Lukas ZPH 3-4 User Manual
Operating instructions
Hand Pumps ZPH and HM
84120300085 GB
Edition 11.2010
replaces 11.2009
(Translation of the original operating instructions)
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3
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 8
6. Connection options for hydraulic equipment 9
6.1 Connecting nipples 9
6.2 Quick-disconnect couplings 10
6.3 Monocouplings 11
7. Commissioning 12
7.1 Locking the pump 12
7.2 Bleeding the pump 12
8. Operation 13
8.1 Operation 13
8.2 Shut-down / Storage 14
9. Transport 14
10. Maintenance and repair 14
10.1 Basic requirements 14
10.2 Maintenance 15
10.3 Changingortoppingupthehydraulicuid 16
10.4 Care 16
10.5 Repair 17
11. Troubleshooting 22
12. Technical data 25
12.1 Hand pump data 25
12.2 Hydraulicuidrecommendation 28
12.3 Operating and storage temperature ranges 28
13. EC Declaration of Conformity 29
14. Notes 30
4
Danger classes1.
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.
Pictogram
Wear helmet with face guard
Wear protective gloves
Damage /
injury to
human
device
- NOTE
Key word Denition Consequences
DANGER! Immediate danger Death or major injury
WARNING!
CAUTION!
ATTENTION!
Proper recycling
Protect the environment
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Potential death or
major injury
Minor or slight injury
Damage to the
equipment, damage
to the environment,
damage to
surrounding materials
No injury / damage
to persons /
environment /
equipment
Wear safety shoes
Read and follow operating
instructions
Product safety2.
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.
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We also recommend that you get instructed by a qualied 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.
Make sure that 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, sufcient
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.
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 uid can
lead to injuries and res.
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 in a
legible condition.
Make sure that all safety covers
are present on the device and
in proper working condition.
Safety equipment must never
be disabled!
Any work procedure that
detracts from the safety and/or
stability of the device should be
abandoned!
The maximum permissible
operating pressure must not be
changed.
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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 ashovers to the
device.
Prevent electrostatic discharge,
which has the possible
consequence of spark
formation, when handling the
device.
The device is lled with
hydraulic uid. These hydraulic
uids 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 uids, 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 specied
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 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 uid, 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!
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WARNING / CAUTION / ATTENTION!
The device is specied exclusively for the purpose represented in the operating
instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is
considered improper. The manufacturer/supplier shall not be held liable for damages
resulting from improper use. The risk shall be borne solely by the user.
Proper use also includes heeding the operating instructions and complying with the inspection
and maintenance requirements.
Never work in a fatigued or intoxicated state!
Proper use3.
The LUKAS hand pump is used for the operation of LUKAS devices.
They can be used as an additional or replacement drive source along with the LUKAS
hydraulic unit (e.g. in areas at risk for explosion).
Use with equipment of other manufacturers is possible, but requires technical testing and
approval of LUKAS on a case-by-case basis.
WARNING / CAUTION / ATTENTION!
Always note the product limitations with respect to operating pressure, load limit
values and operating conditions. The operating pressure should not be higher
than the lowest maximum operating pressure of any system components.
The operating pressure should NEVER be set higher than that which is specied
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 sufcient for operating the connected cylinders or devices.
The required hydraulic uid 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!
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10
Main components of the hand pump4.
5
9
1
3
5
11
12
5
13
6
2
7
4
1
5
8
1
1 Drain valve
2 Bleeding / Filling cap
3 Pump lever
4 Tank
5 Lock
6 Connecting nipples
7 Sealing caps
8 quick-disconnect couplings
(optional)
9 Connecting block for
monocoupling (optional)
10 Monocoupling (optional)
11 Front foot plate (optional)
12 Rear foot plate (optional)
13 Base plate (optional)
1
Functional description5.
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").
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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 tted.
Obviously, the connection options tted can be replaced by others. However, you must
contact an authorised LUKAS dealer or contact LUKAS directly.
Additionally, LUKAS hand pumps can be tted 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.
Connection options for hydraulic equipment6.
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
uid escaping.
6.1 Connecting nipples
The hose lines are connected via ttings to the hydraulic pump.
1. First remove the closure caps from
the ttings.
1.
2.
2.
Then, you can connect the hose lines
to the ttings and tighten them with a
tightening torque of M
= 40 Nm.
A
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.
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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.
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. Decoupling is done in the reverse sequence.
ATTENTION!
Always connect the return line rst 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 functions and
therefore must not be unscrewed and/or interchanged!
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