Portable Hydraulic Power Unit

Transcription

1 Portable Hydraulic Power Unit Operating and Maintenance Manual Features: Light weight dual flow unit High pressure Multi functional Durable protective cover Compact design Temperature stability Operating and Maintenance Manual 1

2 by ROARK TOOLS Forwarding and copying as well as use and communication of the contents of this document are prohibited unless explicitly permitted. Violations oblige to compensation for damages. All rights reserved concerning patent or utility model registrations

3 Contents 1 Regarding this manual Target group Applicable documents Symbols and identifications General safety instructions Approval restrictions Designated use Unintended use Operator's obligations Qualification of staff Structural changes and spare parts Residual risks Environmentally hazardous substances Hydraulic fluids are harmful to human health Risk of slipping caused by escaping hydraulic fluid High pressure in hydraulic systems Fire hazard Surface temperature s in avoidance of material damage Low fluid level Product description Function Detailed description of operation Parts list Components and dimensions Transport and storage Check delivery Transporting the compact hydraulic power pack Storage Installation and assembly Set up the compact hydraulic power pack Connecting compact hydraulic power pack Commissioning Inspect the compact hydraulic power pack First visual check Commission the compact hydraulic power pack Set the pressure Connecting the hydraulic load Faults Troubleshooting table Error codes for Error LED Maintenance Maintenance schedule Cool off the compact hydraulic power pack using the fans

4 8.3 Checking the fluid level and replacing hydraulic fluid Checking the fluid level Change or fill up the hydraulic fluid Installing spare parts Cleaning the compact hydraulic power pack Disassembly and disposal

5 1 Regarding this manual This manual is within delivery scope of the compact hydraulic power pack. It describes the safe and proper use during all operation phases. The Roark Tools accepts no liability whatsoever and makes no guarantee for any and all damages, actual and consequential, caused by failure to observe this manual. Please read the manual carefully before usage Keep manual during entire life cycle of compact hydraulic power pack This manual has to be accessible to the operating and maintenance staff at any time. Forward manual to every subsequent owner or user of the compact hydraulic power pack Update manual with every addition/supplement received from manufacturer. This manual was originally written in English. All other language versions were translated from the original language. 1.1 Target group This manual addresses trained and qualified professional experts who are familiar with the assembly, operation and maintenance of compact hydraulic power packs. Only trained and qualified professional experts may install, operate and maintain the compact hydraulic power pack. Recommendation: Before staff work on the compact hydraulic power pack ensure they are trained and instructed by ROARK TOOLS. Roark Tools Inc. Is not responsible for customer modifications of tools for applications on which Roark Tools Inc. was not consulted. Any warranyt claims or liabitlity claims against Roark Tools/Dekksem become invalid in the following situations: a)if any unauthorized parts or accessories are used with any Roark Tool Products. b)if any Roark Tools/Dekksem equipment is Obtained, Purchased, Rented, Used or Services from an unauthorized Roark Tool/Dekksem distributor, respresentative or reseller. c) Not follwing the Roark Tools Chameleon pump manuals guidlines or procedures. *Please contact Roark Tools Directly to verify Certifications. - ). 1.2 Copyright information This manual may not be electronically or mechanically copied, distributed, modified, transmitted, translated into another language or otherwise used in whole or in part without explicit authorisation of ROARK TOOLS

6 1.3 Symbols and identifications The following symbols and identifications may be used in this document: Danger Danger for persons present. Non-observance will result in death or serious injury. Danger for persons is caused. Non-observance may result in serious injury. Danger for persons. Non-observance may result in minor injuries. Danger Danger due to suspended loads. Danger Fire hazard. Danger Danger due to electric shock. Potentially explosive atmosphere. Danger of burning due to hot surfaces. Irritant substances. Slip hazard. Danger against hand injuries. Danger Danger of injury due to high pressure. against non-ionising electromagnetic radiation. Danger for the environmental due to pollution. See operating instructions. Remove mains plug before assembly. General information. s for understanding or for optimising workflows. Identification of operational instructions Single-step operational instructions 1. Multi-step operational instructions 2. Step 2 3. Step 3 Result Identification of components Components are indicated by figures in brackets, e.g. (0100). These figures represent the item numbers in the parts list and in the hydraulic circuit plan. Components mentioned in the text may also be indicated by a letter, for example. All of the components specified in these instructions can be identified in Chapter 3, "Product description"

7 2 General safety instructions The compact hydraulic power pack has been built according to state-of-the-art and established technical safety rules. Nonetheless, its usage can cause danger for life and limb of the user or third parties and/or affect the product and other assets. The compact hydraulic power pack only in technically faultless condition as intended and keep all aspects of safety and danger in mind. Observe all notes and instructions on the compact hydraulic power pack Regularly carry out all required maintenance activities Eliminate immediately any faults which may affect safety 2.1 Approval restrictions The power packs in this manual are CE stamped, The power packs, object of this manual, are only intended as drive for hydraulic torque wrenches. 2.2 Designated use Operate the compact hydraulic power pack only in the scope of the permissible operating conditions. Other designated use: Follow these instructions, especially the basic safety instructions and the applicable documents (see Applicable documents in Chapter 1, "Regarding this manual") Unintended use All other usages are not in accordance with the designated usage. This includes in particular the following improper usages: Other hydraulic fluids as specified in these instructions Other loads as designated Improperly installed, obsolete, unsecured or damaged pipes and hose lines Excessive operating pressure Continuous operation Use in atmospheres at risk of explosion Structural changes, especially if function and safety are compromised 2.3 Operator's obligations Rules and regulations Install and operate the compact hydraulic power pack only in accordance with regional rules and regulations. In particular, observe Staff all accident prevention regulations and environmental legislation. Employ only professional experts. The professional experts must have sufficient training and experience to detect risks and avoid potential dangers. The staff has read the manual, especially this chapter, and understood it The staff knows and observes the applicable accident prevention and safety instructions Compact hydraulic power pack All labels attached to the compact hydraulic power pack must be legible

8 Take appropriate protective measures against fire and provide extinguishing agents on operation site of the compact hydraulic power pack (For detailed information about fire safety of the hydraulic fluid see the material safety data sheet of the hydraulic fluid manufacturer) Carry out all inspections and maintenance work as prescribed in this manual 2.4 Qualification of staff Only trained and qualified professional experts may install, operate and maintain the compact hydraulic power pack. Recommendation: Before staff work on the compact hydraulic power pack ensure they are trained and instructed by ROARK TOOLS. Personnel must have received professional training to have sufficient technical expertise in dealing with hydraulic systems. This includes the following knowledge: Knowledge regarding the structure, function and interaction of the individual hydraulic components Reading and understanding of hydraulic or electro-hydraulic circuit diagrams Work performed on electrical equipment must only ever be executed by an electrician or by a trained person working under the supervi sion of an electrician. Staff may only carry out work and be trained on the compact hydraulic power pack under supervision. 2.5 Structural changes and spare parts Modifications and structural changes endanger operational safety. compact hydraulic power pack may not be modified without permission from ROARK TOOL Use only original spare parts from ROARK TOOLS 2.6 Residual risks Please be aware of the following residual risks.: Environmentally hazardous substances When working on the compact hydraulic power pack, hydraulic fluids may escape. Do not release hydraulic fluid into the environment! Collect cleaning, operating, lubricating and additive agents in suitable containers and dispose of according to local regulations. Components contaminated with hydraulic fluid are to be disposed of in accordance with local regulations Collect electronic waste separately and dispose of according to regional regulations Hydraulic fluids are harmful to human health Contact with hydraulic fluid may cause skin rashes and other health problems. For detailed information on hydraulic fluid see safety data sheet of the hydraulic fluid manufacturer. In many cases the following applies: Avoid prolonged skin contact with hydraulic fluid

9 Wear protective gloves and protective goggles. Thoroughly clean body parts that were in contact with hydraulic fluid Heed all further safety instructions of the hydraulic fluid manufacturer Risk of slipping caused by escaping hydraulic fluid Slip hazard. Puddles of hydraulic fluid can lead to serious accidents. Remove hydraulic fluid puddles immediately with suitable binding agents (For information on suitable binding agents see safety data sheet of the respective hydraulic fluid manufacturer) Dispose of binding agents according to local regulations High pressure in hydraulic systems Danger Improper dismantling may result in unforeseeable dangerous movements of hydraulic drives (e.g. cylinders) which may cause severe injury. Before working on the hydraulics Switch off the main switch on the compact hydraulic power pack. Disconnect the mains plug, securing against reconnection The hydraulic system must be unpressurised Further measures Wear protective gloves and goggles during operation Heed prescribed maintenance intervals Attend to damaged hoses and fittings immediately For connections and hose lines: always ensure proper installation Observe manufacturer's instructions when replacing hoses Fire hazard Hydraulic fluids are flammable and oxidising For more detailed information, see safety data sheet of the respective hydraulic fluid manufacturer. In many cases the following applies: Avoid fire, naked light and smoking in the vicinity of the compact hydraulic power pack Ensure that no hydraulic fluid is escaping Do not use flammable or caustic cleaning agents Surface temperature the compact hydraulic power pack and the solenoids of the control vales heat up during operation. The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. Pressing the red button will restart the fans and cool the compact hydraulic power pack

10 2.7 s in avoidance of material damage Low fluid level An insufficient fluid level damages the compact hydraulic power pack. It may cause the compact hydraulic power pack to fail. When the fluid level is low: Compact hydraulic power pack must be turned off immediately Inspect fluid level visually Correct fluid level Version without level switch: Check compact hydraulic power pack and lines and pipes for external leaks. Visually check the fluid level via the level indicator (see level indicator above in the tank filling hole) (see Chapter 8.3, "Checking the fluid level and replacing hydraulic fluid")

11 3 Product description 3.1 Function The compact hydraulic power pack generates, controls and regulates volumetric flows. These normally operate hydraulic loads in machines/systems. The design of the compact hydraulic power pack is presented in detail in the hydraulic circuit plan (see Chapter 10, "Appendix"). If loads are presented in the hydraulic circuit plan, these serve only to explain the compact hydraulic power pack and this does not indicate that they are included in the delivery. The loads are not part of the compact hydraulic power pack and will not be described in this document. Assembling the compact hydraulic power pack into a complete system changes the potential hazards. This is particularly the case if mechanical movements are generated. This fact, along with other potential legal requirements, must be taken into account for the documentation of the complete system Detailed description of operation Operation The compact hydraulic power pack is operated via the wired remote control. The following items describe typical use as a sequence of steps 1. Switch on main switch on compact hydraulic power pack Compact hydraulic power pack becomes ready for operation, duration ~5 seconds The fans start up 2. Press and hold the green button on the remote control The pump on the compact hydraulic power pack starts up 3. The operator continues to hold the green button If you hold the green button for a sustained period (> 3 minutes) the compact hydraulic power pack may overheat. Always leave short breaks between actuations. Pressure builds up at port A. The compact hydraulic power pack generates pressure up to the maximum pressure set via the pressurelimiting valve. 4. Release the green button on the remote control The pressure immediately switches to port B At a pressure value of 100 bar, the compact hydraulic power pack switches to circulation mode 5. If you press the green button on the remote control, the cycle starts again as in step 3 If you do not proceed with step 5: the motor switches off automatically after an afterrun period of 20 seconds 6. The operator can start from the beginning with step 2 7. Emergency stop: The compact hydraulic power pack can be put into a unpressurised state and it's pump stopped at any time by pressing the red button once. This state is also used for afterrun cooling of the compact hydraulic power pack (fans continue to run). 8. Suspending emergency stop: Press the green button once (for approx. 1 second) to cancel the stop command 9. The operator can start from the beginning with step 2 10.If you switch off the main switch, the compact hydraulic power pack will become de-energised Compact hydraulic power pack is switched off and unpressurised

12 3.2 Parts list For parts list, see Chapter 10, "Appendix". 3.3 Components and dimensions See diagrams and parts list in Chapter 10, "Appendix". The numbers in brackets, e.g. (0100) also correspond to the items in the hydraulic circuit plan and parts list

13 4 Transport and storage 4.1 Check delivery If the compact hydraulic power pack is packed or secured with tightening straps: Remove the tightening straps carefully Check compact hydraulic power pack for completeness based on the parts list compact hydraulic power pack thoroughly for transport damage Take photographs to document all damage and send a damage report to ROARK TOOLS 4.2 Transporting the compact hydraulic power pack Transport the unpacked compact hydraulic power pack using the fixtures provided (transport eyebolt or transport handle). The portable compact hydraulic power pack is relatively heavy, especially when filled with oil. Incorrect lifting, or overloading may result in injury. Never lift the compact hydraulic power pack with a bent back. Where possible, use straps or chains with the transport eyebolt to lift and carry the compact hydraulic power pack or use the carry handle with the help of a second person. A B Wear gloves, protective goggles and protective clothing when transporting, installing or performing maintenance! The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. Danger Suspended loads may fall and cause severe or lethal injury. Never stand or walk under suspended loads. Wear appropriate protective equipment during all transport activities. E.g. protective helmet, safety shoes and work gloves. Image 1: Transport fixtures on the compact hydraulic power pack A B C Transport handle Transport eyebolt Adjustable feet on the rear C 4.3 Storage The following must be observed when the compact hydraulic power pack is in storage: Store the compact hydraulic power pack such that it stands upright Store in a dry place and protect against moisture Protect against frost Protect against UV light Protect against dust and excessive contamination

14 5 Installation and assembly Wear gloves, protective goggles and protective clothing when transporting, installing or performing maintenance! 5.1 Set up the compact hydraulic power pack the compact hydraulic power pack and the solenoids of the valves may become hot during operation. Therefore, ensure that fresh air can be drawn in and that warm arm can escape. Changes of any kind (mechanical, welding or soldering) are prohibited. The compact hydraulic power pack may only be positioned on the adjustable feet on the rear for the purpose of transport or storage. Position the compact hydraulic power pack such that it is protected from moisture Never place the compact hydraulic power pack in water Position the compact hydraulic power pack so securely that it can never fall down or fall over Position the compact hydraulic power pack such that no large objects call fall onto it 5.2 Connecting compact hydraulic power pack Secure prior to connection The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. Dirt must not enter the compact hydraulic power pack, therefore absolute cleanliness must be ensured! Screw connections must always remain completely clean. All work performed on the compact hydraulic power pack must take place in a clean environment. Clean hands and clothing prior to working on the compact hydraulic power pack. Always keep the quick connectors on the power pack and hose side clean and check for damage or deformations! Do not connect any hydraulic lines if dirt or damage is present. Close any open quick connectors with dust covers. Even when they are not connected, the quick connectors must be aligned with the maximum pressure of the compact hydraulic power pack. Pipes, hose lines and connectors that have an insufficient internal diameter and are too long lead to pressure losses. This impairs the performance of the hydraulic system. Pipes, hose lines and connectors must be designed for the maximum pressure of the system. Compact hydraulic power pack filled with hydraulic fluid ISO 32 and ISO 46 weight Oil. The dimensions of all access and connecting lines must correspond to the specifications of the system Set up pipe and hose connections as follows:

15 Keep the number of screw fittings as low as possible to minimise the likelihood of leaks Keep lines as short as possible and avoid kinks. Do not go below the smallest bend radius specified by the manufacturer. Hydraulically connecting the compact hydraulic power pack 1. Compact hydraulic power pack must be unpressurised 2. In the course of initial connection, remove the sealing plug from the connection bore 3. Check whether the junctions are clean 4. Screw in connectors or screw connections Screw in connectors or screw connections with sufficient torque (note manufacturer specifications!). Only use connectors with check valve function. Screw connections must be closed prior to commissioning. A B Ports: screw connection of port A and port B Size: 1/4-18 NPT See figure on the right It is recommended that you use quick connectors for the ports. The quick connectors of the A and B ports should be different (plug and socket) so that the ports are not mixed up. 5. Connect the remote control Compact hydraulic power pack hydraulically connected Electrically connect the compact hydraulic power pack Ensure power supply unit is set up correctly: E D C Image 2: Port A and B A Port A B Port B C Error lamp D Pressure control valve for pressure settings E Connector for pressure gauge A Keep mains supply line as short as possible Choose a mains supply line with the largest possible cable cross section Ensure power supply unit is stable and secure 1. In order to supply the compact hydraulic power pack with power, connect the mains plug. The rotation direction of the engine is arbitrary. Compact hydraulic power pack ready for commissioning Image 3: Mains plug and main switch B A B Mains supply line with mains plug Main switch (ON/OFF)

16 6 Commissioning Carry out the following measures prior to commissioning: compact hydraulic power pack Ensure that the tank is sealed Check quick connectors and/or screw connections for dirt, foreign bodies or damage before connecting the hydraulic lines 6.1 Inspect the compact hydraulic power pack First visual check Check hydraulic lines and ports for damage and leaks and replace if necessary Check electrical cables and plugs for damage (brittle insulation, scoured areas, etc.) and replace if necessary 6.2 Commission the compact hydraulic power pack 1. Precondition: Compact hydraulic power pack properly connected, positioned and supplied with current 2. Precondition: Ports closed. 3. Check that the housing is not damaged and that the ventilation slots are not dusty or covered. 4. Actuate the main switch The fans start up Compact hydraulic power pack is ready for operation and can be controlled with the remote control. 6.3 Set the pressure The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. 1. Precondition: Compact hydraulic power pack commissioned and inspected. Check the level of the hydraulic fluid. 2. Precondition: Ports A and B securely closed 3. Find out the necessary pressure according to the loads. Information on this can be found in the documents for the respective load. 4. Observe the maximum usable volume of the load 5. Build pressure by pressing the green button on the remote control 6. Set the correct pressure on the pressure-limiting valve (adjustable valve on the front) and check using the pressure gauge 7. Fix the wing nut to the pressure-limiting valve. The pressure setting can now not change itself. In the delivery condition, the pressure of the compact hydraulic power pack may be set to 0 bar. Pressure is set correctly 6.4 Connecting the hydraulic load The power packs, object of this manual, (without CE stamping), are only intended as drive for hydraulic torque wrenches

17 Before a tool is connected, the pressure must be set in accordance with the tool! Potential consequences: Serious injuries and/or damage to the tool. The set pressure must never exceed the maximum permissible operating pressure of the tool. Make sure that all safety measures are complied with for loads or applications that require special caution (e.g. cutting, crushing). Always keep the quick connectors on the power pack and hose side clean and check for damage or deformations! Do not connect any hydraulic lines if dirt or damage is present. Close any open quick connectors with dust covers. Even when they are not connected, the quick connectors must be aligned with the maximum pressure of the compact hydraulic power pack. 1. Precondition: Compact hydraulic power pack inspected 2. Precondition: Compact hydraulic power pack switched off 3. Precondition: Pressure for the loads set correctly. For this purpose, install the compact hydraulic power pack with closed ports in advance. 4. Connecting the load(s) (e.g. tool) The compact hydraulic power pack is ready and can supply hydraulic fluid to the load(s) In the case of new loads, monitor the oil level after initial operation

18 7 Faults 7.1 Troubleshooting table Fault Possible cause Remedy Excessive noise production Insufficient or no pressure build-up Compact hydraulic power pack can no longer be switched on Fluid level in the tank too low (foaming hydraulic fluid) Defective pump Distorted or not tension-free installed pipe work The pressure-limiting valve (adjustable valve on the front) for the pressure setting is set to 0 bar or an insufficient pressure Faulty hydraulic connections Compact hydraulic power pack switched off Defective pump Faulty valves and/or solenoids Insufficient hydraulic fluid Thermal fuse is activated: - Short-circuit - Faulty power supply unit Top-up hydraulic fluid (see Chapter 8.3, "Checking the fluid level and replacing hydraulic fluid") Remove compact hydraulic power pack from operation and replace Check pipe work and remedy acc. to the specifications of the manufacturer. Correct the setting of the pressure-limiting valve Check hydraulic connections Switch on compact hydraulic power pack and check it is operating correctly Remove compact hydraulic power pack from operation Contact ROARK TOOLS See contact data in Chapter 10, "Appendix" Remove compact hydraulic power pack from operation and replace. Check the level of hydraulic fluid Top up if necessary Check power supply unit Allow to cool off for 10 minutes Switch compact hydraulic power pack on again If the problem persists: contact ROARK TOOLS See contact data in Chapter 10, "Appendix" 7.2 Error codes for Error LED Error code Cause Remedy Slow flashing, 1 flash per second Quick flashing, 10 flashes per second Excess temperature on compact hydraulic power pack Error on hydraulic valves Press the red button on the remote control to activate afterrun cooling; do not switch off main switch; allow compact hydraulic power pack to cool down Restart compact hydraulic power pack; if the error occurs again send power pack to the Service department for inspection (see contact data in Chapter 10, "Appendix" ). Permanently on Error on pressure sensor Restart compact hydraulic power pack; if the error occurs again send compact hydraulic power pack to the Service department for inspection

19 8 Maintenance Only trained and qualified professional experts may install, operate and maintain the compact hydraulic power pack. Recommendation: Before staff work on the compact hydraulic power pack ensure they are trained and instructed by ROARK TOOLS The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. Remove the mains plug before commencing any work on the compact hydraulic power pack!

20 8.1 Maintenance schedule Interval Equipment Procedure Prior to each operation Compact hydraulic power pack Check the compact hydraulic power pack for external damage: Housing undamaged Fans not contaminated or covered Ports, valves and pressure gauges undamaged After each tool change or after one month at the latest Perform repairs or replace if necessary Hydraulic fluid Check the level of hydraulic fluid Top up if necessary. For information see Chapter 8.3, "Checking the fluid level and replacing hydraulic fluid" Fresh hydraulic fluid from the tap does not have the highest degree of purity. Fresh hydraulic fluid must therefore always be filtered in advance to ensure high quality. Do not mix hydraulic fluids. Always use hydraulic fluid that is from the same manufacturer, of the same type and with the same viscosity. Monthly Compact hydraulic power pack Check whether both fans in operation are still running. Replace the fans if necessary. Check electrical cables for damage (brittle insulation, scoured areas, kinks, material ageing, etc.) and replace if necessary Check electrical connections and connectors for corrosion and replace if necessary Check for heavy contamination. Clean if necessary. Check hydraulic fluid for sufficient purity Use a calibrated or gauged pressure measurement device to check the pressure gauge for function, correct display and damage. Replace if necessary. Perform a visual check of the hydraulic lines and pipes, fittings, loads and thecompact hydraulic power pack for the following: External leaks Externally recognisable damage (cracks, kinks, detachments, cuts, scoured areas, material fatigue, etc.) Check for hose deformation when unpressurised and when pressurised (see Releasing pressure from the hydraulic system in Chapter 8.3, "Checking the fluid level and replacing hydraulic fluid") Immediate remedy must be carried out! Every 6 months Compact hydraulic power pack Check whether the pressure-limiting valve (adjustable valve on the front) can be set correctly. Check whether all provided control circuits are functioning (see "Detailed description of function and operation" in Chapter 3, "Product description"). Check that remote control is functioning Every 1000 operating hours or every year at minimum Compact hydraulic power pack Change hydraulic fluid Recommendation in the event of heavy contamination or high levels of dust: change the air filter on the power pack tank

21 8.2 Cool off the compact hydraulic power pack using the fans The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. 1. Precondition: Compact hydraulic power pack switched on and in operation 2. Actuate the red button on the remote control The compact hydraulic power pack enters an unpressurised state. The motor stops. The fans continue to run and cool off the compact hydraulic power pack. If a compact hydraulic power pack has become very hot, it must be left to cool off for at least half an hour. 8.3 Checking the fluid level and replacing hydraulic fluid Checking the fluid level The the compact hydraulic power pack is equipped with the following devices for checking and monitoring the fluid level: Optical hydraulic fluid level indicator (A, see level indicator above in the tank filling hole) Via the optical hydraulic fluid level indicator, the hydraulic fluid level can be accurately determined when the compact hydraulic power pack is switched off. The hydraulic fluid level should cover the "max. Oil Level" marking. Image 4: Level indicator on the power pack tank A Example level indicator (here, twin version)

22 8.3.2 Change or fill up the hydraulic fluid 1. Precondition: Compact hydraulic power pack switched off and mains plug disconnected. 2. Precondition: Compact hydraulic power pack unpressurised. 3. Open the filling screw at the top of the tank. Always keep the compact hydraulic power pack clean in the area of the tank opening. A Danger of scalding! The hydraulic fluid may still be warm even an hour after the complete system has been switched off and can cause scalds. Avoid having hydraulic fluid come into contact with the skin. Do not release hydraulic fluid into the environment! Collect operating, lubrication and consumable substances in suitable containers and dispose of according to local regulations. B 4. Changing the hydraulic fluid: Provide a suitable container with sufficient capacity (> 5 litres). 5. Changing the hydraulic fluid: Open the drain screw (hexagonal socket, size 10) and drain hydraulic fluid into the container. 6. Changing the hydraulic fluid: The drain screw should be screwed on securely once again. 7. compact hydraulic power pack with hydraulic fluid until the "max. Oil Level" marking is covered. Image 5: Filling screw and drain screw A Filling screw (filling) B Drain screw (draining) Slip hazard. Puddles of hydraulic fluid can lead to serious accidents. Dirt must not enter the compact hydraulic power pack, therefore absolute cleanliness must be ensured! Screw connections must always remain completely clean. All work performed on the compact hydraulic power pack must take place in a clean environment. Clean hands and clothing prior to working on the compact hydraulic power pack. Fresh hydraulic fluid from the tap does not have the highest degree of purity. Fresh hydraulic fluid must therefore always be filtered in advance to ensure high quality. Do not mix hydraulic fluids. Always use hydraulic fluid that is from the same manufacturer, of the same type and with the same viscosity. 8. Close the tank tightly again using the filling screw 9. compact hydraulic power pack can be operated again The system is ready for operation

23 8.4 Installing spare parts Only trained and qualified professional experts may install, operate and maintain the compact hydraulic power pack. Recommendation: Before staff work on the compact hydraulic power pack ensure they are trained and instructed by ROARK TOOLS Remove the mains plug before commencing any work on the compact hydraulic power pack! Dirt must not enter the compact hydraulic power pack, therefore absolute cleanliness must be ensured! Screw connections must always remain completely clean. All work performed on the compact hydraulic power pack must take place in a clean environment. Clean hands and clothing prior to working on the compact hydraulic power pack. Replacing the pressure gauge 1. Precondition: Compact hydraulic power pack switched off and cooled off. Main plug disconnected. 2. Loosen union nut 3. Remove pressure gauge 4. Install new pressure gauge 5. Tighten union nut Compact hydraulic power pack is ready for operation again Replacing the housing 1. Precondition: Compact hydraulic power pack switched off and cooled off. Mains plug disconnected 2. Precondition: Filling screw and drain screw closed 3. Remove remote control 4. Remove mains supply line 5. Lay compact hydraulic power pack on its side such that one of the ventilation slots is pointing upwards 6. Fully loosen the housing screw connection on the underside of the compact hydraulic power pack 7. Fully loosen and remove frame with transport handle 8. Lift off the housing part at the top 9. Carefully lay the compact hydraulic power pack on the other side. In the process, the compact hydraulic power pack is laid on one of the fans. 10.Remove the other housing part Housing is dismounted 11.Lay out the new housing parts and perform the above steps in reverse order 12.Ensure that the grooves of the housing parts are precisely intertwined 13.Tightening torque for the frame with transport handle and the housing screws: 15 Nm 14.Re-attach the label and cable bracket to the new housing. The label must be re-attached, otherwise the compact hydraulic power pack cannot continue to be used for repair work at ROARK TOOLS. Housing assembled Replacing the fans

24 1. Precondition: Compact hydraulic power pack switched off and cooled off. Mains plug disconnected 2. Precondition: Filling screw and drain screw closed 3. Open the housing on the corresponding side (see "Replacing the housing") The fan to be replaced is exposed and is pointing upwards 4. Loosen the cable tie on the fan plug 5. Loosen the red lock on the plug 6. Pull the plugs apart 7. Using a pen, vertically mark the position of the fan bracket to the tank (so that the fan will be at the correct height after assembly) 8. Carefully loosen the four screws from the fan bracket 9. Remove the fan bracket including the fan 10.Dismount the fan from the fan bracket Fan dismounted 11. Position new fans and mount on the fan bracket. Ensure that the cable is located in the same position as before. 12. Place the fan bracket back on the tank and position it on the markings 13. Retighten the screws on the fan bracket (0.5 Nm). Ensure that the fan bracket is not bent or positioned incorrectly. 14. Reconnect the fan plug 15. Secure the cable with cable tie once more 16. Mount the housing once more (see "Replacing the housing") Fan replaced 8.5 Cleaning the compact hydraulic power pack The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. Remove the mains plug before commencing any work on the compact hydraulic power pack! 1. Precondition: Compact hydraulic power pack unpressurised and disconnected from voltage supply. Remove mains plug. 2. Prevent water from getting into the electrical unit! 3. Clean the compact hydraulic power pack with a cloth and compressed air, for example. Pay particular attention here to cleaning the ventilation slots and, if possible the fan. Do not use high-pressure cleaners or similar to clean the compact hydraulic power pack! Compact hydraulic power pack cleaned

25 9 Disassembly and disposal Only have the compact hydraulic power pack dismounted and disposed of by qualified professional experts. Decommission the compact hydraulic power pack as an item of old equipment: Comply with the currently applicable laws and regulations regarding disposal. The metal surfaces on the compact hydraulic power pack may become very hot during sustained operation. This applies in particular to valve blocks, the power pack tank and valves with solenoids. Allow the compact hydraulic power pack to cool down before touching the metal surfaces. ROARK TOOLS recommends the following for disposal of power packs by refuse type: Mixed scrap: valve bank, valve control, control block Electronic waste: Pump unit with motor, control, mains supply line, remote control, fans Reusable material: housing, transport handle Waste oil: hydraulic fluid If the components cannot be disposed of by separate refuse types, the entire compact hydraulic power pack may be disposed of as mixed scrap. However, the hydraulic fluid must be drained beforehand. Dispose of the hydraulic fluid as waste oil. Do not release hydraulic fluid into the environment! Collect cleaning, operating, lubricating and additive agents in suitable containers and dispose of according to local regulations

26 10.4 Contact data Roark Tools 3 Middlebury Blvd, Unit 1 Randolph, NJ USA Tel Fax info@roarktools.com Contact Customer Service Phone Fax Info@roarktools.com

27 Bill of material Schematic no.: RT H Item no.: Pos. Item no. Name Type Qty Power pack Breather filter G1/2" 1 Terminal box with control system TCW2-21/FL-01/ Remote control with cable Mains cable with flying leads Auxiliary blower Housing GH2KG Cable bracket Carry handle Manifold block 11 NPTF/MS Coupling (male) 1/4NPT (male) Coupling (female) 1/4NPT (female) Pressure gauge 800bar, 1/4NPT radial Valve block Pressure transducer DT Fitting X84 S 1 Klebeschild "elektrische Spannung" / label "electrical voltage" 01/003R 1 Klebeschild "Gebrauchsanweisung"/ label "user manual" 24/205F 1 Klebeschild "stehend verwenden" / label "upright operation" Klebeschild "heiße Oberfläche" / label "hot surface" BGV A8/W Schraubstopfen / screw plug GPN 7001/4-18 NPTF 2 Verpackung / packing Fracht (Luft) / freight (by air) 1 1 1

28 All dimensions in mm (1:5) Chameleon Portable Hydraulic Power Unit Document number 1 : : : C D E F 4 3 1:2 (1:5) Scale: 2 payment damages. Alldesign. rights reserved in the upo even ntrequest. of the grant of a patent, of utility model or Duty to return 1 RT D Drawing number Item number A2 A (1:5) carry handle crane eyes oil filling bore (colored oil level indicator inside) oil drain port plug of main cable power switch with integrated fuse error-led plug of remote control cable relief valve adjustment bar ( psi) oil port A, B 1/4-18 NPTF mains cable A B B C D E F 8 411