Lukas Hydraulic Power Pack

Operating instructions
for rescue equipment

Issue 12.2009
175010085 GB
Hydraulic units
(Translation of the original operating instructions)
replaces 03.2009
2
Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 9
4. Labelling of the units 9
5. Functional description 10
5.1 General information 10
5.2 Motor variants 10
5.3 Valve variants 11
5.4 Pumps 12
5.5 Frames 13
5.6 Connection to the rescue equipment 14
5.7 Connection options 14
6. Assembly of coupling systems 15
6.1 Mono-couplings 15
6.2 Direct connection 15
6.3 Quick-disconnect couplings 16
6.4 Adapter for direct connection to mono-coupling valve block 16
7. Connection of the hoses 17
7.1 Coupling the mono-couplings 18
7.2 Coupling the quick-disconnect couplings 19
7.3 Direct connection 20
8. Set-up and start-up 20
8.1 Set-up 21
8.2 Start-up 21
9. Operation 22
9.1 Starting the motors 22
9.2 Stopping the motors 23
9.3 Controlling the valves 24
10. Dismantling the equipment / deactivation following operation 27
11. Maintenance and service 28
11.1 Recommended testing periods 28
11.2 Hydraulic units with combustion engine 29
11.3 Hydraulic units with electric motor 29
3
12. Repairs 30
12.2 Preventive service 31
12.3 Repairs 33
13. Troubleshooting 40
14. Notes 44
4
Wear helmet with face protection
Wear safety gloves

Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specifc hazard
and possible consequences.
Hazard classes 1.
Pictogram
Damage /
injury to
Key word Defnition Consequences
h
u
m
a
n
DANGER! Immediate danger
Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION!
Less dangerous
situation
Minor or slight
injury
d
e
v
i
c
e
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment
5
Product safety 2.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design. Moreover, the operating
instructions are intended to ensure LUKAS products are used safely.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without restriction.
We further recommend that a qualifed instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read through the following safety instructions once again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
The department responsible
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is to
be shut down immediately and
secured!
Wear protective clothing, safety
helmet with visor, safety shoes
and protective gloves.
Inspect the equipment before
and after use for visible defects
or damage.
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work is
absolutely imperative, additional
mechanical supports must be
used.
Inspect all lines, hoses and
screwed connections for leaks
and externally visible damage. If
necessary, repair immediately!
Squirting hydraulic liquids can
result in injuries and fres.
In the event of malfunctions,
immediately shut down the
equipment and secure it. The
malfunction is to be repaired
immediately.
Do not carry out any changes
(additions or conversions) to the
equipment without obtaining the
prior approval of LUKAS.
6
Comply with all the instructions
regarding safety and danger
on the equipment and in the
operating instructions.
All the instructions regarding
safety and danger on the
equipment are to be kept
complete and in a legible
condition.
Please ensure that all safety
covers are present on the
equipment and that they are in
proper and adequate condition.
Any method of operation which
impairs safety and/or stability of
the equipment is prohibited!
Safety devices may never be
deactivated!
The maximum operating
pressure set on the equipment
must not be changed!
Before the equipment is
switched on / started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation of
the equipment.
Comply with all specifed
dates or dates specifed in the
operating instructions pertaining
to regular checks / inspections
of the equipment.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
Only original LUKAS
accessories and spare parts
may be used for repairs.
When working with this
equipment or when transporting
it, ensure that you do not get
caught up in the hose or cable
loops and trip.
The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
equipment.
When working with combustion
engine pumps, never touch
the motor and exhaust system,
since there is a risk of burning.
Motor pumps may not be used
in explosion hazard areas!
Combustion engines must not
be used in enclosed spaces, as
there is a danger of poisoning
and/or asphyxiation!
If fuel for combustion engines
is spilled, this fuel must be
removed completely before
starting the motor.
Filling up during operation of
the combustion engine is strictly
prohibited!
7
Keep combustion engines and
their fuel away from ignition
sources, as otherwise there is
the danger of an explosion.
All damaged electrical
components e.g. scorched
cables, etc. are to be replaced
immediately!
To avoid the danger of fre
when using combustion
engines, ensure suffcient
ventilation and maintain a
safety distance of at least 1 m
(39.4 in.) to the walls and other
screens.
Damage to electrical
components may only be
repaired by a qualifed
electrician in compliance with
all applicable national and
international safety guidelines
and regulations.
Please ensure that the
combustion engine pumps
are always placed on as fat a
surface as possible in order to
prevent fuel from leaking.
When setting up the units, it
must be ensured that they are
not impaired by the infuences
of extreme temperatures.
The equipment is flled with
hydraulic fuid. These hydraulic
fuids can be harmful to your
health if swallowed or if their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic fuids
can also have a negative effect
on biological systems.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired by
the effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Ensure adequate lighting when
you are working.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Always keep these operating
instructions within reach where
the equipment is used.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic fuid and packaging
materials.
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions!
8
WARNI NG / DANGER / CAUTI ON!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter "Proper use"). Any form of use beyond this is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such use.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are covered by the defnition of proper use.
Never work when you are overtired or intoxicated!
9
Proper use 3.
Spare parts and accessories for the rescue equipment can be ordered from your authorised
LUKAS dealer!
WARNING / DANGER / CAUTION!
Always observe the safety notes of these operating instructions with regard to
place of installation and type of installation! The units must not be used in all
atmospheres, since there could be a danger of explosion!
LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment with
hydraulic fuid so that this equipment can be used to rescue victims of road, rail or air traffc
accidents as well as from buildings.
Their use for supplying pressure / fuid to rescue equipment of other manufacturers is
possible, yet requires the technical inspection and approval by LUKAS in each individual
case.
Labelling of the units 4.
P 640 I G D
Coding for
hydraulic units
Type group
Valve variants
Motor variants
Frame variants
HR -
Specifcations
(e.g. HR = with
mounted reels)
Valve variants:
O = Single operation
A = Alternative operation
I = Automatic operation (ISV valve)
S = Simultaneous operation
T = Triple-fow operation (TRIMO)
Motor variants:
E = Electric motor (operation via mains
supply)
B = Electric motor (operation via battery)
G = Gasoline / petrol engine
D = Diesel engine
Frame variants:
(no entry) = Standard frame
D = D frame
U = U frame
S = Frame for rescue sets
F = F frame
-
10
The main components (see sample illustration) of all LUKAS hydraulic units are:
1 Fluid reservoir
2 Motor
3 Pump
4 Frame
5 Connecting block with control valve
6 Carrying handle

As a general principle on all LUKAS hydraulic units, a hydraulic pump is operated with a
motor (combustion engine or electric motor) that feeds the fuid from the reservoir and builds
up the pressure. The distribution of the fuid is controlled by mounted valves.
The mounted frame serves as a simple protective cage and as a mounting base for
accessories that can be ftted. The hydraulic unit can also be carried by the frame or using
carrying handles mounted on it.
Functional description 5.
5.1 General information
5.2 Motor variants
1
2
3
5
6
1
2
3
5
4
1
5
6
For all motor variants, also comply with the separate operating instructions of
each motor manufacturer.
5.2.1 Electrical
These hydraulic units are equipped with an electric motor. The electric motor is driven by
electricity from the mains supply or by electricity produced by generators. In the case of
operation with generators, make sure that voltage fuctuations do not occur, as these have a
direct infuence on the pumping capacity and stability of the hydraulic unit.
The possible operating voltage, the current frequency and the required intensity of current
can be found in the separate instructions for your unit in the chapter entitled "Technical
data".
11
The engines of type Briggs & Stratton have a main switch, which must be actuated for
switching the aggregate on and off. The accelerator cable of these engines does not have to
be readjusted and is fxed in the position . Nevertheless, if it is necessary in exceptional
cases to switch the engine into idle running, the accelerator lever can be lifted over the
adjusting plate and be switched into the position .
5.3 Valve variants
5.2.2 Gasoline / petrol
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
petrol".
(For specifc details, please consult the separate operating instructions of the engine
manufacturer!)
In all cases, the valves are designed as connecting blocks. This block is frmly integrated into
the hydraulic unit. Both hoses (pressure and return) are always connected to the connecting
block. There are various connection blocks with different valve variants available for the
different requirements of operators and the various areas of application.
REMARK:
For certain regions, the selection of the control valves is limited due to applicable
standards and legal regulations.
Bear in mind that only the variants that are offcially approved for your region will
be deployed!
CAUTION!
When operating several pieces of rescue equipment with one unit, ensure that
the usable volume of hydraulic fuid in the reservoir is greater than the maximum
possible operating fuid volume of all connected rescue equipment.
5.3.1 Control valve "single operation"
This variant only enables the connection of one pressure hose and one return hose. Turning
a lever / switch controls the pressure application to the pressure hose, i.e. the pressure on
the pressure hose is switched on or off.
5.3.2 Control valve "alternative operation"
This valve enables the connection of two pressure hoses and two return hoses. Turning a
lever / switch controls the pressure application to the pressure hoses. However, only one
device can be provided with pressure at any one time.
As a general principle, there are two different connection blocks for each connection block
variant. A block is conceived for screwing in mono-couplings directly and for screwing on
hoses. On the mono-coupling variants, an adapter can be used to screw on hoses directly.
On the hose connection variant, the built-in connection nipples can be replaced by quick-
disconnect coupling halves.
It goes without saying that LUKAS can also provide adapter sets to connect mono-couplings
to a hose connection block. These adapter sets consist of a supply and return hose with a
mono-coupling ftted on one end.
5.2.4 Diesel
These hydraulic units are equipped with a combustion engine driven by the fuel "diesel".
(For specifc details, please consult the separate operating instructions of the engine
manufacturer!)
12
5.4 Pumps
Depending on the type, a single-fow, double-fow or triple-fow pump is built into LUKAS
hydraulic units.

Single-fow pump 1 pump capacity

Double-fow pump 2 pump capacities

Triple-fow pump 3 pump capacities
The pumps used are always equipped with two pressure levels for each pump capacity, one
low-pressure and one high-pressure level.
Low-pressure level (ND) = up to 16 MPa*
High-pressure level (HD) = up to 70 MPa*
The changeover from low pressure to high pressure is carried out automatically in the pump.
The maximum pressure is limited by a pressure limiting valve.
For reasons of safety, the pressure set on this valve must not be adjusted
(without direct authorisation from LUKAS)!
5.3.3 Control valve "automatic operation (ISV valve)"
This valve enables the connection of two pressure hoses and two return hoses. The
patented LUKAS ISV valve provides one device at each connecting block with pressure
without a manual switching procedure. Changeover between the two pressure hoses is
automatic. With this control valve, the frst driven and pressure-operated connected device
is always provided with hydraulic fuid. The second connected device, on the other hand, is
automatically disconnected from fuid supply.
5.3.4 Control valve "simultaneous operation"
This valve enables the connection of two pressure hoses and two return hoses. It has two
switching options, each of which controls the pressure application of the pressure hose
that is marked accordingly. This means two devices can be supplied with pressure
simultaneously and independently of one another. Without impairing the work output, it
enables work with two devices simultaneously and independently of one another.
5.3.5 Control valve "triple-fow operation"
This valve enables the connection of three pressure hoses and three return hoses. It has
three switching options, each of which controls the pressure application of the pressure hose
that is marked accordingly. This means three devices can be supplied with pressure
simultaneously and independently of one another. Without impairing the work output, it
enables work with three devices simultaneously and independently of one another.
*) 1 MPa = 10 bar)
13
5.5 Frames
As a general principle, all hydraulic units from the rescue equipment range come with a
frame to make them easier to transport.
5.5.1 Standard frame
The standard frames vary depending on the type of hydraulic unit. They range from simple
handles through to bow-type handles all the way to a frame adapted according to the unit.
It therefore cannot be guaranteed that the entire unit can ft inside the exterior dimensions of
the frame of standard frames.
5.5.2 D frame
As a general principle, the D frame dimensions are 500 mm x 440 mm x 480 mm.
On D frames, all parts of the unit are located within the frame.
In addition, there are mounting possibilities for connection hose reels (one double and two
single hose reels).
The dimensions mean that this frame fts into in the standard fxing devices of rescue service
vehicles.
5.5.3 U frame
The U frame differs from the D frame with regard to outer dimensions and shape. There are
currently no mounting possibilities for hose reels on this frame.
14
5.6 Connection to the rescue equipment
5.7 Connection options
Connection with the rescue equipment is via extension hose pairs or hose reels. These
are available in various lengths, coloured bend protections and with various connection
options.
The individual hoses of a hose pair are to be differentiated by colour to prevent confusion of
the pressure and return hoses.
(For specifc details, please consult the LUKAS range of accessories or contact your
LUKAS dealer).
The connections for the hydraulic hoses are always on the valve block.
In the standard range, only mono-couplings or alternatively direct connections, or quick-
disconnect couplings or alternatively direct connections are envisaged. Depending on the
coupling variant, an autonomous connecting block is ftted on the unit.
In order to be able to use the direct connection as an alternative possible connection, an
adapter or connection nipple (male) must be ftted in the connecting block beforehand.
(Fitting the adapter, see chapter "Assembly of coupling systems")
5.5.4 Frame for rescue sets
The frame for rescue sets is specifcally designed for the motor / engine and all the
components included in a rescue set. In some cases, these frames have additional mounting
options or special attachment parts.
(For specifc information, please contact your authorised LUKAS dealer or LUKAS directly.)
5.5.5 F frames
The F frame is currently the largest frame in the LUKAS range. This frame is deployed if
the size of the motor and mounted parts makes other frame variants too small. The special
shape of this frame enables mounting of connection hose reels (one double and two single
hose reels).
This frame is mainly used for combustion engine units with triple-fow control valves (TRIMO
units).
15
Assembly of coupling systems 6.
6.1 Mono-couplings
6.2 Direct connection
Only female mono-coupling halves are mounted
on the connecting block of the hydraulic unit.
The female coupling is screwed into the valve
block with a tightening torque of M
A
= 40 Nm.
On the connecting block of the hydraulic unit, the connection nipple (male) is screwed into the
valve block with a tightening torque of M
A
= 40 Nm.
Subsequently, suitable locking elements (e.g. locking ball with nut) must be screwed onto the
connection nipples or the hoses must be connected immediately.
16
6.3 Quick-disconnect couplings
6.4 Adapter for direct connection to mono-coupling valve block
On the connecting block of the hydraulic unit, the connection nipples are replaced by quick-
disconnect couplings to enable connection of hoses equipped with this coupling system.
First of all, remove the connection nipples and then screw in the quick-disconnect couplings.
The return hose connection (marked in blue) must always be equipped with a female
quick-disconnect coupling. Both the female quick-disconnect couplings and the male quick-
disconnect couplings are screwed into the valve block with a tightening torque of M
A
=
40 Nm. To conclude, quick-disconnect couplings must be sealed with matching dust
protection caps.
Connection nipples and adapters must be mounted on the connecting block of the hydraulic
unit so that the hoses can be screwed onto them directly.
To achieve this, frst of all remove the mono-couplings and locking screws of the return
connections, then screw in the connection nipples and adapters.
The connection nipples and adapters are screwed into the valve block with a tightening
torque of M
A
= 40 Nm.
To conclude, suitable locking elements (e.g. locking ball with nut) must be screwed onto the
connection nipples or the hoses must be connected immediately.
17
CAUTION!
When connecting the hose assemblies, always ensure that the connection
components are not soiled; clean beforehand if necessary!
REMARK:
The devices can be equipped with different coupling systems. They usually
only differ with regard to the article number and not the designation.
It goes without saying that the coupling systems can also be re-equipped at a
later time.
The coupling system for the factory status of the equipment can be found in the
separate instructions for your unit in the chapter entitled "Technical data".
Before connecting equipment, make sure that all the components
used are suitable for the maximum operating pressure of the
hydraulic unit! In cases of doubt, you must consult LUKAS
directly before connecting the equipment!
Connection of the hoses 7.
REMARK:
Before you want to connect hoses to and disconnect hoses from the hydraulic
unit as well as to couple and uncouple hoses with quick-disconnect couplings,
ensure that the actuating valves of the pump unit have been set at static pressure
or that the unit has been switched off or, in the case of electric pumps, has been
disconnected from the mains!
18
7.1 Coupling the mono-couplings
The hydraulic hoses are connected without the risk of confusion via mono-coupling halves
(male and female) to the hydraulic pump.
Mono- c oupl i ng
halve (male)
Mono- coupl i ng
halve (female)
Dust protection caps
Before coupling, remove dust protection caps, then connect male and female, and turn
the locking sleeve of the female to direction "1" until the locking sleeve locks into place.
The connection is now in place and secure. Decouple by turning the locking sleeve to
direction "0".
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
At low ambient temperatures and if you are using extension hoses / hose reels,
we recommend connecting the coupling halves at static pressure, as otherwise
coupling can require the application of a great deal of force.
To protect against dust, the accompanying dust protection caps must be replaced.
The mono-couplings must not be screwed off the hoses and / or the hoses must
not be swapped!
19
The equipment is connected to the hydraulic pump via quick-disconnect coupling halves
(male and female).
Before coupling, remove the dust protection caps, then pull back and hold the locking sleeve
of the female coupling (position X). Connect the nipple and female coupling and let go of the
locking sleeve. To conclude, turn the locking sleeve into position Y. The connection is now in
place and secure. Uncouple in reverse order.
Some quick-disconnect couplings have special functions. Therefore it is not
permitted to screw them off the hoses or to swap them!
X
Y
To protect against dust, the accompanying dust protection caps must be replaced.
REMARK:
Coupling of the devices is only possible when the hoses are depressurised.
7.2 Coupling the quick-disconnect couplings
CAUTION!
Always couple the return hose frst and then the supply hose!
On disconnecting, you should always disconnect the supply line frst and then
the return pipe!
20
Set-up and start-up 8.
7.3 Direct connection
The hydraulic hoses are screw-connected to the connecting block of the hydraulic unit.
Screw-in sleeves or adapters are mounted in the valve block. The hoses are secured directly
onto these screw-in sleeves or adapters by means of union nuts. To do so, you must frst
remove the dust protection caps or locking screws and the steel balls underneath, then ft
the corresponding hydraulic hose and use the union nut of the hose to screw it frmly to the
screw-in sleeve or adapter. Please observe the torque of 35 Nm.
CAUTION!
Before commissioning the 620, the locking screw of the hydraulic fuid reservoir
must be replaced by the supplied flling screw with venting function. The locking
screw only serves the purpose of securing the hydraulic reservoir during
transportation and is to be stored in line with accepted principles.
REMARK:
In order to be able to mount the hoses directly onto the connecting block, adapters
or connection nipples have to be screwed into the valve block beforehand.
CAUTION!
Always connect the return hose frst and then the supply hose!
21
8.1 Set-up
8.2 Start-up
Combustion engine units and most electrical units must not be used in a
potentially explosive situation (danger of the formation of sparks). Units with
combustion engines must not be used in enclosed spaces, as there is a danger
of poisoning and/or asphyxiation!
The unit is to be set up in a suitable location (safe location / fat surface / suffcient distance
from vehicles, loads, sources of ignition, etc.).
LUKAS units work perfectly at an angle of up to 30. However, in order to guarantee maximum
safety and fuid withdrawal, they should be operated in as horizontal a position as possible.
Please proceed as follows:
1. First of all, check the hydraulic fuid level of the unit.
Depending on the unit type, the fuid level is indicated at
a fuid inspection glass (maximum = centre of inspection
glass; fuid must be topped up if the fuid level is no
longer visible in the inspection glass) or by a fuid dipstick
(usually ftted to a fuid flling screw). If necessary, you
should top up the fuid to the maximum level.
2. Now connect the mains plug of the hydraulic units with electric motor to the power supply
(exception: units for accumulator operation).
3. Then vent the hydraulic unit. Set all levers of the distributor valve to circulation at static
pressure (see chapter "Valve variants"). The actual venting is carried out in the units in a
different manner, depending on the drive motor:
a) Gasoline / petrol engine:
- Remove plug connector from the spark plug.
- Slowly turn the starter rope several times.
For a motor with electric starter, activate the starter several times.
- Then replace the plug connector.
b) Diesel engine:
- Slowly turn the starter rope several times in such a way that the engine
does not start.
c) Electric motor (power and accumulator operation):
- Turn the motor on and after nearly 10 seconds off again, do this a few times.
(Before switching back on, the motor must be at a standstill!)
This procedure means that the pump can slowly extract and be well vented. The hydraulic
fuid reservoir is equipped with automatic venting, which means no further venting
measures are required.
4. Check the level of the fuid in the reservoir once more. If necessary, top up the fuid.
5. To conclude, you can now connect the extension hoses and/or hose reels (unless already
connected to the unit) and/or couple the rescue equipment.
MAXIMUM
MINIMUM
MAXIMUM MINIMUM
22
Operation 9.
CAUTION!
As a general principle, before starting up the motor, the hydraulic unit is to
be switched to circulation at static pressure (i.e. the outlet valves are to be
opened, for example). Only in this way is it possible to start the unit without a
hydraulic load.
9.1.1 Gasoline / petrol and diesel engines
Before starting the combustion engines, check that the fuel tank is full and that the engine oil
level is within the permitted tolerances. If necessary, top up the relevant fuid.
Flow chart for starting Briggs & Stratton motors, unit type 640:
1. Open gasoline / petrol tap and switch the main switch
to position '1' (ON).
2. Move the lever from switch position A to switch
position C, if not fxed in position C.
3. Pull the starter rope or activate the E starter
Lever at top
Lever at bottom
E F
G H
K J
9.1 Starting the motors
Please consult the separate operating instructions of the motor manufacturer for the precise
procedure for starting the combustion engine!
Flow chart for starting Intek motors, unit type 640:
1. Open gasoline / petrol tap
2. Move top lever from switching position E to switching
position F
3. Move bottom lever (choke) from switching position G
to switching position H
4. Pull the starter rope or activate the E starter
5. When the motor is running, switch bottom lever back
to switching position G.
Flow chart for starting Honda motors, unit type 620:
1. Open gasoline / petrol tap
2. Switch the ON/OFF switch to ON.
3. Move lever from switching position J to switching
position K (choke)
4. Pull starter rope
5. When the motor is running, switch lever back to
switching position J
A
C
23
An electric starter is available from the LUKAS range of accessories for some units.
(For specifc details, please consult the LUKAS range of accessories or contact your LUKAS
dealer).
On these units, after checking the fuid levels, proceed as follows:
1. Switch to "START ENGINE"
2. Turn the ignition key clockwise.
Charge the accumulator of the electric starter:
1. Switch to "CHARGE BATTERY"
2. Connect the supplied charger to the mounted socket.
10.1.2 Electric motors
Before starting the electric motors, check that all electrical connections and cables are in
proper order. First of all, connect the power cable (for motors with power supply) to the
supply socket.
The motor is started by turning the ON/OFF switch to the ON position.
CAUTION!
Electric motors need a brief, very high starting current. When using a generator,
you should therefore check to see that it can also supply the relevant current
strength.
The current supply has to be fused with min. 25 A (triple-fow operation
min. 30 A)
9.2 Stopping the motors
9.2.1 Gasoline / petrol and diesel engines
The gasoline / petrol and diesel engines stop automatically when the fuel tank is empty.
Should they stop moving beforehand, the following procedure is required:
Flow chart for stopping Briggs & Stratton motors, unit type 640:
1. Switch the main switch to position '0' (OFF).
(The throttle lever has not to be switched back to
position A!)
2. When the engine has come to a standstill, close the
fuel tap.
Flow chart for stopping Intek motors, unit type 640:
1. Move the top lever from switching position F to
switching position E
fuel tap.
Lever at top
Lever at bottom
E F
G H
A
C
24
9.3 Controlling the valves
Flow chart for stopping Honda motors, unit type 620:
1. Set the ON / OFF switch to the OFF position.
fuel tap.
Please consult the separate operating instructions of the motor manufacturer for the precise
procedure for stopping combustion engines!
WARNING / CAUTION!
Never touch the hot motor / engine parts: this could result in severe burns!
9.2.2 Electric motors
The movements of the electric motors are stopped by changing the ON/OFF switch to the
OFF position. This also stops the pumping output of the connected hydraulic pump.
For valves which can be connected to several rescue devices, you must ensure
all unnecessary connections are closed with steel fasteners (supplied with the
valve blocks).
9.3.1 Control valve "single operation"
A lever is ftted on this valve. The pressure application of the pressure hose is controlled by
turning a lever.
There are 2 switching stages:
0 = circulation at static pressure (no pressure supplied to the hydraulic hose)
1 = pressure supply to the pressure hose
9.3.2 Control valve "alternative operation"
A lever is ftted on this valve. The pressure application of the pressure hoses is controlled
by turning a lever.
There are 3 switching stages:
A = pressure supply to the pressure hose 1
B = pressure supply to the pressure hose 2
C = pressure relief of both pressure hoses 1 and 2
CAUTION!
As a general principle, before starting up the motor, the hydraulic unit is to
be switched to circulation at static pressure (i.e. the outlet valves are to be
opened, for example). Only in this way is it possible to start the unit without a
hydraulic load.
25
9.3.3 Control valve "automatic operation (ISV valve)"
There is no direct control option for this valve, since the pressure application is controlled
automatically. Nonetheless, the unit also has 2 levers or switches. The top lever controls
whether or not one device (switching position "A") or two devices (switching position A + B)
should be operated. The side switch is to control the outlet valve, which means that in switch
position "0" the unit is switched to circulation at static pressure.
Control lever for
switch positions
Control switch / lever
for the outlet valve
Special feature for the operation of control valves "automatic operation (ISV valve)":
Case 1: Two hose pairs and two rescue devices connected:
As a rule, two hose pairs are connected to the valve. Changeover between the two connected
rescue devices is automatic.
Switch the control lever for switch positions to position "A+B".
To supply the connected rescue equipment with hydraulic fuid, the control lever for the outlet
valve must be switched to position "1". To return the valve to circulation at static pressure,
the control lever for the outlet valve must be switched to position "0".
Case 2: One hose pair and one rescue device are connected (at connection A):
If only one hose pair is connected at the valve, the following instructions are important:
1. The valve connections where no hoses are connected, must be sealed by means of
special locking screws, for example, in such a way that no hydraulic fuid can escape on
pressure application.
2. The control lever for switch positions must be in position "A".
3. The hydraulic fuid supply of the connected rescue equipment and switching to circulation
at static pressure take place by switching the control lever for the outlet valve. ("1" = fuid
supply; "0" = circulation at static pressure)
REMARK:
Single-device operation is only possible at connection A.
26
9.3.4 Control valve "simultaneous operation"
Two levers are ftted on this valve. Each lever is assigned to one pressure port. The pressure
application of the relevant pressure hose is controlled by turning the relevant lever.
There are 2 switching stages for each lever:
9.3.5 Control valve "triple-fow operation"
Three levers are ftted on this valve. Each lever is assigned to one pressure port. The pressure
application of the relevant pressure hose is controlled by turning the relevant lever.
There are 2 switching stages for each lever:
Case 3: Two hose pairs and one rescue device are connected (at connection A):
If two hose pairs are connected and there is only one rescue device at the hose pair of
connection "A", the following instructions are important:
1. The control lever for switch positions must be in position "A".
2. The hydraulic fuid supply of the connected rescue equipment and switching to circulation
at static pressure take place by switching the control lever for the outlet valve. ("1" = fuid
supply; "0" = circulation at static pressure)
Case 4: Two hose pairs (with quick-disconnect couplings) and one rescue device are
connected (at connection B):
If two hose pairs are connected and a rescue device is only connected at the hose pair of
connection "B", the device works neither in switch position "A" nor in switch position "A+B".
The second hose pair at connection A without a connected rescue device indicates to the
valve that a device is connected at connection A that has to be supplied with maximum
operating pressure. This switches off connection B, which is no longer supplied with hydraulic
fuid.
To exclude this possibility, you should either connect a second rescue device or join the
supply and return hoses of the connection that is not used (short-circuiting).
Case 5: Two hose pairs (with mono-couplings) and one rescue device connected (at
connection B):
If two hose pairs are connected and a rescue device is only connected at the hose pair
of connection "B", the device only works in switch position "A+B". This is made possible
by the female mono-coupling halve, which enables an internal fuid circulation when not
connected.
27
Once work has been completed, all connected equipment is to be reset to its base position
before the unit is shut down. You can now stop the motor of the unit / switch it off and, if using
an electric motor (without accumulator), disconnect it from the mains supply.
Mono-couplings:
If the connected hose assemblies have to be dismantled during shut-down, decouple as
described in chapter "Coupling the mono-couplings". Ensure that you replace the dust
protection caps onto the mono-coupling halves.
Clean heavy soiling caused during use of the hydraulic unit before storage.
Quick-disconnect couplings:
If the connected hose assemblies have to be dismantled during shut-down, decouple as
described in chapter "Coupling the quick-disconnect couplings". Ensure that you replace the
dust protection caps onto the mono-coupling halves.
Clean heavy soiling caused during use of the hydraulic unit before storage.
Direct connection:
This connection should only be unscrewed when it is absolutely necessary, e. g. when you
have a longer storage time, when decommissioning, for maintenance tasks, etc.
If the connected hose assemblies have to be dismantled during shut-down, frst of all
disconnect the pressure hose and then the return hose. Ensure that you replace the dust
protection caps onto the screw-in sleeves and onto the hoses. Clean heavy soiling caused
during use of the hydraulic unit before storage.
If the equipment is to be stored for a longer period of time, the exterior is to be cleaned
completely and the mechanical moving parts are to be lubricated. If storing a unit with
combustion engine, you should also remove the fuel from the fuel tank.
Avoid storing the hydraulic units in a damp environment.
Please observe the regulations in the chapter entitled "Safety regulations for hoses".
Dismantling the equipment / deactivation 10.
following operation
CAUTION!
Depending on the size and the weight of the hydraulic unit, it should be transported
to the storage site by one person or several people.
28
Maintenance and service 11.
The hydraulic units are subject to very high mechanical loads. A visual inspection is therefore
to be carried out after every use: however, at least one visual inspection is to be carried out
every six months.
This reveals wear and tear in good time; punctual replacement of these wearing parts
prevents damage to the equipment. Also check regularly that all the securing screws are
tightened (if applicable, comply with prescribed tightening torques)
Every 3 years or when there might be doubts regarding the safety or reliability of the unit, an
additional function check is to be carried out (in this connection, comply with the applicable
national and international regulations with regard to the maintenance intervals of rescue
equipment). In the Federal Republic of Germany, regular safety inspections according to the
regulations of the Gesetzliche Unfallversicherung (GUV; 'statutory accident insurance') are
mandatory.
CAUTION!
Clean off any dirt before checking the equipment!
In order to carry out maintenance and repair work, tools appropriate for the job
and personal protection equipment obligatory (including protective covers).
LUKAS offers a suitable test kit for the function test of the hydraulic units.
(For specifc details, please consult the LUKAS range of accessories or contact your
LUKAS dealer).
11.1 Recommended testing periods
11.1.1 Visual inspection
11.1.2 Function test
A visual inspection must be made after each use / latest once a year.
Operating time per day Function test
up to 1 hour once per year
up to 8 hours once per 3 months
up to 24 hours once per month
Beyond these testing periods, a function test should be accomplished, if the aggregate
makes suspicious noises, or there is a reasonable suspicion of an internal damage of the
aggregate.
If the noises or suspicious factors named above should occur several times during one
month or the hydraulic unit does not reach the nominal pressure (75% of the maximum
pressure) during the functional test, you will have to contact the LUKAS customer service
immediately. You will fnd the contact information in the chapter 'Troubleshooting'.
29
Visual inspection
Hydraulic units
Check that all hydraulic connections are tightened,
General tightness, no leakage (the hot oils do not have any infuence on the function)
Is there any damage apparent on the motor, valve blocks or on the casing?
Existence and stability of carrying frame
Are type plate, all activation plates, signs, identifcation marks and warning labels are
present and legible?
Are all covers (e.g. protective roof, exhaust cover) present and undamaged?
Are all liquid levels within the specifed tolerances?
Are the starters in proper working order and undamaged?
Couplings must be easy to couple
Dust protection caps must be available
All necessary accessories (such as spark plugs, plug socket and fuel canister must be
present.
Hoses (see also "Safety regulations for hydraulic hoses")
Visual check for visible damage
Check for leaks.
Function test
No suspicious noises.
Test for maximum load.
(Recommendation: use the LUKAS test kit, including testing instructions, for the function
test).
11.2 Hydraulic units with combustion engine
11.3 Hydraulic units with electric motor
Visual inspection
Hydraulic units
Check that all hydraulic connections are tightened
General tightness, no leakage (the hot oils do not have any infuence on the function)
Is there any damage apparent on the motor, valve blocks or on the casing?
Existence and stability of carrying frame
Are the type plate, all activation plates, signs, identifcation marks and warning labels
present and legible?
Are all covers (e.g. protective roof, fan cover) present and undamaged?
Are all liquid levels within the specifed tolerances?
ON/OFF switch in proper working order, undamaged
Couplings must be easy to couple
Dust protection caps must be available
All electrical attachments (such as cables and plugs) must be present and undamaged
Hoses (see also "Safety regulations for hydraulic hoses")
Visual check for visible damage
Check for leaks
30
REMARK:
Please always return the guarantee registration card to LUKAS Hydraulik GmbH.
Only then are you entitled to the extended guarantee.
CAUTION!
Since LUKAS hydraulic units are designed for top performance, only those
components in the spare parts lists of the relevant unit may be replaced.
Further components in the unit may only be replaced if:
- You have participated in appropriate LUKAS service training,
- You have the explicit permission of the LUKAS customer service (on request,
check for granting permission. Check is necessary in each individual case!)
REMARK:
Do not carry out any repairs without the relevant LUKAS spare parts list, since
this contains the necessary torques for screws and / or important additional
information.
CAUTION!
Attention must be paid to ensuring that no fuel can escape from units with
combustion engines during repair work!
Repairs 12.
Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturer and by authorised LUKAS dealers.
Only LUKAS spare parts may be used to replace all components (see spare parts list) since
special tools, assembly instructions, safety aspects, inspections might have to complied with
(see also chapter "Maintenance and service).
During assembly, ensure the complete cleanliness of all components, since dirt can
damage the rescue equipment!
Protective clothing must be worn when repairs are being carried out, since
parts of the units can also be pressurised in an idle state.
Function test
No suspicious noises
Test for maximum load
test).
REMARK:
Before you use couplings from a different company, you must contact LUKAS or
an authorised dealer.
31
12.2 Preventive service
12.2.1 Care regulations
The exterior of the equipment is to be cleaned from time to time in order to protect it from
external corrosion. Oil is to be applied to the metallic surfaces.
12.2.2 Function and load test
If there is any doubt regarding the safety or reliability of the equipment, a function and load
test must also be performed.
LUKAS offers appropriate test equipment.
12.2.3 Replacing the hydraulic fuid
- After approx. 200 deployments, but after three years at the latest, replace the hydraulic
fuid
- The fuid should be replaced when it is warmed up.
- The motor must be switched off!
- The old hydraulic fuid must be disposed of properly.
Procedure:
1. Place the collection basin underneath the drain plug of the unit.
2. Undo the venting and drain plug of the unit and let the fuid fow into the collection basin.
This enables easy cleaning of the hydraulic unit.
32
4. Remove the reservoir and the seal below it.
5. Free the entire reservoir of dirt using a smooth cloth.
6. When ftting the reservoir, replace the reservoir seal and tighten the fastening screws
(tightening torque, see spare parts list or separate instructions for your unit in the chapter
entitled "Technical data".).
7. Also replace the seal ring of the drain plug and ft it as specifed in the spare parts list.
8. Add the new hydraulic fuid to the reservoir through the flling plug.
9. Finally, the unit must be vented as described in the chapter entitled "Start-up"
3. The fastening screws of the hydraulic fuid reservoir must then be loosened.
33
12.3 Repairs
When carrying out permitted repairs, please observe the relevant spare parts lists with the
remarks and drawings they contain.
Should there be any uncertainties regarding the repairs, please contact your authorised
LUKAS dealer or LUKAS Customer Service.
CAUTION!
Valve blocks and motors / engines may only be replaced by qualifed personnel
(e.g. equipment supervisor) taking account of all applicable standards, regulations
and laws.
12.3.1 Replacing the handle / frame
Replace the handles or frame if they are severely deformed or broken. To replace the frame,
undo the fastening screws of the handle or frame and replace it with a new one. Tighten
the fastening screws. Please consult the appropriate spare parts lists for any torques and
additional assembly instructions.
34
12.3.2 Mono-couplings
The mono-couplings on the connection hoses on the equipment must be replaced in the
event of:
- external damage
- the locking device not working
- hydraulic fuid continually leaking in a coupled/uncoupled state.

Never repair couplings: they are to be replaced by original LUKAS parts!
Procedure when mounted on hoses:
1. Remove the cover from the couplings.
2. Loosen the union nuts of the hose assembly and remove the coupling.
3. Position the new coupling and tighten the union nuts of the hose assemblies
with a torque of M
A
= 40 Nm and push the cover of the couplings back on.
Procedure when mounted into the valve block:
1. Remove the coupling from the valve block.
2. Position the new coupling and tighten it with a torque of M
A
= 40 Nm.
CAUTION!
As the case may be, make sure that port 'T' or 'T1' of the unit is always connected
to port 'T' of the mono-coupling.
35
12.3.5 Replacing hoses
Replace hoses if they are leaky or defective, and if they are older than 10 years. To replace
the hoses, undo the union nuts of the hose connections, remove the hose to be replaced
and replace it with a new hose. Tighten the union nut during the assembly with a torque of
M
A
= 40 Nm.
REMARK when using mono-couplings:
If you want to replace the hoses, you have to dismantle the mono-couplings
(if mounted).
CAUTION (with mono-coupling-system)!
As the case may be, make sure that port 'T' or 'T1' of the unit is always connected
to port 'T' of the mono-coupling.
12.3.3 Quick-disconnect couplings
The quick-disconnect couplings must be replaced in the event of:
- external damage
- the locking device not working

Procedure when mounted on hoses:
1. Loosen the union nut of the hose assembly and remove the coupling.
2. Position the new coupling and tighten the union nut of the hose assemblies
with a torque of M
A
= 35 Nm.
Procedure when mounted into the valve block:
1. Remove the coupling from the valve block.
2. Position the new coupling and tighten it with a torque of M
A
= 40 Nm.
12.3.4 Direct connection
The screw-in sleeves must be replaced in the event of:
- external damage
- hydraulic fuid continually leaking in connected / unconnected state.
Procedure:
1. Remove the screw-in sleeve from the valve block.
2. Position the new screw-in sleeve and tighten it with a torque of M
A
= 40 Nm.
36
CAUTION with (quick-disconnect-system)!
As the case may be, make sure that reservoir port 'T' or 'T1' of the unit is always
equipped with a female quick-disconnect coupling.
On the other hand, the supply ports must be equipped with a male quick-
disconnect coupling.
12.3.6 Replacing the valve blocks
Replace the valve blocks if they are leaky or defective and direct repair of the valve block by
a dealer or LUKAS is no longer possible. The valve block may only be replaced when the
hydraulic unit is switched off. Electric motors must be disconnected from the power supply.
Replacing the valve blocks of the 640 units:
1. Disconnect all hoses from the valve block.
2. Loosen the fastening screws of the hydraulic
fuid reservoir and remove the fuid fller
caps.
3. Remove the hydraulic fuid reservoir.
Please ensure that the hydraulic fuid does not
become contaminated, or replace the hydraulic fuid.
4. Loosen the union nut on the piping of the
valve block and the fastening screws of the
valve block.
5. Remove this and the seal underneath it.
6. Remove the connection nipple for the piping and the
return pipe from the valve block.
37
7. Clean the fastening point and the connection nipple for the piping using a non-fbrous
cloth.
8. Screw the connection nipple for the piping and the return pipe into the valve block and
tighten.
9. Apply seal using sealant.
10. Place a new seal on the fastening point and bolt the new valve block to the unit once
again.
Please consult the spare parts lists for the necessary torques. If no torques are specifed,
the screws are to be tightened in such a way that no leakage and overload of the screwed
connections can occur.
11. Reassemble the hydraulic fuid reservoir. (If necessary, replace the reservoir seal).
Please consult the spare parts lists for the necessary torques.
12. Vent the unit once the repairs are complete.
Replacing the valve blocks of the 620 units:
1. Disconnect all hoses from the valve block.
2. Loosen the fastening screw of the valve block.
CAUTION! Do not loosen the fastening screw of
the connection fange!
3. Remove the valve block.
4. Position the new O-rings at the correct points of the
connection fange.
Observe the relevant spare parts list.
38
5. Position the new valve block on the connection fange, making sure you do not move or
damage the O-rings.
6. Now screw on the fastening screws of the valve block and tighten.
Please consult the spare parts lists for the necessary torques.
7. Vent the unit once the repairs are complete.
12.3.7 Replacing the engines / motors
Replace the engines / motors if they are defective and direct repair of the valve block by a
dealer or the manufacturer is no longer possible. The engine / motor may only be replaced
with the hydraulic motor switched off. Electric motors must be disconnected from the power
supply.
Engines / motors may only be replaced as a complete component. Empty the fuel tanks of
combustion engines beforehand and make sure that no engine oil escapes when you are
removing the engine.
Procedure for replacing the engine / motor:
1. Loosen the fastening screws of the engine / motor.
Observe the relevant spare parts list.
2. Pull the engine / motor off. Please ensure that you do not
damage the engine / motor shaft mount.
3. Equip the shaft of the new engine / motor with an appropriate
adjusting key (provided it is not already in place).
4. Grease the shaft of the new engine / motor and push the
shaft of the new engine / motor into the engine / motor shaft
mount.
Ensure that the adjusting key of the engine / motor shaft is
inserted into the correct guide of the engine / motor shaft
mount.
5. Assemble the engine / motor using fastening screws and
tighten.
Please consult the spare parts list for the necessary
torques.
6. For combustion engine pumps, top up the necessary liquid levels (e.g. engine oil, fuel).
For electric motor pumps, connect the necessary electrical cables.
39
7. Perform a function test with the hydraulic unit (as described in the chapter entitled
"Maintenance and service").
test).
12.3.8 Labels
All damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.
Procedure:
1. Remove damaged and/or illegible labels.
2. Clean the surfaces using acetone.
3. Attach new labels.
Make sure that the labels are attached in the right position. If you are no longer sure about
this, contact your authorised LUKAS dealer or LUKAS directly.
40
Troubleshooting 13.
In the case of defects which directly affect the motor / engine, please consult the separate
operating instructions of the motor / engine manufacturer.
Trouble Cause Solution
Electric motor does not
start following activation of
the switch
Power cable not connected Connect power cable
correctly
Battery fat Charge battery
Electric motor defective or
overloaded due to another
defect in the unit
Shut down immediately
and have repaired by
authorised dealer, motor
/ engine manufacturer or
directly by LUKAS
Combustion engine will not
start
Fuel tank empty Top up fuel
Electric starter battery fat Charge electric starter
battery
Fuel tap not open Open the fuel tap
Starting switch is not at
ON
Set starting switch to ON
Lever not set to choke Set lever to choke
Combustion engine
defective or overloaded
due to another defect in
the unit
Have repaired by
authorised dealer, motor
/ engine manufacturer or
directly by LUKAS
Too low ambient
temperature
For the solution, consult
the separate operating
instructions of the motor /
engine manufacturer.
The motor / engine is
running, but the connected
rescue equipment is not
moving / moving very
slowly upon activation of
the valve.
Hose assembly not
connected properly or is
damaged
Inspect the connection of
the hose assembly and, if
necessary, reconnect
Valve in the connecting
block not switched for
pressure application in the
supply line.
Switch valve in the
connecting block for
pressure application in the
supply line.
Connecting block defective Replace connecting block
Have repaired by
authorised dealer or
directly by LUKAS
Defective pump unit Have repaired by
directly by LUKAS
Mono-coupling (female)
defective
Replace mono-coupling
(female)
41
The connected rescue
equipment does not move
on activation of the valve,
or moves only very slowly
or unevenly.
Air in the hydraulic supply Vent the hydraulic system
Pressure relief on the unit
is still active (circulation at
static pressure)
Check the switching
positions of the valve
lever(s) and, if necessary,
reset (as far as the fnal
position)
For the ISV valve: Have
repaired by authorised
dealer or directly by
LUKAS
Connecting block defective Replace connecting block
Have repaired by
directly by LUKAS
Defective pump unit Have repaired by
directly by LUKAS
Mono-coupling (female)
defective
Replace mono-coupling
(female)
Connected rescue device
does not reach its fnal
position
Insuffcient fuid in the
hydraulic reservoir
Top up hydraulic fuid to
the maximum flling level
Caution! Before
topping up the rescue
equipment, return to the
base position!
Usable hydraulic fuid
volume of the unit is
insuffcient
Use a different rescue
device with a usable
quantity below the
maximum usable quantity
of the unit
does not reach its specifc
performance data
Maximum permitted
operating pressure of the
pump is not reached
Have the pressure limiting
valve reset or repaired
by authorised dealer or
directly by LUKAS
Pump or connecting block
defective
Have repaired by
directly by LUKAS
42
Fluid leaks from the
hydraulic fuid reservoir
(especially from the fller
screw)
Return of the hydraulic
fuid from the rescue
device exceeds the
reservoirs maximum
quantity when flled.
Reduce the level in the
hydraulic fuid reservoir to
the mark on the dipstick or
inspection glass
Defective seal Have repaired by
directly by LUKAS
Leaking fuid between
engine and fange bearing
Radial shaft seal on the
drive shaft is defective
Have repaired by
directly by LUKAS
Hydraulic fuid milky and
cloudy
Water / condensation in
the system
Immediately replace
hydraulic fuid
With mono-coupling-
system: hose assembly
cannot be coupled
Pressure too high (e.g.
caused by excessive
ambient temperature)
Switch valve block to
circulation at static
pressure
LUKAS
Coupling defective Coupling needs to be
replaced immediately
With mono-coupling-
system: It is frequently not
possible to couple hose
assemblies
Hydraulic fuid not adapted
to the application situation
Hydraulic fuid must be
replaced (see chapter
Recommended hydraulic
fuids)
With quick-disconnect
coupling system: hose
assembly cannot be
coupled
Pressurised Switch valve block to
circulation at static
pressure
LUKAS
With mono-coupling-
system: Leak in the
couplings
43
If it is not possible to rectify the malfunctions, inform an authorised LUKAS dealer or the
LUKAS Customer Service department immediately!
The address for the LUKAS Customer Service department is:
LUKAS Hydraulik GmbH
Weinstrae 39, D-91058 Erlangen
Postfach 2560, D-91013 Erlangen
Tel.: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
REMARK:
Before shipping units of the type P620x, the locking screw for transport protection
must be bolted onto the unit once again. (Reverse order as shown in the chapter
"Set-up and start-up").
coupling system: Leak in
the coupling (male)
Safety valve reacted After pressure release,
there is no more leakage.
Coupling (male) defective Coupling (male) needs to
be replaced immediately
coupling system: Leak in
the coupling (female)
Female coupling defective Female coupling needs to
be replaced immediately
Hydraulic fuid leak on the
hoses or the connections
Leak, possible damage Replace hoses
Damage on the surface of
the hydraulic hoses
Mechanical damage or
contact with aggressive
agents
Replace hoses
44
Notes 14.
45
46
47
Tel.: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
e-mail: lukas.info@idexcorp.com
Made in GERMANY
Copyright 2010 LUKAS Hydraulik GmbH Aggregate_BA_GB_175010085_1209.indd
Please dispose all packaging materials and
dismantled parts properly.
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Before connecting equipment, make sure that all the
components used are suitable for the maximum
operating pressure of the hydraulic unit! In cases
of doubt, you must consult LUKAS directly before
connecting the equipment!

B
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Vor Installation und Inbetriebnahme der Pumpe mu dieses Handbuch aufmerksam durchgelesen werden.
Read carefully this manual before installing and using the pump.
Avant dinstaller la pompe et de la mettre en service, lire attentivement dun bout lautre le prsent manuel.
Lean atentamente este manual antes de la instalacin y el uso de la bomba.
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Hy Hy Hy Hy Hydr dr dr dr draulik aulik aulik aulik aulikpumpen dr pumpen dr pumpen dr pumpen dr pumpen druc uc uc uc uck kk kkluftbetrie luftbetrie luftbetrie luftbetrie luftbetrieben ben ben ben ben
Hy Hy Hy Hy Hydr dr dr dr draulic Pumps pneuma aulic Pumps pneuma aulic Pumps pneuma aulic Pumps pneuma aulic Pumps pneumatically oper tically oper tically oper tically oper tically opera aa aated ted ted ted ted
P PP PPompes hy ompes hy ompes hy ompes hy ompes hydr dr dr dr drauliques commande pneuma auliques commande pneuma auliques commande pneuma auliques commande pneuma auliques commande pneumatique tique tique tique tique
Bombas hidrulicas pneumticas Bombas hidrulicas pneumticas Bombas hidrulicas pneumticas Bombas hidrulicas pneumticas Bombas hidrulicas pneumticas
AHP 2-1E-632
2
COD. 193555075 - v.2 - UPD 220207
1
6
2
1
4
7
1
0
9
1
2
9
320
1
5
5
3
6
Fig.1
6
6
6
R
=
3
236
6
6
9
0
Fig.2
Fig.4 Fig.3
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COD. 193555075 - v.2 - UPD 220207
Fig.5
Fig.6 Fig.7
Fig.9 Fig.8
E
4
COD. 193555075 - v.2 - UPD 220207
INHAL INHAL INHAL INHAL INHALT TT TT
ALLGEMEINE HINWEISE ......................................................................................................................................................................................... 6
1 TRANSPORT, LAGERUNG UND AUSPACKEN DER PUMPE ................................................................................................................................ 6
2 BESCHREIBUNG ...................................................................................................................................................................................................... 6
3 SICHERHEIT .............................................................................................................................................................................................................. 7
4 TECHNISCHE MERKMALE ...................................................................................................................................................................................... 8
5 INSTALLATION UND INBETRIEBNAHME ............................................................................................................................................................... 9
5.1 Fllen des ltanks (sofern die Pumpe leer geliefert wird) ............................................................................................................................... 9
5.2 Hydraulikanschlsse der Pumpe ..................................................................................................................................................................... 9
5.3 Vorbereitung der Pumpe .................................................................................................................................................................................. 9
5.3.1 Vorbereitung der liegend (horizontal) installierten Pumpe ............................................................................................................................... 9
5.3.2 Vorbereitung der stehend (vertikal) installierten Pumpe .................................................................................................................................. 9
5.3 Druckluftanschlu ............................................................................................................................................................................................ 9
6 BETRIEB.................................................................................................................................................................................................................... 9
6.1 Betrieb des Pedals ........................................................................................................................................................................................... 9
6.2 Betrieb der Steuerungen ................................................................................................................................................................................ 10
7 WARTUNG ............................................................................................................................................................................................................... 10
7.1 berprfung der Anschlsse ......................................................................................................................................................................... 10
7.2 Reinigung des Luftfilters ................................................................................................................................................................................ 10
7.3 Kontrolle des Hydraulikls ............................................................................................................................................................................. 10
7.4 Hydrauliklwechsel ........................................................................................................................................................................................ 10
7.5 Betriebsstrungen und Abhilfen ...................................................................................................................................................................... 11
8 VERSCHROTTUNG UND ENTSORGUNG DER PUMPE ....................................................................................................................................... 11
BETRIEBSSCHEMA................................................................................................................................................................................................ 12
GARANTIE ............................................................................................................................................................................................................... 12
ERSATZTEILE ......................................................................................................................................................................................................... 12
CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS
GENERAL PRECAUTIONS ..................................................................................................................................................................................... 13
1 TRANSPORT, STORAGE AND UNPACKING......................................................................................................................................................... 13
2 DESCRIPTION ......................................................................................................................................................................................................... 13
3 SAFETY ................................................................................................................................................................................................................... 14
4 TECHNICAL SPECIFICATIONS .............................................................................................................................................................................. 15
5 INSTALLATION AND START-UP............................................................................................................................................................................. 16
5.1 Filling the reservoir (if the pump is supplied without oil) ................................................................................................................................ 16
5.2 Pump hydraulic connections .......................................................................................................................................................................... 16
5.3 Setting up the pump ....................................................................................................................................................................................... 16
5.3.1 Setting up the pump - horizontal position ...................................................................................................................................................... 16
5.3.2 Setting up the pump - vertical position........................................................................................................................................................... 16
5.4 Connecting the compressed air line .............................................................................................................................................................. 16
6 OPERATION ............................................................................................................................................................................................................ 16
6.1 Using the treadle ............................................................................................................................................................................................ 16
6.2 Using the controls .......................................................................................................................................................................................... 17
7 MAINTENANCE ....................................................................................................................................................................................................... 17
7.1 Connections checking .................................................................................................................................................................................... 17
7.2 Cleaning the air filter ...................................................................................................................................................................................... 17
7.3 Checking the hydraulic oil. ............................................................................................................................................................................. 17
7.4 Hydraulic oil change....................................................................................................................................................................................... 17
7.5 Troubleshooting ............................................................................................................................................................................................. 18
8 SCRAPPING AND DISPOSING OF THE PUMP..................................................................................................................................................... 18
OPERATION DIAGRAM .......................................................................................................................................................................................... 19
WARRANTY ............................................................................................................................................................................................................. 19
SPARE PARTS......................................................................................................................................................................................................... 19
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COD. 193555075 - v.2 - UPD 220207
NDICE NDICE NDICE NDICE NDICE
ADVERTENCIAS GENERALES.............................................................................................................................................................................. 27
1 TRANSPORTE, ALMACENAMIENTO Y DESEMBALAJE ..................................................................................................................................... 27
2 DESCRIPCIN ........................................................................................................................................................................................................ 27
3 SEGURIDAD ............................................................................................................................................................................................................ 28
4 CARACTERSTICAS TCNICAS ............................................................................................................................................................................ 29
5 INSTALACIN Y PUESTA EN FUNCIN ............................................................................................................................................................... 30
5.1 Llenado del depsito del aceite (si la bomba se suministra vaca) ............................................................................................................... 30
5.2 Conexiones hidrulicas de la bomba ............................................................................................................................................................. 30
5.3 Preparacin de la bomba ............................................................................................................................................................................... 30
5.4 Conexin del aire comprimido ....................................................................................................................................................................... 30
6 USO ....................................................................................................................................................................................................................... 30
6.1 Uso del pedal ................................................................................................................................................................................................. 30
6.2 Uso de los mandos ........................................................................................................................................................................................ 31
7 MANTENIMIENTO ................................................................................................................................................................................................... 31
7.1 Verificacin de las conexiones ....................................................................................................................................................................... 31
7.2 Limpieza del filtro del aire .............................................................................................................................................................................. 31
7.3 Control del aceite hidrulico .......................................................................................................................................................................... 31
7.4 Sustitucin del aceite hidrulico .................................................................................................................................................................... 31
7.5 Problemas y soluciones ................................................................................................................................................................................. 32
8 DEMOLICIN Y ELIMINACIN DE LA BOMBA .................................................................................................................................................... 32
ESQUEMA DE FUNCIONAMIENTO ....................................................................................................................................................................... 33
GARANTA ............................................................................................................................................................................................................... 33
PIEZAS DE REPUESTO.......................................................................................................................................................................................... 33
SOMMAIRE SOMMAIRE SOMMAIRE SOMMAIRE SOMMAIRE
GENERALITES ........................................................................................................................................................................................................ 20
1 TRANSPORT, STOCKAGE ET DBALLAGE DE LA POMPE............................................................................................................................... 20
2 DESCRIPTION ......................................................................................................................................................................................................... 20
3 SCURIT ............................................................................................................................................................................................................... 21
4 CARACTRISTIQUES TECHNIQUES .................................................................................................................................................................... 22
5 INSTALLATION ET MISE EN SERVICE ................................................................................................................................................................. 23
5.1 Remplissage du rservoir huile (dans la mesure o la pompe est livre vide) .......................................................................................... 23
5.2 Raccordements hydrauliques de la pompe ................................................................................................................................................... 23
5.3 Prparation de la pompe................................................................................................................................................................................ 23
5.3.1 Prparation de la pompe installe plat ( lhorizontale) .............................................................................................................................. 23
5.3.2 Prparation de la pompe installe debout ( la verticale) ............................................................................................................................. 23
5.4 Prparation de la pompe................................................................................................................................................................................ 23
6 FONCTIONNEMENT ............................................................................................................................................................................................... 23
6.1 Fonctionnement de la pdale ........................................................................................................................................................................ 23
6.2 Fonctionnement des commandes.................................................................................................................................................................. 24
7 ENTRETIEN ............................................................................................................................................................................................................. 24
7.1 Contrle des raccordements .......................................................................................................................................................................... 24
7.2 Nettoyage du filtre air .................................................................................................................................................................................. 24
7.3 Contrle de lhuile hydraulique ...................................................................................................................................................................... 24
7.4 Vidange de lhuile hydraulique ....................................................................................................................................................................... 24
7.5 Drangements et remdes ............................................................................................................................................................................ 25
8 MISE LA FERRAILLE ET LIMINATION DE LA POMPE ................................................................................................................................... 25
SCHEMA DE FONCTIONNEMENT ......................................................................................................................................................................... 26
GARANTIE ............................................................................................................................................................................................................... 26
PIECES DE RECHANGE......................................................................................................................................................................................... 26
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COD. 193555075 - v.2 - UPD 220207
ALL ALL ALL ALL ALLGEMEINE HINWEISE GEMEINE HINWEISE GEMEINE HINWEISE GEMEINE HINWEISE GEMEINE HINWEISE
Vor Installation und Benutzung dieser Pumpe mu das vorliegende Handbuch aufmerksam durchgelesen werden, da es wichtige
Hinweise fr Ihre Sicherheit enthlt.
Dieses Handbuch mu immer bei der Pumpe und der Maschine, an der sie installiert wird, bleiben, auch wenn sie verkauft bzw.
veruert wird.
Vor Installation und Inbetriebnahme der Pumpe mu sichergestellt werden, da sie whrend des Transports nicht beschdigt wurde,
da das Pumpengehuse keine Risse oder Beulen aufweist, und da kein l aus der Pumpe austritt. Eventuell festgestellte Mngel
sind dem Frachtfhrer zu melden. INSTALLIEREN SIE DIE PUMPE IN DIESEM FALL NICHT, sondern erbeten Sie vom Hersteller
weitere Anweisungen.
Der Hersteller haftet nicht fr Personen-, Tier-, Sach- oder Maschinenschden, die durch
Montage und Benutzung einer beschdigten Pumpe verursacht werden.
1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPORT TT TT, L , L , L , L , LA AA AAGER GER GER GER GERUNG UND A UNG UND A UNG UND A UNG UND A UNG UND AUSP USP USP USP USPA AA AACKEN DER PUMPE CKEN DER PUMPE CKEN DER PUMPE CKEN DER PUMPE CKEN DER PUMPE
Aufgrund des geringen Gewichts der Pumpe sind beim Transport keine besonderen Vorsichtsmanahmen notwendig.
Falls die Pumpe zunchst eingelagert, und erst lngere Zeit nach ihrem Kauf benutzt werden soll, mu diese in Rumlichkeiten
aufbewahrt werden, die einen angemessenen Schutz gegen Witterungseinflsse gewhrleisten, und deren Temperatur zwischen 10
und 50C liegt.
Aufgrund der Struktur der Pumpe und deren Verpackung drfen maximal 4 einzelne Kartons aufeinander gestellt werden. Wenn die
Pumpen auf Paletten geliefert werden, empfiehlt es sich, sie erst bei Montage aus der Original-verpackung zu nehmen.
Die leere Verpackung mu gem den im betroffenen Land geltenden gesetzlichen Vorschriften entsorgt werden.
2 - BESCHREIB 2 - BESCHREIB 2 - BESCHREIB 2 - BESCHREIB 2 - BESCHREIBUNG UNG UNG UNG UNG
Bei dem gelieferten Gert handelt es sich um eine Pumpe, mit dem aus Druckluftzufuhr eine hydraulische Druckleistung (siehe Kap.
4 "Technische Merkmale") gewonnen werden kann.
Diese Pumpe kann zur direkten Versorgung von einfach oder doppelt wirkenden hydraulischen Vorrichtungen eingesetzt werden.
Jede sonstige Verwendung der Pumpe ist als unsachgem zu betrachten und kann gefhrliche Unflle
verursachen. Der Hersteller lehnt jede Haftung fr Schden, die durch den unvorschriftsmigen
Gebrauch der Pumpe verursacht werden.
Der Hersteller steht jederzeit fr Rckfragen zur Verfgung, um jeden Zweifel bezglich Installation und korrekte Benutzung
der Pumpe zu klren.
Auf Abb.10 sind die verschiedenen Teile der Pumpe dargestellt.
Abb. 10
Einfll- und Entlftungsdeckel.
Anschlu fr doppelt wirkende
Vorrichtungen fr den Abla in den Tank
Pumppedal
Anschlsse fr die
Hydraulikschluche
Entlftungsschraube
Anschlu
Drucklufteinla
Pedalsperre
Gehuse / Tank
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COD. 193555075 - v.2 - UPD 220207
3 - SICHERHEIT 3 - SICHERHEIT 3 - SICHERHEIT 3 - SICHERHEIT 3 - SICHERHEIT
Alle nachstehend beschriebenen Vorschriften sind strikt zu befolgen, denn sie sind von grter Bedeutung fr Ihre eigene Sicherheit
und fr die Sicherheit anderer Personen. Neben den Angaben dieses Kapitels sind auerdem auch alle sonstigen in diesem Handbuch
enthaltenen Anweisungen zu befolgen.
VERSUCHEN SIE UNTER KEINEN UMSTNDEN, DIE INSTALLIERTEN SCHUTZVORRICHTUNGEN ABZUNEHMEN ODER ZU
VERNDERN. VERNDERN SIE AUCH KEINE TEILE DER PUMPE, DA DADURCH GEFAHRENSITUATIONEN ENTSTEHEN
KNNEN, AUF DIE DER BENUTZER, BZW. DIE FR DIE WARTUNG ZUSTNDIGE PERSON NICHT VORBEREITET SIND.
BEI ENTFERNUNG ODER VERNDERUNG VON AN DER PUMPE INSTALLIERTEN SICHERHEITS-VORRICHTUNGEN
VERFLLT SOFORT JEDER GARANTIEANSPRUCH UND DER HERSTELLER WIRD VON JEDER HAFTPFLICHT BEFREIT.
l Die Pumpe und die Maschine, an der die Pumpe installiert wird, darf nur von erwachsenen Personen, die die Maschine und die
Pumpe gut kennen und dieses Handbuch ganz durchgelesen haben, benutzt werden.
l Minderjhrigen, jedoch nicht unter 16 Jahren, ist die Benutzung der Pumpe nur unter Aufsicht einer zur Benutzung der Pumpe
befugten erwachsenen Person gestattet.
l Der Arbeitsbereich mu freigehalten werden, damit die Pumpe korrekt und sicher bedient werden kann. Achten Sie auf eventuell
herunterfallende Gegenstnde, die die Pumpe versehentlich bettigen knnten.
l Der Arbeitsbereich mu sauber sein. Insbesondere sind Reste von l, Fett oder sonstigen rutschigen und korrosiven Substanzen
zu verhindern.
l Die Pumpe mu von bermig heien Bereichen, lodernden Flammen oder Funken ferngehalten werden. Die maximale
Betriebstemperatur darf 50C nicht berschreiten.
l Arbeiten Sie niemals mit weiter oder offener Kleidung. Tragen Sie die vom Abteilungsleiter vorgeschriebene Schutzkleidung.
l Steigen Sie nicht auf die Pumpe um diese zu bedienen. Es gengt ein leichter Druck mit dem Fu um den inneren Mechanismus
zu bettigen.
l Falls es sich als erforderlich erweisen sollte, die Zuleitungen und den Hydraulikkreislauf abzuhngen, ist sicherzustellen, da sie
nicht unter Druck stehen.
l Fr den Anschlu der Pumpe mssen die in Kapitel 5 Installation und Inbetriebnahme genau befolgt, und immer bescheinigte
Schluche und Anschlsse verwendet werden.
l Versuchen Sie nicht, die Pumpe bei Betriebsstrungen selbst wieder in Gang zu setzen oder zu reparieren. Unterbrechen Sie die
Stromzufuhr zur Pumpe, schalten Sie die Maschine, an der sie montiert ist, aus und benachrichtigen Sie die fr die Wartung der
Pumpe zustndige Person.
l Verndern Sie den Standort der Pumpe nicht eigenmchtig. Die Pumpe darf nur in der vom Hersteller der Maschine vorgesehenen
Position benutzt werden.
8
COD. 193555075 - v.2 - UPD 220207
ZU VERWENDENDE L ZU VERWENDENDE L ZU VERWENDENDE L ZU VERWENDENDE L ZU VERWENDENDE LTYPEN TYPEN TYPEN TYPEN TYPEN
MOBIL DTE 11 - SHELL TELLUS OIL T 15 - CASTROL HYSPIN AWH15 - oder gleichwertige Typen
4 - TECHNISCHE MERKMALE 4 - TECHNISCHE MERKMALE 4 - TECHNISCHE MERKMALE 4 - TECHNISCHE MERKMALE 4 - TECHNISCHE MERKMALE
Typ AHP21E-632
Teile-Nr. HR149 463 260
Druck am Lufteinlass (bar) 2,8 10
Luftanschluss G
Innengewinde
Max. Betriebsdruck*, lseitig (MPa) 63
1
Frderleistung (l/min.) s.folgendes Diagramm
lmenge in liegender Stellung (l) / 2,4
nutzbare Menge (l) 2,1
lmenge in stehender Stellung (l) / 2,2
nutzbare Menge (l) 1,5
Hydr. Anschluss,Druck M14x1,5
Innengewinde
Hydr. Anschluss, Rcklauf M14x1,5
Innengewinde
Geruschpegel 75 dB(A)/1m
Abmessungen ** (L x B x H) 365x155x210
Gewicht mit l (Kg) < 7,5
* Fr Einstellung u. Prfung der Drcke unbedingt Manometer mit max. Messbereich bis 1000 bar (100 MPa)
und der Genauigkeitsklasse 0,1 oder besser verwenden!
** Mablatt s. Abb.1. Seite 2
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COD. 193555075 - v.2 - UPD 220207
5 - INST 5 - INST 5 - INST 5 - INST 5 - INSTALL ALL ALL ALL ALLA AA AATION UND INBETRIEBN TION UND INBETRIEBN TION UND INBETRIEBN TION UND INBETRIEBN TION UND INBETRIEBNAHME AHME AHME AHME AHME
In diesem Kapitel wird die Installation der Pumpe beschrieben. Die folgenden Anleitungen werden als die optimale Vorgangsweise
empfohlen. Der Kufer der Pumpe - also der Hersteller der Maschine, an der die Pumpe montiert wird - kann zwar beschlieen, die
Montage in anderer Weise vorzunehmen und Bgel oder sonstiges Zubehrmaterial, das er fr zweckmig hlt, verwenden, JEDOCH
OHNE DIE FORM ODER DIE ORIGINALEINHNGUNG DER PUMPE AUF IRGENDEINE WEISE ZU VERNDERN, UND
JEDENFALLS OHNE IRGENDEINE DER AN DER PUMPE ANGEBRACHTEN SCHUTZVORRICHTUNGEN ZU ENTFERNEN BZW.
DIE PUMPE AUF IRGENDEINE WEISE GEFHRLICH ZU MACHEN. Falls nderungen solcherart vorgenommen werden, ist er
allein haftbar fr jeden Unfall, der whrend der Benutzung der Pumpe verursacht werden sollte.
Die Pumpe kann sowohl liegend (horizontal) als auch stehend (vertikal) montiert werden.
Auf Seite 2, Abb. 3 ist die Bohrschablone dargestellt, die fr die Planung der Befestigungsbasis der Pumpe zu verwenden ist. Danach
mu die Pumpe mit vier Schrauben verankert werden.
Achtung: die Befestigungslcher drfen nicht tiefer als 20 mm gebohrt werden.
5.1 - Fllen des ltanks (sofern die Pumpe leer geliefert wird)
Auf Seite 8 sind die lmengen angegeben, die je nach Positionierung der Pumpe in den Pumpentank einzufllen sind. In derselben
Tabelle sind auch die effektiv nutzbaren lmengen angegeben.
Verwenden Sie die auf Seite 8 angegebenen ltypen. le mit anderen Charakteristiken knnen die Pumpe ernsthaft beschdigen und
unbrauchbar machen. DER HERSTELLER HAFTET NICHT FR PERSONEN-, MASCHINEN- ODER SACHSCHDEN, DIE DURCH
BENUTZUNG UNGEEIGNETER LTYPEN ODER ALTL VERURSACHT WERDEN. IM FALLE VON SCHDEN AN DER PUMPE
AUS DEN OBENGENANNTEN GRNDEN VERFLLT JEDER GARANTIEANSPRUCH MIT SOFORTIGER WIRKUNG.
l Den Einflldeckel (Abb.120, Seite 6) mit Hilfe eines flachen Schraubenziehers herausziehen und ganz abnehmen.
l Die richtige lmenge wie in der Tabelle auf Seite 8 angegeben in den Tank leeren.
l Die Einfllffnung mit einem sauberen Lappen subern; den Deckel wieder einsetzen und ganz hineindrcken.
5.2 - Hydraulikanschlsse der Pumpe
l Die Hydraulikschluche an der Ausgangsffnung (A, Abb. 3) und an der Tankffnung (B, Abb. 3) der Pumpe anschlieen. Die
Schluche mssen mit einem Verbindungsstck M14x1,5 versehen sein.
5.3 - Vorbereitung der Pumpe
5.3.1 - Vorbereitung der liegend (horizontal) installierten Pumpe
l Wenn die Pumpe in horizontaler Stellung benutzt wird, die Entlftungsschraube (Abb.4, Seite 2) mit einem passenden
Schraubenzieher um drei oder vier Drehungen aufschrauben.
5.3.2 - Vorbereitung der stehend (vertikal) installierten Pumpe
l Wenn die Pumpe in vertikaler Stellung benutzt wird, den Entlftungsdeckel (Pos.D auf Abb.5, Seite 3) mit Hilfe eines flachen
Schraubenziehers bis zur ersten Einrastung herausziehen.
5.3 - Druckluftanschlu
l Am Druckluftanschlu (Abb.10, Seite 6) eine fr Ihre Anlage passende Schnellverbindung festschrauben, deren Gewinde zuvor mit
Teflonband umwickelt wurde.
l Die Schnellverbindung wird an eine Zuleitung angeschlossen, die einen Druck zwischen 2,8 und 10 bar liefern kann (siehe Tabelle
Technische Merkmale auf Seite 8).
6 - BETRIEB 6 - BETRIEB 6 - BETRIEB 6 - BETRIEB 6 - BETRIEB
6.1 - Betrieb des Pedals
Ihre Pumpe kann mit aussetzendem Betrieb oder im Dauerbetrieb verwendet werden.
l Aussetzender Betrieb: drcken Sie das Pedal, um die Pumpe zu bettigen (Abb.6, Seite 3), und lassen Sie es los, um die Pumpe
anzuhalten.
l Dauerbetrieb: drcken Sie das Pedal (Abb.6, Seite 3) und schieben sie den Sperrstift (Abb.7, Seite 3) zu, um die Pedalsteuerung
in Arbeitsposition zu halten.
Nun kann die Pumpe je nach Typ des installierten Triebs auf unterschiedliche Weise benutzt werden.
Um den lflu zu unterbrechen, fest auf die Pedalsteuerung drcken, um den Sperrstift zu lsen.
10
COD. 193555075 - v.2 - UPD 220207
7 - WAR 7 - WAR 7 - WAR 7 - WAR 7 - WARTUNG TUNG TUNG TUNG TUNG
Alle nachstehend beschriebenen Eingriffe der ordentlichen Wartung mssen von erfahrenem Personal durchgefhrt werden, das sich
mit der Pumpe und deren Betrieb gut auskennt und das vorliegende Handbuch ganz durchgelesen hat. Bei Durchfhrung der
Wartungseingriffe mu vorsichtig vorgegangen werden, um Unflle zu vermeiden. Die in diesem Kapitel beschriebenen Vorgnge sind
die einzigen zulssigen Eingriffe. Jeder unbefugte Wartungseingriff bewirkt den sofortigen Verfall der Garantie der Pumpe und
befreit den Hersteller von jeder Haftung.
7.1 - berprfung der Anschlsse
Die hydraulischen und pneumatischen Anschlsse mssen jede Woche berprft werden. berzeugen Sie sich, da die Anschlsse
an der Pumpe nicht aufgeschraubt oder gelockert sind und keine Risse oder sonstige Beschdigungen aufweisen. Stellen Sie sicher,
da die Leitungen nicht beschdigt oder zerschnitten sind.
7.2 - Reinigung des Luftfilters
Im Innern des pneumatischen Anschlusses befindet sich ein Luftfilter (Abb.8, Seite 3).
l Mit Hilfe eines flachen Schraubenziehers der entsprechenden Gre den Filter im Druckluftanschlu aufschrauben und ganz
herausnehmen.
l Den Filter durch Blasen mit Druckluft reinigen, dann wieder einsetzen und festschrauben. Nicht zu fest zudrehen, um das Gewinde
nicht zu beschdigen.
l Die vorher mit Teflonband umwickelte Schnellverbindung wieder zuschrauben.
Falls der Filter bermig verschmutzt oder beschdigt sein sollte, mu er durch einen neuen ersetzt werden. Dieser kann beim
Hersteller bestellt werden, zu diesem Zweck verweisen wir auf die Ersatzteilliste am Ende dieses Handbuchs.
7.3 - Kontrolle des Hydraulikls
Regelmig kontrollieren Sie, ob die Pumpe die korrekte Menge Hydraulikl enthlt. Der lstand wird am Schauglas am Pumpentank
(Abb.9, Seite 3) berprft. Wenn der lstand bei eingefahrenen Zylindern den sichtbaren Mindeststand (E auf Abb.9) erreicht hat, mu
geeignetes l (siehe Angabe der vorgeschriebenen ltypen auf Seite 8) nachgefllt werden.
7.4 - Hydrauliklwechsel
Alle 250 Betriebsstunden mu das l ersetzt werden. Dieser Vorgang mu bei ganz eingefahrenem Zylinder durchgefhrt werden:
l Wenn die Pumpe stehend montiert ist, mu sie ausgebaut und liegend positioniert werden.
l Mit Hilfe eines flachen Schraubenziehers den Einflldeckel (Abb. 10, Seite 6) ganz herausnehmen.
l Die Pumpe ber einem Auffangbehlter fr das Altl umdrehen und ausleeren.
l Das ganze im Tank enthaltene l entleeren und dann die Pumpe mit neuem l fllen. lmengen und -typen sind auf Seite 8
angegeben.
l Die Einfllffnung mit einem sauberen Lappen subern, den Deckel wieder einsetzen und hineindrcken bis er fest sitzt, bzw. falls
erforderlich in Entlftungsposition bringen.
6.2 - Betrieb der Steuerungen
Die Pumpe ist fr die Verbindung mit einem 3/2 oder 4/2 Wegesitzventil mit Anschlu CETOP 03 ausgelegt.
Fr einen korrekten Anschlu des Ventils CETOP an der Pumpe verweisen wir auf die dem Ventil beiliegende technische Dokumentation.
ACHTUNG: nach der erstmaligen Installation der Pumpe kann es unter Umstnden vorkommen, da der Kreislauf wegen
vorhandener Luftblasen leer erscheint. Wenn es der Pumpe nicht gelingt, das l unter Druck zu setzen, wie nachstehend
beschrieben vorgehen.
Falls die Pumpe stehend montiert ist, mu sie ausgebaut und waagerecht auf den Boden gelegt werden.
Fllung der Pumpen mit Wegesitzventil 3/2
l Das Pedal der Pumpe drcken und das Ventil ca. 15 Sekunden lang auf Abla positionieren.
l Einen Zylinder anschlieen und kontrollieren, ob die Pumpe gefllt ist. Wenn sich der Zylinder nicht bewegt, mu der Vorgang
wiederholt werden.
Fllung der Pumpen mit Wegesitzventil 4/2
l Die druckseitige ffnung ber einen passenden Schlauch mit dem Abla verbinden und das Pedal ca. 15 Sekunden lang drcken.
l Einen Zylinder anschlieen und kontrollieren, ob die Pumpe gefllt ist. Wenn sich der Zylinder nicht bewegt, mu der Vorgang
wiederholt werden.
11
COD. 193555075 - v.2 - UPD 220207
7.5 - Betriebsstrungen und Abhilfen
Im folgenden Abschnitt sind einige Anomalien aufgefhrt, die whrend des Betriebs auftreten knnen, daneben sind die entsprechende
Abhilfen beschrieben. Falls die Probleme nicht mit den hier beschriebenen Eingriffen behoben werden knnen, mu der Hersteller zu
Rate gezogen werden.
8 - VERSCHRO 8 - VERSCHRO 8 - VERSCHRO 8 - VERSCHRO 8 - VERSCHROTTUNG UND ENTSOR TTUNG UND ENTSOR TTUNG UND ENTSOR TTUNG UND ENTSOR TTUNG UND ENTSORGUNG DER PUMPE GUNG DER PUMPE GUNG DER PUMPE GUNG DER PUMPE GUNG DER PUMPE
Wenn die Pumpe verschrottet werden soll, mu das enthaltene l entleert und gem den in dem betroffenen Land gltigen gesetzlichen
Vorschriften entsorgt werden. Dasselbe gilt fr die anderen Teile der Pumpe, die nach den Werkstoffen, aus den sie bestehen (Kunststoff/
Eisen), zu trennen sind.
Betriebsstrung
Die Pumpe startet nicht.
Bei Belastung bleibt die Pumpe stehen
Die Pumpe funktioniert zwar, setzt
aber das l nicht unter Druck.
Die Pumpe erreicht nicht den
Hchstdruck.
Die Pumpe erzeugt Druck, aber die
Last bewegt sich nicht.
Der Kolben fhrt ein obwohl das Pedal
losgelassen wird.
Der Kolben luft nicht zurck (einfach
wirkender Zylinder)
Der Kolben luft nicht zurck (doppelt
wirkender Zylinder)
Ungengende Pumpenleistung.
Abhilfe
Sicherstellen, da Druckluft zur Pumpe
gelangt.
Sicherstellen, da der Zuleitungsdruck der
Pumpe (Druckluft) zwischen 2,8 und 10
bar liegt
Luftfilter subern oder ersetzen.
berprfen, ob eine Leckstelle vorhanden
ist, und gegebenenfalls reparieren.
berprfen, ob in der Pumpe eine
Leckstelle vorhanden ist, und falls ja, zur
Reparatur an den Hersteller schicken.
lstand kontrollieren und falls erforderlich
l nachfllen.
Pumpe (Druckluft) zwischen 2,8 und 10
bar liegt
Hersteller kontaktieren.
Belastung reduzieren.
Kontrollieren, ob die Leitungen Engpsse
aufweisen oder eingeklemmt sind, und ob
der Zylinder defekt ist.
Leckstelle in der Pumpe berprfen und
Hersteller kontaktieren.
lzuleitung berprfen.
Zylinder beschweren.
Zylinder reparieren.
lzuleitung berprfen.
Pumpe (Druckluft) zwischen 2.8 und 10
bar liegt
Luftfilter subern oder ersetzen.
Tank wie in Kapitel 5 auf Seite 9
beschrieben entlften.
Mgliche Ursache
Die Druckluftzuleitung ist geschlossen oder
verstopft.
Luftdruck zu niedrig.
Luftfilter verschmutzt oder verstopft.
Aus der Hydraulikanlage tritt l aus.
Leckstelle in der Pumpe
Zu niedriger lstand.
Inneres Sicherheitsventil verstellt.
berlastung.
Das l zirkuliert nicht korrekt.
Defekt in der Pumpe.
lzuleitung eingeklemmt oder Steck-
verbindung nicht richtig angeschlossen.
Bei Rcklauf mittels Schwerkraft:
mangelnde Belastung auf dem Zylinder.
Zylinderfeder schadhaft.
Freigabeventil des Zylinders funktioniert
nicht.
lzuleitung eingeklemmt oder Steck-
verbindung nicht richtig angeschlossen.
Freigabeventil des Zylinders funktioniert
nicht.
Luftfilter verschmutzt oder verstopft.
Tank wurde nicht entlftet
12
COD. 193555075 - v.2 - UPD 220207
BETRIEBSSCHEMA BETRIEBSSCHEMA BETRIEBSSCHEMA BETRIEBSSCHEMA BETRIEBSSCHEMA
a
b
A
S
A = Lufteintritt
a und b = lverwendung
S = ltank
ERSA ERSA ERSA ERSA ERSATZTEILE TZTEILE TZTEILE TZTEILE TZTEILE
BESTELLUNG VON ERSATZTEILEN
Bei Bestellung von Ersatzteilen sind immer folgende Angaben erforderlich:
1) Bestellnummer des Ersatzteils
2) Bezeichnung des Teils
3) Pumpentyp
4) Fabrikationsnummer der Pumpe
Einschrnkungen:
1) Bevor er an der Maschine Reparatureingriffe in Garantie vornimmt, mu der
Vertragshndler vom Hersteller hierzu befugt werden.
2) Die Garantie ist auf die vom Hersteller als defekt anerkannten Teile beschrnkt.
3) Fr Eingriffe in Garantie werden keine Transportkosten anerkannt.
4) Fr Produkte, an denen keine korrekte und regelmige Wartung durchgefhrt
wurde, die unsachgem benutzt wurden, die Unflle erlitten haben, an denen
unerlaubte Reparaturen oder sonstige Vernderungen vorgenommen wurden,
wird keine Garantie gewhrt.
G GG GGARANTIE ARANTIE ARANTIE ARANTIE ARANTIE
Garantie auf Material- und Fabrikationsfehler der Pumpen wird entsprechend den allgemeinen Lieferbedingungen geleistet.
13
COD. 193555075 - v.2 - UPD 220207
Fig.10
Filler and breather plug
Double acting connection
for drain into reservoir
Treadle
Compressed air inlet connection
Pedal locking pushbutton
Pump body/reservoir
Breather screw
Hydraulic pressure
hose ports
GENERAL PRECA GENERAL PRECA GENERAL PRECA GENERAL PRECA GENERAL PRECAUTIONS UTIONS UTIONS UTIONS UTIONS
This manual contains important safety information: read carefully before installing and using the pump.
This manual must always accompany both the pump and the machine on which the pump is installed, even when pump and machine
or the pump alone is sold, loaned or otherwise transferred to other premises. Before installing the pump and setting it up for operation
make sure it has not been damaged during transportation: check that there are no cracks or dents on the body and that there are no
traces of oil leaks. If damage is noticed, inform the carrier of the problem immediately. DO NOT INSTALL THE PUMP. Ask the
manufacturer for instructions.
The manufacturer shall not be held liable for injury to people or animals or damage to
property caused by installation and operation of a damaged pump.
1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPORT TT TT, ST , ST , ST , ST , STORA ORA ORA ORA ORAGE AND UNP GE AND UNP GE AND UNP GE AND UNP GE AND UNPA AA AACKING CKING CKING CKING CKING
Given the modest weight of the pump, no particular transport precautions are necessary.
Is the pump set aside for use some time after the date of purchase, it must be stored in a place that is adequately protected against the
weather at a temperature between 10 and 50 C.
Given the structure of the pump and its packaging, a maximum of 4 single boxes can be stacked one on top of the other. If the pumps
are delivered packed on pallets, they should be left in their original packing and unpacked immediately prior to installation.
Dispose of packing materials in accordance with the prescriptions of the law in the country in which the pump is unpacked.
2 - DESCRIPTION 2 - DESCRIPTION 2 - DESCRIPTION 2 - DESCRIPTION 2 - DESCRIPTION
The device supplied is an air-powered hydraulic pump that converts a compressed air supply into a pressurized hydraulic flow (see
Technical specifications Chapter 4).
The pump can be utilized to directly power single and double acting hydraulic devices.
All other uses of the pump shall be considered improper and can cause serious accidents. The
manufacturer declines all liability for damages resulting from improper use of the pump.
Ask the manufacturer if in doubt about the correct installation or use of the pump.
Figure 10 shows the components of the pump.
14
COD. 193555075 - v.2 - UPD 220207
3 33 33 - SAFETY - SAFETY - SAFETY - SAFETY - SAFETY
Observe all the following safety rules. They are of the maximum importance for your own safety and the safety of others. In addition to
the indications in this chapter, observe also the prescriptions in all other sections of the manual.
DO NOT TAMPER WITH THE PROTECTIONS AND SAFETY DEVICES AND DO NOT MODIFY THE PUMP IN ANY WAY TO AVOID
CREATING POTENTIALLY HAZARDOUS SITUATIONS FOR WHICH THE OPERATOR OR SERVICE TECHNICIAN IS
UNPREPARED.
REMOVING OR TAMPERING WITH ANY OF THE SAFETY DEVICES ON THE PUMP AUTOMATICALLY INVALIDATES THE
WARRANTY AND ABSOLVES THE MANUFACTURER FROM ALL LIABILITY.
l The pump and the machine on which the pump is installed must be used exclusively by people over 18 years of age who have read
this manual and have a thorough knowledge of the machine and the pump.
l The pump may be used by persons over the age of 16 provided they are supervised by an adult.
l The work area must be kept clear of obstructions so that the pump can be operated in safe conditions.
Pay attention to falling objects which could strike the pump treadle and set the pump into operation.
l The work area must be kept clean and the floor must bear no traces of oil, grease and slippery or corrosive substances of any type.
l Keep the pump well clear of heat sources, naked flames and sparks. Maximum operating temperature of the pump is 50 C.
l Work clothes must be close fitting and buttoned up. Wear the protective clothing stipulated in the place where the pump is installed.
l Do not attempt to operate the pump by standing on the treadle, use only light foot pressure to operate the pump mechanism.
l Do not disconnect the air supply hose or the hydraulic oil hose until you are sure that the circuits are not pressurized.
l When connecting the pump follow the prescriptions in chapter 5 Installation and start-up and always use certified hoses and
couplings.
l If the pump develops a fault, do not attempt to repair it unassisted. Disconnect the compressed air supply, switch off the machine
to which the pump is connected and call the maintenance technician.
l Do not arbitrarily move the pump to different locations. The pump must be used in the position designated by the manufacturer of
the machine to which it is connected.
15
COD. 193555075 - v.2 - UPD 220207
4 - TECHNICAL SPECIFICA 4 - TECHNICAL SPECIFICA 4 - TECHNICAL SPECIFICA 4 - TECHNICAL SPECIFICA 4 - TECHNICAL SPECIFICATIONS TIONS TIONS TIONS TIONS
RECOMMENDED OIL TYPES RECOMMENDED OIL TYPES RECOMMENDED OIL TYPES RECOMMENDED OIL TYPES RECOMMENDED OIL TYPES
MOBIL DTE 11 - SHELL TELLUS OIL T 15 - CASTROL HYSPIN AWH15 - or equivalent
Model AHP21E-632
Part No.. HR149 463 260
Air inlet pressure (bar) 2,8 10
Air connection G
internal thread
Maximum working pressure* (MPa) 63
1
Rated flow (l/min.) see the following diagram
Reservoir capacity/ usable capacity 2,4
in horizontal position (I) 2,1
Reservoir capacity/usable capacity 2,2
in vertical position (l) 1,5
Hydraulic connection, inlet M14x1,5
internal thread
Hydraulic connection, outlet M14x1,5
internal thread
Noise level 75 dB(A)/1m
Dimensions ** (L x B x H) 365x155x210
Weight with oil (Kg) < 7,5
* In order to regulate and test the pressure use manometers with max. Measuring range up to 1000 bar (100 MPa)
and the accuracy class 0.1 or better only!
** Dimensional outline see fig.1, page 2.
16
COD. 193555075 - v.2 - UPD 220207
5 - INST 5 - INST 5 - INST 5 - INST 5 - INSTALL ALL ALL ALL ALLA AA AATION AND ST TION AND ST TION AND ST TION AND ST TION AND STAR AR AR AR ART TT TT-UP -UP -UP -UP -UP
This chapter describes the methods of installation of the pump. The method here recommended will give excellent results. The
purchaser of the pump, i.e. the manufacturer of the machine on which the pump will be installed, may opt for different types of
installation, using brackets or any other types of accessory considered to be necessary. HOWEVER, THE ORIGINAL SHAPE AND
ATTACHMENT OF THE PUMP MUST NOT BE MODIFIED, THE PROTECTIONS APPLIED TO THE PUMP MUST NOT BE TAMPERED
WITH AND NO ACTION MUST BE TAKEN THAT COULD MAKE THE PUMP POTENTIALLY DANGEROUS. If these instructions are
disregarded, the person who is responsible for the modifications automatically assumes full liability for any accidents that may occur
during use of the pump.
The pump can be installed in a horizontal or vertical position.
Figure 3 on page 2 shows the drilling template to use when designing the pump baseplate. The pump must be anchored to the
baseplate using four screws.
IMPORTANT: the fixing hole depth is 20 mm. This length must not be exceeded.
5.1 Filling the reservoir (if the pump is supplied without oil)
Page 15 shows the oil quantities required to fill the pump reservoir. The table also shows the actual usable oil capacities.
Use the oil types specified on page 15. The use of oil with different characteristics can result in serious damage to the pump and render
it unsuitable for use. THE MANUFACTURER SHALL NOT BE HELD RESPONSIBLE FOR INJURY TO PERSONS OR DAMAGE TO
PROPERTY CAUSED BY THE USE OF UNSUITABLE OR EXHAUST OIL. DAMAGE TO THE PUMP RESULTING FROM THE
ABOVE MENTIONED CAUSES IS NOT COVERED BY THE WARRANTY.
l Use a slotted tip screwdriver to remove the filler plug (fig.10, page 13)
l Pour the correct quantity of oil into the reservoir (refer to the table on page 15)
l Clean the edges of the filler opening with a clean cloth and refit the plug, pressing it down fully.
5.2 - Pump hydraulic connections
l Connect the hydraulic pressure hoses to the outlet port (A, fig. 3, page 2) and reservoir port (B, fig. 3) on the pump. The hoses must
be fitted with a M14x1.5 coupling.
5.3 - Setting up the pump
5.3.1 - Setting up the pump - horizontal position
l If the pump is to be used in the horizontal position, unscrew the breather screw (fig.4, page 2) by three or four turns using the correct
type of screwdriver.
5.3.2 - Setting up the pump - vertical position
l If the pump is to be used in the vertical position, use a slotted tip screwdriver to extract the breather plug to the first click (pos. D in
fig. 5, page 3).
5.4 - Connecting the compressed air line
l Select a quick coupler that is suitable for your air line, bind the thread with Teflon tape, and then screw it into the compressed air
inlet connection (fig.10, page 13).
l The quick coupler must be connected to an air line supplying compressed air at between 2.8 and 10 bar (see Specifications, page 15).
6 - OPERA 6 - OPERA 6 - OPERA 6 - OPERA 6 - OPERATION TION TION TION TION
6.1 - Using the treadle
The pump in your possession can be used for either continuous or intermittent duty:
l Intermittent duty: press and release the treadle to start and stop the pump (fig.6, page 3).
l Continuous duty: press the treadle (fig.6, page 3) then push in the locking pin (fig.7, page 3) to lock the treadle control in the on
position. The pump will now start working, the operating mode depending on the type of actuator installed.
Press the treadle firmly to release the pin and stop the oil flow.
17
COD. 193555075 - v.2 - UPD 220207
6.2 - Using the controls
The pump can be connected to a 3/2 or 4/2 directional control valve with a CETOP 03 connection.
For instructions on connecting the CETOP valve correctly, refer to the documentation supplied with the valve itself.
WARNING: immediately after the pump installation, the circuit may contain air locks that prevent pressurization. If the pump
is unable to pressurize the oil circuit, proceed as described below.
If the pump is mounted vertically, disassemble it and place it in a horizontal position on the floor.
Priming the pump with 3/2 directional control valve
l Press the pump treadle and position the valve on releasing position for about 15 seconds.
l Connect to a cylinder and check that the pump is primed. If the cylinder does not move, repeat the operation.
Priming the pump with 4/2 directional control valve
l Using a suitable pressure hose, connect the pressurized oil delivery port to the drain side and press the treadle for about 15
seconds.
l Connect to a cylinder and check that the pump is primed. Repeat the operation if the cylinder does not move.
7 - MAINTEN 7 - MAINTEN 7 - MAINTEN 7 - MAINTEN 7 - MAINTENANCE ANCE ANCE ANCE ANCE
The routine maintenance work described below must be performed exclusively by a skilled technician who has a thorough knowledge
of the pump and its operation and who has read this manual completely. Maintenance must be carried out with maximum caution to
prevent possible accidents. This chapter describes the only maintenance procedures permitted. Execution of any unauthorised
maintenance work will automatically invalidate the warranty and free the manufacturer from all liability.
7.1 - Connections checking
Check the hydraulic and pneumatic connections once a week. Ensure that the couplings on the pump are screwed down tightly and
show no signs of breakage, cracks or other damage. Ensure that the hoses are not damaged in any way (cuts, abrasion, cracks, etc.).
7.2 - Cleaning the air filter
There is an air filter inside the air inlet connection (fig.8, page 3).
l Use a slotted tip screwdriver of the appropriate size to unscrew the filter from the air inlet connection until it is extracted.
l Clean the filter with compressed air and then refit and screw it into position. Do not over-tighten the filter or damage may ensue.
l Reconnect the air line quick coupler after binding the thread with Teflon tape.
If the air filter is excessively contaminated or damaged, it must be renewed. Order a new filter from the manufacturer, referring to the
list of spare parts at the end of this manual.
7.3 - Checking the hydraulic oil.
Periodically check that the pump contains the correct quantity of hydraulic oil by checking the level on the sight glass (fig.9, page 3).
If the oil level, with cylinder closed, is below minimum (E, fig.9), refill using the reccomended types of oil on page 15.
7.4 - Hydraulic oil change
Change the oil at intervals of 250 duty hours. This operation must be performed when the cylinder is fully retracted:
l If the pump is mounted vertically, disassemble it and position it horizontally.
l Use a slotted tip screwdriver to remove the filler plug (fig.10, page 13).
l Empty the pump of oil by turning it upside down over a suitable container.
l Allow all the oil to flow into the container and then fill the pump with the quantity and type of new oil specified on page 15.
l Clean the filler opening with a clean cloth and refit the plug, pressing it fully down or, if necessary, to the partially inserted breather
position.
18
COD. 193555075 - v.2 - UPD 220207
PROBLEM
Pump cannot be started
Pump stops working under load
Pump operates but no pressurized oil is
delivered
Pump fails to reach maximum pressure
Pump delivers pressurized oil but load
is not lifted
Piston retracts although treadle is not
pressed on RELEASE side
Piston fails to perform retract stroke
(single acting cylinder)
Piston fails to perform retract stroke
(double acting cylinder)
Pump flow rate insufficient
POSSIBLE CAUSE
Compressed air line closed or clogged
Insufficient air pressure
Air filter dirty or clogged
Oil leak in the main hydraulic circuit
Pump internal leak
Low oil level
Internal relief valve incorrectly set
Excess load
Oil circulation fault
Pump internal fault
Oil pressure line obstructed or coupling
incorrectly connected
If piston is designed to return under gravity,
ensure load is sufficient.
Cylinder spring broken
Cylinder release valve not working
Oil pressure line obstructed or coupling
incorrectly connected
Cylinder release valve not working
Air filter dirty or clogged
Reservoir breather plug or screw not
opened
CORRECTIVE ACTION
Check compressed air supply to pump
is between 2.8 and 10 bar
Clean or renew
Check the circuit for leaks and repair
as necessary
Check for leaks and return pump to
manufacturer for repair
Check level and top up as necessary
Contact manufacturer
as necessary
Reduce
Check if pipelines are obstructed or if
cylinder is working correctly
as necessary
Check for leaks and ask the
manufacturer
Check oil pressure line
Increase load on cylinder
Repair
Repair cylinder
Check oil pressure line
Repair cylinder
Clean or renew
Open breather plug or screw as
described in chapter 5, page 16.
7.5 - Troubleshooting
The following chart describes the main problems that could occur during operation of the pump, together with an indication of the
appropriate corrective action. If the prescribed action fails to solve the problem, contact the manufacturer.
8 - SCRAPPING AND DISPOSING OF THE PUMP 8 - SCRAPPING AND DISPOSING OF THE PUMP 8 - SCRAPPING AND DISPOSING OF THE PUMP 8 - SCRAPPING AND DISPOSING OF THE PUMP 8 - SCRAPPING AND DISPOSING OF THE PUMP
If the pump is no longer required for duty, empty the oil and dispose of it in accordance with the law of your country. The same procedure
must be followed for other parts of the pump, in observance of the type of material (plastics or metals).
19
COD. 193555075 - v.2 - UPD 220207
OPERA OPERA OPERA OPERA OPERATION DIA TION DIA TION DIA TION DIA TION DIAGRAM GRAM GRAM GRAM GRAM
a
b
A
S
A = Air inlet
a and b = Oil use
S = Oil reservoir
SP SP SP SP SPARE P ARE P ARE P ARE P ARE PAR AR AR AR ARTS TS TS TS TS
HOW TO ORDER SPARE PARTS
When ordering spare parts, always provide the following:
1) Part number
2) Part description
3) Pump type
4) Serial number
WARRANTY WARRANTY WARRANTY WARRANTY WARRANTY
The pump is guaranteed against material and manufacturing defects according to our standard terms and conditions for export valid at
the time of placing the order.
LIMITATIONS:
1) The dealer must get authorization from the manufacturer before carrying out
any repair work on equipment still under warranty.
2) The warranty is limited only to parts acknowledged by the manufacturer as
being defective.
3) Transportation expenses will not be refunded for repairs carried out under
warranty.
4) Any products that have not been maintained with the correct routine
maintenance procedures, that have been used improperly, involved in accidents
or subject to unauthorised repairs or alterations of any kind will not be covered
by the warranty in any way.
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COD. 193555075 - v.2 - UPD 220207
GENERALITES GENERALITES GENERALITES GENERALITES GENERALITES
Avant dinstaller la pompe et de lutiliser, lire attentivement dun bout lautre le prsent manuel, car il contient des remarques importantes
pour votre scurit.
Ce manuel doit toujours rester proximit de la pompe et de la machine sur laquelle elle est installe, mme en cas de vente ou de
changement de propritaire.
Avant dinstaller la pompe et de la mettre en service, il faut sassurer quelle na pas t dtriore pendant le transport, que le corps
de pompe ne prsente pas de fissures et nest pas caboss, et quil ne schappe pas dhuile de la pompe. Signaler des vices
ventuellement constats au transporteur. DANS CE CAS, NINSTALLEZ PAS LA POMPE, mais consultez le fabricant.
Le fabricant ne rpond pas de dommages corporels, matriels, ne de dommages causs
des animaux ou des machines, et qui sont imputables au montage et lutilisation dune
pompe dtriore.
1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPOR 1 - TRANSPORT TT TT, , , , , ST ST ST ST STOCKA OCKA OCKA OCKA OCKAGE ET DB GE ET DB GE ET DB GE ET DB GE ET DBALL ALL ALL ALL ALLA AA AAGE DE L GE DE L GE DE L GE DE L GE DE LA POMPE A POMPE A POMPE A POMPE A POMPE
En raison du faible poids de la pompe, des mesures de prcaution particulires ne sont pas ncessaires pour le transport. Si la pompe
est dabord stocke et quil doit scouler un long intervalle de temps entre lachat et lutilisation, il faut lentreposer dans des locaux
garantissant une bonne protection contre les intempries, et dont la temprature se situe entre 10 C et 50 C.
En raison de la structure de la pompe et de son emballage, il faut empiler au maximum 4 cartons les uns sur les autres.
Si les pompes sont livres sur palettes, il est recommand de ne les retirer de lemballage dorigine quau montage.
Lemballage vide doit tre limin en conformit avec les prescriptions en vigueur dans le pays concern.
2 - 2 - 2 - 2 - 2 - DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION
Avec lappareil livr, il sagit dune pompe permettant dtablir une pression hydraulique partir de lalimentation en air comprim (voir
chap. 4 Caractristiques techniques).
Cette pompe peut tre utilise pour lalimentation directe de dispositifs hydrauliques simple et double effet.
Toute autre utilisation de la pompe doit tre considre comme incorrecte et peut provoquer de
graves accidents. Le fabricant dcline toute responsabilit pour des dommages rsultant de
lutilisation de la pompe, non conforme aux prescriptions.
Le fabricant se tient tout moment votre disposition pour des demandes de prcisions, afin dliminer tout doute relatif
linstallation et lutilisation correcte de la pompe.
Sur la figure 10 sont reprsentes les diffrentes pices de la pompe.
Fig.10
Corps / Rservoir
Blocage de la pdale
Raccordement de
lentre dair comprim
Pdale de pompage
Vis de purge
Raccordements pour les
tuyaux flexibles hydrauliques
Couvercle de remplissage et damorage
Raccordement de dispositifs double effet
pour dcharge dans le rservoir
21
COD. 193555075 - v.2 - UPD 220207
3 - 3 - 3 - 3 - 3 - SCURIT SCURIT SCURIT SCURIT SCURIT
Toutes les prescriptions dcrites ci-aprs doivent tre strictement observes, car elles sont de la plus grande importance pour votre
propre scurit et pour la scurit dautres personnes. Outres les indications figurant dans le prsent chapitre, il faut aussi observer
toutes les autres directives se trouvant dans ce manuel.
Nessayez en aucun cas denlever ou de modifier les dispositifs de protection installs. Ne modifiez non plus aucune pice
de la pompe, car il pourrait sensuivre des situations dangereuses auxquelles ne sattend pas lutilisateur ou la personne
responsable de lentretien.
Lenlvement ou la modification des dispositifs de scurit installs sur la pompe entrane la dchance immdiate de tout
droit la garantie, et le fabricant est dgag de toute responsabilit civile.
l La pompe et la machine sur laquelle la pompe est installe ne doivent tre utilises que par des personnes adultes qui connaissent
bien la machine et ont lu entirement le prsent manuel.
l Des mineurs, toutefois pas au-dessous de 16 ans, ne sont autoriss utiliser la pompe que sous la surveillance dune personne
adulte habilite utiliser la pompe.
l La zone de travail doit tre maintenue libre afin quil soit possible de commander la pompe de faon correcte et fiable. Veillez au
risque doutils pouvant ventuellement tomber et actionner inopinment la pompe.
l La zone de travail doit tre propre. Il faut tout particulirement carter des restes dhuile, de graisse ou dautres substances
glissantes et corrosives.
l La pompe doit tre tenue lcart de zones excessivement chaudes, de flammes jaillissantes ou dtincelles. La temprature
maximale de fonctionnement ne doit pas dpasser 50 C.
l Ne travaillez jamais avec des vtements amples ou ouverts. Portez les vtements de protection prescrits par le chef de service.
l Ne montez pas en pieds sur la pompe pour la manoeuvrer. Elle est suffisante une lgre pression du pied pour actionner le
mcanisme de la pompe.
l Sil devait savrer ncessaire de dposer les tuyauteries dalimentation et le circuit hydraulique, sassurer quils ne sont pas sous
pression.
l Pour le raccordement de la pompe, il faut suivre exactement les prescriptions figurant au chapitre 5 "Installation et mise en service"
et toujours utiliser des tuyaux flexibles et raccords certifis.
l En cas de drangements, nessayez jamais de remettre vous-mmes la pompe en marche ou de la rparer. Interrompez lalimentation
lectrique de la pompe, arrtez la machine sur laquelle elle est monte, et informez la personne comptente pour lentretien de la
pompe.
l Ne modifiez pas de votre propre autorit le lieu dimplantation de la pompe. La pompe ne doit tre utilise que dans la position
prvue par le fabricant de la machine.
22
COD. 193555075 - v.2 - UPD 220207
4 - 4 - 4 - 4 - 4 - CARA CARA CARA CARA CARACTRISTIQUES TECHNIQUES CTRISTIQUES TECHNIQUES CTRISTIQUES TECHNIQUES CTRISTIQUES TECHNIQUES CTRISTIQUES TECHNIQUES
TYPES DHUILE UTILISER TYPES DHUILE UTILISER TYPES DHUILE UTILISER TYPES DHUILE UTILISER TYPES DHUILE UTILISER
MOBIL DTE 11 - SHELL TELLUS OIL T 15 - CASTROL HYSPIN AWH15 - ou des types quivalents
Modle AHP21E-632
Part Nr. HR149 463 260
Pression lentre dair (bars) 2,8 10
Raccordement dair G
filet interne
Pression maximale de fonctionnement* (MPa) 63
1
Capacit nominale (l/min.) voir le diagramme suivant
Quantit dhuile en position horizontale / 2,4
quantit utile (l) 2,1
Quantit dhuile en position verticale / 2,2
quantit utile (l) 1,5
Raccordement hydraulique, entre M14x1,5
filet interne
Raccordement hydraulique, sortie M14x1,5
filet interne
Niveau acoustique 75 dB(A)/1m
Dimensions ** (L x L x H) 365x155x210
Poids avec huile (Kg) < 7,5
* Pour rgler et vrifier la pression, utiliser seulement des manomtres avec un champ de mesure maximum
jusquaux 1000 bar (100 MPa) et classe de prcision 0.1, ou meilleur!
** Schma dimensionnelle voir fig.1, page 2.
23
COD. 193555075 - v.2 - UPD 220207
5 - INST 5 - INST 5 - INST 5 - INST 5 - INSTALL ALL ALL ALL ALLA AA AATION TION TION TION TION ET MISE EN SER ET MISE EN SER ET MISE EN SER ET MISE EN SER ET MISE EN SERVICE VICE VICE VICE VICE
Dans ce chapitre est dcrite linstallation de la pompe. Les directives suivantes sont recommandes comme la faon optimale de
procder. Lacheteur de la pompe - donc le fabricant de la machine sur laquelle la pompe est monte - peut bien dcider de procder
diffremment au montage, et utiliser des triers ou autres accessoires quil tient pour appropris, TOUTEFOIS SANS MODIFIER EN
QUELQUE FAON LA FORME OU LA SUSPENSION DORIGINE DE LA POMPE ET, EN TOUT CAS SANS ENLEVER LUN
QUELCONQUE DES DISPOSITIFS DE PROTECTION QUI SONT POSS SUR LA POMPE, NI RENDRE LA POMPE DANGEREUSE
EN QUELQUE FAON. Sil procde de telles modifications, il est seul responsable de tout accident ventuellement provoqu par
lutilisation de la pompe.
La pompe peut tre monte aussi bien plat ( lhorizontale) que debout ( la verticale).
la page 2, la fig. 3 reprsente le gabarit de perage utiliser pour la planification de la base de fixation de la pompe.
Cest daprs lui que doit tre ancre la pompe au moyen des quatre vis.
ATTENTION: la profondeur des trous de fixation ne doit pas dpasser 20 mm.
5.1 - Remplissage du rservoir huile (dans la mesure o la pompe est livre vide)
la page 22 figurent les quantits dhuile vider dans le rservoir en fonction du positionnement de la pompe
Dans le mme tableau figurent aussi les quantits dhuile effectivement utiles.
Utilisez les types dhuile indiqus la page 22. Des huiles prsentant dautres caractristiques peuvent dtriorer srieusement la
pompe et la rendre inutilisable. LE FABRICANT NE RPOND PAS DE DOMMAGES CORPORELS, MATRIELS OU AFFECTANT
LA MACHINE, QUI SONT IMPUTABLES LUTILISATION DE TYPES NON APPROPRIS DHUILES OU LUTILISATION DHUILE
DE VIDANGE. LE FAIT QUE DES DOMMAGES AFFECTANT LA POMPE SONT DUS AUX RAISONS CI-DEVANT ENTRANE LA
DCHANCE IMMDIATE DE TOUT DROIT GARANTIE.
l Retirer au moyen dun tournevis plat le couvercle de remplissage (fig.10, page 20), et lenlever compltement.
l Vider dans le rservoir la bonne quantit dhuile telle quelle figure dans le tableau, page 22.
l Nettoyer lorifice de remplissage avec un chiffon propre ; poser de nouveau le couvercle et lenfoncer compltement.
5.2 - Raccordements hydrauliques de la pompe
l Raccorder les tuyaux flexibles hydrauliques lorifice de sortie (A, fig. 3) et louverture du rservoir (B, fig.3) de la pompe. Les
tuyaux flexibles doivent tre pourvus dun raccord M14x1,5.
5.3 - Prparation de la pompe
5.3.1 - Prparation de la pompe installe plat ( lhorizontale)
l Si la pompe est utilise lhorizontale, dvisser de trois ou quatre tours la vis de purge (fig.4, page 2) avec un tournevis correspondant.
5.3.2 - Prparation de la pompe installe debout ( la verticale)
l Si la pompe est utilise la verticale, dvisser au moyen dun tournevis plat, le couvercle damorage (rep. D sur la fig.5, page 3)
jusquau premier encliquetage.
5.4 - Prparation de la pompe
l Visser fermement sur le raccordement dair comprim (fig.10, page 20) un raccord rapide convenant votre installation, et dont
vous avez au pralable entour le filetage de ruban en tflon.
l Le raccord rapide doit tre branch sur une tuyauterie pouvant livrer une pression entre 2,8 et 10 bars (voir tableau Caractristiques
techniques, page 22)
6 - 6 - 6 - 6 - 6 - FONCTIONNEMENT FONCTIONNEMENT FONCTIONNEMENT FONCTIONNEMENT FONCTIONNEMENT
6.1 - Fonctionnement de la pdale
Votre pompe peut tre utilise en service intermittent ou continu.
l Service intermittent: Appuyez sur la pdale pour actionner la pompe (fig.6, page 3), et lchez-la pour arrter la pompe.
l Service continu: Appuyez sur la pdale (fig.6, page 3) et poussez la broche de verrouillage (fig.7, page 3) pour que la commande
par pdale soit maintenue en position de travail.
Maintenant, suivant le type dentranement install, la pompe peut tre utilise de diffrentes faons.
Pour interrompre le dbit dhuile, appuyer fermement sur la pdale pour dbloquer la broche de verrouillage.
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COD. 193555075 - v.2 - UPD 220207
7 - 7 - 7 - 7 - 7 - ENTRETIEN ENTRETIEN ENTRETIEN ENTRETIEN ENTRETIEN
Toutes les interventions dentretien rgulier dcrites ci-aprs doivent tre excutes par du personnel expriment qui connat bien la
pompe et son fonctionnement et a lu entirement le prsent manuel. Dans lexcution des travaux dentretien, il faut procder
prcautionneusement afin dviter des accidents. Les oprations dcrites dans ce manuel sont les seules interventions admissibles.
Toute intervention dentretien par du personnel ny tant pas habilit provoque la dchance immdiate de la garantie de la
pompe et dgage de toute responsabilit le fabricant.
7.1 - Contrle des raccordements
Il faut vrifier chaque semaine les raccordements hydrauliques et pneumatiques. Persuadez vous que les raccordements sur la
pompe ne sont pas dvisss ou desserrs, et ne prsentent pas de fissures ou autres dtriorations. Assurez-vous que les tuyauteries
ne sont pas dtriores ni taillads.
7.2 - Nettoyage du filtre air
lintrieur du raccord pneumatique se trouve un filtre air (fig. 8, page 3).
l Au moyen dun tournevis plat ayant la taille voulue, dvisser le filtre dans le raccordement dair comprim et le retirer compltement.
l Nettoyer le filtre lair comprim, puis le reposer et le visser. Ne pas trop serrer afin de ne pas dtriorer le filetage.
l Visser de nouveau le raccord rapide pralablement envelopp de ruban en tflon. Si le filtre est excessivement encrass ou
dtrior, il faut le remplacer par un neuf. Ce dernier peut tre command chez le fabricant; cet effet, nous renvoyons la liste
des pices de rechange la fin du prsent manuel.
7.3 - Contrle de lhuile hydraulique
De temps autre, il faut contrler si la pompe contient la quantit correcte dhuile hydraulique. Le niveau dhuile se contrle au verre
de regard sur le rservoir de la pompe (fig.9, page 3). Si le niveau dhuile a atteint le repre minimal visible (E sur la fig.9), il faut rajouter
de lhuile dune des marques conseilles a page 22.
7.4 - Vidange de lhuile hydraulique
Il faut remplacer lhuile hydraulique toutes les 250 heures de fonctionnement. Cette opration doit tre effectue quand le vrin est
compltement rentr:
l Si la pompe est monte la verticale, il faut la dposer et la positionner lhorizontale.
l Au moyen dun tournevis plat, retirer compltement le couvercle de remplissage (fig.10, page 20).
l Retourner la pompe au-dessus dun bac de rcupration dhuile de vidange et la vider.
l Faire couler toute lhuile contenue dans le rservoir puis remplir la pompe dhuile neuve. Quantits et types dhuiles figurent la
page 22.
l Nettoyer lorifice de remplissage avec un chiffon propre, reposer le couvercle et lenfoncer jusqu ce quil tienne bien ou, si
ncessaire, le mettre en position de dsarage.
6.2 - Fonctionnement des commandes
La pompe est conue pour tre relie un distributeur siges 3/2 ou 4/2 voies avec raccordement CETOP 03
Pour un raccordement correct de la vanne CETOP sur la pompe, nous renvoyons la documentation technique jointe la vanne.
ATTENTION : Aprs la premire installation de la pompe, il peut arriver ventuellement que le circuit paraisse vide du fait de
la prsence de bulles dair. Si la pompe ne russit pas mettre lhuile sous pression, procder comme dcrit ci-aprs.
Si la pompe est monte la verticale, il faut la dposer et la poser lhorizontale sur le sol.
Remplissage de la pompe avec distributeur siges 3/2 voies
l Appuyer sur la pdale de la pompe et positionner le distributeur environ 15 secondes sur dcharge.
l Raccorder un vrin et contrler si la pompe est remplie. Si le vrin ne se dplace pas, rpter lopration.
Remplissage dde la pompe avec distributeur siges 4/2 voies
l Au moyen dun tuyau flexible appropri, relier lorifice ct pression la dcharge, et appuyer environ 15 secondes sur la pdale
l Raccorder un vrin et contrler si la pompe est remplie. Si le vrin ne se dplace pas, rpter lopration.
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COD. 193555075 - v.2 - UPD 220207
8 - 8 - 8 - 8 - 8 - MISE L MISE L MISE L MISE L MISE LA FERRAILLE ET LIMIN A FERRAILLE ET LIMIN A FERRAILLE ET LIMIN A FERRAILLE ET LIMIN A FERRAILLE ET LIMINA AA AATION DE L TION DE L TION DE L TION DE L TION DE LA PO A PO A PO A PO A POMPE MPE MPE MPE MPE
Si la pompe doit tre mise la ferraille, il faut vider lhuile quelle contient et lliminer conformment aux dispositions lgales en
vigueur dans le pays concern. La mme chose sapplique aux autres pices de la pompe qui doivent tre spares par catgories de
matriaux (matire plastique/fer).
Drangement
La pompe ne dmarre pas.
Sous charge la pompe sarrte.
La pompe fonctionne bien mais ne met
pas lhuile sous pression.
La pompe natteint pas la pression
maximale.
La pompe tablit une pression, mais la
charge ne se dplace pas.
Le piston rentre bien que la pdale soit
relche.
Le piston ne revient pas (vrin simple
effet)
Le piston en revient pas (vrin double
effet)
Dbit insuffisant
Cause possible
La tuyauterie dalimentation en air
comprim est ferme ou engorge.
Pression dair trop faible
Filtre air encrass ou colmat
De lhuile schappe de linstallation
hydraulique.
Point de fuite dans la pompe
Niveau dhuile trop bas
Soupape intrieure de sret drgle
hydraulique.
Surcharge
Lhuile ne circule pas correctement.
hydraulique.
Panne dans la pompe
Tuyauterie dalimentation en huile coince
ou raccord rapide mal raccord
En cas de retour par gravit: manque de
charge sur le vrin
Ressort du vrin dtrior
La soupape de relchement du vrin ne
fonctionne pas.
Tuyauterie dalimentation en huile coince
ou raccord rapide mal raccord
La soupape de relchement du vrin ne
fonctionne pas.
Filtre air encrass ou colmat
Le rservoir na pas t purg.
Remde
Assurer que lair comprim arrive la
pompe.
Assurer que la pression dans la tuyaute-
rie dalimentation de la pompe (air
comprim) se situe entre 2,8 et 10 bars.
Nettoyer le filtre air ou le remplacer.
Vrifier sil y a un point de fuite, et le
rparer le cas chant.
Vrifier sil y a un point de fuite dans la
pompe ; si oui, lexpdier chez le
fabricant pour quil la rpare.
Contrler le niveau dhuile et, si
ncessaire, faire lappoint.
Prendre contact avec le fabricant.
Rduire la charge.
Vrifier si les tuyauteries prsentent des
goulots dtranglement ou sont
coinces, et si le vrin est dtrior.
Vrifier le point de fuite dans la pompe,
et prendre contact avec le fabricant.
Vrifier la tuyauterie dalimentation en
huile.
Charger le vrin.
Rparer le vrin.
Rparer le vrin.
Vrifier la tuyauterie dalimentation en
huile.
Rparer le vrin.
Nettoyer le filtre air ou le remplacer.
Purger le rservoir comme dcrit au
chapitre 5, page 23.
7.5 - Drangements et remdes
Dans le chapitre suivant sont exposes quelques anomalies qui peuvent apparatre pendant le fonctionnement; en face sont dcrits
les remdes correspondants. Si les problmes ne peuvent pas tre rsolus au moyen des interventions dcrites ici, il faut consulter le
fabricant.
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COD. 193555075 - v.2 - UPD 220207
SCHEMA DE FONCTIONNEMENT SCHEMA DE FONCTIONNEMENT SCHEMA DE FONCTIONNEMENT SCHEMA DE FONCTIONNEMENT SCHEMA DE FONCTIONNEMENT
A = Entre dair
a et b = Utilisation dhuile
S = Rservoir huile
a
b
A
S
G GG GGARANTIE ARANTIE ARANTIE ARANTIE ARANTIE
Pour des vices de matriau ou de fabrication de la pompe, il est donn une garantie de 12 (douze) mois partir de la date de livraison.
RESTRICTIONS:
1) Avant de procder des travaux de rparation sur la machine sous
garantie, le concessionnaire doit y tre habilit par le fabricant.
2) La garantie se limite aux pices reconnues par le fabricant comme
dfectueuses.
3) Pour des travaux sous garantie, les frais de transport ne sont pas
accepts.
4) Il nest pas accord de garantie pour des produits qui nont pas fait
lobjet dun entretien correct et rgulier, qui ont t utiliss de faon
incorrecte, qui ont subi des accidents, sur lesquels ont t
effectues des rparations ou diverses modifications pas permises.
PIECES DE RECHANGE PIECES DE RECHANGE PIECES DE RECHANGE PIECES DE RECHANGE PIECES DE RECHANGE
COMMANDE DE PICES DE RECHANGE
la commande de pices de rechange, les indications suivantes sont toujours ncessaires :
1) Numro de rfrence de la pice de rechange
2) Dnomination de la pice
3) Type de pompe
4) Numro de fabrication de la pompe
27
COD. 193555075 - v.2 - UPD 220207
AD AD AD AD ADVER VER VER VER VERTENCIAS GENERALES TENCIAS GENERALES TENCIAS GENERALES TENCIAS GENERALES TENCIAS GENERALES
Antes de la instalacin y el uso de esta bomba lean atentamente todo lo detallado en el presente manual, ya que el mismo contiene
advertencias importantes para su seguridad.
Este manual deber acompaar siempre a la bomba y a la mquina en la que se halle instalada, incluso en caso de venta o cesin de
la misma.
Antes de instalar y hacer operativa la bomba, comprueben que la misma no haya sufrido daos durante el transporte, que el cuerpo no
presente grietas o abolladuras y que no existan prdidas de aceite de la bomba. En caso contrario,notifiquen al transportista lo advertido,
NO INSTALEN LA BOMBA y contacten al fabricante para recibir informacin al respecto.
El fabricante no responder de los daos a personas, animales, cosas o maquinarias
provocados por el montaje y el uso de una bomba estropeada.
1 TRANSPOR 1 TRANSPOR 1 TRANSPOR 1 TRANSPOR 1 TRANSPORTE, ALMA TE, ALMA TE, ALMA TE, ALMA TE, ALMACEN CEN CEN CEN CENAMIENT AMIENT AMIENT AMIENT AMIENTO Y DESEMB O Y DESEMB O Y DESEMB O Y DESEMB O Y DESEMBAL AL AL AL ALAJE AJE AJE AJE AJE
El peso de la bomba es reducido, por lo que no debern adoptarse medidas especiales de transporte.
El almacenamiento de la bomba, en caso de que sta sea puesta en el almacn y utilizada bastante tiempo despus de la compra,
deber efectuarse en locales protegidos adecuadamente contra los agentes atmosfricos y en los que la temperatura est comprendida
entre 10 y 50 Centgrados.
La estructura de la bomba y de su embalaje consiente un apilamiento mximo de cuatro cajas individuales. En caso de que las
bombas se entreguen ya embaladas sobre palets, se recomienda quitarlas del embalaje original slo en el momento de su montaje.
Eliminar el embalaje vaco siguiendo lo prescrito por la ley del pas en el que ese lleve a cabo dicha operacin.
2 - DESCRIPCIN 2 - DESCRIPCIN 2 - DESCRIPCIN 2 - DESCRIPCIN 2 - DESCRIPCIN
El aparato suministrado es una bomba que permite conseguir un caudal hidrulico bajo presin (vase cap. 4 Caractersticas tcnicas)
de una alimentacin neumtica.
Esta bomba puede alimentar directamente dispositivos hidrulicos de simple o de doble efecto.
Cualquier otro uso de la bomba deber considerarse inadecuado, pudiendo originar serios
accidentes. El fabricante declina toda responsabilidad por los daos ocasionados como
consecuencia de un uso incorrecto de la bomba.
El fabricante estar a su disposicin para aclarar cualquier duda respecto a la instalacin o al uso correcto de la bomba.
La Fig.10 ilustra los distintos componentes de la bomba.
Fig.10
Cuerpo / depsito
Racor entrada aire
comprimido
Pulsador de bloqueo del pedal
Pedal de accionamiento Tapn de llenado y de purga.
Racor de doble efecto para
descarga en depsito
Tornillo de purga
Uniones para
tubos hidrulicos
28
COD. 193555075 - v.2 - UPD 220207
3 - SEGURID 3 - SEGURID 3 - SEGURID 3 - SEGURID 3 - SEGURIDAD AD AD AD AD
Sigan atentamente todas las reglas descritas a continuacin, ya que son muy importantes para su seguridad y la de las dems
personas. Adems de las indicaciones detalladas en este captulo, debern tener en cuenta todas las dems sealadas en el manual.
NO INTENTEN ALTERAR LAS PROTECCIONES INSTALADAS, NI MODIFIQUEN NINGN COMPONENTE DE LA BOMBA, YA
QUE PODRAN CREARSE SITUACIONES DE PELIGRO PARA LAS QUE NI EL OPERADOR NI EL ENCARGADO DEL
MANTENIMIENTO ESTN PREPARADOS.
LA ELIMINACIN O LA ALTERACIN DE CUALQUIER DISPOSITIVO DE SEGURIDAD APLICADO EN LA BOMBA HAR QUE
LA GARANTA PIERDA SU VALIDEZ DE INMEDIATO Y EXIMIR AL FABRICANTE DE TODA RESPONSABILIDAD.
l El uso de la bomba y de la mquina en la que se halla instalada la misma est reservado a personas mayores de edad, que
conozcan bien la mquina y la bomba y que hayan ledo este manual en su totalidad.
l Estar consentido el uso a menores de edad, en cualquier caso de edad no inferior a 16 aos, slo bajo la supervisin de un mayor
de edad habilitado para el uso.
l Mantengan libre de obstculos la zona de trabajo, con el fin de poder maniobrar correctamente y de forma segura la bomba.
Presten atencin a eventuales objetos que, al caer, pudieran accionar la bomba inadvertidamente.
l El rea de trabajo deber estar limpia, evitando especialmente la presencia de aceites, grasa u otras sustancias resbaladizas o
corrosivas.
l Mantengan la bomba lejos de zonas de calor excesivo, llamas vivas o chispas. La temperatura mxima de uso no deber superar
los 50 Centgrados.
l La bomba deber ser accionada exclusivamente con los pies. No intenten maniobrarla con cualquier otra parte del cuerpo, ya que
podran provocarse accidentes.
l No trabajen con ropas anchas o desatadas. Pnganse todas las prendas de proteccin exigidas por el jefe de reparto.
l No se suban a la bomba para maniobrarla. Bastar con ejercer con el pie una ligera presin para accionar el
mecanismo interno.
l No se suban a la bomba para maniobrarla. Bastar con ejercer con el pie una ligera presin para accionar el mecanismo interno.
l En caso de ser necesario, desconecten las tuberas de alimentacin y del circuito hidrulico; asegrense de que no haya presin.
l Para acoplar la bomba sigan minuciosamente las indicaciones del captulo 5 Instalacin y puesta en funcin y utilicen siempre
tubos y racores certificados.
l En caso de avera, no intenten desbloquear o reparar la bomba solos. Desconecten la bomba de la alimentacin, apaguen la
mquina a la que se halla conectada y contacten al encargado del mantenimiento.
l No cambien la bomba de puesto de manera arbitraria. La bomba deber usarse en la posicin dispuesta por el fabricante de la
mquina en la que est aplicada.
29
COD. 193555075 - v.2 - UPD 220207
4- CARA 4- CARA 4- CARA 4- CARA 4- CARACTERSTICAS TCNICAS CTERSTICAS TCNICAS CTERSTICAS TCNICAS CTERSTICAS TCNICAS CTERSTICAS TCNICAS
Modelo AHP21E-632
Part No.. HR149 463 260
Presin entrada aire (bares) 2,8 10
Unin aire G
hilo de rosca interno
Presin mxima de utilizacin* (MPa) 63
1
Caudal nominal (l/min.) vea el diagrama siguiente
Contenido aceite en pos. 2,4
horizontal /cantidad utilizable (I) 2,1
Contenido aceite en pos. 2,2
vertical /cantidad utilizable (I) 1,5
Unin hidrulica, entrada M14x1,5
Unin hidrulica, salida M14x1,5
Ruido 75 dB(A)/1m
Dimensiones ** (L x A x A) 365x155x210
Peso con aceite (Kg) < 7,5
* Para regular y probar la presin, utilizar solamente manmetros con un campo de medida mximo hasta el 1000
bar (100 MPa) y clasifica de precisin 0.1, o mejor!
** Esquema dimensional vea fig.1, pg. 2.
TIPOS DE A TIPOS DE A TIPOS DE A TIPOS DE A TIPOS DE ACEITE A UTILIZAR CEITE A UTILIZAR CEITE A UTILIZAR CEITE A UTILIZAR CEITE A UTILIZAR
MOBIL DTE 11 SHELL TELLUS OIL T 15 CASTROL HYSPIN AWH15 o equivalentes
30
COD. 193555075 - v.2 - UPD 220207
5 INST 5 INST 5 INST 5 INST 5 INSTAL AL AL AL ALA AA AACIN Y PUEST CIN Y PUEST CIN Y PUEST CIN Y PUEST CIN Y PUESTA EN FUNCIN A EN FUNCIN A EN FUNCIN A EN FUNCIN A EN FUNCIN
En este captulo se describen las modalidades de instalacin de la bomba. Dichas indicaciones son aconsejadas como ptimas. El
comprador de la bomba, y por lo tanto fabricante de la mquina que lleva montada la misma bomba, podr optar por diferentes tipos
de montaje, utilizando estribos o cualquier otro accesorio que estime oportuno, PERO SIN VARIAR DE NINGN MODO LA FORMA
O EL ENGANCHE ORIGINAL DE LA BOMBA Y, EN CUALQUIER CASO, SIN ALTERAR NINGUNA PROTECCIN APLICADA A LA
MISMA O HACER QUE LA BOMBA PUEDA RESULTAR, DE ALGN MODO, PELIGROSA. Tras dichas modificaciones, l ser el
nico responsable de todos aquellos accidentes que pudieran verificarse durante el uso.
La bomba podr montarse tanto en posicin horizontal como en posicin vertical.
En la fig. 3 de la pg. 2 aparece indicado el escantilln para horadar a utilizar para hacer la base de fijacin de la bomba.
La bomba deber fijarse luego utilizando cuatro tornillos.
ATENCIN: la profundidad til de la perforacin de fijacin es de 20 milmetros y sta no debe ser superada.
5.1 - Llenado del depsito del aceite (si la bomba se suministra vaca)
En la pg.29 se indican las cantidades de aceite a verter en el depsito de la bomba con relacin a la colocacin de la misma bomba.
En la misma tabla se indican las cantidades de aceite efectivamente utilizables.
Utilicen los aceites indicados en la pg.29. El uso de aceites con caractersticas diferentes puede provocar graves daos a la bomba
y hacerla inutilizable.
EL FABRICANTE NO RESPONDER DE LOS DAOS ORIGINADOS A PERSONAS, MQUINAS O COSAS COMO
CONSECUENCIA DEL USO DE ACEITES INAPROPIADOS O DE VACIADOS.
EN CASO DE QUE SE PROVOQUEN DAOS A LA BOMBA POR LOS MOTIVOS CITADOS ANTERIORMENTE, LA GARANTA
PERDER INMEDIATAMENTE SU VALIDEZ.
l Con la ayuda de un destornillador de hoja plana, extraigan, hasta quitarlo, el tapn de llenado (fig.10, pg.27).
l Viertan en el depsito la cantidad exacta de aceite de acuerdo con lo indicado en la tabla de la pg. 29.
l Limpien la boca con un trapo limpio y vuelvan a colocar el tapn apretndolo hasta que quede bloqueado.
5.2 - Conexiones hidrulicas de la bomba
l Conecten los tubos hidrulicos a la boca de salida (A en fig.3, pg.2) y a la boca del depsito (B en fig.3) de labomba. Los tubos
debern estar dotados del acoplador M14x1,5 .
5.3 - Preparacin de la bomba
5.3.1 - Colocada horizontalmente
l Si se utiliza la bomba colocada horizontalmente, desenrosquen el tornillo de purga (fig.4, pg.3) de tres o cuatro vueltas utilizando
un destornillador adecuado.
5.3.2 - Colocada verticalmente
l Si se utiliza la bomba colocada verticalmente, con la ayuda de un destornillador de hoja plana, extraigan hasta escuchar el primer
clic el tapn de purga (pos.D en fig.5, pg.3).
5.4 - Conexin del aire comprimido
l Enrosquen en el racor de entrada para el aire comprimido (fig.10, pg.27) un racor rpido adecuado para su instalacin, enrollando
previamente la rosca con cinta de Tefln.
l El acoplamiento rpido ir conectado a una lnea que pueda suministrar una presin comprendida entre 2,8 y 10 bares (vase
tabla Datos Tcnicos en pg.29).
6 - USO 6 - USO 6 - USO 6 - USO 6 - USO
6.1 - Uso del pedal
La bomba que se halla en su haber podr ser empleada de modo intermitente o continuado:
l Empleo intermitente: aprieten el pedal para accionar la bomba (fig.6, pg.3) y sultenlo para detenerla.
l Empleo continuado: aprieten el pedal (fig.6, pg.3) y empujen luego el perno de bloqueo (fig.7, pg.3) para detener el pedal en
la posicin de funcionamiento.
La bomba podr utilizarse de manera diferente segn el tipo de actuador que se halle instalado.
Para interrumpir el flujo de aceite, aprieten con decisin el pedal de manera que el perno se desenganche.
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COD. 193555075 - v.2 - UPD 220207
6.2 - Uso de los mandos
La bomba est preparada para la conexin a una vlvula direccional 3/2 4/2 con unin CETOP 03.
Para efectuar una unin correcta de la vlvula CETOP a la bomba, consulten la documentacin que acompaa a la vlvula.
ATENCIN: puede que, tras la primera instalacin de la bomba, el circuito est descargado por la presencia de burbujas de
aire. En caso de que la bomba no logre poner bajo presin el aceite, efecten lo descrito seguidamente.
Si la bomba est colocada verticalmente, desmontela y coloqela horizontalmente en el piso
Cebado de la bomba con vlvula direccional 3/2.
l Aprieten el pedal de la bomba y coloquen la vlvula en descarga durante unos 15 segundos.
l Conecten un cilindro y verifiquen si la bomba est cebada. Si el cilindro no se mueve, repitan la operacin.
Cebado de la bomba con vlvula direccional 4/2.
l Conecten con un tubo adecuado la boca de impulsin en descarga y aprieten el pedal durante unos 15 segundos.
l Conecten un cilindro y verifiquen si la bomba est cebada. Si el cilindro no se mueve, repitan la operacin.
7 - MANTENIMIENT 7 - MANTENIMIENT 7 - MANTENIMIENT 7 - MANTENIMIENT 7 - MANTENIMIENTO OO OO
Todas las operaciones de mantenimiento ordinario descritas a continuacin debern ser llevadas a cabo por personal preparado, que
conozca bien la bomba y su funcionamiento y que haya ledo en su totalidad el presente manual. El mantenimiento deber efectuarse
prestando la mxima atencin, con el fin de evitar accidentes. Las operaciones descritas en este captulo son las nicas que estn
permitidas. Toda operacin de mantenimiento no autorizada har que la garanta de la bomba pierda inmediatamente su
validez y eximir al fabricante de cualquier responsabilidad.
7.1 - Verificacin de las conexiones
Verifiquen cada semana las conexiones hidrulicas y neumticas, comprueben que los racores de la bomba no estn desenroscados
o aflojados, ni presenten roturas, grietas o abolladuras. Verifiquen que las tuberas no estn daadas o cortadas.
7.2 - Limpieza del filtro del aire
En el interior del racor neumtico de entrada se halla alojado un filtro para el aire (fig.8, pg. 3).
l Con la ayuda de un destornillador de hoja plana de dimensiones adecuadas, desenrosquen, hasta su completa extraccin, el filtro
que se haya alojado en el interior del racor de entrada para el aire comprimido.
l Lmpienlo soplando con aire comprimido, luego vuelvan a situarlo en su posicin y enrsquenlo en su alojamiento sin forzar
excesivamente para evitar que se rompa.
l Vuelvan a conectar el racor de acoplamiento rpido, enrollndolo, antes de enroscarlo, con cinta de Tefln.
En caso de que el filtro estuviera excesivamente sucio o daado, habr que sustituirlo por uno nuevo. Realicen el pedido al fabricante
tras haber consultado la lista de repuestos que se halla al final de este manual.
7.3 - Control del aceite hidrulico
Controlen de vez en cuando que la bomba contenga la cantidad correcta de aceite hidrulico, verificndola a travs del ojo situado en
el depsito de la bomba (fig. 9, pg. 3).
Cuando el nivel del aceite, con el cilindro retrado, alcance el mnimo visible (E en fig. 9), efecten el llenado utilizando para ello los
aceites aconsejados en la pg. 29.
7.4 - Sustitucin del aceite hidrulico
Sustituir el aceite cada 250 horas de trabajo; dicha operacin deber efectuarse con el cilindro completamente retrado:
l Si la bomba se halla montada en posicin vertical, desmntenla y colquenla en horizontal.
l Con la ayuda de un destornillador de hoja plana, extraigan, hasta quitarlo, el tapn de llenado (fig.10, pg.27).
l Vuelquen la bomba sobre un contenedor que pueda recoger el aceite de vaciado.
l Dejen escurrir todo el aceite contenido en el depsito y rellenen luego la bomba con aceite nuevo. Las cantidades y los tipos de
aceite aparecen indicados en la pg.29.
l Limpien la boca con un trapo limpio y vuelvan a colocar el tapn apretndolo hasta bloquearlo o en posicin de purga si es
necesario.
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7.5 Problemas y soluciones
En el apartado siguiente se indican algunas anomalas que pueden advertirse durante el funcionamiento de la bomba y su solucin.
Si, actuando del modo descrito, no pudiera resolverse dicha situacin crtica, consulten al fabricante.
PROBLEMA
La bomba no se pone en marcha
La bomba se bloquea bajo carga
La bomba funciona pero no manda
aceite bajo presin
La bomba no alcanza la mxima
presin
La bomba alcanza la presin pero la
carga no se mueve
El pistn se retrae aunque no se
apriete el pedal RELEASE
El pistn no retorna (Cilindro de simple
efecto)
El pistn no retorna (Cilindro de doble
efecto)
Caudal de la bomba insuficiente
POSIBLE CAUSA
La lnea del aire comprimido est cerrada u
obstruida.
Presin del aire demasiado baja.
Filtro del aire sucio u obstruido.
Prdida de aceite en la instalacin hidrulica
general.
Prdida interna de la bomba.
Nivel del aceite demasiado bajo.
Vlvula interna de seguridad fuera de calibrado.
general.
Carga excesiva.
El aceite no circula correctamente.
general.
Avera interna de la bomba.
Lnea de alimentacin de aceite estrangulada
o acoplamiento mal conectado.
Si el retorno est previsto por gravedad,
posible falta de carga en el cilindro.
Muelle del cilindro roto.
Vlvula de liberacin del cilindro no
funcionante.
Lnea de alimentacin de aceite estrangulada
o acoplamiento mal conectado.
Vlvula de liberacin del cilindro no
funcionante.
Filtro del aire sucio u obstruido.
El depsito no ha sido purgado.
SOLUCIN
Verificar que llegue aire comprimido a
la bomba.
Verificar que la presin de alimentacin
de la bomba (aire comprimido) est
comprendida entre 2,8 y 10 bares.
Limpiar o sustituir el filtro del aire.
Verificar la presencia de la prdida y
reparar donde sea necesario.
Verificar la prdida en la bomba y
enviarla al fabricante para su
reparacin.
Verificar el nivel del aceite y, si es
necesario, rellenar.
Contactar al fabricante.
Disminuir la carga.
Verificar que las tuberas estn libres
de estrangulamientos y que el cilindro
no sea defectuoso.
Verificar la prdida en la bomba y
contactar al fabricante.
Verificar la lnea de alimentacin de
aceite.
Cargar el cilindro.
Reparar el cilindro.
Verificar la lnea de alimentacin de
aceite.
Limpiar o sustituir el filtro del aire.
Purgar el depsito como se describe
en el captulo 5 en pg.30
8 DEMOLICIN Y ELIMIN 8 DEMOLICIN Y ELIMIN 8 DEMOLICIN Y ELIMIN 8 DEMOLICIN Y ELIMIN 8 DEMOLICIN Y ELIMINA AA AACIN DE L CIN DE L CIN DE L CIN DE L CIN DE LA BOMB A BOMB A BOMB A BOMB A BOMBA AA AA
En caso de que la bomba deba ser tirada, vaciar el aceite contenido en la misma y eliminarlo siguiendo lo prescrito por la ley vigente
en el pas en el que se lleve a cabo la eliminacin. Actuar del mismo modo con los dems componentes de la bomba, teniendo en
cuenta la tipologa de los materiales que la constituyen, plsticos o ferrosos.
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COD. 193555075 - v.2 - UPD 220207
a
b
A
S
A = Entrada aire
a y b = Uso del aceite
S = Depsito del aceite
ESQUEMA DE FUNCION ESQUEMA DE FUNCION ESQUEMA DE FUNCION ESQUEMA DE FUNCION ESQUEMA DE FUNCIONAMIENT AMIENT AMIENT AMIENT AMIENTO OO OO
G GG GGARANTA ARANTA ARANTA ARANTA ARANTA
La bomba posee una garanta que cubre defectos de material y fabricacin durante un periodo de 12 (doce) meses, contados a partir
de la fecha de entrega.
LIMITACIONES:
1) El concesionario deber ser autorizado por el fabricante antes de actuar s obr e
la mquina para efectuar reparaciones en garanta.
2) La garanta se limitar slo a las piezas que el fabricante reconozca c o mo
defectuosas.
3) No ser reconocido ningn gasto de transporte para intervenciones en
garanta.
4) No se reconocer ninguna garanta para aquellos productos que no hayan
recibido un correcto mantenimiento peridico, que hayan sido utilizados de
manera inapropiada, que hayan sufrido accidentes, reparaciones no
autorizadas o alteraciones de cualquier clase.
PIEZAS DE REPUEST PIEZAS DE REPUEST PIEZAS DE REPUEST PIEZAS DE REPUEST PIEZAS DE REPUESTO OO OO
PARA REALIZAR EL PEDIDO DE PIEZAS DE REPUESTO
Cuando realicen el pedido de piezas de repuesto, especifiquen siempre los siguientes puntos:
1) Nmero de cdigo del repuesto
2) Descripcin de la pieza
3) Tipo de bomba
4) Nmero de matrcula de la bomba
34
COD. 193555075 - v.2 - UPD 220207
T T
T TTAB AB
AB AB AB.1 .1
.1 .1 .1
35
COD. 193555075 - v.2 - UPD 220207
ERSA ERSA ERSA ERSA ERSATZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SPARE P ARE P ARE P ARE P ARE PAR AR AR AR ARTS TS TS TS TS
(T (T (T (T (TAB AB AB AB AB. 1) . 1) . 1) . 1) . 1)
POS. Bezeichnung Description Artikelnr./Part.no.
1 Kunststofftank Reservoir 309310030
2 Deckel Cover 182840010
3 Dichtung Tankdeckel Cover seal 139220110
4 lstand Oil level 428407010
6 Selbstklebendes Typenschild Identification label 193515051
7 Luftfilter Air filter 139110010
8 Luftanschlu Swivel coupler 128690040
9 Luftanschluflansch Swivel coupler flange 147010010
10 Seegerring Retaining ring 427270140
11 O-RING O-RING 425830021
12 Selbstschneidende Schraube Thread-forming screw 426446355
13 O-RING O-RING 425831074
14 Stiftfeder Zyklusbeginn Beginning cycle pin spring 151050300
15 QUAD-RING QUAD-RING 425880020
16 Stift Zyklusbeginn Pin 102130090
17 QUAD-BALL QUAD-BALL 428630070
18 Sicherheitsventilfeder Relief valve spring 151050320
19 Seegerring, gezahnt Cogged retaining ring 427260040
25 Klebeschild Tankbelftung Reservoir ventilation label 193515053
26 O-RING O-RING 425830011
27 Schraube Screw T.C. 426321170
28 Dichtung Cover seal 139220100
46 O-RING O-RING 425820086
47 O-RING O-RING 425830024
48 Anschlu leinfllung Filter plug 128690050
49 Kegeldeckel 3/8" Taper plug 426620250
104 Ring, P.T.F.E. P.T.F.E. ring 141440010
105 Verbindungszapfen Connecting pin 141210110
106 Unteres Pedal Lower pedal 171000050
108 Pedalfeder Pedal spring 151050140
109 Klebeschild Freigabe Sticker Release 193517055
110 Sperrstift Stop pin 141210100
111 Sperrfeder Stop spring 151050350
112 Unterlegscheibe Washer 426826020
113 Klebeschild Sperre Sticker Stop 193517054
114 Oberes Pedal Upper pedal 171000051
115 Bedienungsblock Control block 142100090
121 Schalldmpfer Foam tube 139220140
36
COD. 193555075 - v.2 - UPD 220207
LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUESTOS OS OS OS OS
POS. Denomination Descripcin Part nr./Nr.artculo
1 Rservoir Dposito del aceite 309310030
2 Couvercle Tapa 182840010
3 Joint du couvercle du rservoir Junta de la tapa del dposito 139220110
4 Niveau dhuile Nivel del aceite 428407010
6 Plaque signaltique autocollante Placa descriptiva autoadhesiva 193515051
7 Filtre a air Filtro del aire 139110010
8 Raccordement dair Conexin del aire 128690040
9 Bride de raccordement dair Brida de la conexin del aire 147010010
10 Circlip Anillo de retencin 427270140
11 Joint torique O-Ring 425830021
12 Vis autotaraudeuse Tornillo roscadora automtica 426446355
14 Ressort de la tige, debut du cycle Resorte del perno, principio ciclo 151050300
15 Bague QUAD-RING QUAD-Ring 425880020
16 Tige, debut du cycle Perno, principio ciclo 102130090
17 Bille QUAD-BALL QUAD-Ball 428630070
18 Ressort de soupape de surete Resorte vlvula de descarga 151050320
19 Segment darret crante Anillo de retencin dentado 427260040
25 Plaque signaltique autocollante Placa descriptiva autoadhesiva 193515053
27 Vis T.C. Tornillo T.C. 426321170
28 Joint Junta 139220100
48 Raccord de remplissage dhuile Conexin cargamento aceite 128690050
49 Couvercle conique 3/8" Tapa cnica 3/8" 426620250
104 Bague en P.T.F.E. Anillo P.T.F.E. 141440010
105 Tige reliante Perno de conexin 141210110
106 Pdale infrieure Pedal inferior 171000050
108 Ressort de la pdale Resorte del pedal 151050140
109 Plaquette adhsive retour Placa adhesiva vuelta 193517055
110 Tige darrt Perno de paro 141210100
111 Ressort darrt Resorte de paro 151050350
112 Rondelle Arandela 426826020
113 Plaquette adhsive arrt Placa adhesiva paro 193517054
114 Pdale suprieure Pedal superior 171000051
115 Bloc commande Bloque del mando 142100090
121 Silencieux Silenciador 139220140
37
COD. 193555075 - v.2 - UPD 220207
5
5
5
4
6
-
6
.
3
m
m
5
0
5
1
5
2
5
7
5
6
1
1
T
O
O
L
5
8
5
2
5
3
5
5
5
4
5
9
6
0
8
5 8
4
8
6
6
2
6
1
6
3
8
7
8
8
8
0
8
1
8
2
8
1
8
0
9
1
9
3
6
4
6
5
6
6
6
7
6
8
7
0
6
9
7
1
7
2
7
3
7
7
9
0
7
9
8
3
8
9
9
2
9
3
9
4
9
5
1
2
9
7
9
6
8
3
9
8
1
0
3
9
9
1
0
1
1
0
0
1
0
2
7
5
7
4
7
9
7
8
7
7
7
6
T
T
T
TT
A
B
A
B
A
B
A
B
A
B
.
2
.
2
.
2
.
2
.
2
38
COD. 193555075 - v.2 - UPD 220207
ERSA ERSA ERSA ERSA ERSATZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SP TZTEILLISTE - LIST OF SPARE P ARE P ARE P ARE P ARE PAR AR AR AR ARTS TS TS TS TS
POS. Bezeichnung Description Artikelnr./Part.no.
11 O-Ring O-Ring 425830021
50 Verbindung Deckel-Kopf Cover-Head adapter 309040010
51 Befestigungsklammer Verbindung Locking adapter staple 141070010
52 O-Ring O-Ring 425830084
53 Dichtung Seal 139200010
54 O-RING-Hlse Bushing 116010010
55 O-Ring O-Ring 425830006
56 Schraube M5x0,5x25 Screw M5x0,8x25 426116057
57 Kopfdeckel Head plug 182050030
58 Befestigungsklammer Kopf Locking head staple 141070020
59 Kopf Head 184000060
60 Umkehrkolbenzapfen Plunger 102170010
61 Laufbuchsendichtung Cylinder seal 139200050
63 Umkehrkolben Inverter piston 160900020
64 Dichtung Laufbuchse-Kopf Cylinder-Head seal 139220090
65 Laufbuchse Cylinder 309000020
66 Dichtscheibe Washer seal 141480030
67 Schraube Screw 426310137
69 Kolben Piston 160900010
70 Pumpenelement Piston 160900040
71 Feder-Unterlegscheibe Spring washer 141500120
72 Stodmpfer Bumper 139220030
73 Feder Pumpenelement Piston spring 151050310
74 Unterlegscheibe Kupfer Copper washer 451430007
75 Versorgungszapfengehuse Supplying pin seat 172150040
77 Kugelfhrung Ball guide 150050020
78 Versorgungszapfenfeder Supplying pin spring 151100090
79 Kugel D. 1/4" Ball D. 1/4" 428620042
80 BK-Ring BK-Ring 425784034
81 O-Ring O-Ring 425837022
82 Versorgungszapfen Supplying pin 102040030
84 Pumpengehuse Pump body 131050090
86 Kopf Fhrung Pumpenelement Piston guide head 184000030
87 Verbindung Saugfilter Suction filter adapter 128510021
88 lfilter Oil filter 139000010
90 Feder Anschlu labsaugung Oil suction adapter spring 151100100
91 Unterlegscheibe f.Feder Spring support washer 141500110
92 O-Ring O-Ring 425830108
93 Schellenhalter Strap support 177000030
94 Schlauchklemme standard Standard pipe clamp 427102100
95 O-Ring O-Ring 425830136
96 Flansch Flange 147130020
98 Sicherheitsventilfeder Relief valve spring 151050030
100 Ventilsitz Valve seat 172150030
101 Ventilverschlu Spear valve 182260010
102 Anschlu Sicherheitsventil Relief valve adapter 128630040
103 Stift f. Sicherheitsventil Relief valve sprig 141400070
39
COD. 193555075 - v.2 - UPD 220207
LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUEST LISTE DES PIECES DE RECHANGE - REPUESTOS OS OS OS OS
POS. Denomination Descripcin Part nr./Nr.artculo
50 Raccord Couvercle-Tte Conexin Tapa-Cabeza 309040010
51 Agrafe de fixation raccord Grapa fijacin conexin 141070010
54 Douille de joint torique Buje retencin O-Ring 116010010
56 Vis M5x0,8x25 Tornillo M5x0,8x25 426116057
57 Bouchon de la tte Tapn de cabeza 182050030
58 Agrafe de fixation tte Grapa fijacin cabeza 141070020
59 Tte Cabeza 184000060
60 Pivot de piston reversible Perno pistn de inversin 102170010
61 Joint boite de glissement Junta del cilindro 139200050
63 Piston reversible Pistn de inversin 160900020
64 Joint Boite de glissement-Tte Junta Cilindro-Cabeza 139220090
65 Boite de glissement Cilindro 309000020
66 Rondelle detancheite Arandela 141480030
67 Vis Tornillo 426310137
69 Piston Pistn 160900010
70 lment de pompe Pistn 160900040
71 Rondelle arrt ressort Arandela detiene resorte 141500120
72 Amortisseur Amortiguador 139220030
73 Ressort lement de pompe Resorte pistn 151050310
74 Rondelle cuivre Arandela de cobre 451430007
75 Sige axe dalimentation Asiento perno dalimentacin 172150040
77 Guide bille Gua bola 150050020
78 Ressort axe dalimentation Resorte perno dalimentacin 151100090
79 Bille D.1/4" Bola D. 1/4" 428620042
80 Bague BK Anti-Extrusin 425784034
82 Axe dalimentation Perno dalimentacin 102040030
84 Corps de pompe Cuerpo de la bomba 131050090
86 Tte guide lement de pompe Cabeza gua pistn 184000030
87 Raccord filtre daspiration Conexin filtro de aspiracin 128510021
88 Filtre a huile Filtro de aceite 139000010
90 Ressort raccord daspiration dhuile Resorte conexin aspiracin aceite 151100100
91 Rondelle support ressort Arandela apoyo resorte 141500110
93 Support dagrafe Apoyo grapa 177000030
94 Collier pour tuyau flexible standard Cuello para tubo flexible standard 427102100
96 Bride Brida 147130020
98 Ressort soupape de sret Resorte vlvula de seguridad 151050030
100 Sige soupape Asiento vlvula 172150030
101 Tournant de la soupape Obturador de la vlvula 182260010
102 Raccord soupape de sret Conexin vlvula de seguridad 128630040
103 Tige soupape de sret Perno vlvula de seguridad 141400070
A Unit of IDEX Corporation
Weinstrae 39, 91058 Erlangen Germany
Postfach 2560, D-91013 Erlangen Germany
Telefon +49 (0) 91 31 / 6 98-0
Telefax +49 (0) 91 31 / 6 98-394

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Rescue
Publication 12.2008
179101085 GB
Hand pump LH2
and accessories
2
3
Contents Page
1. Danger classes 4
2. Product safety 4
3. Proper use 7
4. Main components of the hand pump 8
5.1 Base pump 8
5.2 Adapter blocks 9
6. Connection options for rescue equipment 9
6.1 Fittings 9
6.2 Quick-disconnect-couplings 10
6.3 Monocouplings 11
7. Commissioning 12
7.1 Unlocking the pump 12
7.2 Retracting the handle 12
7.3 Bleeding the pump 12
8. Operation 13
8.1 Operation 13
8.2 Shutdown / storage 14
9. Transport 14
10. Maintenance and repair 14
10.1 Basic requirements 14
10.2 Maintenance 15
10.3 Hydraulic fuid change or adding hydraulic fuid 16
10.4 Care 16
10.5 Repair 17
12. Technical data 23
12.1 Data of the hand pumps 23
12.2 Hydraulic fuid recommendation 24
12.3 Hose lines 25
12.4 Operating and storage temperature ranges 25
13. Notes 26
4
Wear helmet with face guard
Wear protective gloves

Wear safety shoes
We distinguish between various categories of safety instructions. The table shown below
shows you the overview, via the assignment of symbols (pictograms) and signal words, of
the concrete danger and the possible consequences.
Danger classes 1.
Pictogram
Damage /
injury to
h
u
m
a
n
Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION!
Less dangerous
situation
Minor or slight
injury
d
e
v
i
c
e
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- NOTE
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment
Product safety 2.
LUKAS products are developed and produced in order to ensure the best performance and
quality with proper use.
The safety of the operator is the most important consideration in the product design.
In addition, the operating instructions are to help in using the LUKAS products safely.
In addition to the operating instructions, all generally applicable, statutory and other
binding rules for accident prevention and for environmental protection must be heeded and
disseminated.
The device must only be operated by educated persons who are trained in safety technology,
since otherwise there is a risk of injury.
We advise all users before using the device to carefully read through the operating instructions
and to follow the instructions contained therein without exception.
Proper recycling
Protect the environment
Read and follow operating
instructions
5
We also recommend that you get instructed by a qualifed trainer in the use of the product.
WARNING / CAUTION!
devices must also be heeded!
Even if you have already received instruction, you should read the following safety instructions
again.
Make sure that no body parts
or clothing get between the
openly visible moving parts of
the device.
Immediately report changes
that occur (including changes
in operating behaviour) to
the appropriate persons/
departments! If necessary,
immediately shut down and
secure the device!
Wear protective clothing,
protective helm with visor,
safety shoes and protective
gloves.
Check the device for visible
defects or damage before and
after use.
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, suffcient
mechanical supports are
additionally required.
Check all lines, hoses and
and externally visible damages
and repair immediately!
Escaping hydraulic fuid can
lead to injuries and fres.
shut down the device
immediately and secure it. You
should have the malfunction
repaired immediately.
Do not make any changes
(add-ons or conversions) on the
device without the approval of
LUKAS.
Heed all safety instructions
and hazard warnings on the
device and in the operating
instructions.
All safety instructions and
hazard warnings on the device
are to be kept intact and in a
legible condition.
Make sure that all safety covers
are present on the device and
in proper working condition.
Any work procedure that
detracts from the safety and/or
stability of the device should be
abandoned!
Safety equipment must never
be disabled!
The maximum permissible
operating pressure must not be
changed.
6
Before switching on/engaging
the device or while operating
the device, it must be ensured
that no one is endangered by
the operation of the device.
Observe all intervals that
are prescribed or specifed
in the operating instructions
for recurring tests and/or
inspections.
When working in the vicinity
of live components and lines,
take appropriate measures for
preventing current transfers or
high voltage fashovers to the
device.
For repairs only original LUKAS
accessories and spare parts are
to be used.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Prevent electrostatic discharge,
which has the possible
consequence of spark
formation, when handling the
device.
When the hand pumps are set
up, care needs to be taken
that they are not impaired by
extremely strong temperature
changes.
The device is flled with
fuids can be detrimental to
health if they are swallowed
or their vapours are inhaled.
Direct contact with the skin
should be avoided for the same
reason. Also, when handling
hydraulic fuids, note that they
can negatively affect biological
systems.
When operating and/or storing
the device, make sure that the
device are not impaired by
strong external temperature
differences or that the device is
damaged. Keep in mind that the
device can also heat up when it
is continuously used.
Make sure there is adequate
lighting while working.
Before transporting the device,
always check to see that the
accessories are positioned
securely to prevent the
possibility of an accident.
instructions easily accessible
at the site where the device is
used.
Make sure you properly dispose
of all removed parts, leftover
hydraulic fuid, leftover oil and
packing materials.
In addition to the safety instructions of these operating instructions, all generally applicable,
statutory and otherwise binding national and international rules for accident prevention need
to be heeded and disseminated!
7
WARNI NG / CAUTI ON / ATTENTI ON!
The device is specifed exclusively for the purpose represented in the operating
instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is
considered improper. The manufacturer/supplier shall not be held liable for damages
resulting from improper use. The risk shall be borne solely by the user.
Proper use also includes heeding the operating instructions and complying with the inspection
and maintenance requirements.
Never work in a fatigued or intoxicated state!
Proper use 3.
Accessories and spare parts for the rescue equipment can be obtained from your authorised
LUKAS dealer!
The LUKAS hand pump is used for the operation of LUKAS rescue devices.
They can be used as an additional or replacement drive source along with the LUKAS
hydraulic unit (e.g. in areas at risk for explosion).
Use with equipment of other manufacturers is possible, but requires technical testing and
approval of LUKAS on a case-by-case basis.
WARNING / CAUTION / ATTENTION!
Always note the product limitations with respect to operating pressure, load limit
values and operating conditions. The operating pressure should not be higher
than the lowest maximum operating pressure of any system components.
The operating pressure should NEVER be set higher than that which is specifed
in the "Technical Data" chapter. A higher setting may cause property damage
and/or injuries.
Make sure that the usable capacity of the hand pump (see chapter "Technical
Data") is suffcient for operating the connected cylinders or devices.
The required hydraulic fuid operating quantity can be found in the chapter
"Technical Data" or in the operating instructions of the devices to be operated.
8
Main components of the hand pump 4.
1
2
3
4
5
6
7
1 Drain valve
2 Connection plate with
fttings or couplings
3 Vent / fll cap
4 Retractable pump
lever
5 Tank
6 Lock
7 Base plate
5.1 Base pump
All LUKAS hand pumps of this series are two-speed, i.e. they have two operating speeds:
A high speed in the low pressure range (LP) for fast extension of the cylinder or device
while unloaded
A low speed in the high pressure range (HP) for controlled extension of the cylinder or
device while loaded
The switch from low pressure (LP) to high pressure (HP) is automatic at the factory setting
for changeover pressure (see chapter "Technical Data").
A pressure port "P" with a G1/4" thread and a return port "T" with an M10 thread are directly
available as ports on the pump.
To connect rescue equipment, adapter blocks must be installed (see subchapter "Adapter
blocks" for more information). In the case of the hand pumps sold by LUKAS, one of these
adapter blocks is always included as standard equipment and is already installed.
Of course, the installed adapter blocks may be replaced with other ones. However, you must
contact an authorised LUKAS dealer or contact LUKAS directly.
The retractable handle of the LUKAS hand pump combines low required pumping force with
compact dimensions for storage and transport.
In addition, the LUKAS hand pumps for rescue equipment are equipped with a base plate to
ensure a more stable position during operation.
9
5.2 Adapter blocks
Adapter block Function/use
Connection plate
with fttings
Possibility of connecting hose
lines directly to the hand
pump
Connection
plate with quick-
disconnect-couplings
pump via quick-disconnect-
couplings
Connection plate
with monocouplings
pump via monocoupling
Connection options for rescue equipment 6.
ATTENTION!
Make sure to store all plugs, screw plugs and/or dust caps in a way that
prevents them from getting dirty or lost.
After completion of the work, seal off all lines using screw plugs and/or dust
caps to prevent contamination of the hand pump.
When connecting lines to the hand pump, we recommend positioning it
vertically so that the ports point upward. This reduces the danger of hydraulic
fuid escaping.
6.1 Fittings
The hose lines are connected via fttings to the hydraulic pump.
1.
2.
1. First remove the closure caps from
the fttings.
2. Then, you can connect the hose lines
to the fttings and tighten them with a
tightening torque of M
A
= 40 Nm.
ATTENTION!
The return hose must always be connected at the "T" port of the
connection block.
The supply hose line must instead be connected at the "P" port.
10
The hose lines are connected via quick-disconnect coupling halves (female and male) to the
hydraulic pump in such a way that they cannot be reversed.
Before connecting the couplings, remove the dust cap, then pull back and hold the locking
sleeve of the female coupling (Position X). Push the male and female couplings together and
release the locking sleeve. Finally, turn the locking sleeve into Position Y. The connection is
then made and secured. Decoupling is done in the reverse sequence.
The quick-disconnect-couplings have special functions, in part, and therefore
must not be unscrewed and/or reversed!
X
Y
For dust protection, the supplied dust caps must be reattached.
NOTE:
Coupling the equipment is only possible if the hoses are depressurised.
6.2 Quick-disconnect-couplings
ATTENTION!
Always connect the return line frst and then the supply line!
11
6.3 Monocouplings
Male coupling Female coupling
Dust caps
Before coupling, remove dust caps, then connect male and female couplings and turn locking
sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection
is then made and secured. The decoupling is accomplished by turning the locking sleeve in
direction "0".
The coupling of the devices under pressure is also possible, assuming the connected
equipment is not turned on.
NOTE:
We recommend, when ambient temperatures are low and extension hoses /
hose winders are used, connecting the coupling halves in a depressurised state
because decoupling may otherwise require a very large exertion of force.
The monocouplings must not be unscrewed and/or the hose lines reversed!
12
NOTE:
With the LUKAS hand pump, a little idle stroke may occur when the unit is frst
used in the high pressure range.
However, this idle stroke independently stops after a device is operated
2-3 times.
7.1 Unlocking the pump
Unlock (1.) the shipping lock of the pump by
sliding the locking pin in the direction of the
hand wheel until it comes against the stop.
To lock (2.) the pin, move it until it comes
against the stop in the other direction. To do
this, the lever must be in the home position
(at the tank).
Locking pin
ATTENTION!
The hand pump should be as close to horizontal as possible, because otherwise
the usable amount changes!
The oil fll plug must always be unscrewed one turn before starting operation of
the hand pump! This enables the aeration and bleeding of the hydraulic tank.
After the work is completed but before transport, the oil fll plug should be
retightened!
Commissioning 7.
7.2 Retracting the handle
You can pull out the handle by applying pressure to both sides of the thrust piece and
simultaneously pulling in the direction of the handle end until the thrust piece re-engages.
1. 2.
1.
2.
7.3 Bleeding the pump
1. Open the discharge valve.
2. Open the oil fll screw plug on the tank container and check the oil fll level. The oil fll
level should come up to approximately 1-2 cm below the top edge of the oil reservoir.
3. In this state, work the pump handle several times.
Hand wheel
13
NOTE:
To bleed connected equipment, make sure that the highest point of the connected
devices are below the level of the pump.
Before operating the pump, you should also open the oil fll screw plug. Only in this
way can any trapped air escape the hydraulic system when the pump is operated.
You should operate the connected equipment several times without load.
When you do this, also follow the separate operating instructions of the connected
devices.
WARNING / CAUTION!
Under certain circumstances, the pump handle can "kick back". Make sure that
your body remains to the side of the pump.
ATTENTION!
Never attach an extension to the pump handle that does not belong to the
device. These extensions usually cause the pump to become unstable during
operation.
Operation 8.
NOTE:
In order to limit the required force in high pressure operation, we recommended
using short strokes with the pump handle. The greatest pumping effect is produced
in the last 5 degrees of the stroke.
Should you use a female quick-disconnect-coupling as the port, quick stop may be
triggered if the discharge valve is opened too quickly (turning counter-clockwise),
i.e. the check valve incorporated in the male quick-disconnect coupling blocks
the return fow of oil while the connection between pump and female quick-
disconnect coupling is depressurised. This is provided as a safety function in case
the connection between the female quick-disconnect-coupling and pump starts
to leak and the pressure drops abruptly. In this case, the "quick stop" prevents,
for example, an abrupt drop in the load when an hydraulic cylinder is operated.
In order to release the quick stop again, more pressure must frst be supplied to
the device. Then, the pressure can be decreased again by slowly opening the
discharge valve.
Procedure:
1. Close discharge valve on the hand pump completely (rotate clockwise).
2. Connect the return line of the device at the return port "T" and then the high pressure line
at the pressure port "P".
3. Move the locking pin into the operating position.
4. Supply the device with hydraulic fuid or pressurise by operating the pump lever (up and
down movements).
5. To reduce the pressure of the device, slowly open the discharge valve of the hand pump
(turn counter-clockwise). In this way, you can meter the pressure reduction precisely.
8.1 Operation
14
Transport 9.
8.2 Shutdown / storage
To shut down or store the pump, seal all hydraulic connections with the associated screw
plugs or dust caps.
After sealing the hydraulic ports, open the drain screw (not up to the stop!) to depressurise
the pump.
Then carefully clean the external dirt off of the hand pump.
In addition, with a longer storage time, the outside of the device should be cleaned and all
visible mechanical moving parts need to be oiled.
ATTENTION!
After completion of the work but before transport, check to make sure the oil fll
screw plug is screwed in tightly!
Make sure the pump is not stored in a damp environment.
The pump lever is used as a carrying handle! Special pumps may be the exception in this
case. These pumps are custom-assembled for each customer; therefore, there may be a
different transport device or none! In these cases, please refer to your authorised dealers
or LUKAS directly. The lever must be locked for transport, as described in the chapter
"Unlocking the pump".
Maintenance and repair 10.
Service work may only be performed by the device manufacturer or by personnel trained by
the device manufacturer and authorised LUKAS dealers.
All components must be replaced with original LUKAS spare parts, which are listed in the
spare parts list, because in this context even required special tools, assembly instructions,
safety aspects and/or checks absolutely must be taken into consideration.
During the assembly work, pay particular attention to the cleanliness of all components
because dirt can damage the equipment!
10.1 Basic requirements
To perform maintenance and repairs, personal safety equipment appropriate for
the work is an absolute requirement. (incl. shields).
Assembly and repair work on the pump may only be performed if the entire
hydraulic system is depressurised!
Couplings should not be repaired; they should be replaced with original LUKAS
parts!
NOTE:
Always send the warranty tab back to LUKAS hydraulics GmbH.
You should always contact LUKAS or an authorised dealer before using outside
couplings.
Do not perform any repairs without the corresponding LUKAS spare parts list,
because necessary tightening torques for screw connections and/or in some
cases also important additional information are listed there.
15
The equipment is subject to very high mechanical stresses. Therefore, a visual inspection
needs to be made after each use, at least once per month (if continually used, once per
week).
In this way, early signs of wear are recognisable so that damage to the device can be
avoided by prompt replacement of these worn parts. Also check regularly to make sure that
all attachment screws are tightened (heed any applicable tightening torque specifcations).
At least once a year (if continually used once every half year) or if there is a doubt about
the safety or reliability, a functional check should be also performed (for this purpose, also
heed the corresponding applicable national and international specifcations related to the
maintenance intervals of the devices).
ATTENTION!
Clean the device before checking for dirt!
Do not use any aggressive agents for cleaning; it could cause damage to the
equipment.
Because LUKAS devices are designed for the highest performance, only
components may be replaced that are listed in the spare parts lists of the
corresponding device.
Additional components of the equipment may only be replaced if:
- You have participated in a corresponding LUKAS service training course.
- You have the express permission of LUKAS customer service (by request,
check on the grant of permission. A check is necessary in each individual
case).
10.2 Maintenance
Before performing maintenance work, clean the hand pump thoroughly.
After performing the maintenance work, you should carefully coat all metallic parts with oil
to prevent any corrosion.
Checks (Maintenance measures):
Perform a visual inspection of the hand pump at least once per month; in the case of
continuous use, once a week.
Visual inspection
Hand pump
are all hydraulic connections still tightened,
generally sealed, no leaks present (oil "sweat" has no effect on the operation),
is damage to pump housings, valve blocks or attachment parts recognisable, especially
on the moving parts such as the piston rods,
are all fuid levels within the prescribed tolerances,
are all non-moving parts frmly attached,
is there no corrosion,
freedom of movement for the pump lever and the hand wheels
(check in the depressurised state),
the couplings are easy to couple (if attached),
are dust caps in place,
are identifcation plate, all control decals, instruction decals, labels and warnings present
and legible.
16
NOTE:
In this test, an idle time of approximately 2 minutes needs to be observed and
the hand pump needs to be reloaded to operating pressure.
The resulting max. operating pressure must not drop by more than 5% after
10 seconds.
A test pressure gauge is available from the LUKAS line of accessories.
Perform an operational check of the hand pump at least once per year; in the case of
continuous use, once every half year.
Operational check
no suspicious noises,
tests at maximum load.
Execution:
Place the hand pump on a solid base to operate. Then, connect a test manometer to the
supply hose line. Release the pump lever lock and close the discharge valve. Then, the
pressurisation to operating pressure corresponding to the specifcation on the identifcation
plate occurs.
10.3 Hydraulic fuid change or adding hydraulic fuid
The hydraulic fuid should be changed if dirty at least once a year. When the hand pump is
operated in an especially dusty environment, we recommend changing the fuid at least once
every half year.
ATTENTION!
Add hydraulic fuid only if the hand pump is disconnected from the lines or the
equipment operated with the pump is hydraulically depressurised. Otherwise,
after flling the entire hydraulic system could contain more hydraulic fuid than
the tank can hold.
Procedure:
1. Open the bleed/fll cap on the tank.
2. Add hydraulic fuid until the fuid level comes up to 1-2 cm below the top edge of the oil
tank.
3. Bleed the hand pump as described in the chapter "bleeding the pump".
4. Check the fuid level again and close the tank again at the correct fuid level with the
vent/fll cap on the tank. Should the tank no longer be suffciently full after bleeding, start
the fll procedure again at item 2.
NOTE:
Should the fuid level in the tank still not be reached after repeated reflling (during
maintenance), we recommend searching for leaks in the hydraulic system.
10.4 Care
If possible, do not store the hand pump in a damp or extremely dusty environment in order
to ensure a long service life. If this is unavoidable, you should perform more frequent
maintenance and/or shield the pump from these effects if possible.
Regularly coat all metal parts with oil to prevent any corrosion.
17
10.5 Repair
ATTENTION!
corresponding device and whose replacement is described here.
- You have the express permission of LUKAS customer service (by request,
check on the grant of permission. A check is necessary in each
individual case).
10.5.1 Base plate replacement
The base plate must be replaced if external damage is present that represents a danger for
user and device upon further use. In particular, the base plate must be replaced if the stability
of the hand pump can no longer be ensured.
Procedure:
1. Remove screws A and B.
2. Remove base plate C and replace it with a new one.
3. Reinsert screws A and B and tighten.
A
C
B
10.5.2 Removing tank for cleaning, replacing the tank or the seals
The tank should be cleaned at least once per year in order to remove the accumulated dirt.
The tank must be replaced if there is any external damage that impairs the safety of
the device.
The tank seals must be replaced if there are any leaks at the junction points of the tank.
Procedure:
1. Remove base plate as described in the chapter "Replacing
base plate".
2. Empty tank by removing the screw plug (item D) and emptying
the tank.
D
ATTENTION!
Properly dispose of the removed hydraulic fuid and all
damaged components!
18
E F G H Tank J K L
3. Remove the nut (item E) and sealing ring situated under it (item F).
4. Remove base plate (item G) and the sealing ring (item H).
5. Remove tank and the seal (item J) as well as the connection plate (item K) and seal
(item L).
6. The assembly is done in reverse order. Replace all damaged parts with new ones.
The tightening torque of the nuts is 40 Nm.
10.5.3 Lever replacement
The lever must be replaced if external damage is present that represents a danger for user
and device upon further use.
Procedure:
1. Drive out dowel pin (item M).
M
N
2. Remove lever (item N) and replace with a new one.
3. Reinsert dowel pin (item M).
10.5.4 Couplings
parts!
10.5.4.1 Monocouplings
The monocouplings must be replaced if:
- exterior damage is present,
- the lock does not function,
- in the coupled and/or decoupled state, hydraulic fuid continuously escapes.
19
Procedure for installation in the valve block:
1. Unscrew coupling from connection plate.
2. Screw new coupling into the connection plate with a torque of M
A
= 40 Nm.
10.5.4.2 Quick-disconnect-couplings
The quick-disconnect-couplings should be replaced if:
Procedure:
1. Unscrew and remove coupling.
2. Screw in new screw-on male coupling and tighten with a torque of M
A
= 35 Nm.
ATTENTION!
The return port must always be equipped with a female quick-disconnect-coupling.
The supply port should instead be equipped with a male quick-disconnect-coupling.
10.5.5 Decals
All damaged and/or illegible decals (safety instructions, identifcation plate, etc.)
must be replaced.
Procedure:
1. Remove damaged and/or illegible decals.
2. Clean surfaces with acetone or industrial alcohol.
3. Adhere new decals.
Make sure to adhere the decals in the correct positions. If this is no longer known, you should
consult your authorised LUKAS dealer or contact LUKAS directly.
20
Troubleshooting 11.
Problem Cause Remedy
Connected device
does not move, moves
only slowly or moves
intermittently.
Fluid level in the hydraulic
tank too low
Add hydraulic fuid up to
max. fll level.
Discharge valve open Close discharge valve.
Hose line not properly
connected or damaged
Check connection of the
hose line and reconnect it
if necessary.
Load on the device
too high
Use a different device.
Air in the hydraulic system Bleed system as described
in the chapter Bleeding
the pump.
Defect on the device Heed the specifcations
of the separate operating
instructions of the
device.
Connected device moves,
but does not hold pressure
or does not render the
specifed performance.
if necessary.
Leaking seal Locate the leak and have
the hand pump serviced by
an authorised dealer, by
personnel specially trained
by LUKAS or by LUKAS
directly.
Internal leakage of the
pump
Have the hand pump
serviced by an authorised
dealer, by personnel
specially trained by LUKAS
or by LUKAS directly.
21
Device does not move
back into the starting
position, moves
incompletely back toward
the starting position or
moves more slowly into
the starting position than
normal.
Discharge valve closed Open discharge valve.
tank too high
Reduce hydraulic fuid
down to max. fll level.
Loose hydraulic coupling Check all couplings and
retighten them.
Enclosed air in the system Bleed pump as described
the pump.
Line length too long Use shorter lines.
Use hydraulic fuid with
a different, more suitable
viscosity.
instructions of the
device.
Connected device not
reaching its limit position
tank too low
max. fll level.
Attention: move the
device back into the
base position before
adding fuid!
quantity of the pump is
insuffcient
Use a different device with
a usable quantity below
the maximum usable
quantity of the pump.
does not achieve its
power-related performance
data
Max. permissible operating
pressure of the pump is
not reached
Replace pressure
control valve or have
it recalibrated by an
directly by LUKAS.
Fluid leaks on the
hydraulic fuid tank
(especially at the refll tap)
Due to return fow of the
hydraulic fuid from the
device, the maximum fll
quantity of the tank is
exceeded
Seals defective Replace seal.
Hydraulic fuid with milky
cloudiness
Water or condensation
water in the system
Perform hydraulic fuid
change immediately.
22
In the case of a
monocoupling system:
Hose lines cannot be
coupled
They are under excessive
pressure (e.g. due to
excessive ambient
temperature)
Open discharge valve and
bleed device.
Coupling defective Coupling should be
replaced immediately.
In the case of a
Hose lines frequently
cannot be coupled
Hydraulic fuid of the
application situation not
adapted
Hydraulic fuid needs
to be changed (see the
chapter Hydraulic fuid
recommendation for more
information).
In the case of a quick-
disconnect coupling
system: Hose lines cannot
be coupled
System is under pressure Open discharge valve and
bleed device.
In the case of a
Leakage at the couplings
disconnect coupling
system: Leakage on the
male coupling
Safety valve has
responded (in the
decoupled state)
After depressurisation, no
further leakage occurs.
Male coupling defective Male coupling should be
disconnect coupling
system: Leakage at the
female coupling
Female coupling defective Female coupling should be
Hydraulic fuid escaping
from the hoses or at the
joints
Leakage, possible damage Replace hoses.
the hydraulic hoses
media
Replace hoses.
If the defects cannot be remedied, notify an authorised LUKAS dealer or contact LUKAS
Customer Service directly!
The address of LUKAS customer service is:
Phone: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
23
Technical data 12.
Because all values are subject to tolerances, there cannot be any differences between the
data of your device and the data of the following tables!
12.1 Data of the hand pumps
12.1.2 Dimensions, weight, usable quantity and fll quantity
NOTE:
The dimensions of the hand pumps are exclusively dependent on the size of the
hydraulic fuid tank. The types of hand pumps are not outwardly distinguishable
from the outside at the pump head.
The weights, usable quantities and fll quantities of the hand pumps are
exclusively dependent on the size of the hydraulic fuid tank.
LH 2 / 1.8 - 50
Tank size max. operating
pressure in MPa
(1 MPa = 10 bar)
12.1.1 Pump labelling
Model series
NOTE:
The automatic pressure switch from low pressure to high pressure occurs at
2 MPa (= 20 bar)
Hand pump with fttings:
Hand pump with monocouplings:
Tank size Dimensions Weight min. required
l x w x h
(incl. max. hydraulic
fuid fll level)
Fill quantity
1,8 [l]
660 x 200 x 160 [mm] 7 [kg] 2,38 [l]
25.98 x 7.87 x 6.30 [in.] 15.4 [lbs.] 0.63 [gal.-US]
3,8 [l]
676 x 200 x 160 [mm] 11,3 [kg] 4,61 [l]
26.61 x 7.87 x 6.30 [in.] 24.9 [lbs.] 1.22 [gal.-US]
l x w x h
fuid fll level)
Fill quantity
1,8 [l]
761 x 200 x 160 [mm] 7,5 [kg] 2,38 [l]
29.96 x 7.87 x 6.30 [in.] 16.5 [lbs.] 0.63 [gal.-US]
3,8 [l]
777 x 200 x 160 [mm] 11,8 [kg] 4,61 [l]
30.59 x 7.87 x 6.30 [in.] 26.0 [lbs.] 1.22 [gal.-US]
24
Hand pump with quick-disconnect-couplings:
12.2 Hydraulic fuid recommendation
12.1.4 Flow rates
NOTE:
The fow output per piston stroke of the hand pumps depend exclusively on the
model series.
Model series
Flow output per piston
stroke (low pressure)
Flow output per piston
stroke (high pressure)
LH 2
17 [cm] 1,7 [cm]
0.85 [Cubic in.] 0.10 [Cubic in.]
Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others
Oil temperature range Oil code Viscosity rating Remarks
A -20 .... +55C HM 10 VG 10
A -4.0 .... +131F HM 10 VG 10
recommended viscosity range: 10...200 mm/s (10200 cSt.)
Supplied with HM 10 DIN ISO 6743-4.
ATTENTION!
Before using hydraulic fuids that do not correspond to the aforementioned
specifcations and / or are not purchased from LUKAS, you must contact
LUKAS!
l x w x h
fuid fll level)
Fill quantity
1,8 [l]
724 x 200 x 160 [mm] 7,3 [kg] 2,38 [l]
28.96 x 7.87 x 6.30 [in.] 16.1 [lbs.] 0.63 [gal.-US]
3,8 [l]
740 x 200 x 160 [mm] 11,6 [kg] 4,61 [l]
29.13 x 7.87 x 6.30 [in.] 25.6 [lbs.] 1.22 [gal.-US]
25
A -20 .... +55C HM 10 VG 10
A -4.0 .... +131F HM 10 VG 10
12.3 Hose lines
12.4 Operating and storage temperature ranges
Bending radius Rmin = 38 mm (Rmin = 1.5 in.)
Pressure resistance
Safety factor: Burst pressure / max. Operating pressure, min.
4 : 1
Temperature resistance - 40C ... + 100C (- 40F + 212F)
Operating fuid Mineral oil according to DIN EN ISO 6743-4
Operating temperature [C] / [F] -20 +55 -4 +131
Ambient temperature
(device in operation)
[C] / [F] -25 +45 -13 +113
Storage temperature
(device not in operation)
[C] / [F] -30 +60 -22 +140
26
Notes 13.
27
Copyright 2008 LUKAS Hydraulik GmbH LH2_RG_BA_GB_1790101085_1208.indd
Please properly dispose of all packing
materials and removed parts.
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Phone: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
Made i n GERMANY
1
Operating Instructions
Rescue Tools
115001085 GB
Issue 10.2007
Battery Pump P 600 OB
1 Main switch
2 Indicator pin
3 Battery
4 Connection for charger cable
5 Connection for external power supply 24 V DC
6 Charge indication panel
7 Dump valve
8 Carry harness
1
6
5
3
4
2
7
8
2
Contents page
1 Basic Operation and designated Use of the Machine 3
2 Organizational Methods 3
3 General Safety Instructions 3
4 Instructions for Maintenance and Service 4
5 Safety Instructions for Hydraulic Hoses 5
6 Intended Use 7
7 Description 7
8 Commissioning 9
9 Operation 10
10 Maintenance 13
11 Problems / Trouble Shooting 15
12 Repair 16
13 Battery 16
14 Technical Data 17
3
1 Basic operation and designated use of the machine
1.1 The machine has been built in accordance with state-of-the-art standards and the recognized
safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties,
or cause damage to the machine and to other material property.
1.2 The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine. Any functional disorders,
especially those affecting the safety of the machine/plant, should therefore be rectified immediately!
1.3 The machine is exclusively designed for the use described in the operating manual. Using the
machine for purposes other than those mentioned in the manual, such as driving and controlling
other hydraulic systems, is considered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely
with the user.
Operating the machine within the limits of its designated use also involves observing the instructions
set out in the operating manual and complying with the inspection and maintenance directives.
2 Organizational methods
2.1 The operating manual must always be at hand at the place of use of the machine!
2.2 In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and environmental
protection.
This also applies for wearing protective clothing, helmet with visor or goggles and protective gloves.
2.3 In order to avoid injuries, the machine must only be operated by a specially trained operator
who has undergone a safety training.
2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety
instructions and warnings attached to the machine are always complete and perfectly legible.
2.5 Never make any modifications, additions or conversions without the suppliers approval.
2.6 For repairs only genuine LUKAS spare parts, accessories or system components must be
used.
2.7 Adhere to prescribed intervals or those specified in the operating manual for routine checks
and inspections.
2.8 Make sure to dispose properly of packing material and dismounted parts!
3 General safety instructions
3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defects
rectified immediately.
3.2 Before starting up or setting the machine in motion and during operation of the machine make
sure that nobody is at risk.
4
3.3 Before transporting the machine always check that the accessories have been safely stowed
away.
3.4 Make sure that there is enough lighting during work.
3.5 Avoid any operation that might be a risk to machine stability.
3.6 Check the machine at least after every operation for obvious damage and defects. Report any
changes (incl. changes in the machines working behaviour) to the competent organization /person
immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwed
connections have to be checked for leaks and obvious damage. Repair damage immediately.
Splashed oil may cause injury and fire.
3.7 All safety equipment has to be checked for completeness and flawless condition:
- instruction markings and warning signs (safety instructions)
- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if
they are in good condition.
3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work is
indispensable sufficient mechanical supports are needed additionally.
3.9 The pump is filled with hydraulic fluid. Never swallow or breath in this fluid as this could be
dangerous to your health ! Avoid direct contact between the fluid and your skin !
Be aware that hydraulic fluid may cause negative effects to any kind of biologic systems.
4 Instructions for maintenance and service
4.1 For the execution of maintenance and service work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
Work on the hydraulic system must be carried out only by personnel having special knowledge and
experience with hydraulic equipment.
4.2 Before putting into operation clean the machine, especially connections and threaded unions,
of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use
aggressive detergents. Use lint-free cleaning rags and pay attention that the components are
meticulously clean during reassembling after repair.
4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquids
completely, so that they cannot reach the ground. They have to be disposed properly according to
the instructions.
4.4 Always tighten any screwed and thread connections that have been loosened during
maintenance and repair. Observe the stipulated torques.
4.5 Work on the electrical system or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such electrician and
in accordance with the applicable electrical engineering rules.
4.6 The electrical equipment of machines is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.
4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary to
clean the whole machine if it must be exceptionally operated under such conditions or gets into touch
with these materials. Additionally, the machine must be checked as described under 3.6.
5
4.8 Should you observe a loss of speed of the rescue tool during operation the battery must be
recharged. Do not continue with the operation until the motor stops. Otherwise there is the risk of
the battery becoming deep discharged which would reduce its lifetime.
5 Safety Instructions for Hydraulic Hoses
- by no means the hose must be exposed to brake fluid as this fluid will destroy outer
layer of hose
- do not expose the hose to any of the following aggressive fluids:
acid, lye or solvent
alcohol and fuel
battery and automatic transmission fluid
phosphate ester
Clean hose immediately with water and detergent when it was exposed to such fluids.
A T T E N T I O N !
1
2
3
4
5
Bild 2
6
6
5.1 Handling of hoses
- never exceed the permissible working pressure as stated on hose and/or literature
- avoid any tension (see figure 1) and do not hang any load onto the hose
- never exceed the minimum bend radius as resulting kink will cause failure of hose (see figure
2)
- do not allow hose to contact sharp edges or rough objects (see figure 3)
- avoid any twisting of hose (see figure 4)
- do not run over hose with any vehicle or equipment ! Hoses which are put on the surface of
sidewalk or street have to be suitably protected (see figure 5)
- do not allow hose to contact areas of high temperature such as mufflers, exhaust manifold,
heaters or burners. Protect the hose as shown in figure 6 or install it in sufficient distance
from the source of heat.
- it is not allowed to attach weights to the hoses
- make sure that no objects fall on the hoses.
5.2 Protection of the working area in case of breakdown of hoses
Hoses have to be installed or protected in such a way that dangers are prevented, if possible, in
case of breakdown of the hoses.
Danger can be caused by:
- Uncontrolled hose movement after a hose rupture caused e.g. by external influence.
- Emerging of the pressure medium under pressure.
- Inflammation of pressure medium near igniting sources
Dangers can be prevented by e.g. protective coverings or shieldings
5.2.1 Do not go near leaks!
- High pressure oil easily punctures skin causing serious injury,
gangrene or death!
- If injured, seek emergency medical help! Immediate surgery is
required to remove oil!
- Do not use finger or skin to check for leaks!
- Lower load or relieve hydraulic pressure befor loosening finttings!
5.3 Storage of hoses
- Hoses are subject to a natural aging even if they are stored correctly. Therefore, their storage
and service time is limited.
When storing the hoses please observe the following:
- Store them cool, dry and dustless (eventually wrapped with plastics sheeting); prevent direct
solar radiation and UV rays; shield heat sources which are near the hoses.
- Do not use any ozone producing lamps (e.g. fluorescent light sources, mercury-vapor lamp)
or electrical devices next to the hoses.
- Hoses have to be stored freely of tension and in a horizontal position. If they are stored in
rings the smallest bending radius determined by the manufacturer must not fall below.
5.4 Marking of hoses
- The hose is marked with the manufacturer's name and quarter/year of production.
- The max. allowable pressure and month/year of production is indicated on the hose end fitting.
7
Bild 4
5.5 Inspection and replacement intervals of hoses
- After each operation the hoses have to be checked for external damages, cracks,
kinks and bubbles!
- The operator has to replace the hoses in appropriate period of times, even if there are no
visible security defects on the hoses.
- The hoses have to be replaced 10 years as from date of manufacture at the
latest (see marking on the hose)!
Hoses are subject to a natural aging even if they are stored correctly. Therefore, their
storage and service time is limited.
- Hoses have to be checked by a skilled person before the first putting into
operation of the technical device and afterwards at least once a year for their
safe working condition.
A skilled person is somebody having sufficient knowledge concerning hydraulic hoses
due to his special training and knowledge. He/she must be acquainted with the local
safety working conditions, accident prevention regulations, technical regulations and
approved standards (e.g. DIN-Standards), so that he/she is capable to estimate the
safety working conditions of the hydraulic hoses.
5.6 Examples for possible defects of hoses
- Damages of the surface and the interior (e.g. chafe marks, cuts or fissures).
- Embrittlement of the surface (fissuration of the hose material).
- Deformations, which are not in accordance with the natural shape of the hoses, in
pressureless condition or under pressure or in case of bendings, e.g. separation of
material layers, blister formation, squeezing or break spots.
- Leakage points.
- Instructions for installation were not observed.
- Emerging of the hose from the end fittings.
- Damages or deformations of the end fittings which deteriorate the function and stability of
the end fittings or the connection between hose and end fitting.
- Corrosion of the end fittings or the metal inlets, which deteriorates the function and stability.
- Storage and operation periods were exceeded.
6 Intended use
The power package as described below must be used only in connection
with LUKAS rescue tools. The use with other tool brands is possible, but
details of intended use must be discussed with and approved by LUKAS in
each individual case.
7 Description
7.1 The LUKAS Battery Pump P 600 OB is serving as a portable
power unit for genuine LUKAS Rescue Tools. It consists of a
drive unit with pump and motor and a exchangable battery unit
which is sitting underneath the pump unit.
8
7.2 Drive unit with pump and motor
7.2.1 Motor
A 24V DC electric motor (2) with a power of 480 W is used for driving the hydraulic pump.
7.2.2 Hydraulic pump with valves
The hydraulic pressure is produced by a LUKAS radial piston pump (1) with:
- low pressure circuit (up to 8 MPa) =LP
- high pressure circuit (up to 63 MPa) =HP
(10 bar =1 MPa)
Necessary valves are also integrated in the pump unit:
- switch-over from low to high pressure is made automatically by a switch-over valve (3)
- the max. system pressure is limited by a pressure relief valve (4) set to 63 MPa
- with the dump valve (5) pressure can be released manually.
7.2.3 Oil container
The hydraulic circuit is designed as a closed loop without connection to the atmosphere. There-
fore the hydraulic oil is stored in a flexible diaphragm reservoir which compensates oil level
changes occuring during operation of rescue tools.
7.2.4 Hydraulic hoses
Two hoses are permanently connected with the pump unit. The pressure hose (mounted at
port P) is equipped with a quick- connect plug (type StNi61, closed ended). Pressure can be
released from the hose through the drain valve on the pump.
7.2.5 Quick connect couplings
A rescue tool can be connected to the pump by means of non-interchangeable quick couplers.
7.3 The battery
The battery is mounted inside a separate housing which can be connected with the pump unit by
means of a slide-lock mechanism. The housing has a connector for the charging cable.
7.4 The carry harness
For comfortable transport a carry harness is provided. With the harness the pump unit can be
accomodated on your back so that both hands are free for rescue work.
By means of the handle on top of the harness the pump can be carried, as well.
9
8 Commissioning
8.1 First commissioning
Prior to first commissioning the battery (item 3, see cover page) must be charged. Connect the
charger to a suitable power supply. Connect the plug on the charging cable with the charging
socket in the battery housing (item 4, see cover page)
8.2 Commissioning
8.2.1 Connection between battery and pump unit
Make sure that the pump unit is switched off (check with the main switch position), otherwise
sparks might occur. Put the battery on a level, non-slip surface. Put the pump unit on top of the
battery and adjust it so that the marks on pump body and battery housing are in line with each
other (see picture 5). This is to make sure that the contact pins are aligned with the corresponding
holes in the contact ring of the battery (see picture 6).
Push the pump housing downwards (see picture 7) and turn it clockwise until the contact pins
engage in the end position of the contact ring. Now the pump unit and the battery are connected
both mechanically and electrically.
For disconnecting the battery reverse the sequence described above.
Remark: As the contact ring is using a spring-loaded mechanism, the mechanic connection is not
absolutely rigid, i. e. a slight swivelling of the pump unit as against the battery is acceptable.
8.2.2 The Dump Valve
Open the dump valve (see picture 8) by turning it counterclockwise.
The dump valve is now open, and the hoses can be connected
with a rescue tool.
picture 6
contact pins
contact ring
with holes
picture 7
picture 5
picture 8
10
8.2.3 Connection between pump and rescue tool
The hydraulic hoses are connected free of confusion via mono-coupling halves (male and female)
to the hydraulic pump.
Before coupling, remove dust protection caps, then connect male and female, and turn the locking
sleeve of the female to direction 1 until the locking sleeve locks into place. The connection is now
in place and secure. Decoupling is by turning the locking sleeve to direction 0.
The equipment can also be coupled under pressure provided the connected equipment is not
activated.
REMARK:
We recommend coupling the coupling halves in a pressurel ess state, when working in areas
with low ambient temperature and the usage of extension hose assemblies / hose reels,
otherwise decoupling could need very high expenditure of force.
To protect them from dust, the accompanying dust protection caps must be put back on.
CAUTION!
The mono-couplings may not be screwed off the hose assemblies and / or the hose assemblies
be confused!
9 Operation
9.1 Warning:
Due to the risk of electric sparks the pump unit must not be used in explosive atmosphere !
Under extreme operating conditions it may happen that metal parts of the pump are becoming very
hot ! Do not touch metal parts due to the risk of burnings !
mono-coupling
halve (male)
mono-coupling
halve (female)
11
9.2 Function of the main switch
With the main switch (see picture 9) the pump can be switched
on or off. In the on position the main switch is illuminated.
To prevent damage of the pump unit through voltage peaks a
circuit breaker is integrated into the main switch. When activated
the circuit breaker would set the main switch automatically to the
off position. As soon as the voltage peak is over the pump
can be switched on again.
9.3 Working with pump and connected rescue tool
When the rescue tool is connected with the pump (see chapter 8.2.3), the dump valve must be
closed (see chapter 8.2.2). The tool is now supplied with hydraulic oil and can be operated by
means of the star grip.
9.4 The charge indication panel
When the pump is switched on, the charge condition of the battery can be visually checked with
three lights in different colours:
- green means that the battery is full
- yellow means that the battery is approx. half full
- the red light goes on when the battery is almost empty
Should you observe a loss of speed of the rescue tool and the red light is permanently on, charge
the battery immediately or change it against a fresh one. Do not continue with the operation until
the motor stops !
Otherwise there is the risk of the battery becoming deep discharged which would reduce its lifetime.
Remark: The true battery capacity can be seen only when the pump is in no-load condition.
Depending on the stress situation of the rescue tool the battery voltage may vary so that the red
light goes on just for a second, e. g. when an extreme cutting job is made.
9.5 External power supply
The P 600 OB pump can optionally be driven by an external battery
e. g. the truck battery. It must be made sure, however, that the
battery has 24 V and no more than 20 A ! Never exceed these
valnes, otherwise the pump may be destroyed.
For connection of such a battery the P 600 OB is equipped with a
connection point (see picture 10). A suitable connection cable can
be supplied upon request.
9.6 Change of battery
For changing the battery refer to chapter 8.2.1.
9.7 The indicator pin
On top of the pump unit is a pin (item 2, see cover page) which is connected with the hydraulic oil
reservoir. Should the reservoir be overfilled the pin would be pushed upwards so that the red shaft
becomes visible. In this case excess oil must be drained from the reservoir (see chapters 9.8 and
10.3).
picture 10
picture 9
12
9.8 Succesive operation of several LUKAS rescue tools
Depending on the rescue situation it might be necessary to employ the pump for a second or third
rescue tool (of course one after another). In such cases observe the following:
Prior to connection of a second tool it must be made sure that the first tool has been fully
closed/retracted ! Of course, the second tool must also be fully closed prior to connection
of a third one and so on. This is necessary for keeping the oil volume of the closed circuit
on the same level throughout the whole operation cycle.
Attention: Do never use the P 600 OB for closing/retracting a rescue tool which has already been
extended with a second pump. Otherwise there is the risk of the diaphragm tank being damaged
by too large oil volume !
9.9 The carry harness
9.9.1 Description
The pump is delivered complete with a carry harness
(item 8, see cover page). The harness consists of a stable
yet extremely light frame with handle, two shoulder straps
with quickadjust mechanism, a adjustable belly girt and a
fixing rail (item 11.2) with arresting lever (item 11.1) The
counter part for accomodation of the fixing rail is mounted
on the housing of the pump by means of two allen screws
(see picture 12, item 12.1).
9.9.2 Individual adjustment of the accommodation rail
The position of the accommodation rail can be individually
adjusted by opening the two allen screws. Set the rail to the most
comfortable position and tighten the screws properly.
It is also possible to mount the accommodation rail on the opposite
side of the pump housing:
remove the two allen screws with plastic disks completely and set the rail to the wanted position.
Place the thinner plastic disk on top of the rail and make sure that harness and pump are aligned
in the vertical position. Tighten the rail with the two allen screws.
9.9.3 Handling of the harness
For fixing the harness on the pump put it in the position as shown on picture 12. Open the arresting
lever (12.3) as far as possible. Push the harness forward until it engages into the accomodation
rail (see picture 13). Depress the arresting lever completely and make sure that the rail is safely
locked.
Hang the unit over your shoulders, use the D-clamps for pushing the shoulder straps forward and
pull them tight (see picture 14). Finally, close the belly girt and pull it tight.
Bild 11
11.1
11.2
13
9.10 General remark
When the connected rescue tool is not needed for a longer period of time, open the dump valve
(see picture 8) and switch the pump off so as to save battery capacity.
10 Maintenance
10.1 Pump unit
After each operation all components have to be checked on proper function (clean them first if
necessary):
- check whether hydraulic fittings and couplers are tightened; tighten them if necessary
- check pump unit, metal hood, battery housing, valves and hoses on external damage
- check whether all signs, warning labels and switching symbols are complete and legible
- check the oil tank on correct oil level (see chapter 10.3)
- check the unit on oil leakage. Defective seals must be replaced immediately.
10.2 Hydraulic tightness
Check the unit on oil leakage and make sure that eventually damaged seals are replaced
immediately.
10.3 Checking hydraulic oil
Attention: Carry out the following procedure over an oil pan and dispose of used oil according to
local regulations and laws !
The P 600 OB is filled with hydraulic oil viscosity class HLP 22.
- check oil level in the reservoir after each operation; refill/drain oil if necessary (observe
LUKAS oil recommendation 10.5)
- change hydraulic oil after approx. 50 operations, however after 2 years at the latest
Remark: Select type of hydraulic oil according to prevailing ambient temperature
conditions (see LUKAS oil recommendation10.5)
Bild 12
12.2
12.1
12.4
12.3
13.1
Bild 13
Bild 14
14
For checking of the hydraulic oil level proceed as follows:
1) Remove the hood on top of the pump unit by opening the 8
allen screws on the bottom end of the hood.
2) Remove the yellow filler screw on top of the oil reservoir.
3) Push the diaphragm downwards until oil is coming out of the
filler screw so as to make sure that no air remains in the tank
and lock the tank with the filler screw.
4) For checking the correct filling volume adjust the upper part of
the oil tank to a horizontal position. Measure the distance bet-
ween reservoir bottom and upper edge.
The correct distance would be 147 mm.
5) Should the distance be other than 147 mm, refill or drain hydraulic oil.
10.4 Changing hydraulic oil
For changing of the hydraulic oil proceed as follows:
1) Remove the hood on top of the pump unit by opening the 8 allen screws on the bottom end
of the hood.
2) Remove the yellow filler screw on top of the oil reservoir
3) Put the pump upside down and drain the oil completely
4) Adjust the tank so that the distance between reservoir bottom and upper edge is 147 mm.
5) Fill in fresh hydraulic oil until oil is coming out of the filler screw so as to make sure that no
air remains in the tank..
6) Hold the tank in its position and lock the tank with the filler screw.
7) Connect the battery (see 8.2), couple the two hydraulic hoses with each other and open
the drain valve (see 8.3).
8) Switch the motor several times on and immediately off again before it reaches high speed.
9) Switch the motor on, close the drain valve and keep the motor running for a few seconds.
10) Open the dump valve, switch the motor off and uncouple the hoses.
11) Open the filler screw again and repeat the procedure as per para 5 and 6, if necessary.
12) Lock the tank with the filler screw and clean the tank surface with a suitable cloth.
13) Mount the hood again.
10.5 For LUKAS hydraulic devices, use mineral oil in accordance with
DIN 51 524 and others
Recommended viscosity range: 10 ... 200 mm/s,
147
picture 11
Range of oil temperature Viscosity rating Remarks
A - 24 ... +30 C HL 5
B - 18 ... +50 C HLP 10
C - 8 ... +75 C HLP 22
D +5 ... +80 C HLP 32
E - 8 ... +70 C HF - E 15 biodegradable
15
11 Problems / trouble shooting
Index: P =problem S =symptom C =check
P: pump fails to deliver oil
S: rescue tool doesnt move when the star grip is turned
C: hoses and quick couplers properly connected ? Battery properly charged ?
-> After adding or changing hydraulic oil the pump must be vented (see 10.3)
-> Is the red light on the charge indication panel on ?
-> Recharge the battery.
P: system pressure is not reached
C: check with a testing pressure gauge
-> Spring of the pressure relief valve needs readjustment
-> Valve must be readjusted by an authorized dealer
-> Radial piston pump doesnt function properly
-> Function of piston elements to be checked by an authorized dealer
P: hose couplings cannot be connected
S: the hose is still presurized
-> Open the dump valve to release pressure from the hose
P: the connected rescue tool cannot be fully opened
C. the tool can be properly closed
-> The oil quantity in the reservoir is not sufficient
-> Close and uncouple the tool. Refill hydraulic oil as per para 10.3. Please read also
Para 9.8 operation of several rescue tools
P: the thermo breaker on the main switch is activated
S: the main switch returns to off automatically
C: check correct power supply 24V DC and max. 20A
-> switch the pump on again
-> should the thermo switch open again, the electric system must be checked by an
authorized dealer
P: the indicator pin is extended
S: the red shaft of the pin becomes visible
-> adjust the hydraulic oil level as per para 10.3
F: Pump cannot be switched off
S: The pump is running even with the main switch set to off
-> Remove the battery from the pump (see chapter 9.6)
Attention! This will cause sparks on the electric contacts. In hazardous atmosphere
there is the risk of a explosion. Take suitable measures for your personal protection so
as not to come in contact with eventual sparks.
F: No rescue tool is connected, the hoses on the pump are pressurized and the dump valve is
faulty.
S: Couplings cannot be connected, even when the dump valve is opened
-> Make sure that the pump intentionally or unintentionally cannot be switched on and
contact a authorized LUKAS dealer or the LUKAS service department.
If the defects cannot be repaired, contact an authorized LUKAS dealer or the LUKAS service
department. The address: LUKAS Hydraulik GmbH, Weinstrae 39, 91058 Erlangen Germany,
Tel. +49 / 9131 698 348, Fax +49 / 9131 698-353.
16
12 Repair
For all repairs only genuine LUKAS spare parts as listed in the spare parts list may be used, since
it is absolutely necessary to consider for this purpose spezial tools, safety aspects and checks that
might be required (see chapter 4).
13 Battery
13.1 The P 600 OB is supplied complete with a CP-100 9 Ah battery pack.
13.2 Special safety instructions for the battery:
The CP-100 Pack 9 Ah includes a lead-acid battery which is fully sealed. However, observe the
following:
- do not charge the battery in gas-tight rooms
- when charging the battery, put it on its rubber feet on a level, non-slip surface
- do never short-circuit the electric contact points
- dont throw the battery into open fire
- do not dispose of an old battery with the normal waste
- make sure that the battery is recycled in ecology-friendly manner and observe local regula-
tions on recycling
13.3 Charging the battery
It is possible to charge the battery both separated from or being connected with the pump unit. In
the later case it is essential that the main switch on the pump is set to off, otherwise the battery
will not be charged.
For charging only the LUKAS charger ref. 84150/7506 must be used. The sleeve for connection to
the charger is on the front side of the battery housing. The charging time is 6 hours, a quick-
charging is not possible. Observe the operating manual of the charger !
Attention: The connection sleeve on the battery housing must only be used to connect the
charger. It is not permissible to insert a power cord into this sleeve (e. g. for powering an
external consumer device). A contact of the sleeve with electrically conductive objects will
cause a total damage of the battery.
13.4 Charger
The carger is a special device with automatic voltage adjustment. It is available with LUKAS under
ref. no. 84150/7506.
17
14 Technical data
14.1 Pump unit
14.2 Battery The working time with one battery under average rescue conditions is
30 to 45 min.
14.2.1 Technical data
14.3 Noise emission
14.4 Others
14.5 LUKAS Hoses
Voltage 24 VDC
Current max. 20 A
Motor power max. 480 W
Protection class IP 12
Hydraulic oil filling 1.6 l
Usable oil quantity 1.2 l
Oil delivery low pressure 1.33 l/min
Oil delivery high pressure 0.33 l/min
Dimensions (h x w x d) 570 x 179 x 174 mm
Weight (incl. oil filling) 18.8 kg
Temperature range -15 up to +50 C
Working position vertically (with the battery downwards) - horizontal
position is also possible
Voltage 24 VDC
Current max. 20 A
Nominal capacity 9 Ah
Dimensions (l x w x h) 179 x 174 x 170 mm
Weight (battery only) 6.6 kg
Following the regulations of EN ISO 3744:
measuring distance above ground level 1.0 m
no load full load
Measuring distance 1 m 73 dB(A) 77 dB(A)
Working temperature -20 ... +55C
Ambient temperature (power pack in operation) -24 ... +45C
Storage temperature (power pack not in operation) -30 ... +60C
Bending radius Rmin =25 mm
Burst resistance safety factor: burst pressure / max. operating pressure, min. 4 : 1
Temperature resistance - 40C ... +100C
Operating medium Mineral oil according to DIN 51524
18 P600OB_BA_GB_115001085.p65 subject to revision

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L
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G
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A Unit of IDEX Corporation
Weinstrae 39, 91058 Erlangen
Postfach 2560, 91013 Erlangen Germany
Telefon +49(0)9131/698-0 Telefax +49(0)9131/698-394
E-mail: lukas.info@idexcorp.com
176101085 GB
Hose reels
Issue 08.2009
2
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Description 9
4.2 Single hose reel 9
4.3 Double hose reel 10
4.4 Mounted single hose reel 12
5. Connecting the equipment 12
5.1 On the side of the hydraulic unit 12
5.2 On the side of the equipment 12
5.3 Coupling the mono-couplings 13
5.4 Coupling the quick-disconnect-couplings 14
5.5 Direct connection of the hose reels to the hydraulic pump or the
control unit 15
6. Operation 15
6.1 Safety notes 15
6.2 Start-up 16
6.3 Parking brake (applies only to double hose reels) 16
6.4 Unrolling 17
6.5 Coiling 17
7. Dismantling the equipment / deactivation following operation 18
7.1 Equipment 18
7.2 Hydraulic unit 18
7.3 Hoses 18
7.4 Hose reel 19
8. Maintenance and service 19
9. Assembly of mounted hose reels onto hydraulic unit frames 20
9.1 Mounted single hose reel 20
9.2 Double hose reel 20
10. Assembly of auxiliary sets on hose reels 21
10.1 Double hose reel (auxiliary set with quick-disconnect-couplings) 21
10.2 Double hose reel (auxiliary set with mono-couplings) 21
Content Page
3
11. Repairs 23
11.2 Preventative service 24
11.3 Repairs 25
13. Technical Data 35
13.1 General reel identifcation 35
13.2 Maximum operating pressure 35
13.3 Technical data for the hose reels 35
13.4 Further technical datas of the hose reels 36
13.5 Further technical datas of the hose reels 36
14. EC Declarations of conformity 37
15. Notes 38
4
Wear helmet with face protection
Wear safety gloves

Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
We distinguish between various categories of safety notes. The table below gives you an
overview of the assignment of symbols (pictograms) and key words to the specifc hazard
and possible consequences.
Hazard classes 1.
Pictogram
Damage /
injury to
h
u
m
a
n
Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION!
Less dangerous
situation
Minor or slight
injury
d
e
v
i
c
e
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment
5
Product safety 2.
Wear protective clothing, safety
helmet with visor, protective
gloves
Inspect the equipment before
and after use for visible defects
or damage.
The responsible department
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is
to be deactivated immediately
and secured!
Inspect all cables, hoses and
and externally visible damage.
Repair them immediately!
Squirting hydraulic liquids can
result in injuries and fres.
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
immediately.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design.
Moreover, the operating instructions are intended to help the safe use of LUKAS products.
The generally applicable, legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be implemented in addition to
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.

We further recommend that a qualifed trainer train you in the use of the product.
WARNING / CAUTION!
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes through again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the max. operating pressure!
6
Observe all safety and danger
notes on the equipment and in
All safety and danger notes
on the device are to be kept
complete and in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
Comply with all specifed
dates or dates specifed in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
Safety devices may never be
deactivated!
The maximum permitted
operating pressure noted on
the equipment may not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you dont get stuck in the
looped hoses and trip.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
The formation of electrostatic
charging with the potential
formation associated with
handling this equipment is to
be avoided.
The equipment is flled with a
fuids can be dangerous to
health if swallowed or their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic fuids
can have a negative effect on
biological systems.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects of stark
external temperatures or that
the equipment is damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Ensure adequate lighting when
you are working.
Before transporting the
equipment, always ensure that
the accessories are positioned
such that they cannot cause an
accident.
instructions within reach where
the equipment is used.
Ensure the proper disposal of
all removed parts, left-over oil,
left-over hydraulic fuid and
packaging materials.
7
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
W A R N I N G / C A U T I O N !
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter Proper Use). Any other or further use is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
8
Proper use 3.
Spare parts and accessories for the rescue tool can be ordered from your authorisied
LUKAS-dealer!
The LUKAS hose reels are used for mounting extension hose pairs between the hydraulic
supply and the equipment (hose pairs are included as standard in the delivery). The extension
hose pairs are connected to the hose reel and coiled onto the drum.
The use of a LUKAS hose reel with extension hose pairs enables a greater distance
between the hydraulic supply and the equipment. This allows the hydraulic unit to stay on the
emergency vehicle, for example. During use, unrolling / coiling enables optimum adaptation
of the hose length, thereby reducing the amount of unnecessary / annoying hoses lying
around.
In a coiled state, the extension hose pairs can also be transported more easily, and storage
is easier.
The hose reels can also be used under water at a depth of up to 40 m (131 ft).
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
CAUTION!
Because of possible loss of pressure, only extension hose lines having a maximum
length of 20 m may be connected on the equipment side and on the device side
the length may also be no more than max. 30 m!
9
Description 4.
4.2 Single hose reel
The single hose reel comprises one carrier frame and one shaft with hose drum. One
extention hose pair can be connected to the equipment side of the reel.
Connection to the hydraulic pump or control unit is made by screwing the connecting hose
pair directly into the control unit or valve block on the pump or by connecting the hose pair to
the pump or the control unit by means of couplings.
1
2
3
4
5
6
Quick-disconnect coupling
system:
8
7
Mono-coupling system:
Basically, a reel comprises a carrier, shaft and hose drum.
We distinguish between:

Single hose reel: - Connection of a extension hose pair
- Delivery with carrier frame
Double hose reel: - Connection of two extension hose pairs
- Delivery with carrier frame
- Parking brake
Mounted single hose reel: - Connection of a extension hose pair
- connection to the side of a unit frame
Coiling / unrolling of all models is being carried out by a hand crank, which can either be
plugged in or is fx connected with the hose drum.
Connection to the hydraulic pump is being carried out via screwing the connection hose pairs
directly into the valve block of the pump or via connecting the connection hose pairs to the
pump by using couplings.
1 Hose drum
2 Carrier
3 Extension hose pair
4 Connection hose pair
5 Mono-coupling (male)
6 Mono-coupling (female)
7 Quick-disconnect-coupling
(male)
(female)
10
4.3 Double hose reel
11
10
1
2
3
4
5
6
7
9
8
12
13
Quick-disconnect coupling
system:
The double hose reel comprises one carrier frame and one shaft with two hose drums. Two
extension hose pairs or extension hoses can be connected to the reel on the device side
(one extension hose per drum). Depending on the connector version, connection on the
equipment side is made by one or two short return hoses and one short extension hose
per extension hose or extension hose pair. These connecting hoses are attached to the
connection block of the hydraulic pump or a control unit directly or by means of couplings.
The double hose reel also has a parking brake for simultaneously securing both hose drums
in their positions. The basic model of the double hose reel comes as a mounted / installed
reel. It can be affxed directly to a D-unit frame, a frame for connection hose reels or be
permanently integrated into a vehicle. The fxing elements required for the assembly are
contained in the delivery.
1 Hose drum
2 Carrier
3 Extension hose pair 1
4 Extension hose pair 2
5 Supply hose A
6 Supply hose A1
7 Return hose T
8 Mono-coupling (female) 1
9 Mono-coupling (female) 2
(male)
(female)
12 Parking brake
13 Hand crank
Mono-coupling system:
11
For easier transport of the double hose reel, an auxiliary set is available as an accessory:
this is screwed onto the reel.
Auxiliary set with mono-couplings:
The mono-coupling halves included in the auxiliary set must be connected with the supply
hoses / the return hose as follows:

Coupling 1, connection P: supply hose A

Coupling 1, connection T: return hose T
Coupling 2, connection P: supply hose A1

Coupling 2, connection T: return hose T1 (contained in the auxiliary set)
Auxiliary set with quick-disconnect-couplings:
The quick-disconnect-coupling halves included in the auxiliary set must be connected with
the supply hoses / the return hose as follows:
Steckkupplungsmuffe: supply hose

Steckkupplungsnippel: return hose
12
4.4 Mounted single hose reel
Connecting the equipment 5.
5.1 On the side of the hydraulic unit
5.2 On the side of the equipment
The mounted single hose reels are basically assembled the same as the single hose reels.
The only difference is the carrier used. This is designed only for mounting onto a hydraulic
unit frame. It isnt possible to use this carrier as the basis for transport or erection. The fxing
elements required for the assembly are contained in the delivery.
REMARK:
The devices can be equipped with different coupling systems.
They are distinguished only by the item/article number.
Of course the coupling systems can also be reequipped at a later time.
There are short hoses on the side of the unit: they are connected to the pump unit. All hose
assemblies are marked with a colour, enabling them to be unmistakably connected:
HD = High pressure / supply (grey) T = Return (blue)
Connection on the equipment side can be made the screwing the hose(s) directly into the
connection block of the hydraulic pump or the control unit or by means of couplings.
Refer to the Repairs chapter for the tightening torque to be used when attaching the hose
lines to the connection block or the control unit.
Please see also the chapter Repairs for the screw-in torque of the hose assemblies in the
couplings.
The hose pairs of the double hose reel are also distinguished by the different-coloured
antikink covers.
The extension hose pairs are on the side of the equipment: they are connected with the
equipment by means of couplings. All hose assemblies are marked with a colour and have
coupling halves to enable unmistakable connection:
HD = High pressure / supply (grey) T = Return (blue)
The hose pairs of the double hose reel are also distinguished by the different-coloured
antikink covers.
WARNING / CAUTION!
Before connecting the equipment you have to pay attention that all
used components are suitable to the max operation pressure of
the pump unit! In the case of doubt you have to inquire LUKAS
directly!
13
5.3 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
Before coupling, remove dust protection caps, then connect male and female, and turn
the locking sleeve of the female to direction 1 until the locking sleeve locks into place.
The connection is now in place and secure. Decoupling is by turning the locking sleeve to
direction 0.
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature otherwise decoupling could need
very high expenditure of force.
WARNING / CAUTION!
The mono-couplings may not be screwed off the hose assemblies and / or the
hose assemblies be confused!
mono-coupling
halve (male)
mono-coupling
halve (female)
dust protection caps
14
5.4 Coupling the quick-disconnect-couplings
X
Y
The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves
(male and female).
Before coupling unlock the connect socket by turning the sleeve into position X. Retract
sleeve and connect plug and socket. Release sleeve and turn it into position Y.
Now the connection has been made and locked. Uncoupling is done in the reverse order.
WARNING / CAUTION!
The quick-disconnect-couplings partly have special functions. Therefore it is not
allowed to screw them off from the hoses or to exchange them!
REMARK:
Coupling of the devices is only possible, when the hoses are depressurized.
CAUTION!
Always connect the return line frst and afterwards the supply line!
REMARK when using the quick-disconnect-coupling system:
Overpressure protection of the rescue equipment
(model with yellow coupling nipple on the return hose)
If the equipments hoses are not connected to a hydraulic unit or a rescue tool,
temperature increases can inadvertently cause pressure to build up in the
equipment. Hence, the return hose of the equipment is equipped with a safety
coupling (quick-disconnect coupling male, yellow). Unwanted overpressure
(approx. 1.5 Mpa) is automatically released via this nipple: a small amount of
hydraulic fuid leaks.
Should an hydraulic fuid leak on the coupling male be more frequent, please
contact your dealer or LUKAS itself.
15
CAUTION!
5.5 Direct connection of the hose reels to the hydraulic pump or
the control unit
WARNING / CAUTION!
Unused connections on the hydraulic equipment or the control unit must be
sealed. This can be accomplished through use of a suitable coupling half, an
already connected device or an appropriate threaded plug.
When making this type of connection, there is no design feature to prevent inadvertent mix-
up of the connections. For this reason, when making the connections you must ensure that
the supply lines on the equipment side are always connected to the supply connection of
the equipment or control unit. The same applies regarding the return lines.
The hose lines are attached to the existing fttings (nipples) on the equipment or control
unit by means of coupling nuts. (tightening torque M
A
= 40 Nm)
Operation 6.
6.1 Safety notes
World-wide, safety guidelines pertaining to the specifc country are to be observed and
complied with. In the Federal Republic of Germany, regular safety inspections according
to the regulations of the Gesetzlichen Unfallversicherung (GUV; connoted Legal accident
insurance) are mandatory.
The following are to be worn when working with the hose reel:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves
- and, if necessary, ear protection
WARNING / CAUTION!
When working with the hose reel, those not involved must maintain an appropriate,
suitable safe distance, so that they are not endangered in the event of failure
of the hose.
16
6.3 Parking brake (applies only to double hose reels)
A
B
C
A
B
C
C
6.2 Start-up
Before start-up and following repairs, the hose assemblies of the hose reel must be
deaerated:
- Connect the hose reel to the hydraulic pump (see chapter Connecting the equipment).
- Switch on the hydraulic unit and pressurize the supply hoses for some time.
- Switch the hydraulic unit to depressurized circulation or switch it. If necessary, you have
to top-up hydraulic fuid.
CAUTION!
The working equipment has to be disconnected!
REMARK when using mono-couplings:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature otherwise decoupling could
need very high expenditure of force.
REMARK when using quick-disconnect-couplings:
When using quick-disconnect-couplings on extension hoses, each quick-
disconnect-coupling (male) has to be connected with a quick-disconnect-
coupling (female).
After the deaeration the working equipments can be reconnected to the hose reel.
REMARK when using quick-disconnect-couplings:
Decouple the quick-disconnect-coupling halves.
The parking brake prevents the extension hose pairs from unrolling during transport!
In order to release the parking brake, turn the knob A anti-clockwise until there is a distance
of approx. 5 mm / 0.2 in. between the brake shaft B and the hose drums C.
In order to activate the parking brake, turn the knob A clockwise until brake shaft B is fnger-
tight with the hose drums C.
fg. 9
17
6.4 Unrolling
6.5 Coiling
To unroll, pull at the extension hoses until the required length has been unrolled from the
hose reel.
CAUTION!
For unrolling the hose from the double hose reel, the parking brake must frst of
all be released. This prevents damage to the reel and the hoses.
REMARK:
We recommend the use of the hand crank for coiling the hose!
- First of all, put the hand crank onto the shaft of the hose reel (except models with fx
mounted hand crank).
- Check that the parking brake of the double hose reels has been released.
- Aligning the hose as depicted in fgure 10 simplifes coiling of the hose.
- Now, you can turn the hand crank to coil the extention hose pair.
Please note that the winding direction depicted in fgure 11 must always be observed!
fg. 10
fg. 11
winding direction
Coiling
hose
ellbow
18
Dismantling the equipment / deactivation following 7.
operation
7.1 Equipment
7.2 Hydraulic unit
7.3 Hoses
If the hose reel is to be disconnected from the unit and the equipment, please proceed as
follows:
On the side of the equipment (with quick-disconnect-couplings):
First of all, decouple the supply hose then the return hose as described in chapter Connecting
the equipment.
Ensure that you put the dust protection caps back on to the quick-disconnect-couplings.
On the side of the equipment (with mono-couplings):
Decouple the hoses as described in chapter Connecting the equipment.
Ensure that you put the dust protection caps back on to the mono-couplings.
On the side of the hydraulic unit (with quick-disconnect-couplings):
First of all, decouple the supply hose then the return hose as described in chapter Connecting
the equipment.
Ensure that you put the dust protection caps back on to the quick-disconnect-couplings.
Ensure that the extention hose pair is always properly coiled on the hose drum.
This is usually guaranteed by guiding the extention hose pair with your hand (see fgure
12) during the coiling process.
- Finally, you must put the parking brake of the double hose reel back on.
fg. 12
Basically, all used equipment must be safely stored following deactivation.
When using a LUKAS hydraulic unit with mounted hose reel, it is possible to store the
equipment on a special storage device (available from the LUKAS range of accessories).
It isnt necessary to disconnect the hose assemblies from the hydraulic unit and / or the
equipment.
Once work has been completed, the equipment is to be reset to its basic position.
Upon completion of work, the unit must be deactivated.
19
7.4 Hose reel
On the side of the hydraulic unit (with mono-couplings):
Decouple the hoses as described in chapter Connecting the equipment.
Ensure that you put the dust protection caps back on to the mono-couplings.
On the side of the hydraulic unit (with direct connection):
First of all, unscrew the supply hose then the return hose as described in chapter Assembly
of mounted hose reels onto hydraulic unit frames.
Ensure that you screw the protection caps back onto the connectors.
Maintenance and service 8.
Coil the extention hose pairs onto the hose reel.
Apply the parking brake on double hose reels.
Visual inspection
Hose reel
General tightness (leaks),
Operability of the hose drums,
All fastening screws are in place and tightened,
Carrier, frame and drum are undamaged,
Hand crank in place and undamaged,
Parking brake of the double hose reel in place and in working order,
Labels completely existent and legibly,
Hoses
Visual control for visible damage,
Control for leaks.
The hose connection must be tightly attached to the mounted reel, and not leak,
Couplings must be easy to couple,
Dust protection caps must be available.
Function test
Undisturbed coiling and unrolling of the extension hose pairs.
no suspicious noises.
A visual inspection is to be carried out after every use: however, at least one visual inspection
is to be carried out annually. A function test is also to be carried out every three years or
should there be any doubt regarding the safety or reliability of the equipment.
(Please also observe the relevant valid national and international regulations pertaining to
service intervals of rescue equipment). In the Federal Republic of Germany, regular safety
inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;
connoted Legal accident insurance) are mandatory.
CAUTION!
Clean off any dirt before controlling the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.
20
Assembly of mounted hose reels onto hydraulic 9.
unit frames
9.1 Mounted single hose reel
The mounted single hose reel is to be mounted on the LUKAS aggregates with D-frames or
mounted frames as follows:
- Position the carrier of the reel to the side of the
frame such that the fastening bores of the carrier
overlap with those of the frame, and use screws,
washers and nuts to affx (see fgure 13).
- Now connect the equipment-side hoses to the
equipments connection block or the control unit as
described in Connecting the equipment chapter.
fg. 13
9.2 Double hose reel
The double hose reel is to be mounted on the LUKAS aggregates with D-frames or mounting
frames as follows:
- Place the reel at the open side of the frame such that the fxing holes in the support align
with those in the frame and then secure with the aid of bolts, lock washers, washers and
threaded plate (see Fig. 15).
- Now connect the equipment-side hoses to the equipments connection block or the control
unit as described in the Connecting the equipment chapter.
fg. 15
frame washer bolt lock washers threaded plate
21
The auxiliary set consists of two handles, two quick-disconnect-couplings (female), one quick-
disconnect-coupling (male) as well as assembly material.
Assemble the set as follows:
- Slide carrying handles B into the
curved pieces of sheet metal C and
fasten in place using bolts D, lock
washers E, washers F and bars G.
To secure properly, lock nut H must still
be attached and tightened. (see Fig. 17)
J
K
L
N
T
T1
A
A1
L
N
fg. 18
Assembly of auxiliary sets on hose reels 10.
10.1 Double hose reel (auxiliary set with quick-disconnect-couplings)
10.2 Double hose reel (auxiliary set with mono-couplings)
The auxiliary set consists of two handles, two mono-couplings, two antikink covers, one
return hose and assembly material.
Assemble the handles as follows:
- Slide carrying handles B into the curved pieces of sheet metal C and fasten in place
using bolts D, lock washers E, washers F and bars G. To secure properly, lock nut
H must still be attached and tightened. (see Fig. 17)
D
The short hose assemblies to the hydraulic pump
must be equipped with quick-disconnect-couplings
as follows (see fgure 18):
- Connect quick-disconnect-coupling (male) G to
return hose F,
- Connect one quick-disconnect-coupling (female)
J to each supply hose H
- All quick-disconnect-couplings must be
tightened with a torque of 35 Nm
E
F
C
B
G
H
fg. 17
22
Assemble the return hose of the auxilary set as follows:
- Remove the plug and the steel ball from the connection T1 of the reel shaft and tighten
the return hose instead (see fgure 19).
(torque M
A
= 40 Nm)
T
T1
A
A1
M1
M2
T T1
A A1
T T1
A A1
fg. 20
fg. 19
The short hose assemblies to the hydraulic pump
must have be assembled with the mono-couplings
as follows (see fgure 20):
- Put the antikink cover (blue) onto the supply
hose A and return hose T.
- Put the antikink cover (grey) onto the supply
hose A1 and return hose T1.
- Connect the mono-coupling (male) H1 with the
supply hose A and the return hose T.
- Connect the mono-coupling (male) H2 with the
supply hose A1 and the return hose T1.
CAUTION!
Take care that the port T / T1 of the hose reel is always connected to the port
T of the mono-coupling.
The hoses must be tighten onto the mono-couplings (male) with a torque of
40 Nm!
23
- Following that shift the antikink cover till dead stop of the mono-coupling.
Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturer and by authorised LUKAS dealers.
Only LUKAS spare parts may be used to replace all components (see spare parts list) since
special tools, assembly advice, safety aspects, inspections might have to complied with (see
also chapter Maintenance and Service).
During assembly, ensure the complete cleanliness of all components, since dirt can
damage the rescue equipment!
Repairs 11.
WARNING / CAUTION!
Protective clothes must be worn when repairs are being carried out, since parts
of the units can also be pressurised in an idle state.
REMARK:
Please always return the guarantee registration card to LUKAS Hydraulik GmbH.
Only then are you entitled to the extended guarantee.
REMARK:
Before you use couplings from a different company, you must contact LUKAS or
an authorised dealer.
CAUTION!
Because LUKAS of rescue equipment are appropriate for highest achievements,
only components may be exchanged, which are specifed in the spare parts list
of the appropriate equipment.
Further components of the equipment may only be exchanged, when:
- you have participated on a appropriate LUKAS service training.
- you have the explicit permission of the LUKAS Service department (After inquiry,
examination for the distribution of permission. Examination in each individual
case necessarily!)
24
11.2.1 Care regulations
The exterior of the equipment is to be cleaned from time to time in order to protect it from
external corrosion. Oil is to be applied to the metallic surfaces.
11.2.2 Function and load test
If there is any doubt regarding the safety or reliability of the equipment, a function and load
test must also be performed.
11.2.3 Changing the hydraulic fuid
- The hydraulic fuid must be changed after after three years at the latest.
- It must always be changed whenever the hydraulic fuid for the accompanying pump
(motor / hand pump) is changed. This is to prevent the fresh hydraulic fuid from becoming
contaminated by the used fuid from the rescue equipment.
Procedure:
1. Change the hydraulic fuid of the pump. Please observe the separate operating instructions
for the pump being used!
2. Screw off the return hose on the pump:
- With direct hose connection to the pump or control unit:
completely unscrew the connection nut of the connection piece of the blue return hose.
- With hose connection to the pump or control unit via mono-coupling:
remove the cover from the mono-coupling (male).
completely unscrew the connection nut of the blue returnhose on the mono-coupling
(male).
- With hose connection to the pump or control unit via quick-disconnect coupling:
completely unscrew the connection nut on the quick-disconnect-coupling of the blue
return hose.
3. Put the return hose into a separate collecting basin for the hydraulic fuid still in the
equipment.
4. Activate the hydraulic pump and pressurize the supply hose. Pressurize the supply hose
as long as it needs to scavenge the whole used hydraulic fuid out of the hose reel.
The period of pressurization depends on the length of the hose assemblies (Fluid volume
in the hose reel) and the fow rate of the pump. You will fnd fhe fuid volume of the hose
reel in the chapter technical data.
5. Switch the pump off (motor pump) / no longer activate it (e.g. hand pump) and dispose the
collected hydraulic fuid properly and according to the legal specifcations.
6. Reconnect the return hose to the pump:
- With direct hose connection to the pump or control unit:
screw the connection nut of the connection piece of the blue return hose back on.
(Please observe the necessary torque of M
A
= 40 Nm!)
- With hose connection to the pump or control unit via mono-coupling:
screw the connection nut of the blue return hose back onto the mono-coupling (male).
A
= 40 Nm!)
Pull back the cover on the couplings as far as the limit stop.
- With hose connection to the pump or control unit via quick-disconnect coupling:
screw the connection nut back onto the quick-disconnect-coupling of the blue return hose.
A
= 35 Nm!)
11.2 Preventative service
REMARK when using hose reels with quick-disconnect-couplings:
When using hose reels with quick-disconnect-couplings on the extension
hose pairs, each quick-disconnect-coupling (male) has to be connected with
a quick-disconnect-coupling (female) of the same hose pair.
25
11.3 Repairs
11.3.1 Changing or tightening connection hoses
Hose assembly of the supply and/or return hose leaks or hoses are defective. Tighten the
hose connections on the shaft.
(CAUTION! Observe torque of M
A
= 40 Nm!)
11.3.2 Changing or tightening extension hose pairs
Hose assembly of the supply and/or return hose leaks or hose pairs are defective. Pull back
the protectiv cover and tighten the hose connections on the ellbows.
(CAUTION! Observe torque of M
A
= 40 Nm!)
7. Control and top up the hydraulic fuid level in the hydraulic pump.
REMARK when using hose reels with quick-disconnect-couplings:
When using hose reels with quick-disconnect-couplings on extension hoses,
they have to be disconnected again.
ellbow
protectiv cover
hose
CAUTION!
Set of protectiv covers must be assembled on the reel!
26
11.3.3 Mono-couplings
The mono-couplings must be replaced in the event of:
- external visible damage,
- the locking device not working,

Procedure:
1. Remove the cover from the couplings.
2. Loosen the connection nuts of the hose assembly and remove the coupling.
3. Position the new coupling and tighten the connection nuts of the hose assemblies
with a torque of M
A
= 40 Nm and push the cover of the couplings back on.
WARNING / CAUTION!
CAUTION!
Take care that the port T / T1 of the hose reel is always connected to the port
T of the mono-coupling.
27
11.3.4 Quick-disconnect-couplings
The quick-disconnect-couplings must be replaced in the event of:
- the locking device not working,

WARNING / CAUTION!
Procedure:
1. Loosen the connection nut of the hose assembly and remove the coupling.
2. Position the new coupling and tighten the connection nut of the hose assemblies
with a torque of M
A
= 35 Nm.
CAUTION (side of the equipment)!
The return hoses, which are screwed onto the port T / T1 of the hose reel,
must always be equipped with quick-disconnect-couplings (female).
However the supplying hose lines must be equipped with quick-disconnect-
couplings (male).
CAUTION (side of the aggregate)!
The return hoses, which are screwed onto the port T / T1 of the hose reel,
must always be equipped with quick-disconnect-couplings (male).
However the supplying hose lines must be equipped with quick-disconnect-
couplings (female).
28
11.3.5 Ellbows on the single and double hose reels
The ellbows must be replaced in the event of:
- hydraulic fuid continually leaking on the ellbow pipes.
Procedure:
1. Remove the extension hose pairs.
2. Loosen the ellbow and remove it.
3. Position the new ellbow and tighten it with a torqu of M
A
= 40 Nm.
winding direction
Coiling
hose
ellbow
CAUTION!
Take care that the ellbows are
allways mounted in the correct
oriented manner (see illustration
on the right).
protectiv covers
Do not forget to push the protective covers
back again over the screwed-connections
(siehe illustration on the left).
29
11.3.6 Changing the hose drum on the single hose reel
Damaged hose drums must be immediately replaced. Before you can change the hose
drums, however, you must dismantle the extension hose pairs!
Procedure (see illustration):
1. Remove fxing bolts A, lock washers B and washers C.
2. Remove the hose drum D and replace it with a new one.
A
3. Assembly is now carried out in reverse order. Please ensure all screws are once again
tightened after the hose drum has been changed.
(torque max. M
A
= 7 Nm)
B
C
D
30
11.3.7 Changing the hose drum on the double hose reel
Damaged hose drums must be immediately replaced. Before you can change the hose
drums, however, you must dismantle the extension hose pairs!
1. Remove both screws A and washer B.
2. Remove the shaft with both hose drums C.
3. Remove fxing bolts D, lock washers E and washers F.
4. Remove the hose drum and replace it with a new one.
5. Assembly is now carried out in reverse order. Please ensure all screws are once again
tightened after the hose drum has been changed.
(torque max. M
A
= 7 Nm)
The screws A must be tightened with a torque of M
A
= 30 Nm and be secured with a screw
securing paste (e.g. Loctite 243).
D
A
B
E F C D E F C
31
11.3.8 Parking brake on the double hose reel
If the parking brake on the double hose reel is damaged / non-functional, it must be
replaced
1. Remove bolts A, washers B, lock washers C and nuts D.
2. Remove the damaged parking brake D and replace it with a new one.
3. Assemble screws A, washers B and nuts C, and tighten.
A
11.3.9 Labels
All damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.
Procedure:
1. Remove damaged and/or illegible labels.
2. Clean the surfaces using acetone or industrial alcohol.
3. Attach new labels.
Ensure that you attach the labels in the right position. If you are no longer sure about this,
then please contact your authorised LUKAS dealer or LUKAS itself.
E
B
D
C
32
Troubleshooting 12.
Trouble Control Cause Solution
Equipment doesnt
move when activated
Hose assemblies
connected
properly?
Hose assemblies
not connected
Reaffx hose
assemblies or re-
couple them
Does the pump
unit work?
Equipment or
hydraulic unit
defective
See separate
operating instructions
for hydraulic unit or
equipment.
Equipment
moves slowly or
jerkily when activated
Are the hoses
connected
correctly?
Air in the hydraulic
system
Deaerete hydraulic
system
Does the pump
unit work?
with mono-coupling-
system: Hoses
cannot be coupled
Pressure too high
(e.g. caused by
too-high ambient
temperature)
Set hydraulic pump
to pressureless
circulation
with mono-
coupling-system:
It is frequently not
possible to couple
hose assemblies
Control the
degree of viscosity
and application
temperature of
the used hydraulic
fuid
Hydraulic fuid
not adapted to
the application
situation
Hydraulic fuid
must be replaced
(see chapter
Recommended
Hydraulic fuids)
with quick-
disconnect-coupling-
system: Hoses
cannot be coupled
Is the pump
working?
Pressurized Relieve pump
Damages of the
surface of the
hydraulic hoses
Mechanical
damages or
contact with
aggressive agents
Replace hoses
Leak in the couplings Is the coupling
damaged?
coupling damaged Coupling must be
Hydraulic fuid leaking
from the hoses or
connections
Hoses defective? Leak, possible
damage
Replace hoses
33
Leakage of hydraulic
fuid in the inner area
of the hose reel.
Hose extension
pairs defective?
Hoses defective Replace hoses
Connection of the
hoses tighten?
Hoses not
tightened properly
onto the elbows.
Tighten the screwed
connection between
hoses and elbow.
Leckage on
the connection
between elbow
and shaft?
Defective elbow /
defective sealing
below the elbow
Replace elbow /
sealing
Defective shaft Repair by an
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
Leakage of
hydraulic fuid on the
connections between
connection hoses
and reel shaft.
Connection hoses
defective?
Hoses defective Replace hoses
Connections of the
hoses tighten?
Hoses / fttings not
tightened properly.
Tighten the screwed
connection of the
hoses / fttings.
Leackage between
ftting and shaft?
Fittings not
tightened properly.
Tighten the screwed
connection.
Sealing between
ftting and shaft
defective.
Replace sealing
Fitting defective Replace ftting.
Leckage on
connection between
hub and shaft
Sealing between
hub and shaft
defective.
Repair by an
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
with mono-coupling-
system: Leak in the
couplings
Is the coupling
damaged?
with quick-
disconnect-coupling-
system: Leak in the
couplings
Is the coupling
damaged?
Is the leak only
on the coupling
male (when
uncoupled)?
Safety valve
reacted
After pressure
release there is no
more leakage.
Trouble Control Cause Solution
34
If it isnt possible to rectify the malfunctions, inform an authorised LUKAS dealer or the
LUKAS customer service department immediately!
The address for the LUKAS customer service department is:
Tel.: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
35
Technical Data 13.
13.1 General reel identifcation
DHR 20 - 66 blgr
13.2 Maximum operating pressure
70 [MPa]* = 10,153 [psi.]
* 1 [MPa] = 10 [bar]
13.3 Technical data for the hose reels
This information can be found in the separate, supplemental instructions
for your hose reel model.
Since all values are subject to tolerances, minor differences may occur between the data on
your equipment and the data listed here!
Type of hose reel
SHR = single hose reel
DHR = double hose reel
Length of the
extension hose
pairs in [m]
Length of the
extension hose
pairs in [ft.]
Colour of the antikink
cover of the extension
hose pairs
bl = blue
bc = black
gr = grey
At the double hose
reels both of the anti-
kink cover colours are
specifed, that means
blgr signifes:
antikink cover 1 = blue
antikink cover 2 = grey
The max. operating pressure of all STREAMLINE-hose reels is:
36
13.4 Further technical datas of the hose reels
A -24 .... +30C HL 5 VG 5
B -18 .... +50C HM 10 VG 10
C -8 .... +75C HM 22 VG 22
D +5 .... +80C HM 32 VG 32
E -8 .... +70C HF-E15 VG 15 Bio-oil
A -11.2 .... +86F HL 5 VG 5
B -0.4 .... +122F HM 10 VG 10
C +17.6 .... +167F HM 22 VG 22
D +41.0 .... +176F HM 32 VG 32
E +17.6 .... +158F HF-E15 VG 15 Bio-oil
13.5 Further technical datas of the hose reels
Ambient temperature
[C] / [F] -25 +45 -13 +113
Storage temperature
[C] / [F] -30 +60 -22 +140
CAUTION!
Before using hydraulic fuids, which do not correspond to the above-mentioned
specifcations and/or are not purchased from LUKAS, you have to contact
LUKAS itself!
NOTE:
When hose reels with a mono-coupling are used, we recommend an oil in the
viscosity class VG 10, as the force required for coupling can otherwise be very
high.
37
EC Declarations of conformity 14.
This information can be found in the separate, supplemental instructions
for your hose reel model.
38
Notes 15.
39
Please dispose all packaging materials and
dismantled parts properly
Tel.: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
Made in GERMANY
Copyright 2009 LUKAS Hydraulik GmbH Schlauchhaspeln_BA_GB_176101085_0809.indd
s
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b
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Edition 11.2010
84120300085 GB
Hand Pumps ZPH and HM
replaces 11.2009
2
3
Contents Page
1. Danger classes 4
2. Product safety 4
3. Proper use 7
4. Main components of the hand pump 8
6. Connection options for hydraulic equipment 9
6.1 Connecting nipples 9
6.2 Quick-disconnect couplings 10
6.3 Monocouplings 11
7. Commissioning 12
7.1 Locking the pump 12
7.2 Bleeding the pump 12
8. Operation 13
8.1 Operation 13
8.2 Shut-down / Storage 14
9. Transport 14
10. Maintenance and repair 14
10.1 Basic requirements 14
10.2 Maintenance 15
10.3 Changing or topping up the hydraulic fuid 16
10.4 Care 16
10.5 Repair 17
12. Technical data 25
12.1 Hand pump data 25
12.2 Hydraulic fuid recommendation 28
12.3 Operating and storage temperature ranges 28
13. EC Declaration of Conformity 29
14. Notes 30
4
Wear helmet with face guard
Wear protective gloves

Wear safety shoes
We distinguish between various categories of safety instructions. The table shown below
shows you the overview, via the assignment of symbols (pictograms) and signal words, of
the concrete danger and the possible consequences.
Danger classes 1.
Pictogram
Damage /
injury to
h
u
m
a
n
DANGER! Immediate danger Death or major injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION!
Less dangerous
situation
Minor or slight injury
d
e
v
i
c
e
ATTENTION!
Danger of damage
to device /
environment
Damage to the
equipment, damage
to the environment,
damage to
surrounding materials
- NOTE
Advice for
application and
other important /
useful information
and advice
No injury / damage
to persons /
environment /
equipment
Product safety 2.
LUKAS products are developed and produced in order to ensure the best performance and
quality with proper use.
The safety of the operator is the most important consideration in the product design. In
addition, the operating instructions are to help in using the LUKAS products safely.
In addition to the operating instructions, all generally applicable, statutory and other
binding rules for accident prevention and for environmental protection must be heeded and
disseminated.
The device must only be operated by educated persons who are trained in safety technology,
since otherwise there is a risk of injury.
We advise all users before using the device to carefully read through the operating instructions
and to follow the instructions contained therein without exception.
Proper recycling
Protect the environment
Read and follow operating
instructions
5
We also recommend that you get instructed by a qualifed trainer in the use of the product.
WARNING / CAUTION!
devices must also be heeded!
Even if you have already received instruction, you should read the following safety instructions
again.
Make sure that no body parts
or clothing get between the
openly visible moving parts of
the device.
Immediately report changes
that occur (including changes
in operating behaviour) to
the appropriate persons/
departments! If necessary,
immediately shut down and
secure the device!
Wear protective clothing,
protective helm with visor,
safety shoes and protective
gloves.
Check the device for visible
defects or damage before and
after use.
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, suffcient
mechanical supports are
additionally required.
Check all lines, hoses and
and externally visible damages
and repair immediately!
Escaping hydraulic fuid can
lead to injuries and fres.
shut down the device
immediately and secure it. You
should have the malfunction
repaired immediately.
Do not make any changes
(add-ons or conversions) on the
device without the approval of
LUKAS.
Heed all safety instructions
and hazard warnings on the
device and in the operating
instructions.
All safety instructions and
hazard warnings on the device
are to be kept intact and in a
legible condition.
Make sure that all safety covers
are present on the device and
in proper working condition.
Any work procedure that
detracts from the safety and/or
stability of the device should be
abandoned!
Safety equipment must never
be disabled!
The maximum permissible
operating pressure must not be
changed.
6
Before switching on/engaging
the device or while operating
the device, it must be ensured
that no one is endangered by
the operation of the device.
Observe all intervals that
are prescribed or specifed
in the operating instructions
for recurring tests and/or
inspections.
When working in the vicinity
of live components and lines,
take appropriate measures for
preventing current transfers or
high voltage fashovers to the
device.
For repairs only original LUKAS
accessories and spare parts are
to be used.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Prevent electrostatic discharge,
which has the possible
formation, when handling the
device.
When the hand pumps are set
up, care needs to be taken
that they are not impaired by
extremely strong temperature
changes.
The device is flled with
fuids can be detrimental to
health if they are swallowed
or their vapours are inhaled.
Direct contact with the skin
should be avoided for the same
reason. Also, when handling
hydraulic fuids, note that they
can negatively affect biological
systems.
When operating and/or storing
the device, make sure that the
device are not impaired by
strong external temperature
differences or that the device is
damaged. Keep in mind that the
device can also heat up when it
is continuously used.
Make sure there is adequate
lighting while working.
Before transporting the device,
always check to see that the
accessories are positioned
securely to prevent the
possibility of an accident.
instructions easily accessible
at the site where the device is
used.
Make sure you properly dispose
of all removed parts, leftover
hydraulic fuid, leftover oil and
packing materials.
In addition to the safety instructions of these operating instructions, all generally applicable,
statutory and otherwise binding national and international rules for accident prevention need
to be heeded and disseminated!
7
WARNI NG / CAUTI ON / ATTENTI ON!
The device is specifed exclusively for the purpose represented in the operating
instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is
considered improper. The manufacturer/supplier shall not be held liable for damages
resulting from improper use. The risk shall be borne solely by the user.
Proper use also includes heeding the operating instructions and complying with the inspection
and maintenance requirements.
Never work in a fatigued or intoxicated state!
Proper use 3.
You can obtain accessories and replacement parts for the devices from your authorised
LUKAS dealer!
The LUKAS hand pump is used for the operation of LUKAS devices.
They can be used as an additional or replacement drive source along with the LUKAS
hydraulic unit (e.g. in areas at risk for explosion).
Use with equipment of other manufacturers is possible, but requires technical testing and
approval of LUKAS on a case-by-case basis.
Always note the product limitations with respect to operating pressure, load limit
values and operating conditions. The operating pressure should not be higher
than the lowest maximum operating pressure of any system components.
The operating pressure should NEVER be set higher than that which is specifed
in the "Technical Data" chapter. A higher setting may cause property damage
and/or injuries.
Make sure that the usable capacity of the hand pump (see chapter "Technical
Data") is suffcient for operating the connected cylinders or devices.
The required hydraulic fuid operating quantity can be found in the chapter
"Technical Data" or in the operating instructions of the devices to be operated.
8
Main components of the hand pump 4.
All LUKAS hand pumps of this series are two-speed, i.e. they have two operating speeds:
A high speed in the low pressure range (LP) for fast extension of the cylinder or device
while unloaded
A low speed in the high pressure range (HP) for controlled extension of the cylinder or
device while loaded
The switch from low pressure (LP) to high pressure (HP) is automatic at the factory setting
for changeover pressure (see chapter "Technical Data").
1 Drain valve
2 Bleeding / Filling cap
3 Pump lever
4 Tank
5 Lock
6 Connecting nipples
7 Sealing caps
8 quick-disconnect couplings
(optional)
9 Connecting block for
monocoupling (optional)
10 Monocoupling (optional)
11 Front foot plate (optional)
12 Rear foot plate (optional)
13 Base plate (optional)
3
1
1
1
2
13
4
5
5
5
6
7
8
9
10
12
11
1
5
9
Connection options for hydraulic equipment 6.
ATTENTION!
Make sure to store all plugs, screw plugs and/or dust caps in a way that
prevents them from getting dirty or lost.
After completion of the work, seal off all lines using screw plugs and/or dust
caps to prevent contamination of the hand pump.
When connecting lines to the hand pump, we recommend positioning it
vertically so that the ports point upward. This reduces the danger of hydraulic
fuid escaping.
6.1 Connecting nipples
The hose lines are connected via fttings to the hydraulic pump.
1.
2.
1. First remove the closure caps from
the fttings.
2.

Then, you can connect the hose lines
to the fttings and tighten them with a
tightening torque of M
A
= 40 Nm.
ATTENTION!
The return hose must always be connected at the "T" port of the
connection block.
The supply hose line must instead be connected at the "P" port.
A pressure connection "P" and a return connection "T" with a G1/4 thread are available for
connecting directly to the pump.
To connect equipment, appropriate connectors (connecting nipples, quick-disconnect
couplings or monocouplings) must be attached. On some of the LUKAS hand pumps offered,
one of these connection options is supplied with the pump and is already ftted.
Obviously, the connection options ftted can be replaced by others. However, you must
contact an authorised LUKAS dealer or contact LUKAS directly.
Additionally, LUKAS hand pumps can be ftted with various accessories (e.g. a baseplate),
to adapt the hand pump to the individual application.
You can obtain the appropriate accessory and any necessary replacement parts for the hand
pumps from your authorised LUKAS dealer.
10
Before connecting the couplings, remove the dust cap, then pull back and hold the locking
sleeve of the female coupling (Position X). Push the male and female couplings together and
release the locking sleeve. Finally, turn the locking sleeve into Position Y. The connection is
then made and secured. Decoupling is done in the reverse sequence.
To some extent the quick-disconnect couplings have special functions and
therefore must not be unscrewed and/or interchanged!
X
Y
NOTE:
Coupling the equipment is only possible if the hoses are depressurised.
6.2 Quick-disconnect couplings
ATTENTION!
11
6.3 Monocouplings
Male coupling
Female coupling
Dust caps
Before coupling, remove dust caps, then connect male and female couplings and turn locking
sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection
is then made and secured. The decoupling is accomplished by turning the locking sleeve in
direction "0".
The coupling of the devices under pressure is also possible, assuming the connected
equipment is not turned on.
NOTE:
We recommend, when ambient temperatures are low and extension hoses
are used, connecting the coupling halves in a depressurised state because
decoupling may otherwise require a very large exertion of force.
The monocouplings must not be unscrewed and/or the hose lines reversed!
The hose lines are connected via monocoupling halves (female and male) to the hydraulic
pump in such a way that they cannot be reversed.
12
NOTE:
With the LUKAS hand pump, a little idle stroke may occur when the unit is frst
used in the high pressure range.
However, this idle stroke independently stops after a device is operated
2-3 times.
7.1 Locking the pump
ATTENTION!
The hand pump should be as close to horizontal as possible, because otherwise
the usable amount changes!
The oil fll plug must always be unscrewed one turn before starting operation of
the hand pump! This enables the aeration and bleeding of the hydraulic tank.
After the work is completed but before transport, the oil fll plug should be
retightened!
Commissioning 7.
7.2 Bleeding the pump
1. Open the discharge valve.
2. Open the oil fll screw plug on the tank container and check the oil fll level. The oil fll
level should come up to approximately 1-2 cm below the top edge of the oil reservoir.
3. In this state, work the pump handle several times.
Hand wheel
Unlock: Lock:
ATTENTION!
Always push the locking lever fully to the end position, both when locking and
when unlocking!
When locking the hand pump, the pump lever must always be in the home
position (end position against the pump body)!
13
NOTE:
To bleed connected equipment, make sure that the highest point of the connected
devices are below the level of the pump.
Before operating the pump, you should also open the oil fll screw plug. Only in this
way can any trapped air escape the hydraulic system when the pump is operated.
You should operate the connected equipment several times without load.
When you do this, also follow the separate operating instructions of the connected
devices.
WARNING / CAUTION!
Under certain circumstances, the pump handle can "kick back". Make sure that
your body remains to the side of the pump.
ATTENTION!
Never attach an extension to the pump handle that does not belong to the
device. These extensions usually cause the pump to become unstable during
operation.
Operation 8.
NOTE:
In order to limit the required force in high pressure operation, we recommended
using short strokes with the pump handle. The greatest pumping effect is produced
in the last 5 degrees of the stroke.
Should you use a female quick-disconnect-coupling as the port, quick stop may be
triggered if the discharge valve is opened too quickly (turning counter-clockwise),
i.e. the check valve incorporated in the male quick-disconnect coupling blocks
the return fow of oil while the connection between pump and female quick-
disconnect coupling is depressurised. This is provided as a safety function in case
the connection between the female quick-disconnect-coupling and pump starts
to leak and the pressure drops abruptly. In this case, the "quick stop" prevents,
for example, an abrupt drop in the load when an hydraulic cylinder is operated.
In order to release the quick stop again, more pressure must frst be supplied to
the device. Then, the pressure can be decreased again by slowly opening the
discharge valve.
Procedure:
1. Close discharge valve on the hand pump completely (rotate clockwise).
2. Connect the return line of the device at the return port "T" and then the high pressure line
at the pressure port "P".
3. Move the locking lever into the operating position (unlock).
4. Supply the device with hydraulic fuid or pressurise by operating the pump lever (up and
down movements).
5. To reduce the pressure of the device, slowly open the discharge valve of the hand pump
(turn counter-clockwise). In this way, you can meter the pressure reduction precisely.
8.1 Operation
14
Transport 9.
8.2 Shut-down / Storage
To shut down or store the pump, seal all hydraulic connections with the associated screw
plugs or dust caps.
After sealing the hydraulic ports, open the drain screw (not up to the stop!) to depressurise
the pump.
Then carefully clean the external dirt off of the hand pump.
In addition, with a longer storage time, the outside of the device should be cleaned and all
visible mechanical moving parts need to be oiled.
ATTENTION!
After completion of the work but before transport, check to make sure the oil fll
screw plug is screwed in tightly!
Make sure the pump is not stored in a damp environment.
The pump lever is used as a carrying handle! Special pumps may be the exception in this
case. These pumps are custom-assembled for each customer; therefore, there may be a
different transport device or none! In these cases, please refer to your authorised dealers or
LUKAS directly. The lever must be locked for transport, as described in the chapter "Locking
the pump".
Maintenance and repair 10.
Service work may only be performed by the device manufacturer, or by personnel trained by
the device manufacturer, and authorised LUKAS dealers.
All components must be replaced with original LUKAS spare parts, which are listed in the
spare parts list, because in this context even required special tools, assembly instructions,
safety aspects and/or checks absolutely must be taken into consideration.
During the assembly work, pay particular attention to the cleanliness of all components
because dirt can damage the equipment!
10.1 Basic requirements
To perform maintenance and repairs, personal safety equipment appropriate for
the work is an absolute requirement (incl. shields).
Assembly and repair work on the pump may only be performed if the entire
hydraulic system is depressurised!
parts!
NOTE:
Always send the warranty card back to LUKAS Hydraulik GmbH.
You should always contact LUKAS or an authorised dealer before using couplings
from a different company.
Do not perform any repairs without the corresponding LUKAS spare parts list,
because necessary tightening torques for screw connections and/or in some
cases also important additional information are listed there.
15
The equipment is subject to very high mechanical stresses. Therefore, a visual inspection
needs to be made after each use, at least once per month (if continually used, once per
week).
In this way, early signs of wear are recognisable so that damage to the device can be avoided
by prompt replacement of these worn parts. Also check regularly to make sure that all
attachment screws are tightened (observe any applicable tightening torque specifcations).
At least once a year (if continually used, once every half year) or if there is a doubt about
the safety or reliability, a functional check should also be performed (for this purpose, also
heed the corresponding applicable national and international specifcations related to the
maintenance intervals of the devices).
ATTENTION!
Clean the device before checking for dirt!
Do not use any aggressive agents for cleaning; it could cause damage to the
equipment.
corresponding device.
- You have the express permission of LUKAS customer service (by
request, check on the grant of permission. A check is necessary in each
individual case).
10.2 Maintenance
Before performing maintenance work, clean the hand pump thoroughly.
After performing the maintenance work, you should carefully coat all metallic parts with oil
to prevent any corrosion.
Checks (Maintenance measures):
Perform a visual inspection of the hand pump at least once per month; in the case of
continuous use, once a week.
Visual inspection
Hand pump
are all hydraulic connections still tightened,
generally sealed, no leaks present (oil "sweat" has no effect on the operation),
is damage to pump housings, valve blocks or attachment parts recognisable, especially
on the moving parts such as the piston rods,
are all fuid levels within the prescribed tolerances,
are all non-moving parts frmly attached,
is there no corrosion,
free movement of the pump lever, the locking mechanism and the hand wheels
(check in the depressurised state),
the couplings are easy to couple (if attached),
are dust caps in place,
are identifcation plate, all control decals, instruction decals, labels and warnings present
and legible.
16
NOTE:
In this test, an idle time of approximately 2 minutes needs to be observed and
the hand pump needs to be reloaded to operating pressure.
The resulting max. operating pressure must not drop by more than 5% after
10 seconds.
A test pressure gauge is available from the LUKAS line of accessories.
Perform an operational check of the hand pump at least once a year; in the case of continuous
use, once every half year.
Operational check
no suspicious noises,
tests at maximum load.
Execution:
Place the hand pump on a solid base to operate. Then, connect a test manometer to the
supply hose line. Release the pump lever lock and close the discharge valve. Then, the
pressurisation to operating pressure corresponding to the specifcation on the identifcation
plate occurs.
10.3 Changing or topping up the hydraulic fuid
The hydraulic fuid should be changed if dirty at least once a year. When the hand pump is
operated in an especially dusty environment, we recommend changing the fuid at least once
every six months.
ATTENTION!
Add hydraulic fuid only if the hand pump is disconnected from the lines or the
equipment operated with the pump is hydraulically depressurised. Otherwise,
after flling the entire hydraulic system could contain more hydraulic fuid than
the tank can hold.
Procedure:
1. Open the bleed/fll cap on the tank.
2. Add hydraulic fuid until the fuid level comes up to 1-2 cm below the top edge of the oil
tank.
3. Bleed the hand pump as described in the chapter "bleeding the pump".
4. Check the fuid level again and close the tank again at the correct fuid level with the
vent/fll cap on the tank. Should the tank no longer be suffciently full after bleeding, start
the fll procedure again at item 2.
NOTE:
Should the fuid level in the tank still not be reached after repeated reflling (during
maintenance), we recommend searching for leaks in the hydraulic system.
10.4 Care
If possible, do not store the hand pump in a damp or extremely dusty environment in order
to ensure a long service life. If this is unavoidable, you should perform more frequent
maintenance and/or shield the pump from these effects if possible.
Regularly coat all metal parts with oil to prevent any corrosion.
17
10.5 Repair
ATTENTION!
corresponding device and whose replacement is described here.
- You have the express permission of LUKAS customer service (by
request, check on the grant of permission. A check is necessary in each
individual case!).
10.5.1 Base plate replacement
The base plate must be replaced if external damage is present that represents a danger for
user and device upon further use. In particular, the base plate must be replaced if the stability
Procedure:
1. Remove screws A and B and also washers C and D.
2. Remove base plate E and replace it with a new one.
3. Reft the base plate in the reverse order.
A
C
D
B
E
18
10.5.3 Removing tank for cleaning, replacing the tank or the seals
The tank should be cleaned at least once per year in order to remove the accumulated dirt.
The tank must be replaced if there is any external damage that impairs the safety of
the device.
The tank seals must be replaced if there are any leaks at the junction points of the tank.
Procedure:
1. Remove base plate as described in the chapter "Replacing
base plate".
2. Empty tank by removing the screw plug (item D) and emptying
the tank.
D
2. Remove foot plate C or D and replace it with a new one.
3. Reft the foot plates in the reverse order.
10.5.2 Foot plate replacement
The foot plates must be replaced if external damage is present that represents a danger for
user and device upon further use. In particular, the foot plates must be replaced if the stability
Procedure:
1. Remove screws A or B.
Front foot plate: Rear foot plate:
C
A
D
B
19
Removing the ZPH1/HM1 1l tank:
3. Remove the nut (item E) and sealing ring situated under it (item F).
4. Remove the tank, the seals (item G), the cover (item R) and the flter (item H). On the
rescue hand pumps, the intake pipe (item J), the threaded rod (item K), the washer (item
L), the O-ring (item M), the serrated washers (items N, O and P) and the bracket (item Q)
must also be removed.
6. The assembly is done in reverse order. Replace all damaged parts with new ones. The
tightening torque of the nuts is 40 Nm.
Removing the ZPH1/HM1 5l and 12l tanks:
3. Remove the screws (item R) and the lock washers under them (item S).
4. Remove the tank, the O-rings (items T and U), the serrated washer (item V) and the flter
(item W).
tightening torque for the screws is 10 Nm.
S R
W
V
T
U
F E N Q N G O L M H P G R
K
Tank
J
Pump head
20
10.5.4 Couplings
parts!
10.5.4.1 Monocouplings
The monocouplings must be replaced if:
Procedure for installation in the valve block:
1. Unscrew coupling from connection plate.
2. Screw new coupling into the connection plate with a torque of M
A
= 40 Nm.
Removing the ZPH3 tank:
3. Remove the screws (items A and B) and the lock washers under them (items C and D).
4. Remove the tank, the O-rings (items E and F), the serrated washer (item G) and the flter
(item H).
tightening torque for screws "A" is 24 Nm, and for screws "B" is 10 Nm.
F E H B D
C A Tank
G
21
10.5.4.2 Quick-disconnect couplings
The quick-disconnect-couplings should be replaced if:
Procedure:
1. Unscrew and remove coupling.
2. Screw in new screw-on male coupling and tighten with a torque of M
A
= 35 Nm.
ATTENTION!
The return port must always be equipped with a female quick-disconnect-
coupling.
The supply port should instead be equipped with a male quick-disconnect-
coupling.
10.5.5 Decals
All damaged and/or illegible decals (safety instructions, identifcation plate, etc.)
must be replaced.
Procedure:
1. Remove damaged and/or illegible decals.
2. Clean surfaces with acetone or industrial alcohol.
3. Adhere new decals.
Make sure to adhere the decals in the correct positions. If this is no longer known, you should
consult your authorised LUKAS dealer or contact LUKAS directly.
22
Troubleshooting 11.
Connected device
does not move, moves
only slowly or moves
intermittently.
tank too low
max. fll level.
Discharge valve open Close discharge valve.
if necessary.
Load on the device
too high
Use a different device.
Air in the hydraulic system Bleed system as described
the pump.
instructions of the
device.
Connected device moves,
but does not hold pressure
or does not render the
specifed performance.
if necessary.
Leaking seal Locate the leak and have
the hand pump serviced by
an authorised dealer, by
personnel specially trained
by LUKAS or by LUKAS
directly.
Internal leakage of the
pump
Have the hand pump
serviced by an authorised
dealer, by personnel
specially trained by LUKAS
or by LUKAS directly.
Device does not move
back into the starting
position, moves
incompletely back toward
the starting position or
moves more slowly into
the starting position than
normal.
Discharge valve closed Open discharge valve.
tank too high
Loose hydraulic coupling Check all couplings and
retighten them.
Enclosed air in the system Bleed pump as described
the pump.
Line length too long Use shorter lines.
Use hydraulic fuid with
a different, more suitable
viscosity.
instructions of the
device.
23
Connected device not
reaching its limit position
tank too low
max. fll level.
Attention: move the
device back into the
base position before
adding fuid!
quantity of the pump is
insuffcient
Use a different device with
a usable quantity below
the maximum usable
quantity of the pump.
Connected device does
not achieve its power-
related performance data
Max. permissible operating
pressure of the pump is
not reached
Replace pressure
control valve or have
it recalibrated by an
directly by LUKAS.
Fluid leaks on the
hydraulic fuid tank
(especially at the refll tap)
Due to return fow of the
hydraulic fuid from the
device, the maximum fll
quantity of the tank is
exceeded
Seals defective Replace seal.
Hydraulic fuid with milky
cloudiness
Water or condensation
water in the system
Perform hydraulic fuid
change immediately.
In the case of a
Hose lines cannot be
coupled
They are under excessive
pressure (e.g. due to
excessive ambient
temperature)
Open discharge valve and
bleed device.
In the case of a
Hose lines frequently
cannot be coupled
Hydraulic fuid of the
application situation not
adapted
Hydraulic fuid needs
to be changed (see the
chapter Hydraulic fuid
recommendation for more
information).
disconnect coupling
system: Hose lines cannot
be coupled
System is under pressure Open discharge valve and
bleed device.
In the case of a
Leakage at the couplings
24
disconnect coupling
system: Leakage on the
male coupling
Safety valve has
responded (in the
decoupled state)
After depressurisation, no
further leakage occurs.
Male coupling defective Male coupling should be
disconnect coupling
system: Leakage at the
female coupling
Female coupling defective Female coupling should be
Hydraulic fuid escaping
from the hoses or at the
joints
Leakage, possible damage Replace hoses.
the hydraulic hoses
media
Replace hoses.
If the defects cannot be remedied, notify an authorised LUKAS dealer or contact LUKAS
Customer Service directly!
The address of LUKAS customer service is:
Phone: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
25
Technical data 12.
Because all values are subject to tolerances, there cannot be any differences between the
data of your device and the data of the following tables!
12.1 Hand pump data
12.1.2 Dimensions
ZPH 1A / 1 PN500
rounded usable
volume of the
hydraulic fuid
tank
in [l]
max. operating
pressure in [bar]
(1 MPa = 10 bar)
12.1.1 Pump identifcation
Model series
F
Optional
attachments
e.g.
F = with foot plates
(not for HM1)
NOTE:
Hand pumps in model series HM1 are generally ftted with a base plate.
NOTE:
On hand pumps with the optional foot plate attached, the height H increases by 6
mm.
ZPH1 and HM1:
ZPH 1 HM 1
(1l Tank) (5l Tank)
L
[mm] 621 628 623
[in.] 24.4 24.7 24.5
B
[mm] 112 164 200
[in.] 4.4 6.5 7.9
H
[mm] 195 195 215
[in.] 7.7 7.7 8.5
26
ZPH3:
ZPH 3
(4l Tank) (8l Tank)
L
[mm] 762 762
[in.] 30 30
B
[mm] 150 230
[in.] 5.9 9.1
H
[mm] 231 231
[in.] 9.1 9.1
12.1.3 Fill quantity - Usable quantity
Tank size Usable quantity Max. fll quantity
(according to pump
identifcation)
1 [l]
1,1 [l] 1,3 [l]
0.29 [gal.-US] 0.34 [gal.-US]
4 [l]
4,0 [l] 5,3 [l]
1.06 [gal.-US] 1.40 [gal.-US]
5 [l]
4,5 [l] 5,0 [l]
1.19 [gal.-US] 1.32 [gal.-US]
8 [l]
8,0 [l] 10,5 [l]
2.11 [gal.-US] 2.77 [gal.-US]
12.1.4 Delivery quantity
Pump type Delivery quantity per piston stroke
Low pressure LP High pressure HP
ZPH 1A
10 [cm] 1,6 [cm]
0.61 [cu. in.] 0.10 [cu. in.]
ZPH 3
10,8 [cm] 4,2 [cm]
0.66 [cu. in.] 0.26 [cu. in.]
HM 1
10 [cm] 1,6 [cm]
0.61 [cu. in.] 0.10 [cu. in.]
12.1.5 Max. operating pressure
NOTE:
You can take the max. operating pressure from the pump identifcation.
27
12.1.6 Change-over pressure LP - HP
*) 1 [MPa] = 10 [bar]
Pump type Change-over pressure
ZPH 1A
10 [MPa]*
1,450 [psi.]
ZPH 3
18 [MPa]*
2,611 [psi.]
HM 1
10 [MPa]*
1,450 [psi.]
12.1.7 Weight
Total
weight
Weight
(Pump head)
Weight
(Tank)
Weight
(Accessories)
= + +
Pump type Weight
(Pump head)
ZPH 1A
4,6 [kg]
10.1 [lbs.]
ZPH 3
3,7 [kg]
8.2 [lbs.]
HM 1
4,7 [kg]
10.4 [lbs.]
Tank size Weight
(according to pump
identifcation)
(Tank)
1 [l]
1,4 [kg]
3.1 [lbs.]
4 [l]
4,4 [kg]
9.7 [lbs.]
5 [l]
4,0 [kg]
8.8 [lbs.]
8 [l]
6,2 [kg]
13.7 [lbs.]
Accessories Weight
Base plate
1,28 [kg]
2.83 [lbs.]
Foot plate (front)
0,18 [kg]
0.40 [lbs.]
Foot plate (rear)
0,07 [kg]
0.15 [lbs.]
Connecting nipples
0,04 [kg]
0.09 [lbs.]
Quick-disconnect
coupling, female
0,29 [kg]
0.64 [lbs.]
Quick-disconnect
coupling, male
0,12 [kg]
0.26 [lbs.]
Monocoupling
0,73 [kg]
1.61 [lbs.]
28
12.3 Operating and storage temperature ranges
Ambient temperature
[C] / [F] -25 +45 -13 +113
Storage temperature
[C] / [F] -30 +60 -22 +140
12.2 Hydraulic fuid recommendation
A -20 .... +55C HM 10 VG 10
A -4.0 .... +131F HM 10 VG 10
ATTENTION!
Before using hydraulic fuids that do not correspond to the aforementioned
specifcations and / or are not purchased from LUKAS, you must contact
LUKAS!
29
EC Declaration of Conformity 13.
30
Notes 14.
31
Copyright 2010 LUKAS Hydraulik GmbH ZPH_HM_BA_GB_84120300085_1110.indd
Please properly dispose of all packing
materials and removed parts.
S
u
b
j
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t

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o

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e
v
i
s
i
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n
Phone: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
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