Operating instructions Hydraulic Tools Hand pump LH1 / LH2 and accessories 84129/2430-85 GB Issue 04.2009 replaces 03.
Contents Page 1. Danger classes 4 2. Product safety 4 3. Proper use 7 4. Main components of the hand pump 8 5. Functional description 9 5.1 Base pump 9 5.2 Adapter blocks 9 6. Mounting of base plates and valve blocks 6.1 Basics for mounting base plates and valve blocks 10 11 6.2 Base plates 12 6.3 4/3-way valve 13 6.4 2-way distribution valve 14 6.5 Oil distributor with pressure gauge connection 15 7. Connection options for hydraulic equipment 16 7.
10. Transport 24 11. Maintenance and repair 24 11.1 Basic requirements 24 11.2 Maintenance 26 11.3 Hydraulic fluid change or adding hydraulic fluid 27 11.4 Care 27 11.5 Repair (hand pump) 28 11.6 Repair (accessories) 34 11.7 Repair (couplings and decals) 36 12. Troubleshooting 37 13. Technical data 40 13.1 Data of the hand pumps 40 13.2 Hydraulic fluid recommendation 42 13.3 Operating and storage temperature ranges 42 14.
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.
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. 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.
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 specified 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 flashovers to the device. For repairs only original LUKAS accessories and spare parts are to be used.
WAR N IN G / C A U TION / AT T E NT I O N! 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.
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5.1 Base pump 5. Functional description 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").
2-way-distribution valve N2W 841489903 2,1 Distribution valve to divide one oil flow into two flows. By closing or opening the valve screw, the partial flows could be regulated and harmonized. (Base plate is a basic requirement) Oil distributor with pressure gauge connection N4M 841489905 1,4 By use of the oil distributor one oil flow can be divided into 5 flows. The distributor has 4 pressure ports (G1/4”) and one pressure gauge port (G1/4”). (Base plate is a basic requirement) 6.
6.1 Basics for mounting base plates and valve blocks 1. Remove the closing screw of the return port “T” and the ball behind. 2. 3. Put the o-rings into the designated groovings of the ports “T” and “P” . Take care, that the surfaces are clean and dust-free. NOTE: The o-rings are always part of the mounting kits of the designated adapter kits! (The appropriate mounting kits could be found in the spare parts lists.) 11 Remove the closing screw of the pressure line port “P” and the sealing ring behind.
6.2 Base plates 1. Put the base plate onto the pump head, so that the boreholes “T” and “P” of the base plates matches with the ports of the pump head Take care, that the surfaces are clean and dust-free. 2. 3. Put the 4 screws into the designated boreholes and tighten them with a torque of 20 Nm. When you are connecting the hose assemblies directly to the hand pump, you will have to mount appropriate designated couplings, fittings or closing screws to the ports “P” and “T”.
6.3 4/3-way valve NOTE: The article description and reference number of all listed position numbers could be found in the spare parts lists. 1. Put the 4/3-way valve onto the pump head, so that the boreholes “T” and “P” of the base plates matches with the ports of the pump head Take care, that the surfaces are clean and dust-free. 2. 3. Put the 4 screws (Pos. 6.1) into the designated boreholes and tighten them with a torque of 20 Nm.
6.4 2-way distribution valve NOTE: To mount the 2-way distribution valve, first the base plate without closing screws, fittings and couplings has to be mounted. 1. Put the sealing rings and the 2-way distribution valve onto the pump head, so that the boreholes “T” and “P” of the 2-way distribution valve matches with the ports of the base plate / pump head. Take care, that the surfaces are clean and dust-free. 2. 3. Put the 4 screws into the designated boreholes and tighten them with a torque of 32 Nm.
6.5 Oil distributor with pressure gauge connection NOTE: To mount the oil distributor, first the base plate without closing screws, fittings and couplings has to be mounted. 1. Put the oil distributor onto the base plate, so that the borholes „T“ and „P“ of the oil distributor matches with the ports of the base plate / pump head. Take care, that the surfaces are clean and dust-free. 2. 3. Put the 4 screws into the designated boreholes and tighten them with a torque of 32 Nm.
7. 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 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 fluid escaping. 7.
7.2 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. X Y 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.
e. g. 4/3-way valve: neutral port “A” connecting thread B A hand pump port “B” sealing rings return hose supply hose e. g.
7.5 Direct connection into the oil distributor block 1. 2. Remove the closing screws form the ports „A1“, „A2“, „A3“ and/or „A4“ (according to the number of tools you want to connect). Screw the appropriate hose line / coupling directly into the distributor block and tighten it with a torque of 45 Nm. connecting thread hand pump port “B” sealing ring supply hose NOTE: The port “M” is provided for a pressure gauge, which will be tighten there with a torque of 45Nm.
7.6 Direct connection into the base plate 1. 2. 3. 4. Remove the closing screw from the return line port “T”. Screw the appropriate hose line / coupling for the return line directly into the port “T” and tighten it with a torque of 45 Nm. Remove the closing screw from the supply line port “P”. Screw the appropriate hose line / coupling for the supply line directly into the port “P” and tighten it with a torque of 45 Nm.
8.1 Unlocking the pump 2. 1. Locking pin 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). 8.2 Bleeding the pump 1. 2. 3. Open the discharge valve. Open the oil fill screw plug on the tank container and check the oil fill level.
9. Operation 9.1 Notes for a secure operation of the hand pump 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. NOTE: In order to limit the required force in high pressure operation, we recommended using short strokes with the pump handle.
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. Make sure, that the discharge valve is opened completely and the tool is in basic position before you disconnect the tool. 9.4 Hand pump with 4/3-way valve 1. 2. 3. 4. Close discharge valve on the hand pump completely (rotate clockwise). Connect the lines of the tool or the tools to the ports “A” and ”B”.
9.6 Hand pump with oil distributor and pressure gauge 1. 2. 3. 4. Close discharge valve on the hand pump completely (rotate clockwise). Connect the supply lines of the tool(s) with the pressure port. Move the locking pin into the operating position. Supply the device with 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).
WARNING / CAUTION / ATTENTION! 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.
11.2 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.
11.3 Hydraulic fluid change or adding 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 half year. ATTENTION! Add hydraulic fluid only if the hand pump is disconnected from the lines or the equipment operated with the pump is hydraulically depressurised.
11.5 Repair (hand pump) 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.
Procedure: 1. Disassemble the retaining rings (Pos. 3.3) and extricate the bolt (Pos. 3.2). 3.3 3.2 3.3 lever unit 3. Demount the lever unit. 4. Extricate the piston unit (Pos. 6.1) and after that remove the wiper (Pos. 6.4), backup ring (Pos. 6.3) and the o-ring (Pos. 6.2). 6.1 6.4 6.3 6.2 5. The assembly is done in reverse order. Replace all damaged parts with new ones.
11.5.3 Changing the hand relief valve The hand relief valve must be replaced if there is a permanently leakage on the relief valve, if you see external damages or it does not working. ATTENTION! The hand relief valve itself may only be dismantled as far as described here. Additional repars on the relief valve itself may only be made, when: - You have participated in a corresponding LUKAS service training course.
11.5.4 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. 9.1 Procedure: 1. Emptying the reservoir by demounting the plug screw (Pos. 9.1) and the sealing ring (Pos. 9.2) below and after that emptying the reservoir. 9.
Hand pumps with a 1,8 l reservoir has to be disassembled like shown below: nut (Pos. 16.1), sealing ring (Pos. 15.2), base plate, flat seal (Pos. 17.1), reservoir, connecting plate and sealing (Pos. 15.1). 16.1 15.2 17.1 base plate 17.1 reservoir 15.1 connecting plate Hand pumps with a 3,8 l reservoir has to be disassembled like shown below: nut (Pos. 16.1), sealing ring (Pos. 15.2), base plate, flat seal (Pos. 18.1), reservoir, connecting plate and sealing (Pos. 15.1). 16.1 15.2 18.1 18.1 15.
11.5.5 Replacing pressure limiting valves and filter The pressure limiting valves have to be replaced, when they are damaged. The filter has to be replaced, when the flow of the hydraulic fluid is not possible or it is only possible with difficulties. ATTENTION! Pressure limiting valves must not be disassembled or readjusted; they have to be replaced by new ones with appropriate settings! Procedure: 1.
11.6 Repair (accessories) 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.
11.6.2 4/3-way valve (locating disk and needle bearing replacement) The lever parts must be replaced, when you see external damages or they do not work correct. Procedure (Demount of lever, locating disk and needle bearing): 1. Untighten the screws (Pos. 4) at the cover plate and remove the coverplate. cover plate 2 4 1 2. Remove the needle bearing (Pos. 3.2) and the lever. After that disassemble infolowing parts: lever knob (Pos. 2), lever rod (Pos. 1), locating disk (Pos. 3.1) and needle bearing (Pos.
11.7 Repair (couplings and decals) 11.7.1 Quick-disconnect-couplings (if mounted) The quick-disconnect-couplings should be replaced if: - exterior damage is present, - the lock does not function, - in the coupled and/or decoupled state, hydraulic fluid continuously escapes. WARNING / CAUTION / ATTENTION! Couplings should not be repaired; they should be replaced with original LUKAS parts! Procedure: 1. Unscrew and remove coupling. 2.
12. Troubleshooting Problem Connected device does not move, moves only slowly or moves intermittently. Cause Fluid level in the hydraulic tank too low Hand relief valve open Hose line not properly connected or damaged Remedy Add hydraulic fluid up to max. fill level. Close hand relief valve. Check connection of the hose line and reconnect it if necessary. Use a different device. Load on the device too high Air in the hydraulic system Bleed system as described in the chapter “Bleeding the pump”.
Problem 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. Cause Hand relief valve closed Fluid level in the hydraulic tank too high Remedy Open hand relief valve. Reduce hydraulic fluid down to max. fill level. Loose hydraulic coupling Check all couplings and retighten them. Enclosed air in the system Bleed pump as described in the chapter “Bleeding the pump”.
Problem Cause Remedy In the case of a quickdisconnect coupling system: Leakage on the male coupling Safety valve has responded (in the decoupled state) Male coupling defective After depressurization, no further leakage occurs. In the case of a quickdisconnect coupling system: Leakage at the female coupling Hydraulic fluid escaping from the hoses or at the joints Damage on the surface of the hydraulic hoses Female coupling defective Female coupling should be replaced immediately.
13. 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! 13.1 Data of the hand pumps 13.1.1 Pump labelling LH 2 / 1.8 Tank size Model series - 50 max. operating pressure in MPa (1 MPa = 10 bar) NOTE: The automatic pressure switch from low pressure to high pressure occurs at 2 MPa (= 20 bar) 13.1.
13.1.3 Weight, usable quantities and fill quantities NOTE: The weights, usable quantities and fill quantities of the hand pumps are exclusively dependent on the size of the hydraulic fluid tank. Reservoir size (useable quantity) 13.1.4 0,2 [l] 0,5 [l] 0,9 [l] 1,8 [l] 3,8 [l] weight min. needed (incl. max. hydraulic fluid filling) fill quantity 2,3 [kg] 0,24 [l] 5.1 [lbs.] 0.06 [gal.-US] 4,0 [kg] 0,69 [l] 8.8 [lbs.] 0.18 [gal.-US] 5,7 [kg] 1,23 [l] 12.6 [lbs.] 0.
13.2 Hydraulic fluid recommendation Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range Oil code Viscosity rating A -24 .... +30°C HL 5 VG 5 B -18 .... +50°C HM 10 VG 10 C -8 .... +75°C HM 22 VG 22 D +5 .... +80°C HM 32 VG 32 E -8 .... +70°C HF-E15 VG 15 Bio-oil Oil temperature range Oil code Viscosity rating Remarks A -11.2 .... +86°F HL 5 VG 5 B -0.4 .... +122°F HM 10 VG 10 C +17.6 .... +167°F HM 22 VG 22 D +41.0 ....
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Please dispose all packaging materials and dismantled parts properly LUKAS Hydraulik GmbH Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com Made in GERMANY LH1_LH2_WZH_BA_GB_841292430_0409.
