordered ee separately ATTENTION Pressure connection 14 P and retum line connection 13 T must not be mixed up 1013a94 Page 7 of 24 LINCOLN GmbH e Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual LINCOLN Operation Instructions EE 2 1EN 39007 B11 Mode of Operation HTL 201 gt The HTL 201 lubrication pump is connected by means of the following connecting fittings 3 Lubricant outlet G 1 4 12 1 Throttle below closure plug 13 Return connection T G 1 4 14 Pressure connection P G 1 4 with integrated oil strainer The flow rate and thus the output of the pump can be adapted according to the output diagram fig 6 1 to 6 3 via the regulating throttle valve 12 16 notches of the regulating throttle correspond to one full revolution The oil flows via the pressure connection 14 resp P through an integrated strainer to the control piston In parallel the also activated supply piston moves a pre metered amount of lubricant to the lubricant outlet 3 The oil is returned to the driving system of the carrier unit via the relief line connection 13 resp T D i
11. 5 Close housing with cylinder head screw 15 Fig 4 9 again Operate the pump by switching on the hydraulic unit until lubricant flows out of the opened pump element 3 NOTE The pump delivers lubricant very slowly It may take a while before the lubricant flows out of the outlet without air bubbles 600 1202 Connect the supply hose primed where applicable to the lubrication point with pump ele ment 3 Manual lubrication is possible via the hydraulic lubrication fitting 4 by means of a manually operated grease gun Switch off the carrier device Unscrew the old cartridge Cut off the point of the thread throat 1 2 Fig 4 1 of the new cartridge Press the follower piston 1 1 Fig 4 1 slightly until grease comes out of the cartridge Press cartridge slightly into the cartridge the screw it into the housing hand tightly as shown in Fig 4 10 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 4 9 600 1a02 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 2 1EN 39007 B11 Maintenance continuation Cleaning the Oil Strainer B H TL 201 040f10 Fig 4 11 Oil Strainer in the control housing The oil strainer should be clea
12. M4 220 14101 3 4 Hydraulic fitting 1 8 1 251 14109 6 17 Plug TL 4 119 D11 9 E 233 13100 2 Tab 3 PartsList NOTE Connecting fittingsand cartridges are not included in the scope of delivery and must be ordered separately 6001a02 Accessories Pos Description Qty Part Number Kit of seals for 380 g cartridge TR see Fig 4 2 Adapter kit for 380 g cartridge trapezoidal thread TR 22 x 2 75 see Fig 4 2 542 33136 1 542 34079 1 Adapter kit for 400 g cartridge round thread RD 15 x 2 5 see Fig 4 2 Reservoir for oil incl strainer and adapter kit see Fig 4 8 Adapter kit for 500 g cartridge trapezoidal thread TR 20 x 2 5 see Fig 4 2 542 33133 1 542 33135 1 542 33134 1 Reservoir transparent incl adapter see Fig 4 2 542 33430 1 Reservoir steel incl adapter see Fig 4 2 542 33472 1 Tab 4 Accessories Page 21 of 24 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions 2 1EN 39007 B11 Notes Subject to modifications Page 22 of 24 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 Subject to modifications User Manual Operation Instructions Original Language D EG
13. Subject to modifications User Manual LINCOLN Operation Instructions EE 2 1EN 39007 B11 Hydraulically Operated Lubrication Pump HTL 201 B H TL 201 000a10 810 53303 1B 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 69190 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 notificatio n LINCOLN Phone 29 6227 33 0 hy Fax 49 6227 33 259 E Mail Lincoln lincolnindustrial de 2011 by Page 2 of 24 2 1EN 39007 B11 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 ma Table of Contents Page Introduction Explanation of Symbols Used sess 4 User s Responsibility essen 4 Environmental Protection sse 4 NIIT 4 Safety Instructions Appropriate Use essen enne enne enne nnne 5 MISS E D ce 5 Exclusion of Liability 5 Accident Prevention Regulatio
14. all be operated only with an installed pressure relief valve shall regularly be supplied with clean lubricant cartridges 1509 310g cartridges can t be refilled operate automatically However check at regular intervals approx every 2 days whether the pump effectively de livers lubricant visual check Page 5 of 24 LINCOLN GmbH Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions LINCOLN ma 2 1EN 39007 B11 Safety Instructions continuation Repair Repairs should only be performed by authorized personnel who are familiar with the repair instructions Installation ATTENTION Before installing or disassembling the lubrication pump HTL 201 ensure that the hydraulic system of the carrier unit the supply to the lubrication pump is depres surized 1013A94 It is forbidden to manipulate the protection devices in stalled on the hydraulic unit If necessary these devices may be removed te mporarily during the installation of the pump The devices must be properly put back in place after in stallation Use only original spare parts or spare parts and cartridges authorized by Lincoln see Parts List IMPORTANT Observe the installation guidelines and instructions of the machine unit manu fac 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
15. ations or alterations to an installed system by the customer are subject to prior consultation with the manu facturer of the lubrication system or with its appointed dealers Hydraulically operated lubrication pumps model HTL 201 are not to be installed in the lower area of the hammer must be installed in such a way that the driver operator can always see the position of the low level indicator of the follower piston After each cartridge replacement make sure that the pump delivers lubricant Operation Maintenance and Repair ATTENTION Before beginning with maintenance or repair work on the lubrication pump HTL 201 ensure that the hydraulic system of the carrier unit the supply to the lubrica tion pump is depressurize d 1013A94 ATTENTION It is absolutely forbidden to carry out main tenance or repair work and to replace the cartridge while the hydraulic unit is in op eration ATTENTION A contamination of the oil strainer fig 4 11 can result in poor lubrication of connected lubrication points Depressurize the carrier unit before disas sembling the oil strainer CAUTION Risk of injury in case of contact with hot connection parts or hot oil of the driving hydraulics Let the driving hydraulics cool down before starting any maintenance or repair work to avoid burning or scalding or 1013A94 wear adequate protective clothes Operation Maintenance d operated lubrication pumps HTL 201 sh
16. c10 Fig 3 3 Pressure Relief Valve pos 7 During the operation the piston 3 2 Fig 3 2 sucks in lubri cant from the cartridge via the suction bore hole 3 1 and de livers it to the connected lubrication point through the lubri cant outlet 3 3 An integrated check valve prevents the lubri cant from retuming to the cartridge Piston diameter Lubricant output eese approx 0 22 ccm stroke 3 1 Suction bore 3 2 Piston 3 3 Lubricant outlet G 1 4 The pressure relief valve limits the pressure build up in the system opens when a pressure of 120 bar is reached Alternatively in the case of higher supply pressure a pressure relief valve for a max overpressure of 270 bar can be used NOTE If lubricant is expelled at the pressure relief valve this indicates that there is a blockage to or at the lubrication point 6001 a02 IMPORTANT When using chisel pastes the outlet pres sure P must not exceed 100 bar Page 9 of 24 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 39007 B11 Maintenance CAUTION Risk of injury in case of contact with hot connection parts or hot oil of the driving hydraulics Let the driving hydraulics cool down before starting any maintenance or repair work to avoid buming or scalding or 1013A94 r wear adequate protective clothes Lubr
17. d lever to carefully unlock the follower rod and let it return into the press reservoir thus discharging the empty cartridge gt For initial filling with 400g lubricant cartridge adapt filling variant if necessary see Fig 4 4 4 Remove plastic sealing cover B 1 from grease cartridge B and push cartridge with that side into the press reser voir A 5 Remove tear off lid B 2 from the grease cartridge and then screw the grease reservoir fittings to the HTL adapter Unlock the follower rod from the reservoir s closure cap 7 Remove trapped air if any see chapter Vent housing 9 Page 12 of 24 Adjust filling variant gt Unscrew the reservoir grease gun from the housing of the HTL gt Check the follower piston packing and adjust it if neces sary 1 Unscrew reservoir closure cap 2 Pullthe follower rod together with the spring and the follower piston out of the press reservoir by means of the hand lever 3 Evert packing of follower piston see Fig 4 4 4 Proceed with re assembly of follower piston 5 Screw closure cap to press reservoir again Operation with bulk grease filling in press reservoir gt For initial filling with bulk grease filling adapt filling variant if necessary see Fig 4 4 1 Remove grease reservoir fittings from the HTL adapter 2 Immerge the open end of the press reservoir into the grease container Slowly pull the hand lever backwards while following the sin
18. ella dicharazione Il costrut tore si impegna a mettere a disposizione la documenta zione tecnica ai sensi dell Allegato VII partel B in forma scritta relativa al sum menzionato prodotto dietro richiesta motivata presso le singole sedi nazionali Norme armonizzate applicate in particolare Direttiva Macchine 2006 42 CE Parte 1 e2 Sicurezza delle macchine Concetti basilari principi guida generali Pompe e dispositivi di pompaggio per liquidi Requisiti generali d sicurezza tecnica Doku mentations bevollm chtigter f Documentation agent Responsable du Service de documentation Encargado a de la documentaci n Wolfgang Studer e Heinrich Hertz Str 2 8 69190 Walldorf Walldorf Oct 12 2010 ppa Dr Ing Z Paluncic Director Research amp Development LINCOLN ms Responsabile della documentazione Lincoln GmbH Heinrich Hertz Str 2 8 D 69190 Walldorf Page 23 of 24 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 orthe 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 mos
19. erious damage may affect your device Therefore for the operation of your device always use original parts made by Lincoln 1013A94 GmbH Page 4 of 24 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 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 itisina proper functioning condition and if it is operated in accor dance with the maintenance requirements 3 Theoperating personnel must be familiar with this User 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 suitably qualified If required Lincoln GmbH o
20. ffers 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 Operation Instructions LINCOLN ERE 2 1EN 39007 B11 Safety Instructions Appropriate Use The hydraulically operated lubrication pump model HTL 201 is designed for initial or subsequent retrofit installation It is designed for 1 the automatic lubrication of hydraulic hammers 2 the automatic lubrication of hydraulically driven units The pump is able to deliver lubricants and chisel pastes up to NLGI class 2 or oils from min 40 mm s cSt Misuse Any use of the hydraulically operated lubrication pump HTL 201 that is not expressly mentioned in this Users Man ual will be regarded as misuse If the hydraulically operated lubrication pump HTL 201 is used or operated in a different manner other than specified any claim for warranty or liability will be null and void NOTE If personal injury or material damage occur
21. frame or between two bore holes 6001202 IMPORTANT For fastening of the HTL 201 pump use cylindrical screws DIN 4762 M10x90 6001202 Page 6 of 24 Disposal Dispose of used or contaminated lubricants as well as of parts that were in touch with lubricant according to the legal regula tions pertaining to environmental protection Make sure to observe the safety data sheets of the lubricants used Installation and Maintenance of Hydraulic Hoses ATTENTION The operational safety of the lubrication pump HTL 201 is only guaranteed with a professional installation and maintenance of hydraulic hoses lines The following points must be observed 1013A94 Hydraulic Hose lines may never be subjected to torsion must be installed twist free must not rub against metal components or edges are to undergo regular visual checks and 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 Operation Instructions ERE 2 1EN 39007 B11 Description B HTL201 010f10 Fig 1 1 Components of the Lubrication Pu
22. icant Cartridge 1 1 6007h 07 Fig 4 1 Lubricant Cartridge Adapter B HTL201 040b08 Fig 4 2 Adapter for lubricant cartridges Page 10 of 24 ATTENTION Do not perform any maintenance or repair work or replace the cartridge while the hydraulic system of the carrier device is in operation 1013A94 ATTENTION Before beginning with maintenance or repair work on the lubrication pump HTL 201 and before dismantling it ensure that the hydraulic system of the carrier device is depressurized ed E sins testes eens 150 g 310g Lubricant enr encre up to NLGI class 2 NOTE Cartridges are not included in the sco pe of delivery and must be ordered sepa rately IMPORTANT Never try to refill emptied cartridges After use dispose of emptied cartridges according to the legal regulations pertain ing to environmental protection 600 1202 1 Cartridge 1 1 Follower plate 1 2 Tip of thread throat gt Before the replacement or first insertion of a 380 g 400 g or 500 g cartridge an adapter Fig 4 2 must be mounted to the housing of the cartridge 6 Fig 1 1 Positions Fig 4 2 Designation Bares 24 22 23 2 4 2 5 2 6 2 7 Adapter 380 g TR 42 33136 1 Trapezoidalthreadi 55 95 p Pi EU ale tcs Kit of seals x x x 542 34079 1 Adapter 400 g RD 42 33133 1 Round thread X p x 542 33133 Adapter 500 g TR 542 33135 1 Trapezoida thread
23. ieve pressure of hydraulic system on carrier unit gt Clean oil strainer see Fig 4 11 Fault Lubricant quantity too low Cause Remedy by service personnel Throttle not adjusted correctly 2 Turn the throttle anticlockwise by 1 to 2 notches more lubricant will flow out see Fig 3 1 Clogged oil strainer 2 Fully relieve pressure of hydraulic system on carrier unit gt Clean oil strainer see Fig 4 11 Fault Lubricant quantity too high Cause Remedy by service personnel Throttle not adjusted correctly gt Turn the throttle clockwise by 1 to 2 notches less lubricant will flow out see Fig 3 1 Fault Lubricant leaking at the cartridge inlet Cause Remedy by service personnel Leakage 2 Checkthe sealing ring in the pump unit and replace it if necessary 2 Check whether the cartridge is threaded correctly hand tight seat Fault Lubricant leaking at the grease outlet Cause Remedy by service personnel Leakage 2 Checkthe fittings and retighten them if necessary Fault Oil pressure leaking at the hydraulic system Cause Remedy by service personnel Leakage 2 Checkthe fittings and retighten them if necessary Fault Lubricant leaking at the pressure relief valve Cause Remedy by service personnel Blockage in lubricant feed line or at lube point 2 Checkthe lubricant feed lines and the lube points for possi ble causes of blockage Backpressure in the feed lines too high gt
24. in os 0 1 0 20 40 60 80B HTL201 050d10 close Throttling by means of notches gt gt gt open Fig 6 3 Flowrate diagram at 200 bar averaged curve progression Page 17 of 24 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 39007 B11 Technical Data continuation Hydraulic Circuit B HTL201 050a10 Fig 7 1 Hydraulic Circuit HTL 201 1 Mechanical pump pump element 2 Oil strainer 3 Lubricant outlet 4 Throttle adjustable 5 Rearrangement piston 6 ressure relief valve 120 bar P Pressure connection R Return connection T Page 18 of 24 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 39007 B11 Troubleshooting Fault Pump does not deliver the lubricant Cause Remedy by operator personnel Cartridge empty gt Replace the cartridge see Fig 4 10 Lubricant supply blocked gt Check the cartridge Air entrapments in the suction area of the cartridge gt Vent housing see Fig 4 9 First Insertion of cartridge Cause Remedy by service personnel No oil pressure supply gt Check the hydraulic system and repair it gt Check the tube and hose lines and replace them Clogged oil strainer gt Fully rel
25. king filling level in the grease con tainer This will prevent air from being sucked into the press reservoir during the filling procedure Fig 4 6 B MGP101 020d10 B MGP101 020e10 Fig 4 6 Suction Fig 4 7 Engaging 3 Pull back the follower rod together with the follower pis ton by means of the hand lever from the press reservoir to that extent that the nut in the follower rod becomes visible and engages in the notch of the reservoir s clo sure cap Fig 4 7 4 Screwthe filled press reservoir again Disengage the follower rod from the reservoir s closure cap by means of the hand lever Remove trapped air if any see Chapter Vent housing o CAUTION Risk of injury by unwanted resilience of follower rod If engaged inaccurately Fig 4 6 the fol lower rod may unlatch unwantedly Make sure the latching function works properly and prevent unintended unlatch ing 1013A94 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 Reservoir for Cil LINCOLN ERE 2 1EN 39007 B11 Maintenance continuation Fig 4 8 Reservoir for oil assy B HTL201 040c10 gt Before the replacement or first insertion of a reservoir for oil 2 Fig 4 8 an adapter pos 2 1 to 2 3 must be mounted to the housing of the cartridge 6 Position 2 Fig 4 8
26. mp HTL 201 1 Cartridge 2a Follower piston cartridge full 2b Low level position window of the follower piston cartridge empty 3 Pump element lubricant outlet G 1 4 4 Hydraulic lubrication fitting G s f r manuelles Abschmieren 6 Cartridge housing 7 Pressure relief valve 120 bar 8 Control housing 11 Fastening holes for M 10 bolts 12 Throttle below closure plug 12 1 13 Return connection T G 1 4 14 Pressure connection P G 1 4 15 Oylinder screw M4 x 12 for bleeding The Pump Model HTL 201 is a hydraulically driven grease pump forthe lubrication of hydraulic hammers or other units with an available hy draulic circuit is compact and can therefore be fitted directly to the car rier device Together with the carrier device 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 4 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 2b the cartridge must be replaced is protected by means of a 120 bar pressure relief valve 7 see Fig 6 is equipped with an exchangeable pump element piston unit is equipped with a
27. ncl check valve B HTL201 020a10 Fig 2 1 Hydraulic oil connections of the lubrication pump HTL 201 Setting and Operation Basic Adjustment of the Throttle gt Remove closure plug 12 1 Fig 2 1 of the throttle 9 gt The throttle 9 is factory set to grid 80 see Flow Rate Diagrams fig 6 1 to 6 3 gt Turn the throttle screw 9 according to the lubricant re quirement turning clockwise esses less lubricant turning anticlockwise more lubricant gt Close closure plug 12 1 of throttle 9 again to protect throt tle against contamination IMPORTANT Observe the specified lubricant quantities see Fig 6 1 to 6 3 6001a02 ATTENTION To adjust the throttle stop the hydraulic system operation The throttle may still be pressurized for along time after switching off the hydraulic unit Always check first whether the pressure connection 14 P 1013494 fig 2 1 is depressurized Ee 9 Throttle valve Fig 3 1 Throttle Valve Adjustment Page 8 of 24 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 2 1EN 39007 B11 Setting and Operation continuation Pump element 3 3 B HTL 201 020b10 Fig 3 2 Pump element Pos 3 Pressure Relief Valve B HTL201 020
28. ned every 1000 operating hours at the latest To do this proceed as follows gt Completely relieve pressure of hydraulic system on carrier device gt Remove the pressure line to the lubrication pump HTL 201 gt Oil Strainer 14 1 Fig 4 11 Unscrew oil strainer 14 1 Fig 4 11 from control hous ing 8 Remove and clean oil strainer Screw oil strainer back into the control housing 8 again 8 Control housing 14 Pressure connection P G 1 4 14 1 Oil Strainer Identification Code Example of a type designation HIL 2 01 C7 HIL 2 01 K7 HTL Hydraulic Tool Lubrication Version type series Application Number of pump elements C7 Piston diameter 7 mm for chisel paste increased fit tolerance K7 Piston diameter 7 mm for grease NOTE Part numbers see Parts List 6001a02 Page 15 of 24 LINCOLN GmbH e Postfach 1263 D 69183 Walldorf Tel 49 6227 33 0 Fax 49 6227 33 259 User Manual Operation Instructions Rating Hydraulic system Carrier device Hydraulic input pressure P min run in pressure Lubrication Pump HTL 201 Output s e p max operating pressure lubricant D Pressure relief valve standard Pressure relief valve optionally Admissible operating temperature clle Standard Fitting Connections Pressure connection P Return connection T ss Feed line
29. ns sesseesss 5 General Safety Instructions s ees 5 Operation Maintenance and Repair sese 5 Operation Maintenance s see 5 PROP AUIS sire roret ser nin Da oe HR PIE Re RO ORecE 6 BEI M 6 rcl O REE 6 Installation and Maintenance of Hydraulic Hoses 6 Description The Pump Model HTL 201 sss 7 Working Method ss 8 Adjustment and Operation Basic Adjustment of the Throttle Valve 8 P rtip Eletrert e tien t remet eres 9 Pressure Relief Valve sss eene 9 2 1EN 39007 B11 Page Maintenance Lubricant Cartridge ss 10 Adaplet ian e MEG p DR FUR detbesesteaseec obs 10 Filling of Reservoir ss 11 Operation with lubricant cartridge eee 11 Operation with press reservoir sse 11 Reservoir for OI siis iiiter ettet ba Pete t eaten 13 First Insertion of Cartridge sse 14 Cartridge Replacement ss eee 14 Cleaning the Oil Strainer esse 15 Identification code esee 15 Technical Data gt MHIL 16 DIMENSIONS uiii ioci erir eren eris eo eo paiia ananta PENERE 16 Flow Rate Diagrams ooo eee senem 17 Hydraulic Circuit cens nnion nennen 18 Troubleshooting
30. s as a result of inappropriate opera tion e g if the safety instructions are ignored or resulting from incorrect installa tion of the hydraulically operated lubrica tion pump HTL 201 no claims or legal actions may be taken against the manu facturer 6001a02 Exclusion of Liability The manufacturer of the lubrication pump HTL 201 does not accept any liability for damages caused by tardy replacement of the cartridges lack of lubricant poor lubrication due to air entrapments in the lubricant supply e g after replacement of the cartridge use of lubricants that are inappropriate or only condition ally appropriate for the unit or which are not pumpable inappropriate disposal of used or 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 loss of waranty Regulations for Prevention of Accidents To prevent accidents observe all city state and federal safety regulations of the country in which the product will be used Avoid the operation with unapproved parts insufficient or contaminated lubricants General Safety Instructions Hydraulically operated lubrication pumps model HTL 201 are designed with state of the art technology can be mounted for safe operation Incorrect use may result in bearing damage caused by under or over lubrication Modific
31. t 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 Americas Lincoln Industrial One Lincoln Way Phone 41 314 679 4200 St Louis MO 63120 1578 Fax 41 800 424 5359 USA Home www lincolnindustrial com Europe Africa Asia Lincoln GmbH Heinrich Hertz StraBe 2 8 Phone 49 6227 33 0 69190 Walldorf Fax 449 6227 33 259 Germany E Mail lincoln lincolnindustrial de Asia Australia Pacific Lincoln Industrial 3 Tampines Central 1 Phone 465 6588 0188 Corporation 04 05 Abacus Plaza Fax 65 6588 3438 Singapore 529540 E Mail sales lincolnindustrial com sg DINEN ISO 9001 Copyright 2011 LIU s by GUT
32. tion fitting G s for manual lubrication 6 Cartridge housing 15 Cylinder screws M4 x 12 for bleeding Page 11 of 24 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 39007 B11 Maintenance continuation Operation with press reservoir continuation B MGP101 020b10 u For cartridge 400 g For bulk grease filling Fig 4 4 Adjustment of the follower piston packing Filling Operation with lubricant cartridge 150 310 g without press reservoir If required remove empty cartridge 1 Cutoff cone point of the thread throat of the new car tridge 2 Push follower piston into the cartridge pressing it lightly until grease leaks from the open thread throat 3 Insert cartridge with light pressure into the bore of the HTL housing and hand tighten it 4 Remove trapped air if any see chapter Vent housing Operation with lubricant cartridge 400 g with press reservoir 1 Remove grease reservoir fittings from the HTL adapter 2 Pullback the follower rod together with the follower pis ton by means of the hand lever from the press reservoir to that extent that the nut in the follower rod engages in the notch of the reservoirs closure cap FETT KARTUSCHE y Q REASE CARTRIDGE B 2 B MGP101 020c10 D A QO 8 Fig 4 5 Engaging of the follower rod 3 Usethe han
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