Operating instructions Hand Pumps ZPH and HM
Contents
1. The oil fill 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 fill plug should be retightened 7 1 Locking the pump 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 7 2 Bleeding the pump Open the discharge valve Open the oil fill screw plug on the tank container and check the oil fill level The oil fill level should come up to approximately 1 2 cm below the top edge of the oil reservoir In this state work the pump handle several times Hand wheel 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 fill 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 8 Operation 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 t2. e Ahigh speed in the low pressure range LP for fast extension of the cylinder or device while unloaded e Alow 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 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 fitted Obviously the connection options fitted can be replaced by others However you must contact an authorised LUKAS dealer or contact LUKAS directly Additionally LUKAS hand pumps can be fitted 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 6 Connection options for hydraulic equipment 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 Ei caps to prevent contamination of
3. e are all hydraulic connections still tightened e generally sealed no leaks present oil sweat has no effect on the operation e is damage to pump housings valve blocks or attachment parts recognisable especially on the moving parts such as the piston rods are all fluid levels within the prescribed tolerances are all non moving parts firmly 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 e are dust caps in place e are identification plate all control decals instruction decals labels and warnings present and legible 15 Perform an operational check of the hand pump at least once a year in the case of continuous use once every half year peer check no suspicious noises e 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 specification on the identification plate occurs 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
4. LP High pressure HP 10 cm 1 6 cm ZPH 1A 0 61 cu in 0 10 cu in 10 8 cm 4 2 cm 0 66 cu in 0 26 cu in m ompun ame 0 61 cu in 0 10 cu in 12 1 5 Max operating pressure NOTE li You can take the max operating pressure from the pump identification 26 12 1 6 Change over pressure LP HP Pump type Change over pressure 10 MPa 2 611 psi op OO O Sexe 1 450 psi 12 1 7 Weight Total Weight Weight Weight weight Pump head Tank Accessories Pump type Weight Tank size Weight Pump head according to pump i m identification Tank 7 kg 3 1 Ibs 44 kg 9 7 ibs 0 8 8 2 3 82 ibs 10 4 Ibs 4 kg Ibs 6 kg 13 7 ibs Accessories Weight 1 28 kg PASE pate 2 83 ibs 0 18 kg Foot plate front 0 40 bs 0 07 kg Foot plate rear 0 15 ibs 0 0 04 kg Connecting nipples 0 09 Ibs Quick disconnect 0 29 kg coupling female 0 64 ibs Quick disconnect 0 12 kg coupling male 0 26 ibs 0 73 Ik Monocoupling 1 61 or 27 12 2 Hydraulic fluid recommendation Mineral oil DIN ISO 6743 4 for LUKAS hydraulic equipment and others mE Oil temperature range Viscosity rating 20 55 C HM 10 VG 10 BE Oil temperature range Viscosity rating 4 0 131 F HM 10 VG 10 EEE recommended viscosity range 10 200 mm s 10 200 cSt Supplied with HM 10 DIN ISO 6743 4 ATTENTI
5. confom do ibe EC Machinery Dinca DEMZEG replaced arecive The following standards have been laken into pavticuar consideration DIN EN ISO 12100 pubteaton date 2004404 Satoty of machinery Parts 74 2 OW ENISO 14121 1 publication dale 2007 01 Safety of machinery Principios far risk assesarmen Bei einer nicht mil uns abgestimmien Anderung oder Verwendung der Maschine Ausristung verhert diese Erkl rung Ihre G ltigkeit This dectaratian losas vaniclly in fhe case of alleratons or usage of ihe machinanvequipnant not approved by LUKAS Erlangen 11 11 2009 7 fe j E fn f fe Hartmut Krutsche LUKAS Hydraulik GmbH LUKAS Hydraulik GmbH Neal iiie Ged Br Terre Doge eee Tie For Pa A Tree bares Dear Dr pert ds ringen ipi brenar HH her beget An IDE Fire amp Safety ED nsf Ee Jane ee ee ie i ee 29 14 Notes 30 31 Please properly dispose of all packing materials and removed parts LUKAS Hydraulik GmbH Weinstra e 39 D 91058 Erlangen Postfach 2560 D 91013 Erlangen Phone 49 0 91 31 698 0 Fax 49 0 91 31 698 394 e mail lukas info idexcorp com LU IBEX HYDRAULIC EQUIPMENT GROUP MADE IN GERMANY ZPH HM BA GB 84120300085 1110 indd Copyright 2010 LUKAS Hydraulik GmbH Subject to revision
6. ON Before using hydraulic fluids that do not correspond to the aforementioned specifications and or are not purchased from LUKAS you must contact LUKASI 12 3 Operating and storage temperature ranges Operating temperature C F 20 55 4 131 Ambient temperature a device in operation PCI PF 25 45 13 113 Storage temperature g P device not in operation PC PF 30 60 22 140 28 13 EC Declaration of Conformity por mx LUKAS Hydraulik Gmbh Hurat Welnsiranse J9 LUE AS D168 Erlangen Veter Germany EG Konformit tserkl rung EC Declaration of Conformity im Sinne der EG Maschinenrichtiinie 42 26 Anhang Il A In ccordange wilh ihe EC Machineny Dinecive 4256 Appendix i A Hiermit erkl ren wir dass die nachfolgend bezeichnete Handpumpen Me benndy decimo that the following hand pump ZFF h ni u ZPH TAN PNTOO ZPH IAF PN700 ZPH 15 PFO ZPH 3 4 PNTOO HM 1A FM7OO 2PH 3 4 PESO ZFH34 1D PNSOO ZPHA4 20 PAGO ZPHAB 10 PASO ZPHSS 2DPNEOO SCARS e inden von uns gelieferten Ausf hrung den Bestimmungen der Maschinennichtine O642 E6 ersetzia Richtlinie S23 7 EG und den sie umsetrencden nationalen Rechtsworschriften entsprechen Ber cksich gt wurden insbesondere die Norman DIN EN ISO 12100 Ausgabe 2004 04 Sicherheit von Maschinen Teil 1 und 2 DIN EN ISO 14121 1 Ausgabe 2007 12 Sicherheit wor Maschinen Leits tze zur a ihe vero supped by ve
7. Operating instructions d UK A gt g Hand Pumps ZPH and HM 84120300085 GB Edition 11 2010 replaces 11 2009 Translation of the original operating instructions Contents Danger classes Product safety Proper use Main components of the hand pump Functional description OP Ol ia Oo IN Connection options for hydraulic equipment 6 1 Connecting nipples 6 2 Quick disconnect couplings 6 3 Monocouplings 7 Commissioning 7 1 Locking the pump 7 2 Bleeding the pump 8 Operation 8 1 Operation 8 2 Shut down Storage 9 Transport 10 Maintenance and repair 10 1 Basic requirements 10 2 Maintenance 10 3 Changing or topping up the hydraulic fluid 10 4 Care 10 5 Repair 11 Troubleshooting 12 Technical data 12 1 Hand pump data 12 2 Hydraulic fluid recommendation 12 3 Operating and storage temperature ranges 13 EC Declaration of Conformity 14 Notes 1 Danger classes 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 Damage ae injury to haus ni DANGER Immediate danger Death or major injury Potentially WARNING dangerous Potential death a o major injury situation CAUTION Less dangerous Minor or slight injury situation Damage to the Danger of damage equipment damage ATTENTION to device to the environment environment damag
8. Replace seal Hydraulic fluid with milky Water or condensation Perform hydraulic fluid cloudiness water in the system change immediately In the case of a They are under excessive Open discharge valve and monocoupling system pressure e g due to bleed device Hose lines cannot be excessive ambient coupled temperature Coupling defective Coupling should be replaced immediately In the case of a Hydraulic fluid of the Hydraulic fluid needs monocoupling system application situation not to be changed see the Hose lines frequently adapted chapter Hydraulic fluid cannot be coupled recommendation for more information Coupling defective Coupling should be replaced immediately In the case of a quick System is under pressure Open discharge valve and disconnect coupling bleed device system Hose lines cannot Coupling defective Coupling should be be coupled replaced immediately In the case of a Coupling defective Coupling should be monocoupling system replaced immediately Leakage at the couplings 23 In the case of a quick Safety valve has After depressurisation no disconnect coupling responded in the further leakage occurs system Leakage on the decoupled state male coupling Male coupling defective Male coupling should be replaced immediately In the case of a quick Female coupling defective Female coupling should be disconnect coupling replaced immediately system Leakage at the female coupl
9. accessories 10 3 Changing or topping up the hydraulic fluid The hydraulic fluid 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 fluid at least once every six months ATTENTION Add hydraulic fluid only if the hand pump is disconnected from the lines or the equipment operated with the pump is hydraulically depressurised Otherwise after filling the entire hydraulic system could contain more hydraulic fluid than the tank can hold Procedure 1 Open the bleed fill cap on the tank 2 Add hydraulic fluid until the fluid 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 fluid level again and close the tank again at the correct fluid level with the vent fill cap on the tank Should the tank no longer be sufficiently full after bleeding start the fill procedure again at item 2 NOTE Should the fluid level in the tank still not be reached after repeated refilling 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
10. 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 filter item H 5 The assembly is done in reverse order Replace all damaged parts with new ones The tightening torque for screws A is 24 Nm and for screws B is 10 Nm 10 5 4 Couplings WARNING CAUTION ATTENTION Couplings should not be repaired they should be replaced with original LUKAS parts 10 5 4 1 Monocouplings The monocouplings must be replaced if exterior damage is present the lock does not function inthe coupled and or decoupled state hydraulic fluid continuously escapes 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 40 Nm 20 10 5 4 2 Quick disconnect couplings The quick disconnect couplings should be replaced if exterior damage is present the lock does not function inthe coupled and or decoupled state hydraulic fluid continuously escapes Procedure 1 Unscrew and remove coupling 2 Screw in new screw on male coupling and tighten with a torque of M 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 i
11. and or storing the device make sure that the function and the safety of 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 Before transporting the device always check to see that the accessories are positioned securely to prevent the possibility of an accident Make sure you properly dispose of all removed parts leftover hydraulic fluid 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 WARNING CAUTION ATTENTION The device is specified 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 Ay Never work in a fatigued or intoxicated state A 3 Proper use 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 a
12. dentification 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 21 11 Troubleshooting Connected device Fluid level in the hydraulic Add hydraulic fluid up to does not move moves tank too low max fill level only Slowly See Discharge valve open Close discharge valve intermittently Hose line not properly Check connection of the connected or damaged hose line and reconnect it if necessary Load on the device Use a different device too high Air in the hydraulic system Bleed system as described in the chapter Bleeding the pump Defect on the device Heed the specifications of the separate operating instructions of the device Connected device moves Hose line not properly Check connection of the but does not hold pressure connected or damaged hose line and reconnect it or does not render the if necessary specified performance 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 Have the hand pump pump serviced by an authorised dealer by personnel specially trained by LUKAS or by LUKAS directly Device does no
13. ding 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 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 specifications 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 specifications related to the maintenance intervals of the devices 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
14. e to surrounding materials noe ek No injury damage application and NOTE other important ioe deh J useful information l t and advice a a Q Es Proper recycling O Wear protective gloves ry Protect the environment Wear helmet with face guard alle Wear safety shoes Read and follow operating instructions 2 Product safety 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 We also recommend that you get instructed by a qualified trainer in the use of the product Ay WARNING CAUTION _ The operating instructions for the hoses the accessories and the connected devices must also be heeded Even if you have already received instruction you should read the following safety instructions again Make sure tha
15. emoving 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 D base plate 2 Empty tank by removing the screw plug item D and emptying the tank 18 Removing the ZPH1 HM1 11 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 filter 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 Pump head J 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 121 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 filter item W 6 The assembly is done in reverse order Replace all damaged parts with new ones The tightening torque for the screws is 10 Nm 19 Removing the ZPH3 tank 3 Remove the screws items A
16. h hydraulic fluid 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 13 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 fill screw plug is screwed in tightly Make sure the pump is not stored in a damp environment 9 Transport 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 10 Maintenance and repair 10 1 Basic requirements Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and auth
17. ing Hydraulic fluid escaping Leakage possible damage Replace hoses from the hoses or at the joints Damage on the surface of Mechanical damage or Replace hoses the hydraulic hoses contact with aggressive media If the defects cannot be remedied notify an authorised LUKAS dealer or contact LUKAS Customer Service directly The address of LUKAS customer service is LUKAS Hydraulik GmbH Weinstra e 39 D 91058 Erlangen Postfach 2560 D 91013 Erlangen Phone 49 09131 698 348 Fax 49 09131 698 353 24 12 Technical data 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 1 Pump identification a 1A Ze Model series Optional rounded usable max operating attachments volume of the pressure in bar e g hydraulic fluid 1 MPa 10 bar F with foot plates tank not for HM1 in I NOTE Hand pumps in model series HM1 are generally fitted with a base plate 12 1 2 Dimensions ZPH1 and HM1 On hand pumps with the optional foot plate attached the height H increases by 6 mm 25 ZPH 3 41 Tank 8l Tank 762 Tank size according to pump identification 0 29 gal US 0 34 gal US 1 06 gal US 1 40 gal US 1 19 gal US 1 32 gal US 8 0 I 10 5 I 12 1 4 Delivery quantity Pump type Delivery quantity per piston stroke Low pressure
18. nctions and N therefore must not be unscrewed and or interchanged 10 6 3 Monocouplings The hose lines are connected via monocoupling halves female and male to the hydraulic pump in such a way that they cannot be reversed Dust caps il _ ine l PA Male coupling Female coupling 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 lil 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 For dust protection the supplied dust caps must be reattached A WARNING CAUTION ATTENTION D The monocouplings must not be unscrewed and or the hose lines reversed 11 7 Commissioning NOTE With the LUKAS hand pump a little idle stroke may occur when the unit is first used in the high pressure range However this idle stroke independently stops after a device is operated 2 3 times ATTENTION The hand pump should be as close to horizontal as possible because otherwise the usable amount changes
19. o the pump handle that does not belong to the device These extensions usually cause the pump to become unstable during operation 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 flow 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 first be supplied to the device Then the pressure can be decreased again by slowly opening the discharge valve 8 1 Operation 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 wit
20. orised 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 WARNING CAUTION ATTENTION To perform maintenance and repairs personal safety equipment appropriate for the work is an absolute requirement incl shields Q 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 lil 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 14 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 correspon
21. reas 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 A Always note the product limitations with respect to operating pressure load limit values and operating conditions The operating pressure should not be higher O than the lowest maximum operating pressure of any system components The operating pressure should NEVER be set higher than that which is specified 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 sufficient for operating the connected cylinders or devices The required hydraulic fluid operating quantity can be found in the chapter Technical Data or in the operating instructions of the devices to be operated You can obtain accessories and replacement parts for the devices from your authorised LUKAS dealer 4 Main components of the hand pump 13 Drain valve Bleeding Filling cap Pump lever Tank Lock Connecting nipples Sealing caps quick disconnect couplings optional Connecting block for monocoupling optional Monocoupling optional Front foot plate optional Rear foot plate optional Base plate optional 5 Functional description All LUKAS hand pumps of this series are two speed i e they have two operating speeds
22. should be abandoned The maximum permissible operating pressure must not be changed 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 When working in the vicinity of live components and lines take appropriate measures for preventing current transfers or high voltage flashovers to the device Prevent electrostatic discharge which has the possible consequence of spark formation when handling the device The device is filled with hydraulic fluid These hydraulic fluids 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 fluids note that they can negatively affect biological systems Make sure there is adequate lighting while working Always keep these operating instructions easily accessible at the site where the device is used Observe all intervals that are prescribed or specified in the operating instructions for recurring tests and or inspections 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 When the hand pumps are set up Care needs to be taken that they are not impaired by extremely strong temperature changes When operating
23. t move Discharge valve closed Open discharge valve back into the starting Fluid level in the hydraulic Reduce hydraulic fluid 0 toward tank too high down to max fill level ee caine lo a Loose hydraulic coupling mae ae and moves more slowly into Sree the starting position than Enclosed air in the system Bleed pump as described normal in the chapter Bleeding the pump Line length too long Use shorter lines Use hydraulic fluid with a different more suitable viscosity Defect on the device Heed the specifications of the separate operating instructions of the device 22 Connected device not Fluid level in the hydraulic Add hydraulic fluid up to reaching its limit position tank too low max fill level Attention move the device back into the base position before adding fluid Usable hydraulic fluid Use a different device with quantity of the pump is a usable quantity below insufficient the maximum usable quantity of the pump Connected device does Max permissible operating Replace pressure not achieve its power pressure of the pump is control valve or have related performance data not reached it recalibrated by an authorised dealer or directly by LUKAS Fluid leaks on the Due to return flow of the Reduce hydraulic fluid hydraulic fluid tank hydraulic fluid from the down to max fill level especially at the refill tap device the maximum fill quantity of the tank is exceeded Seals defective
24. t no body parts or clothing get between the openly visible moving parts of the device Wear protective clothing protective helm with visor safety shoes and protective gloves Working under loads is prohibited if they are raised exclusively with hydraulic devices If this work is unavoidable sufficient mechanical supports are additionally required In the event of malfunctions shut down the device immediately and secure it You should have the malfunction repaired immediately Heed all safety instructions and hazard warnings on the device and in the operating instructions Make sure that all safety covers are present on the device and in proper working condition Safety equipment must never be disabled Immediately report changes that occur including changes in operating behaviour to the appropriate persons departments If necessary immediately shut down and secure the device Check the device for visible defects or damage before and after use Check all lines hoses and screwed connections for leaks and externally visible damages and repair immediately Escaping hydraulic fluid can lead to injuries and fires Do not make any changes add ons or conversions on the device without the approval of LUKAS All safety instructions and hazard warnings on the device are to be kept intact and ina legible condition Any work procedure that detracts from the safety and or stability of the device
25. 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 fluid escaping 6 1 Connecting nipples The hose lines are connected via fittings to the hydraulic pump 1 First remove the closure caps from the fittings 2 Then you can connect the hose lines to the fittings and tighten them with a tightening torque of M 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 6 2 Quick disconnect couplings 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 ATTENTION Ey Always connect the return line first and then the supply line NOTE Coupling the equipment is only possible if the hoses are depressurised For dust protection the supplied dust caps must be reattached WARNING CAUTION ATTENTION To some extent the quick disconnect couplings have special fu
26. to prevent any corrosion 16 10 5 Repair ATTENTION 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 and whose replacement is described here 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 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 ifthe stability of the hand pump can no longer be ensured 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 Refit the base plate in the reverse order 17 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 of the hand pump can no longer be ensured Procedure 1 Remove screws A or B Front foot plate Rear foot plate 2 Remove foot plate C or D and replace it with a new one 3 Refit the foot plates in the reverse order 10 5 3 R
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