Lincoln industrial ZPU09 User manual

LINCOLN GmbH • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]• Tx 466088
6.5A-18001-A96
Owner Manual
Operating Instructions and Service Parts Lists
Subject to change without notice
Page 1 of 18
High-Pressure Central Lubrication pump
ZPU09/09A
00000148

LINCOLN GmbH • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]• Tx 466088
6.5A-18001-A96
Owner Manual
Operating Instructions and Service Parts Lists
Subject to change without notice
Page 2 of 18
If persons who are charged with work with the pump/lubrication
system do not have a good command of the German language, it
is the user’s responsibility to take the necessary action to make
the Owner Manual, particularly the Operating Instructions, un-
derstandable to these persons.
The Owner Manual must be read and used by all persons who
are charged with work with the pump/lubrication system, e.g.
• Operation, including adjustment, troubleshooting during ope-
ration, elimination of production waste, maintenance, disposal
of process materials
• Maintenance (inspection, repairs)
• Transport
This Owner Manual is intended to familiarize the user with the
pump/lubrication system and to enable him to use its various fea-
tures.
The Operating Instructions contain important information for
safe, correct and economic operation of the pump/lubrication sy-
stem. Their observance will help avoid hazards, reduce repair
costs and downtime, increase the reliability and prolong the ser-
vice life of the pump/lubrication system.
These Operating Instructions must be completed to include the
respective national regulations concerning the prevention of ac-
cidents and protection of the environment.
The Owner Manual must always be available on the site where
the pump/lubrication system is in operation.
Preface to the Owner Manual
1 Safety Instructions..............................................
2 Description...........................................................
2.1 General ..................................................................
2.2 Appropriate Use ....................................................
2.3 Technical Data .......................................................
2.4 Structure ................................................................
2.5 Electrical Equipment..............................................
2.6 Mode of Operation.................................................
3 Erection and Assembly.......................................
3.1 Erection of the Pump.............................................
3.2 Electrical Connection ............................................
Item Page
Table of Contents
4 Operating Instructions........................................
4.1 Commissioning ......................................................
4.2 Maintenance and Repairs .....................................
4.3 Troubleshooting.....................................................
5 Spare Parts List ...................................................
6 Accessories .........................................................
6.1 Pressure Switch ....................................................
6.2 Dimensional Drawing ............................................
6.3 Motor Data sheet...................................................
Preface and Table of Contents
Item Page

LINCOLN GmbH • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]• Tx 466088
6.5A-18001-A96
Owner Manual
Operating Instructions and Service Parts Lists
Subject to change without notice
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The Operating Instructions include general instructions which
must be followed when a pump/pump unit is installed, operated
or serviced. Therefore, it is absolutely necessary for the fitter and
the specialist/user to read the Operating Instructions before a
unit is installed and commissioned. The Operating Instructions
must always be available on the site where the machine/system
is erected.
All general safety instructions contained in this main chapter on
safety must be observed as well as all special safety instructions
given in other main chapters.
Hazard warnings in the Operating Instructions
The notes referring to safety contained in the Operating Instruc-
tions whose failure to observe may result in personal injury are
marked by the following symbol
Safety symbol acc. to DIN 4844-W9
The symbol
Safety symbol acc. to DIN 4844-W8
warns of an electrical hazard.
If ignoring the safety note might result in machine damages and
malfunction, the word
is added.
Warnings directly fixed to the machine must always be observed
and must be kept in completely legible condition.
1 Safety Instructions
Safety Instructions
10013a94
10014a94
CAUTION
Staff Qualification and Training
The staff responsible for operation, maintenance, inspection and
installation must be adequately qualified for these jobs. The user
must properly regulate the field of responsibility and supervision
of the personnel. If the personnel is not in command of the ne-
cessary expertise, they must receive appropriate training and in-
structions.
If necessary, this can be done by the manufacturer/supplier on
behalf of the machine user. Furthermore, the user must ensure
that the contents of the Operating Instructions are fully under-
stood by the personnel.
Hazards resulting from failure to observe the safety instruc-
tions
Failure to heed the safety warnings may result in damage to
equipment and the environment and/or personal injury.
Failure to observe the safety notes may result in the loss of all
claims for damage.
As an example, in the following we list some dangers which may
result from failure to observe the warnings:
• failure of machine/system to fulfill important functions
• failure of specified methods for maintenance and repair
• personal injury due to electrical, mechanical and chemical in-
fluences
• danger to the environment due to leakage of harmful materials
Safety-Conscious Working
The safety instructions given in the Operating Instructions, the
prevailing national regulations for the prevention of accidents and
any internal working and shop regulations and accident preventi-
on measures of the user must be observed.
Safety Instructions for the User/Operator
• If warm or cold machine parts may involve hazards, the custo-
mer must protect them against accidental contact.
• Do not remove protection devices for moving parts while the
machine is in operation
• Leakages of harmful materials must be disposed of so as to
jeopardize neither persons nor the environment. The require-
ments of the law must be satisfied.
• Danger caused by electrical current must be excluded (for de-
tails refer to the applicable specifications of VDE and the local
power supply companies).

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Unauthorized Modification and Spare Parts Production
Alteration and modifications of the machine are only allowed if
approved by the manufacturer. Original spare parts and acces-
sories authorized by the manufacturer ensure safe operation. If
other parts are used, the manufacturer may be released from
liability for the resulting consequences.
Inadmissible Operating Modes
The operational safety of the supplied product is only granted if
the product is operated according to the instructions given in
chapter 1 - General - of the Operating Instructions. The max. ra-
tings listed in the Technical Data sheet must never be exceeded.
Commissioning of the product (pump/pump unit) within the Euro-
pean Union is forbidden until it has been decided that the machi-
ne in question meets the requirements of the EU guidelines.
Safety Instructions for Maintenance, Inspection and Instal-
lation Services
The user must make sure that all maintenance, inspection and
installation work is executed by authorized and qualified experts
who have throroughly read the Operating Instructions
On no account may work be done on the machine while the ma-
chine is in operation. Follow all instructions for shutting down the
machine as described in the Operating Instructions. Decontami-
nate pumps and pump units delivering harmful materials.
Reassemble all safety and protection devices immediately after
completion of the cleaning procedure.
Dispose of material harmful to the environment in accordance
with the applicable official regulations.
Before putting the pump/pump unit into operation, ensure that all
points given in the chapter „Commissioning“ are observed.
Safety Instructions

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2 Description
Description
2.1 General
This Owner Manual only refers to high-pressure central lubricati-
on pumps of the series ZPU 09/09A.
It is intended for the personnel in charge of the installation, ope-
ration and maintenance of the pump.
If faults should occur although the Operating Instructions have
been followed, please contact our Service Department below:
LINCOLN GMBH
Abt. Zentraler Kundendienst
Postfach 1263
D-69183 Walldorf
Tel [phone]
Fax [phone]
2.2 Appropriate Use
The high-pressure oil pump model ZPU 09 is designed for use in
hydrostatic lubrication systems only.
Take care that the max. ratings mentioned in the Technical Data,
particularly the max. operating pressure of 400 bar, ist not excee-
ded.
Any other use is not in accordance with the instructions and will
result in the loss of claims for guarantee or liability .
2.3 Technical Data
Number of outlets 1 (ZPU09)
2 (ZPU09A)
Lubricant output 8 dm³/h (ZPU09)
2x4 dm³ (ZPU09A)
Operating pressure pmax = 400 bar
Drive speed 60 rpm
Direction of rotation of drive optional
Reservoir capacity 8 dm³
Suitable lubricants industrial lubrication
oils with a viscosity of min.
20 to max. 460 mm²/s
acc. to DIN 51519
(other viscosities on
request)
Safety valve fixed to 410 bar
tamper-proof
Drive motor refer to Motor Data Sheet
Sound level < 70 dB(A)
Connection threads pressure line 3/8"BSP
filling line 3/4"BSP
Note: In the case of 60 Hz motors the speed and thus the lubri-
cant output may be less then the theoretical value calculated.

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2.4 Structure
Description
Abb. 2.4.1: Aufbau der Pumpe ZPU 09
The pump ZPU09/09A mainly consists of:
Item Designation
1 pump housing
2 cover
3 high pressure pump element
4 bearing flange with drive
Item Designation
5 safety valve
6 check valve
7 pressure line connection
8 filling connection
Abb. 2.4.2: Aufbau der Pumpe ZPU 09A
1094a95 1093a95
1087a95 1088a95

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2.5 Electrical Equipment
Flanged gear motor: technical data mentioned in enclo-
sed motor data sheet
2.6 Mode of Operation
The pump element operates as a piston pump with 2 pistons ope-
rating in opposite direction which suck in lubricant alternately and
then feed it through the outlet hole to the pressure line.
The pump element is driven by a hollow shaft with eccentric pin
and roller, by which the rotary movement of the driving shaft is
converted into the oscillating movement of the pump pistons.
With this kind of drive, the direction of rotation of the pump shaft
is therefore optional.
The lubricant supplied by the pump element is fed via a check
valve to the pressure line connection (item 7).
A safety valve (item 5)is also connected with the pressure line
connection.
Description

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Description
1001b94 1002b94
Description of Operation of High-Pressure Pump Element
for Pumps ZPU08, ZPU14, ZPU24
The pump element operates as a piston pump with two pistons
operating in opposite direction which suck in lubricant alternate-
ly and feed it through the outlet hole to the pressure line. The
outlet channels of the high-pressure pistons are controlled by a
floating piston.
The pump element is driven by a hollow shaft with eccentric pin
and roller, by which the rotary movement of the driving shaft is
converted into the oscillating movement of the pump pistons
Legend:
1, 2 = delivery piston
3 = floating piston
I = suction hole for delivery piston 1
II = suction hole for delivery piston 2
III = outlet hole (pressure line connection)
Fig. 2.6.1 Upper final position)
The piston begins to move downwards
(Fig. 2.6.3 Lower final position)
The piston begins to move upwards
1003b94 1004a94
(Fig. 2.6.4 discharge stroke downwards)
Delivery piston 2 displaces the floating piston downwards, toge-
ther with the lubricant stored from the preceding suction stroke.
The lubricant is fed into the pressure line.
Delivery piston 1 sucks in lubricant.
The pump element of pump ZPU09A operates in a simular way,
the difference being however that the control piston alternately
closes one of two outlet holes while it opens the other one.To
each delivery piston, one seperate outlet hole is allotted which is
led in the flange to the outside check valve.
(Fig. 2.6.2 discharge stroke upwards)
Delivery piston 1 displaces floating piston 3 upwards, together
with the lubricant stored from the preceding suction stroke.
Lubricant is delivered into the pressure line via the outlet hole
which is now opened.
A vacuum is generated by delivery piston 2 with the result that
lubricant is sucked in after hole II has been opened.

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Erection and Assembly / Operating Instructions
3 Erection and Assembly 4 Operating Instructions
4.1 Commissioning
Connection of the tube lines and pump filling
Connect the pressure line and relief line to the pump by means of
adequate fittings.
• Take care that no dirt or foreign partic-
les enter the pump housing
• Clean the tube lines before connecting
them
• Avoid dirt in the pump area
Then, fill pump with oil
Venting and Putting Into Operation
Open air release cock (item 35 spare parts list) until oil emerges
without air bubbles.
Let pump run about 5 minutes without backpressure.
Then, vent pump housing by opening air release cock.
All system components connected down-
stream of the pump (tube lines, tube fit-
tings, hoses) must be designed for the
max. system pressure.
3.1 Pump Erection
Requirements on the place of installation
• protected from dust and dirt
• safe against atmospheric influences
• enough space for connecting the tube lines and executing the
maintenance work (the required space depends on the pump
size)
• even, solid and vibration-free place of erection
3.2 Electrical Connection
All electrical work should be underta-
ken only by qualified personnel
Electrical connection of the drive motor:
• terminal diagramm in cover of termi-
nal box
• fuse protection in conformity with the
national regulations in force. Nominal
current consumption mentioned in enclosed motor data sheet.
CAUTION

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Operating Instructions
4.2 Maintenance and Repairs
Repair work should be undertaken only
by qualified personnel using original
spare parts
Before executing any repair on the
pump, take care of the following:
1 Switch drive motor off and secure it
against inadvertent restart. Risk of injury by the stirring
paddle
2 Close shut-off valve in pressure line and filling line.
3 Decrease the pressure in the pump and system down to 0
by loosening the pressure connection fitting. Risk of inju-
ry due to lubricant splashing
4 Let the oil flow from the pump housing (closure plug on
the front side of the pump)
Under the condition that the pump only supplies clean oil, it does
not need any particular maintenance. The pump element lies in
the oil which is supplied and it is lubricated automatically.
It is subject to natural wear which depends on the working time
and adjusted pressure.
Maintenance work
• Replacement of the check valve (spare parts list item 24) about
every 100 operating hours. For this, first remove closure plug
item 25.
To ensure service life, the gears of the flanged motors are filled
with oil in the factory.

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Operating Instructions
• Remedy:
• Check oil flow to the pump. Open venting valve and vent
pump housing
• Replace damaged parts
• Disassemble pump element, clean it and check whether for-
eign particles are lodged in the pump element
• Remedy:
• Replace check valve
• Replace pump element
Note: The pump element cannot be repaired since its pistons
are precision-fitted in our factory
• Remedy:
• Check tube lines. Eliminate blockage
4.3 Troubleshooting
Note: The following only describes pump failures. Failures due to
electrical malfunctioning or system malfunction are indicated in the
System Description.
• Fault: pump does not supply the lubricant
• Cause:
• No oil in the system
• Eccentric shaft damaged or defective
• Suction borehole of pump element clogged
• Fault: pump runs, but there is no pressure
• Cause:
• Check valve (item 7) clogged or defective
• Pump element (item 4) damaged or worn
• Fault: oil leaking from the safety valve
• Cause:
• Blockage in the pressure line system
All repairs which are beyond the knowledge of the user’s person-
nel must be executed by Lincoln’s specialists. For this, either send
the defective pump back to the Repair Department of our Walldorf
factory or call a specialist for the repair on site.
Service Address:
LINCOLN GMBH
Customer Service
Postfach 1263
D-69183 Walldorf
Tel [phone]
Fax [phone]

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5 Spare Parts Drawing and Spare Parts List
Spare Parts Drawing and Spare Parts List
Abb 5.1.1: High-Pressure Central Lubrication pump ZPU 09
without driving assemblies
Item Description Quantity Part No. Item Description Quantity Part No.
1092a95
5.1 High-Pressure Central Lubrication pump ZPU09
1 cover 1 314-18595-1
2 hexagon socket head screw 8 201-12018-5
3 sealing ring 8 209-12158-1
4 O-ring 1 219-12227-1
5 casing 1 314-19305-1
6 sealing ring 1 233-13005-6
7 oil level indicator, with item 6 1 233-13005-1
8 O-ring 1 219-12226-5
9 closure plug 2 203-12095-2
10 hexagon socket head screw 4 201-12028-4
11 pump element with item 12 1 505-30405-3
12 O-ring 1 219-13043-7
13 reducing bushing 1 222-12578-9
14 closure plug 1 303-17440-1
15 bearing flange 1 505-30853-1
16 roller 1 405-23544-1
17 eccentric shaft 1 405-20316-2
18 retaining ring 1 211-12165-6
19 sealing ring 1 306-17856-1
20 safety valve 1 624-27092-1
21 sealing ring 1 226-12491-4
22 pump connection 1 226-12491-6
23 hose clamp 2 226-12334-1
24 check valve, with items 26 + 28 1 505-36089-1
25 closure plug 1 203-12077-3
26 sealing ring 1 209-12158-4
27 check valve 1 524-30812-1
28 O-ring 1 219-13043-8
29 hexagon socket head screw 6 201-12018-5
30 closure plug 1 303-19310-1
31 sealing ring 1 209-12464-8
32 GERV6-SG 1/4A LC 1 223-12372-9
33 hose stud 1 405-20319-2
34 plastic hose 1 111-35065-2
35 venting valve (with wrench) 1 233-13003-3
36 reducing T-piece 1 222-12260-2
37 equal nipple 1 222-12257-6
38 protective plug 1 233-13100-6

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Fig.5.2.1: High-Pressure Central Lubrication pump ZPU 09A
1091a95
5.2 High-Pressure Central Lubrication pump ZPU09A
without driving assemblies
Item Description Quantity Part No. Item Description Quantity Part No.
1 cover 1 314-18595-1
2 hexagon socket head screw 8 201-12018-5
3 sealing ring 8 209-12158-1
4 O-ring 1 219-12227-1
5 casing 1 314-19305-1
6 sealing ring 1 233-13005-6
7 oil level indicator, with item 6 1 233-13005-1
8 O-ring 1 219-12226-5
9 closure plug 2 203-12095-2
10 hexagon socket head screw 4 201-12028-4
11 pump element with item 12 1 505-30884-1
12 O-ring 2 219-13043-7
13 check valve 2 505-30447-1
14 bearing flange 1 505-30883-1
15 roller 1 405-23544-1
16 eccentric shaft 1 405-20316-2
17 retaining ring 2 211-12165-6
18 sealing ring 1 306-17856-1
19 safety valve 1 624-27092-1
20 sealing ring 2 226-12491-4
21 pump connection 1 226-12491-6
22 hose clamp 1 226-12334-1
23 T-union 1 223-12563-7
24 hose stud 1 405-20319-2
25 hexagon socket head screw 1 201-12018-5
26 GERV6-SG 1/4 A LC 1 223-12372-9
27 plastic hose 1 111-35065-2
28 venting valve (with wrench) 1 233-13003-3
29 reducing T-piece 6 222-12260-2
30 equal nipple 1 222-12257-6
31 protective plug 1 233-13100-6
Spare Parts Drawing and Spare Parts List

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1095a95
5.2 Driving assemblies for central lubrication pump
ZPU 09/09A
Item Designation Qty. PartNumber
Drive assemblies for central
lubrication pump ZPU 08 (1)
Assembly for drive with gear motor
1 Flanged gear motor 1 245-13575-1
0.37 kW, , 380-415V/50 Hz, 60 rpm
420-480V/60 Hz, 72 rpm
or
flanged gear motor 1 245-13564-1
0.37 kW, 500 V
50 Hz, 60 rpm
2 Tooth lock washer 4 210-12161-8
3 Hexagon head screw 4 200-12007-5
Spare Parts Drawing and Spare Parts List

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1005a94
Appendix
6 Appendix
6.1 Pressure Switch
Adjustment of pressure switch:
Before adjusting the pressure switch, switch off current supply to
lubrication pump.
After loosening counter nut SW 27, re-adjust the spring tension.
On turning set screw SW 24 clockwise, the compression spring
is tensed and the switching pressure is increased. Inverse proce-
dure will result in a pressure decrease.
Scope of delivery:
As illustrated, please indicate the piston diameter when ordering
To be supplied by customer:
Wiring of limit switch to switch cabinet by means of oil-resisting
cable 3 x 1.5 mm²
Pessure range Pressure Compression Part Num.
reducer spring
Piston and Wire DIA
cylinder DIA
160 - 400 bar 6 mm 4.0 mm 623-25461-2
50 - 115 bar 10 mm 4.0 mm 623-25456-2
* 0 - 15 bar 16 mm 3.0 mm 623-25801-2
*Connection thread 1/2" BSP, further types of presure range on
request
Limit switch: 1 NC contact, 1 NO contact

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6.2 Dimensional Drawing
Fig. 6.2.1: Dimensional Drawing ZPU09
Fig. 6.2.1: Dimensional Drawing ZPU09A
1090b95
1096b95
Appendix

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Appendix
Motor Data Sheet
Standard Multi-Range Three-Phase AC Asynchronus Gear Motors
Pump model ZPU09 Units
Motor manufacturer ABM
Motor type G80F/D71B-4
Part-No. 245-13575-1
Frequency f 50 [Hz]
Nominal power P 0.37 [kW]
Nominal speed n1/n2 1370/60 [min
-1
]
Rated torque M 59 [Nm]
Nominal current I
N
1.80 [A] at 220-240 V
1.05 [A] at 380-415 V
Starting current/
ratio I
A
/I
N
3.9 [A]
Power factor cos
j 0.73
Efficiency h 0.72 [% ]
Frame size 71S
Type of construction B5 A1/160
Type of protection IP 55
Insulation class F
Weight ca. 11 [kg]
Flange Æ 160 [mm]
Shaft end Æ 20X50 [mm]
The motor can be connected to the following networks:
220/380 V ± 5%, 50Hz
230/400 V ± 5% and ± 10%, 50Hz
240/415 V ± 5%, 50Hz
265/460 V ± 5%, 60Hz
254/440 V ± 5%, 60Hz
Other voltages available on request.

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Motor Data Sheet
Three-Phase ACAsynchronus Gear Motors 290/500 V (50Hz)
Pump model ZPU 09 Units
Motor
manufacturer ABM
Motor type G80F/D71B-4
Part No. 245-13564-1
Frequency f 50 [Hz]
Nominal power P 0.37 [kW]
Nominal speed n1/n2 1370/60 [min
-1
]
Rated torque M 59 [Nm]
Nominal current I
N
1.45 [A] at 290 V
0.85 [A] at 500V
Starting current/
ratio I
A
/I
N
3.9 [A]
Power factor cos
j 0.73
Efficiency h 0.72 [% ]
Frame size 71 S
Type of construction B5 A1/160
Type of protection IP 55
Insulation class F
Weight ca. 11 [kg]
Flange Æ 160 [mm]
Shaft end Æ 20X50 [mm]
The motor can bei connected to the following network:
290/500 V ± 10%, 50Hz