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1. electric parts near the ON OFF valve and in the cavities For allowing the spray to reach all points move the movable parts e Clean and dry up completely the tool handles for guaranteeing a firm grip PERIODIC CONTROLS AND SUBSTITUTION OF WORN PARTS e EVERY TIME THE EQUIPMENT IS USED 1 Control the hydraulic oil level 2 Control the level of the engine oil or make the proper maintenance as specified in the manual of the engine manufacturer 3 Control the condition of the hoses and quick couplers 4 Carry out a general control of the equipment 5 Clean carefully the equipment ATTENZIONE WARNING THE ENGINE OIL SHOULD BE COMPLETELY CHANGED AFTER THE FIRST 20 HOURS OF WORK AND THEN AS INDICATED IN THE MOTOR MANUFACTURER S MANUAL EVERY 60 HOURS OF WORK ABOUT EVERY MONTHS 1 Carry out all the controls of the previous paragraphs 2 Control that all screws fastenings and fittings are perfectly locked 3 Control the state of the hydraulic oil that should to be transparent and without foams If necessary replace completely the hydraulic oil changing also the used oil that remains inside the flexible hoses and in the tool 4 Carry out a complete cleaning of the equipment 5 Check and blow the engine air filter with compressed air if it is necessary 6 Clean the equipment carefully EVERY 100 HOURS OF WORK ABOUT EVERY SIX MONTHS 1 Replace completely the hydraulic oil changing also the used oi
2. NOTE The power pack engine is with battery and recoil starting Do not leave battery inactive for long periods they cannot be used if they are left discharged even for quite short periods When they are stored for long periods it is advisable to disconnect the positive pole In these cases it is better to check the charge 1 If the starting is made by recoil rope starting bring the starting switch in ON working position lf the starting is carried out with battery bring the starting key in the START position and use the battery staring FURTHER INFORMATION ON THE COMBUSTION ENGINE STARTING ARE SUPPLIED IN THE MANUALS OF THE ENGINE GIVEN WITH THIS MANUAL CONNECTION OF THE FLEXIBLE HOSES AND HYDRAULIC TOOL TO THE POWER PACK 1 Lay down the flexible hoses avoiding the contact of the couplers with the mud or dirt possible 2 Put the tool on the ground limiting the contact with the mud or dirt Make sure that the tool is in perfect condition and its accessories are efficient and well installed Make sure that the tool trigger is free and released control that the return spring of the trigger is operative and efficient for avoiding an accidental starting 3 First connect the flexible hoses to the power pack whose engine and flow control lever must be OFF Connect the female coupler of the hose to the male coupler of the power pack then make the other connection lf correctly installed the male coupler of the power pack is
3. cans boxes wheelbarrows etc lf you need to work in elevated positions use only stable and safe supports approved by the local safety rules e When you operate in difficult positions do not reach out and never lean against the tool Keep the balance on your legs sure that the equipment is in perfect working conditions without oil leaks e Keep the protection devices always in good conditions and preserve the readability of the safety stickers e The working area must be examined and well known to avoid unexpected situations If you work along roads make well visible your position and warn the traffic by the use of signals flashing lights or other prescribed road signs 14 PERICOLO DANGER WORK ONLY IF THE ENGINES ARE OUTSIDE OR IN A WELL VENTILATED POINT THE EXHAUST GAS THE ENGINES IS ODOURLESS AND ITS INHALATION CAN CAUSE SERIOUS OR FATAL ACCIDENTS THE CONTACT WITH ELECTRIC ENERGIZED LINES CAN BE FATAL Pay the maximum attention when you cut demolish drill etc near energized electric lines that can be buried walled or hidden Be very careful also to gas and water pipes telephone lines or other buried cables or ducts The working area must be free from objects that may fall get spoiled catch fire make trip up or make the operation difficult or dangerous Warn and move away imprudent bystanders or other people not authorized or involved with the job lf you work in narrow or closed r
4. nozzle near the tool to avoid the removal of safety stickers and paint in particular if hot water is used CAUTELA CAUTION e hot washing with very high pressure and with the nozzle very close to the surfaces can cause the removal of the paint and safety adhesives and labels e Do not insist on the engine electric part with the nozzle if it is necessary read on the proper paragraph about cleaning contained in the motor manufacturer s manual 23 After the pressure washing let the water drip from the machine also by moving it for helping the water drain from cavities or recessed points e With an air gun blow all over the power pack eliminating every trace of water and moisture Insist on e With the machine perfectly dry spray a protective dewatering product WD40 all chromed parts and in the tool cavities Spray also the area of the ON OFF valve For allowing the spray to reach all points move the movable parts e Dry up completely the tool handles for guaranteeing a firm grip e Start the power pack and make it work at minimum for a few minutes CLEANING WITH RAGS OR PAPER e The tool can also be cleaned with a damp rag using a brush with gasohol or an air gun for eliminating all traces of dirt and oil e Clean in particular the recessed points and cavities and the connection surface of the quick couplers e With the machine perfectly dry spray a protective dewatering product CRC or WD40 all
5. the female lf the flexible hoses and quick couplers show oil leaks even if the couplers are well screwed into the hose fittings they should be immediately substituted with new parts e Replace hoses that show squeezing unnatural bending deformations swellings etc lf a flexible hose full of oil remains under the sun the oil expansion due to the heat can cause a pressure increase and prevent the connection of the quick couplers To decrease pressure loosen one coupler dripping some oil drops de pressurizing the hose The flexible hose always remains full of oil that depending on the hose length can have a relevant volume If you change the hydraulic oil in the power pack it is recommended to replace also the oil in the hoses This will assure a full replacement and avoid the contamination of the new oil 25 DISPOSAL AND SCRAPPING IMPORTANT THE HYDRAULIC OIL ACID OF THE POWER PACKS HYDRAULIC OIL FILTERS FLEXIBLE HOSES FULL OF OIL ENGINE OIL ALL FUELS ENGINE OIL FILTERS BATTERIES OF THE POWER PACKS Are DANGEROUS WASTES that must be disposed of according to the local regulation of your PERICOLO DANGER country DON T THROW AWAY THE LIQUIDS AND MATERIALS OF THE ABOVE MENTIONED LIST THE INFRINGEMENT OF THE RULES REGARDING THE DISPOSAL OF DANGEROUS WASTES IMPLIES LEGAL RESPONSIBILITIES Also the storing and purchase sales of the materials of the above mentioned list have to be run according to t
6. the one corresponding to the pressure line where the oil gets out from the power pack the correct sequence of couplers installation depends on the positioning of the first male coupler male coupler must always be installed on the left of the valve block see illustration on page 15 19 ATTENZIONE WARNING If a flexible hose full of oil remains under the sun the oil expansion due to the heat can cause a pressure increase and prevent the connection of the quick couplers To decrease pressure loosen one coupler dripping some oil drops de pressurizing the hose 4 Now connect the flexible hose to the hydraulic hose of the hydraulic tool connecting the first the return hose corresponding to the hole with the message OUT of the tool bringing the male coupler on the tool 5 Thus the hydraulic connection is completed 6 Start power pack leaving it at minimum for a few minutes Follow the instruction of the paragraph cold start if the starting is occurring at cold RAPTOR D has manual acceleration the engine must be accelerated manually 7 accelerate the engine by using the lever 8 The toolis now ready for starting 9 Press the tool trigger and work END OF THE OPERATIONS 1 Lay down the tool avoiding and limiting contacts with the mud and dirt if possible 2 PUT THE ENGINE ACCELARATION AT IDLE minimum speed of the engine 3 Put the ON OFF flow lever of the power pack on the LEFT position in idle pos
7. DLES e DO NOT TRY TO LIFT THE POWER PACK ALONE FOR LOADING OR UNLOADING IT FROM VEHICLES THIS CAN CAUSE DANGERS AND ACCIDENTS THE FOLLOWING INSTRUCTIONS AND CHECKS SHOULD BE CARRIED OUT EVERY TIME THE POWER PACK IS USED AFTER A PERIOD OF INACTIVITY OF THE MACHINE OR WHEN IT IS USED BY OTHER PEOPLE 1 CHECK THE LEVEL OF THE ENGINE OIL with cold engine and with the machine in horizontal position visualize its level on the level indicator and fill if necessary 2 CHECK THE FUEL LEVEL be sure that the tank contains enough fuel for finishing the work fill it if necessary using an appropriate fuel DO FILL WITH STARTED ENGINE 3 CHECK THE LEVEL OF THE HYDRAULIC OIL fill with the same and compatible hydraulic oil than that one of the tank do not exceed the suggested level the level should be visible from the level indicating eye In case of very cold temperatures follow carefully the instructions starting at low temperatures below described 4 CHECK THAT THE TOOL USED AND THE POWER PACK HAVE COMPATIBLE HYDRAULIC CHARACTERISTICS IN CASE OF DOUBT DO NOT RISK but ask your DOA dealer or your foreman 5 CLEAN THE POWER PACK PROPERLY if it is dirty in particular clean the cooler eliminating mud or dirt use compressed air if necessary see chapter cleaning and maintenance of the equipment Check and clean also the suction mouth of the cooler cooling air 6 CHECK THAT ALL THE EQUIPMENT IS COMPLETE AND EFFICIEN
8. DOA FOR MORE INFORMATION NORMALLY THERE ARE NO PROBLEMS OF HYDRAULIC OIL COMPATIBILITY MIXING DIFFERENT TYPES OF OILS WHEN A DOA TOOL IS CONNECTED TO THE CIRCUIT OF AN EARTH MOVING MACHINE OR ANOTHER OPERATING MACHINE IF THE OIL OF THESE MACHINES IS OF A GOOD QUALITY AND REGULARLY FILTERED FLEXIBLE HOSES THE POWER PACK ARE USUALLY EQUIPPED WITH A COUPLE OF HYDRAULIC FLEXIBLE HOSES OF 7 M OF LENGTH COMPLETE WITH FLUSH FACE QUICK COUPLERS The following general information can be useful in case of new hose supply o when it is necessary to use hoses with different extensions than the standard ones THE FLEXIBLE HOSE consists of a couple of parallel hoses a PRESSURE hose and a RETURN hose that connect the hydraulic tool to the power source When it is possible do not use long hoses The flexible hose should be long enough to permit a good manoeuvrability of the tool but not too long as a very long hose can be heavy difficult to transport and to handle and may also cause loss of power A flexible hose of ten meters is adequate in most of the cases to guarantee a good manoeuvrability If a longer hose is necessary just connect a second extension hose to the first one e THE FLEXIBLE HOSE ALWAYS REMAINS FULL OF OIL THE FIRST TIME A NEW HOSE IS USED IT WILL GET FULL OF OIL TAKING IT AWAY FROM THE HYDRAULIC CIRCUIT IT WILL BE THEN NECESSARY TO RESTORE ADEQUATELY THE OIL LEVEL IN THE TANK e THE FLEXIBLE HOSES ARE ALWA
9. F VALVE TYPE 3 WAY OPEN CENTER GROUP EHTMA C D ENGINE CHARACTERISTICS ENGINE TYPE DIESEL SINGLE CYLINDER BRAND AND MODEL STD version YANMAR 10 5 HP POWER 10 5 HP 7 7 KW STARTING ELECTRIC AND RECOIL ENGINE ACCELERATION MANUAL with lever FUEL DIESEL FUEL BATTERY TYPE 12 V HYDRAULIC OIL Viscosity at the lower expected ambient temperature max 68 cSt 9 E Viscosity at the higher expected ambient temperature min 22 cSt 3 10 E cSt centistokes E Engler degrees HYDRAULIC OILS CORRESPONDENCE CHART The following chart indicates the most common hydraulic oils recommended for DOA hydraulic tools and power packs The oils in the chart are suggested for standard temperatures the left column indicates oils for Winter operations the right column shows the Summer ones HYDRAULIC OILS OF OTHER BRANDS CAN ALSO BE USED BUT THEY SHOULD HAVE EQUIVALENT CHARACTERISTICS TO THOSE OF THIS CHART HYDRAULIC OIL CORRESPONDENCE WINTER TEMPERATURES SUMMER TEMPERATURES ARNICA 32 ARNICA 46 HLP HV 32 HLP HV 46 CASTROL HYSPIN AWH 32 HYSPIN AWH 46 ELF HYDRELF DS 32 HYDRELF DS 46 ESSO INVAROL EP 32 INVAROL EP 46 MOBIL DTE 13 DTE 15 Q8 HAENDEL 32 HAENDEL 46 SHELL TELLUS T 32 TELLUS T 46 If you use the hydraulic tools in extreme climatic conditions please contact DOA for more information IN CERTAIN COUNTRIES OR IN SOME SPECIAL APPLICATIONS THE USE OF BIODEGRADABLE OIL IS PRESCRIBED BY LAW IN THIS EVENTUALITY CONTACT
10. FICATIONS AT ANY TIME AND WITHOUT PREVIOUS NOTICE SAFETY SYMBOLS SAFETY SYMBOLS This manual contains safety warnings represented by symbols indicating three different levels of danger extremely dangerous which can cause serious accidents or death if proper precautions are not respected PERICOLO This symbol indicates an operation or situation DANGER This symbol indicates a dangerous operation or ATTENZIONE situation that can cause serious accidents or death WARNING 07 i This symbol warns about generic danger that can CAUTION cause accidents and damages to the equipment the properties 1 IMPORTANTE IMPORTANT This symbol indicates important information IMPORTANT WHEN THE EFFECTS OF A CERTAIN ACTION ARE NOT EXACTLY KNOWN REMIND THAT EVEN THE SIMPLEST OPERATION MAY HIDE DANGERS IN CASE OF DOUBTS DO NOT RISK DO NOT MAKE EXPERIMENTS ASK YOUR DOA DEALER OR YOUR FOREMAN PRODUCT DESCRIPTION DESCRIPTION RAPTOR D is a hydraulic power pack powered by ga diesel engine The power pack can deliver a hydraulic power for tools of the groups 20 I min 140 bar 30 I min 140 bar 5 gpm 2000 PSI 8 gpm 2000 PSI Values belonging to EHTMA European Hydraulic Tools Manufacturers Association standard The power packisare equipped with a hydraulic gear pump and heat exchanger with centrifugal fan designed for guaranteeing the ideal values of cool
11. ITIONING OF THE POWER PACK 1 Using the transport handle pull or push the power pack bringing it to the working point After having reached the operating point bend the grips for avoiding bumps or deformations 2 The power pack should be placed in a flat place protected from the traffic in well established firm visible and well ventilated position Inflammable objects or materials should be kept away from the power pack in particular from the discharge side 3 Hoses should be laid down tidily and linearly avoiding knots and tangles also for preventing possible stumbles Be sure that no vehicles or machines pass on the hoses spoiling them 4 Do not work with the power pack left on lorries or on the platform of trucks It is better to leave the power pack on the ground If the power pack should work on vehicles be sure that it is far from the lorry boards or sides so that both the cooling air of the engine or cooler and the exhaust gases can circulate and are properly dissolved 18 IMPORTANT If the hydraulic oil lubricant or fuel is spilt on the ground for any reason remove the spilt liquids using sawdust or rags for avoiding accidents and contamination of the ground ENGINE STARTING IMPORTANT Before starting the engine the flow lever should be brought in OFF position If the lever is left in ON position the starting will be very hard the engine does not start and the battery runs down completely in a few moments
12. NOT START THE POWER PACK AND ITS TOOL IF THEY ARE DAMAGED THERE ARE OIL LEAKS OR SOME PARTS ARE MISSING OR WRONGLY INSTALLED e DO NOT ALLOW THE USE OF THE EQUIPMENT TO PEOPLE THAT ARE NOT TRAINED OR WHO HAVE NOT READ THIS MANUAL DO NOT WORK IF YOU ARE NOT IN PERFECT PHYSICAL AND MENTAL CONDITIONS DO NOT WORK ALONE WHEN IT IS POSSIBLE MAKE SURE THAT SOMEBODY KNOWS WHERE YOU ARE AND WHAT YOU ARE DOING e DO NOT BELIEVE IN MESSAGES OR VOICE WARNINGS GIVEN TO COLLEAGUES IN NOISY ROOMS BE SURE THAT THE WARNING HAS BEEN CORRECTLY UNDERSTOOD DO POINT THE TOOL AGAINST COLLEAGUES NOT STAY WITH THE FACE TOO CLOSE TO THE TOOLS e DO NOT FILL WITH FUEL WHILE SMOKING e DO NOT FILL WITH FUEL OR OIL WITH HOT ENGINE DO NOT USE IMPROVISED OR DIRTY CONTAINERS OR FUNNELS THIS CAN CAUSE ACCIDENTS DANGEROUS SITUATIONS AND FAILURES IN THE EQUIPMENT e KEEP THE POWER PACK AWAY FROM INFLAMMABLE MATERIALS DO NOT WORK IN ENVIRONMENTS WITH VAPOURS AND GASES OR UNKNOWN ODOURS 16 e DO NOT TRY TO REPAIR THE EQUIPMENT IF YOU ARE NOT A QUALIFIED PERSON REPAIRS NOT WELL DONE OR USING INAPPROPRIATE PARTS CAN CAUSE DANGEROUS SITUATIONS DO NOT CARRY OUT CONTROLS ON THE POWER PACK CHECKING OR TOUCHING WITH BARE HANDS AND ENGINE ON ALWAYS STOP THE ENGINE AND COOL DOWN THE EQUIPMENT BEFORE CHECKING AND CLEANING IT e DO NOT PULL THE FLEXIBLE HOSES OF THE POWER PACK IF THE MACHINE SHOULD BE REPOSITIONED USE THE PROPER HAN
13. SAFETY MANUAL USE AND MAINTENANCE DECEMBER 2010 2nd ISSUE HYDRAULIC POWER PACK RAPTOR D IMPORTANT READ THIS MANUAL BEFORE USING THE TOOL A KEEP ALWAYS FOR FUTURE REFERENCES DOA s r l Via Cortiva 5 22060 NOVEDRATE Como ITALY TEL 39 031 792040 FAX 39 031 791917 www doa it e mail info doa it INTRODUCTION SAFETY SYMBOLS CONTENTS OF THE MANUAL DESCRIPTION OF THE PRODUCT Description Typical applications Accessories TECHNICAL CHARACTERISTICS SAFETY RULES General view main components and their functions View of the control panel Weight and dimensions Hydraulic characteristics Engine characteristics Hydraulic oil Flexible hose Quick couplers USE OF THE POWER PACK What not to do Before operating Start and use or the power pack Cold start Positioning of the power pack Engine starting Connection of the hoses and tool to the power pack End of operations MAINTENANCE AND CARE Adjustment of the maximum pressure valve Power pack cleaning Periodical controls and substitution of the wearable parts Maintenance of the flexible hose Disposal and scrapping Repair PROBLEM CAUSE SOLUTION CHART WARRANTY Page N NMO CO 14 INTRODUCTION Dear customer Congratulations for having purchased a DOA product The machine you bought was manufactured with high quality materials to assure your m
14. T that there are not oil leaks and screws joints and plugs are well tightened 17 START AND USE OF THE POWER PACK COLD START 07 CAUTION THE POWER PACK SHOULD BE PROTECTED FROM BAD WEATHER AND TOO HARD CLIMATES THE BATTERY AND ENGINE COULD BE QUICKLY DAMAGED IF THE MACHINE IS LEFT EXPOSED TO RAIN AND LOW TEMPERATURES WITHOUT PROTECTION WHEN THE MACHINE IS NOT USED IT SHOULD BE STORED IN A DRY AND WARM PLACE REPAIRED FROM RAIN AND DAMPNESS IMPORTANT THE POWER PACK IS EQUIPPED WITH A HYDRAULIC OIL COOLER PLACED ON THE SUCTION LINE THIS COOLER POSITIONING BETWEEN THE OIL TANK AND GEAR PUMP ASSURES THAT THE COOLER IS NOT PRESSURIZED AND KEEPS IT PROTECTED FROM HARMFUL PULSATION IMPROVING THE RELIABILITY OF THE MACHINE IF YOU WORK IN BAD WEATHER WHEN THE OIL CAN BE VERY HARD AND VISCOUS IT IS VERY IMPORTANT TO RESPECT THE FOLLOWING INSTRUCTIONS IN ORDER TO AVOID PROBLEMS OF THE PUMP SUCKING THE OIL CAVITATION PHENOMENON 1 USE HYDRAULIC OIL WITH THE RIGHT VISCOSITY SEE THE TABLE OF THE HYDRAULIC OILS IN THE PREVIOUS PAGES 2 AFTER HAVING CONNECTED THE FLEXIBLE HOSES AND THE TOOL TO THE POWER PACK see following paragraph START THE ENGINE KEEPING IT AT THE MINIMUM FOR A FEW MINUTES THEN PUT THE FLOW LEVER IN POSITION MAKING THE OIL CIRCULATING INTO THE HOSES AND THE TOOL UNTIL THE OIL IS LUKEWARM TOUCHING THE TANK IT IS ADVISABLE FOLLOW THIS PROCEDURE IN ALL COLD STARTS POS
15. YS IN CONTACT WITH THE GROUND AND ARE SUBJECT TO STRONG VIBRATIONS AND ABRASION THUS THEY SHOULD BE RESISTANT TO WEAR AND ABRASION 10 FLEXIBLE HOSE TYPE AND DIMENSIONS HOSE LENGTH PRESSURE HOSE RETURN HOSE DIMENSION DIMENSION FITTING TYPE FITTING TYPE UPTO 15 METERS SAE 100 R1 SAE 100 1 Yo BSP MALE Yo BSP MALE THE DIMENSION AND TYPE OF HOSES OF THE CHART REFER TO APPLICATIONS OF HYDRAULIC TOOLS WORKING WITH MAXIMUM FLOW OF 34 L MIN FOR HOSES EXCEEDING 15 METERS OR WITH HYDRAULIC FLOWS HIGHER THAN 34 LITRES PER MINUTE CONTACT DOA FOR INFORMATION THE ILLUSTRATIONS SHOWS THE COUPLERS INSTALLATION SEQUENCE ON THE POWER PACK ON THE HOSES AND ON 20 r O 0 IN OUT HYDRAULIC TOOL 11 QUICK COUPLERS Q Q 5 06 lt 9 5 v O 535 v SS D O 2 2 SS 4 2S s O x x 4 x 0000 52525 624 S 2 Z 22 59000 52525 The DOA power packs and hydraulic tools are equipped with flush face quick couplers as those one shown in the picture The following paragraph supplies information about the couplers and their use The standard quick couplers for hydraulic tools recommende
16. aximum satisfaction and a long lasting service without problems For your safety and obtaining the best result we recommend to read this manual and respect the simple instructions contained this will protect you from accidents and avoid damages to the equipment Keep it always available together with its enclosures so that it can be consulted when necessary IMPORTANT SOME ENCLOSURES CONTAINING INFORMATION ABOUT ACCESSORY PARTS OR SAFETY MANUALS OF THE MANUFACTURERS OF EXPLOSION ENGINES ALTERNATORS OF OTHER SUBCOMPONENTS OF DOA TOOLS COULD HAVE BEEN SUPPLIED TOGETHER WITH THIS MANUAL THESE ENCLOSURES ARE AN INTEGRAL PART OF THE MANUAL AND THEY MUST BE KEPT TOGETHER WITH THE MANUAL ITSELF ATTENZIONE WARNING BE CAREFUL WHEN YOU CONNECT THE POWER PACK TO AN UNKNOWN HYDRAULIC TOOL OR A TOOL WHICH WE DON T KNOW THE HYDRAULIC MAXIMUM TOLERABLE VALUES OF PRESSURE AND FLOW OF FOR AVOIDING ACCIDENTS AND DAMAGES TO THE EQUIPMENT BE SURE THAT THE MAXIMUM VALUES OF PRESSURE AND FLOW OF THE TOOLS CONNECTED TO THE POWER PACK ARE COMPATIBLE WITH THOSE ONE OF THE POWER PACK ITSELF NOTE THE TEXT AND THE ILLUSTRATIONS IN THIS MANUAL ARE AN EXCLUSIVE PROPERTY OF DOA S R L THE PERSON WHO USES THE TEXT OR REPRODUCES EVEN PARTIALLY ILLUSTRATIONS OR PARAGRAPHS FOR NON AUTHORISED PURPOSES CAN BE LEGALLY LIABLE DATA ILLUSTRATIONS AND CHARACTERISTICS OF THIS MANUAL ARE ONLY INFORMATIVE AND NOT BENDING DOA RESERVES THE RIGHT TO MAKE MODI
17. ble hoses quick couplers or other accessories that have not an identification number are covered by a warranty of three months from the date of delivery to the final customer e DOA reserves the right to substitute only those parts recognized to be defective after an inspection of DOA engineers under warranty at its own expenses and in its own plant If the repairs during the warranty period are performed by the customers DOA will reject any charge for labour expenses The warranty will be automatically voided If e Repairs are performed using non original adapted or modified parts e The maximum hydraulic values of pressure back pressure and flow are exceeded or the filtration and other operative conditions of the hydraulic circuits are inadequate to power DOA tools the tool has been modified or used in excessive heavy applications or different from its natural applications lf the attached WARRANTY CARD is not properly filled and mailed to DOA In any case the warranty excludes any redraft or reimbursement for damages of any kind and there are not other explicit or implicit warranties besides the above mentioned one FOR ANY CONTROVERSY THE COMPETENT COURT IS IN COMO ITALY 31
18. d by the ETHMA association are FLUSH FACE QUICK COUPLERS A COMPLETE QUICK COUPLER consists of a male and female element see picture The flush face quick couplers are STANDARDIZED and they can be found at the major manufacturers The flush face quick couplers grant the best values of oil slipping generate minimum pressure drops are easy to clean do not drip during the operation of even accidental connection disconnection and above all they are perfectly sealed out the dirt This is a very important characteristic for preventing oil contamination and damages to the tools FLOW DIRECTION AND INSTALLATION OF THE QUICK COUPLERS The ideal flow direction is from MALE FEMALE An arrow is punched on the couplers showing the right direction FLOW DIRECTION DIREZIONE FLUSSO The couplers must be installed on the flexible hose power packs and tools respecting the sequence previously described The following illustration shows the right installation of the couplers on the hoses If the couplers are properly installed wrong or inverted connection will be impossible and it won t be necessary to pay attention making a connection Every coupler will be connected in the right way 12 USE OF THE QUICK COUPLERS CONNECTION e Make sure that the contact surfaces of the couplers are clean and if necessary wipe the dirt with a rag e Position the male coupler towards the female one centring them e Press the male couple
19. e graduated up to about 200 bar installing it on the pressure line of the power pack at the end of the flexible pressure hose or installing it directly on the female quick coupler and introducing the female coupler into the male one of the power pack 2 Loosen the blocking nut of the RV adjusting screw with a wrench of 13 mm 3 After having heated the power pack motor and the hydraulic oil about 40 50 bring the flow lever in ON position This operation will accelerate the motor Take care that there are not oil leaks in the equipment during this phase 4 Visualize the maximum pressure value indicated in the pressure gauge If the RV has a too high calibration the motor can be stopped because it cannot support the effort caused by a too high load In this case turn the RV anticlockwise lowering the calibration 5 With the accelerated motor adjust the RV acting on the central screw using the Allen wrench of 4 mm Turning CLOCKWISE the pressure INCREASES Turning ANTICLOCKWISE the pressure DECREASES 6 Visualizing the pressure gauge calibrate the valve at a value of about 155 bar this calibration will correspond to a real valve setting of 140 bar The pressure adjusted in this condition is defined also STATIC PRESSURE that is the pressure measured at zero flow The RV of the power pack should be adjusted at a value of 10 higher than the maximum value recommended for the tool This overcalibration is necessary for elimina
20. ediately damage also the other good interface 13 SAFETY RULES GENERAL SAFETY INSTRUCTIONS ATTENZIONE WARNING THE FOLLOWING INSTRUCTIONS ARE GENERAL SAFETY RULES AND HAVE BE RESPECTED IN EVERY WORKS WITH POWER PACKS AND HAND TOOLS WE RECOMMEND TO FOLLOW THEM CAREFULLY IN ORDER TO AVOID ACCIDENTS AND DAMAGES TO THE EQUIPMENT AND THINGS Wear ALWAYS the hard helmet safety goggles gloves safety shoes ear protections and when is prescribed a dust musk e Wear tight fitting clothes and avoid operating with short trousers or t shirts or other bare parts of the body Pay attention to long loose hair gather them to prevent they get in contact and trapped in moving parts e Before operating PREPARE ALWAYS A WORKING PLAN that considers and foresees problems interruptions and avoids most of all dangerous situations This little operation strateqy guarantees safety and improves productivity e Place always the power pack in a plan level in a sure and stable position protected from the traffic and in a well visible position Signal one s position not to cause danger for oneself and others If the power pack is transported on vehicles be sure that it is well positioned on board and it is blocked on the loading platform for avoiding dangerous jerks bumps or overturning e Work only in good physical and mental conditions Always pay the maximum attention e Do not work on unstable or adapted supports Such as oil
21. ent model controlling the oil temperature It is protected by a bumper grid 6 SIDE FOLDING HANDLE allows a comfortable gripping of the power pack and carries out also the function of side bumper bar 7 REAR FOLDING GRIP gives a comfortable gripping of the power pack in the rear part 8 DIESEL ENGINE MODEL YANMAR or HATZ 9 UPPER FRAME consists of a strong square stainless steel tube VIEW OF THE PANEL AND CONTROL VALVE BLOCK CO CN O THE VALVE BLOCK is the seat af all components that controls the hydraulic circuit the part is obtained working a laminated aluminium block 1 OIL INLET HOLE oil enters in pressure in the valve from this hole 2 ROTATING JOINT is an adjustable joint where the quick couplers are installed It permits to fold the quick coupler after the use protecting it against shocks It also allows the flexible hose to have a natural bend avoiding sharp bends 3 FILTER CARTRIDGE 15 the hydraulic oil filter It can easily substituted but it cannot be maintained 4 MALE QUICK COUPLER is the quick coupler which the oil comes out under pressure through from P power pack The male quick coupler should always be installed in this position for guaranteeing the right circulation of the oil 5 ON OFF FLOW LEVER is the lever which the oil is sent to flexible hoses and hydraulic tool through It is OFF placed rightwards it is ON placed leftwards The lever should always be in OFF position at the end of operatio
22. gineers in this case follow these instructions BEFORE DISASSEMBLY e Clean accurately the product and remove any trace of dirt e Keep available a clean working surface paper rags tools an air gun a rubber hammer a brass punch a vice with soft protection for the jaws a clean container for collecting the tool oil e Keep available an exploded view of the tool and part list e Consider that when the tool is completely disassembled it s recommended to replace all exposed seals GENERAL PRE INSPECTION Control that the tool is complete and that all parts and fastenings are in their place and well installed Check that the control and starting devices in particular the safety devices and protections are efficient without deformations and in their original state If they have been modified or repaired adapting them discard them and order new parts lf asafety or warning sticker is damaged illegible or missing order new parts checking the part number on the tool part list Control the tool accessories bits cut off discs hoses etc to be sure that they are of the right type oriented in the right way and they are not the cause of the problems e Control the quick couplers on the tool and on the flexible hoses make sure they are correctly installed that they can be connected in the right way to assure the right oil direction e Control the flexible hoses discarding those damaged worn squeezed etc c
23. he specific regulation For information about the handling and disposal of the dangerous wastes contact the Environment department of your local municipality Except for the liquids and materials of the previous list the other components of the products manufactured by DOA are fabricated with recyclable materials that can be stored disposed and scrapped without particular cautions MATERIALS AND COMPONENTS USED BY DOA DO NOT CONTAIN ASBESTOS OR OTHER TOXIC ELEMENTS THAT REQUIRE SPECIAL CAUTION FOR THEIR USE REPAIR DISASSEMBLY INSPECTION OF THE PARTS REASSEMBLY IMPORTANTE IMPORTANT THE DOA HYDRAULIC TOOLS ARE PROFESSIONAL PRODUCTS THAT SHOULD BE REPAIRED ONLY BY QUALIFIED PERSONNEL THE REPAIR MAY REQUIRE TECHNICAL LITERATURE AND INSTRUMENTS FOR THE CONTROL OF THE HYDRAULIC VALUES AND AN ADEQUATE HYDRAULIC SOURCE NECESSARY FOR CARRYING OUT THE TOOL FUNCTIONING TESTS IT IS THEREFORE ADVISABLE NOT TO START THE COMPLETE DISASSEMBLY OF THE PRODUCT IF YOU ARE NOT A TECHNICIAN AND PROFESSIONAL TOOLS AND EQUIPMENT ARE NOT AVAILABLE 26 REPAIR OF PRODUCTS UNDER WARRANTY IMPORTANT IF THE MACHINE IS STILL UNDER WARRANTY THE REPAIRS MUST BE CARRIED OUT ONLY BY DOA AUTHORIZED SERVICE AGENTS OTHERWISE THE WARRANTY WILL BE AUTOMATICALLY NULLIFIED GENERAL INFORMATION Although we recommend that the repairs have to be carried out only by authorized DOA service agents some minor repairs can be carried out also by other en
24. ing of the hydraulic oil also during summer The engine acceleration is MANUAL by the mean of a acceleration lever TYPICAL APPLICATIONS POWERING OF HYDRAULIC TOOLS breakers dewatering pumps hammer drills disc cutting off machines pruners drills ventilators etc ACCESSORIES HYDRAULIC HOSES OF 7 WITH QUICK COUPLERS HYDRAULIC HOSES OF 10 m WITH QUICK COUPLERS PLASTIC PROTECTIVE COVER TECHNICAL CHARACTERISTICS GENERAL VIEW MAIN COMPONENTS AND THEIR FUNCTIONS Fig 1 HYDRAULIC POWER PACK MODEL RAPTOR D 1 FOLDING HANDLE is a long handle allowing a comfortable manoeuvrability of the power pack on the ground both pulling and pushing Its length assures that feet are not bumped when the power pack is moved pulling it 2 ON OFF FLOW LEVER see description in the following chapter 3 FRONT PANEL on the panel there are the various stickers with working instructions etc On some models on the panel there is the hour meter The panel of some models of RAPTOR there is the flow selection lever that has two positions the upper position is for selecting 20 liters flow the lower position selects 30 liters flow in both position the acceleration is automatic by power on demand ram 4 TANK CONVEYOR BLOCK is a unit manufactured in sheet steel containing the hydraulic oil tank air conveyor and all the accessory parts of the power pack hydraulic part 5 HYDRAULIC OIL COOLER is an aluminium highly effici
25. ing or other problems appear indicate the failure and repair it immediately for avoiding the accidental use of the damaged or faulty machine by other colleagues This could cause dangerous situations MAINTENANCE AND CARE OF THE POWER PACK PRESSURE RELIEF VALVE REGULATION THE PRESSURE RELIEF VALVE abbreviation RV IS SEATED IN THE VALVE BLOCK THE RELIEF VALVE ADJUSTS AND CONTROLS THE MAXIMUM PRESSURE VALUE OF THE HYDRAULIC CIRCUIT PROTECTING THE TOOLS FROM RUPTURES OR EXCESSIVE PERFORMANCE THE RELIEF VALVE IS ORIGINALLY ADJUSTED AT THE CORRECT VALUE THAT IS 130 BAR 2000 PSI 21 IMPORTANT Itis very important to respect the pressure maximum value recommended for the tool An excessive pressure can cause the break of the tool and equipment and can cause accidents A too low pressure value to the tool can cause reduction in the performance and increase in the oil temperature RELIEF VALVE RV REGULATION CAUTELA CAUTION THE FOLLOWING ADJUSTMENT OPERATIONS SHOULD BE CARRIED OUT BY QUALIFIED PERSONNEL WITH PROPER EQUIPMENT DO NOT CARRY OUT REPAIRS OR ADJUSTMENTS WITH EXPERIMENTS OR ATTEMPTS WHICH BESIDES DAMAGING THE EQUIPMENT COULD CAUSE ACCIDENTS 1 Prepare an Allen wrench of 4 mm an adjustable open wrench of 13 mm and a hydraulic tester for measuring the pressure and flow similar to that one shown at the end of this paragraph If you have not a proper tester it is possible to use a simple pressure gaug
26. ition blocking the oil supply to the tool 4 Stop the engine bringing the starting key in OFF position 5 Disconnect the tool from the flexible hose releasing first the PRESSURE HOSE corresponding to the tool hole with IN This operation will prevent accidental pressure trapping inside the tool 6 Disconnect the flexible hose from the power pack 7 Roll up the flexible hose in circles of about 60 cm of diameter connecting the quick couplers at the extremities in the way This operation will protect the couplers against impacts or scraping and will also help in keeping the hoses well rolled up 8 Remove the accessories from the tool and control that they have not been damaged during the use In case of breaks discard them immediately or repair them for preventing their accidental use in the future 20 9 Store the power pack when silencer and engine are cooled down for avoiding possible risks of fire and accident Store the power pack and the equipment in a safe place repaired from bumps and atmospheric agents 10 If the power pack should be transported on lorries or trucks fold the transporting handle and other grips for avoiding deformation during the transport Take care that the machine is loaded in a proper way and blocked for avoiding tilting and harmful jerks and bumps that could damage both the power pack and the vehicles and cause accidents CAUTELA CAUTION If during the work function
27. l that remains inside the flexible hoses and in the tool 24 2 Change engine oil as specified in the manual of the engine manufacturer 3 Replace the engine air filter 4 Carry out all the other engine controls as specified in the manual of the engine manufacturer 5 Check the tightening of bolts and nuts and fittings 6 Check the condition of the flexible hose and hydraulic oil cooler 7 Clean the spark plug 8 Clean the equipment carefully MORE ACCURATE INFORMATION ABOUT THE MAINTENANCE OF THE ENGINE ARE EQUIPPED WITH THE MANUFACTURER S MANUAL ENCLOSED TO THIS MANUAL MAINTENANCE OF THE FLEXIBLE HOSE INSPECTION OF THE HOSE Lay the flexible hoses on the floor and control if there are oil leaks and the hose surfaces are integral without peeled sections showing metallic braid with broken wires e the presence of little sections of wire braid can be tolerated only if the wires are not broken and still braided Control the pressed bushing at the extremity of the hoses and discard immediately hoses showing damaged end terminals with unnatural bending squeezing deformations etc e Check that the quick couplers are well dry without oil leaks and that the knurled bushing on the female quick coupler is intact and can slide freely during the connections The male coupler should be intact without dents and deformations If you try to force the connection of a damaged male coupler this will damage irremediably also
28. ns or when the engine is started and when the Manta power pack is used as a generator The illustration shows the lever as installed on the model SCORPION pointed to the center of the pack on the RAPTOR D the lever is installed on the front part pointed to the exterior but the sense of the ON OFF position is the same the RAPTOR D imagine of the flow is on the illustration at page 11 6 OIL OUT LET HOLE On the model RAPTOR D this hole is plugged as the oil baypasses to tank from an internal passage 7 PRESSURE RELIEF VALVE is the valve adjusting the maximum value of the hydraulic pressure of the power pack It is adjusted originally at a value of 140 BAR It can be adjusted at different values of pressure 8 ROTATING JOINT is an adjustable joint where the quick couplers are installed It permits to fold the quick coupler after the use protecting it against shocks It also allows the flexible hose to have a natural bend avoiding sharp bends 9 FEMALE QUICK COUPLER is the quick coupler which the oil returns to tank The female couplers is in communication with tank and should always be installed in this position for guaranteeing the right circulation of the oil HYDRAULIC POWER PACK RAPTOR D TECHNICAL CHARACTERISTICS WEIGHT AND DIMENSION WEIGHT 98 HEIGHT cm 65 LENGTH cm 85 WIDTH 60 HYDRAULIC CHARACTERISTICS FLOW min max L min 15 30 PRESSURE Bar 130 OIL TANK CAPACITY liters 10 ON OF
29. ontrol also that there are not exposed braids 27 PROBLEM CAUSE SOLUTION CHART The following table is a guide for finding and solving the most common working problems The causes of malfunction often depend on inadequate values of the hydraulic circuit The control of the PRESSURE FLOW BACK PRESSURE values should be carried out with proper instruments and oil at a temperature of about 40 C PROBLEM THE ENGINE DOES NOT START Switch starting key on OFF Bring on ON Fuel tap on OFF Bring on ON Add fuel Low engine oil level Add oil engine Flow lever left on ON Bring the lever on OFF and start again Engine failure Check and or repair PROBLEM THE HYDRAULIC TOOL HAS BAD PERFORMANCE CAUSE SOLUTION Damaged tool Check and or repair the tool 28 Relief valve low calibration Calibrate the relief valve Not calibrated engine acceleration Regulate the engine acceleration Eliminate hose extensions High back pressure of the tool Substitute the hydraulic oil filter Check the quick couplers Damaged quick couplers Check substitute the quick couplers Overheated hydraulic oil Check the cooling system Substitute with oil suitable to the season Damaged gear pump Check and or substitute PROBLEM THE TOOL OVERHEATS QUICKLY CAUSE SOLUTION Hydraulic oil low level Add hydraulic oil Dirty cooler Clean the cooler well Damaged cooler fan Check and or substitute Clogged fan aspiration mouth Free the ob
30. ooms always plan way out that must be kept free Make sure that the operation point is the right one and that there are the proper authorizations of the owners before starting the works Before working always foresee where the demolition fragments water pumped sparks or splinters are going to stop and plan the opportune defences and counter measures Before using the equipment make sure and prevent vehicles machines or people from passing on the equipment hoses or cables Always connect tools to the power pack or other power sources before starting the engine Keep in a safe dry place this manual and its enclosures so they can be always available for future consultations 15 USE OF THE POWER PACK WHAT NOT TO DO ATTENZIONE WARNING THE FOLLOWING LIST IS GIVEN FOR DESCRIBING THE MORE COMMON ERRORS OR IMPROPER AND DANGEROUS USE OF THE POWER PACKS SINCE IT IS IMPOSSIBLE TO FORESEE ANY DANGEROUS SITUATIONS THE RULES ARE NOT SUFFICIENT TO GUARANTEE THE TOTAL SAFETY ITS RECOMMENDED TO USE ALWAYS THE MAXIMUM CAUTION IN EVERY CIRCUMSTANCES IN CASE OF DOUBT DO NOT RISK BUT ASK YOUR FOREMAN e DO NOT USE THE POWER PACK AND THE TOOL IF THERE COULD BE THE POSSIBILITY OF GETTING IN CONTACT WITH ENERGIZED ELECTRIC LINES OR PRESSURIZED PIPES e DO NOT START OR USE THE POWER PACK AND THE EQUIPMENT IN CLOSED ROOMS WITHOUT VENTILATION BE CAREFUL IF THERE ARE STRANGE ODOURS THEY MAY BE DANGEROUS GASES OR EXHALATIONS DO
31. r against the female one e click indicates that the proper connection is made NOTE IF A PROPER CONNECTION CANNOT BE MADE EVEN PRESSING THE COUPLERS WITH STRENGTH IT IS POSSIBLE THAT ONE OR BOTH COUPLERS ARE PRESSURIZED FOR MAKING THE CONNECTION IT WILL BE THEN NECESSARY TO TAKE AWAY PRESSURE BY UNSCREWING THE COUPLERS FROM THEIR FITTINGS AND ALLOW SOME OIL DROPS TO COME OUT IT IS ALWAYS A GOOD PRACTICE FOR AVOIDING PRESSURE TRAPPING BEHIND THE COUPLERS FIRST TO CONNECT THE RETURN HOSE AND DISCONNECT IT LAST DISCONNECTION e Position the knurled bushing of the female coupler so that its slot is in front of the steel ball e Push the bushing against the steel ball e The male coupler will be released and a click will show the disconnection OTHER ADVICE e The connection disconnection of the couplers must be done always WITHOUT OIL CIRCULATION WITHOUT PRESSURE e Disconnect and connect the tools from hoses and power source just after having set the level of the flow switch valve in OFF POSITION e The quick couplers must be dismounted from the power pack only with the engine OFF f you mount or dismount the quick couplers use only the right wrenches If improper tools are used the coupler hexagon can be easily spoiled e The quick couplers CANNOT BE REPAIRED Discard immediately damaged or deformed couplers and not force the connection if one coupler is damaged In this case the damaged coupler will imm
32. struction at air passage Damaged hydraulic tool Check repair RV low calibration Calibrate the Maximum Pressure Valve Eliminate hose extensions High back pressure of the tool Substitute the hydraulic oil filter Check the quick couplers PROBLEM THE ENGINE DOES NOT COME TO THE MINIMUM CAUSE SOLUTION Damaged accelerator cable Check and repair Eliminate hose extensions High back pressure of the tool Substitute the hydraulic oil filter Check the quick couplers Tool ON OFF valve not completely Check and repair pressed deformed trigger IDENTIFICATION Every machine is equipped of a nameplate for the identification Name and address of the Manifacturing Company Model of the machine Serial number Year of construction The machine is supplied with e User manual e Electric wiring system e Declaration CE of conformity of the constructor e Tools of equipment WARRANTY All parts produced by DOA S r l are guaranteed for a period of twelve months from the date of delivery to the final customer against defect of material workmanship assembly Cost of labour and transports are not covered by warranty and should be paid by the customer Parts and complete components not produced by DOA such as engines compressors alternators etc are covered by the warranty of the manufacturer e Batteries of power packs and worn out accessories such as tool bits drill bits cut off discs flexi
33. ting inexactness of the RVs that really discharge cracks the over pressure at a value of about the 10 lower than the calibrated value of the static pressure EXAMPLE if the datum of maximum pressure for the tool is 140 bar the RV should be calibrated at about 155 bar This will correspond at a REAL calibration of about 140 bar 22 7 Atter having calibrated the RV keeping the screw still with the Allen wrench screw the nut of 13 blocking the RV screw in the desired position The adjustment is completed 8 Remove the tester and pressure gauge from hoses and power pack HYDRAULIC TESTER FOR MEASURING THE VALUES OF PRESSURE BACK PRESSURE FLOW AND INTERACTION OF THESE VALUES POWER PACK CLEANING A regular cleaning is very important for the good functioning of the equipment A clean product will immediately allow to find oil leaks or causes of malfunctioning A clean tool is also more comfortable to use and guarantees a firm grip CLEANING WITH HYDRO CLEANER CAUTELA CAUTION THESE INSTRUCTIONS REFER ONLY TO THE ASPID AND RAPTOR MODELS WHICH ARE NOT EQUIPPED WITH CURRENT GENERATOR DO NOT WASH WITH HYDROCLEANER THE GENERATOR OF THE MANTA POWER PACK THE MAINTENANCE OF THE MANTA POWER PACK IS DESCRIBED IN THE FOLLOWING PARAGRAPH The cleaning with hydro cleaner assures the best results in this type of washing Put the power pack on a clean surface or a wooden pallet Be careful not to use too much the water

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