OPERATING MANUAL

Hydraulic Unit Series

LHU-30M/A
LHU-35M/A
LHU-40M/A
LHU-60M/A

GEDORE Torque Solutions GmbH

Bertha-Benz-Strasse 12
D-71665 VAIHINGEN / ENZ
Tel.: 0 70 42 / 94 41 – 0

KEEP FOR FUTURE REFERENCE!

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Content

1.1 Scope of Delivery ......................................................................................................................................................... 3

1.2 Safety Notes ................................................................................................................................................................... 3
1.3 Symbols ........................................................................................................................................................................... 4
1.4 Emissions ........................................................................................................................................................................ 5
1.5 Possible Hazards........................................................................................................................................................... 5
1.6 Electrical Safety ............................................................................................................................................................. 6
2.0 TECHNICAL DATA......................................................................................................................................................... 6
3.0 OPERATION .................................................................................................................................................................... 6
3.1 Taking into Operation ................................................................................................................................................ 7
4.0 TECHNICAL NOTES ...................................................................................................................................................... 9
4.1 General............................................................................................................................................................................. 9
4.2 Bleed valve ..................................................................................................................................................................... 9
4.3 Transport ......................................................................................................................................................................... 9
4.4 High-Pressure Hoses ................................................................................................................................................... 9
4.5 Maintenance ................................................................................................................................................................10
4.6 Troubleshooting.........................................................................................................................................................12
5.0 REMOTE CONTROL ....................................................................................................................................................13
5.1 Manual Control (M) ...................................................................................................................................................13
5.2 Automatic Control (A) ..............................................................................................................................................13
6.0 APPENDIX .....................................................................................................................................................................15
6.1 General Image LHU-30 .............................................................................................................................................15
6.2 General Image LHU-35, LHU-40, LHU-60 ...........................................................................................................16

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1.0 GENERAL INFORMATION

1.1 Scope of Delivery

The scope of delivery of the LHU contains the following equipment:

• GEDORE Hydraulic Unit LHU oil-filled and operational
• Manual/automatic control
• Factory Calibration Certificate for pressure gauge incl. pressure setting table
• Operating instructions

1.2 Safety Notes

Carefully read all these instructions. Errors in compliance with the following
instructions may lead to serious injury.

Incorrect operation, use for other than the intended purpose and misuse pose
A HAZARD TO:
• Life and limb of the operator
• The machine and other property

KEEP THESE INSTRUCTION IN A SAFE PLACE!

Work Area

Keep your work area clean and tidy.

Untidiness and unlit working areas can lead to accidents.
Do not use the equipment in an area subject to the risk of explosion, in which flammable liquids,
gases or dusts are present.
Hydraulic units generate sparks that can ignite dust or vapour.
Keep children and other persons at a distance during use of the hydraulic unit. Distraction can cause
you to lose
control of the equipment.

Electrical safety

The mains plug of the hydraulic unit must fit properly in the socket. The plug must not be modified in
any way. Do not use any adapter in conjunction with electrically earthed devices. Unmodified plugs
and matching sockets reduce the risk of an electric shock.
Do not misuse the cable to carry or suspend the unit or to pull the plug from the socket. Keep the cable
away from heat, oil, sharp edges and moving parts of equipment.
Damaged or entangled cables increase the risk of an electric shock.

Personal safety

Be alert! Think about what you are doing and act responsibly when working with a hydraulic unit.
Do not use the unit if you are tired or under the influence of drugs, alcohol or medicines. A moment of
inat-tention when using the unit can lead to serous injuries.
Wear personal safety equipment. Wearing personal safety equipment, including non-slip work gloves,
ear defenders and protective glasses, appropriate to the type and use of the hydraulic unit, prevents
the risk of injuries.

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Avoid unintentional start-up of the hydraulic unit. Before plugging the unit into the mains, ensure that
the starting button (13.2) at the control is not pressed. Carrying the unit with your finger on the switch
or connecting the unit to the power supply while switched on can lead to accidents.
Do not overestimate your capability. Ensure you have a secure stance and that you are balanced at all
times. This allows you to control the unit better in unexpected situations.
Wear suitable clothing. Do not wear lose clothing or jewellery. Keep hair, clothing and gloves away
from moving parts. Loose clothing, jewellery and long hair can be caught by moving parts.

Careful handling and use of hydraulic units

Do not overload the unit. Use the hydraulic unit rated for the work you are carrying out. You work
better and safer in the specified power range with the properly rated hydraulic unit.
Do not use a hydraulic unit with a defective switch or control.
A hydraulic unit that cannot be switched on or off is dangerous and must be repaired.
Unplug the hydraulic unit from the mains before changing accessories or storing the hydraulic unit.
This precautionary measure prevents unintentional starting of the unit.
Keep unused hydraulic units out of the reach of children. Do not let anyone use the unit who is not
familiarized with it or has not read these instructions. Hydraulic units are dangerous if used by
inexperienced persons.
Look after the unit with care. Check that the moving parts of the unit are working properly and not
jamming. Check whether any parts are broken or damaged to such an extent that the proper operation
of the unit is impaired. Have damaged parts repaired before using the unit.

1.3 Symbols

Read the operating manual carefully

before use.

Do not dispose of hydraulic units in domestic

waste! In accordance
with the European Waste Electrical and Electronic
Equipment Directive
2002/96/EC (WEEE) and the corresponding
national legislation, waste electrical
tools must be collected separately and taken for
environmentally compatible recycling.

Protection class I / Protective ground

Sign used to identify important passages in the

text.

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1.4 Use for Intendend Purpose

The GEDORE hydraulic unit must be used exclusively to supply energy to hydraulic torque wrenches
equipped with a double-acting hydraulic system and designed for an operating pressure of 800 bar.
All hydraulic connectors in the forward flow line must be rated to an operating pressure of 800 bar.

Regular checks of the accuracy and repeatability of the screwing system must be performed by the
user.
A redundancy of the measurement is achieved via a plausibility check of the torque and angle of
rotation, carried out by the user.

Deviations of the pressure gauge must be corrected by the operator based on the pressure setting
table of the aggregate. An annual recalibration of the pressure gauge at GEDORE is recommended.

GEDORE hydraulic torque wrenches must meet these requirements

The GEDORE hydraulic unit must not be used in explosive atmospheres, for example in explosive gas,
steam or dust.
Use for anything other than the intended purpose is deemed to be improper use.
Any unauthorized conversions or modifications of the GEDORE hydraulic unit are prohibited on safety
grounds.
The operating and maintenance provisions contained in this operating manual must be complied with.

1.5 Emissions

The continuous sound pressure of the hydraulic unit as per DIN 45635 is 65 dB (A) when idling and 83
dB (A) at the maximum pressure of 800 bar.
Vibration is less than 2.5 m/s².
Oil leakage is a hazard to the environment and must therefore be safely collected or soaked up and
disposed of professionally.

1.6 Possible Hazards

Oil spraying out under high-pressure.

Ensure correct connection of the plug-in couplings and tighten the locking ring to secure against
unintentional disconnection.

Couplings and nipples of high-pressure hoses must not be modified or reversed.

If high-pressure hoses are linked together for extension purposes, use connection fittings. Keep the
plug-in couplings clean and avoid damaging the connectors. Check before use and make sure the
connection is tight.
In the event of a power failure or failure on the GEDORE hydraulic unit, switch off the unit’s motor and
put the hydraulic torque wrench in a safe place.
Risk of tilting or falling of the GEDORE hydraulic unit.
Make sure that the GEDORE hydraulic unit is in a safe position and is secured during work above
ground level.

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1.7 Electrical Safety

For use outdoors or in wet rooms, comply with the relevant EN standards!
Protect the GEDORE hydraulic unit from wet.
Stop using the GEDORE hydraulic unit if the motor housing, control box, cable or electric connections
are damaged.
Do not drag the GEDORE hydraulic unit by its cable.
Unplug the unit from the mains before carrying out any work on the electrical system.

1.8 Operator

Minimum age: 18 years

The operator must read and carefully understand the operating manual before using the hydraulic
unit.
The operator is responsible for other people in his range of work.

2.0 TECHNICAL DATA

Hydraulic oil type: ISO VG 46

Protection class: IP56

Further technical data is set out on the relevant label.

3.0 OPERATION

The GEDORE hydraulic unit may be taken into operation only if the mains supply is rated in accordance
with the voltage and frequency of the GEDORE hydraulic unit and provided that all hydraulic couplers
to the hydraulic torque wrench have been properly connected throughout and provided that the
hydraulic torque wrench complies with the minimum requirements for safe operation.

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3.1 Taking into Operation

Connecting high-pressure hoses

Connect the high-pressure hoses (Fig. 2/3) (11) to the hydraulic torque wrench and the GEDORE
hydraulic unit.
The forward flow “A” (piston side – high pressure) must have a high-pressure plug nipple and the
return flow “B” (piston-rod side – low pressure) a plug-in coupling, both manufactured by Cejn.
The hydraulic hoses (11) must be equipped in pairs with plug-in couplings (11.2) and plug nipples
(11.1) to ensure that the flow and return flow are controlled into the piston side and the piston-rod
side of the hydraulic cylinder, without the risk of reverse connection.

Fig. 2 Fig. 3

Incorrect connection of the plug-in couplings (11.2) or connection of two pairs of hoses without
intermediate
connectors (12) causes a reversal of the flow direction and of control of the hydraulic torque wrench.

Fig. 4

This would cause a malfunction of and damage to the hydraulic cylinder if the piston-rod side of the
hydraulic cylinder is not designed for high-pressure.
Even numbers of hose pairs must therefore only be connected with an intermediate connector (12).
(Fig. 4)
Take particular care to ensure that all connectors fit tightly and that hydraulic oil is able to flow. An
interruption of the return flow will cause high-pressure to build up on the piston-rod side of the
hydraulic cylinder, which can lead to the destruction of the hydraulic cylinder.

Before starting work, carry out a functional check at an operational pressure of no more than 100
bar.

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Plug the GEDORE hydraulic unit power cable into the mains socket (7).
Plug the manual control cable (6.1) into the output socket (6.2) and tighten the locking ring. (Fig. 5)

Fig. 5

The bleed valve always has to be open during the hydraulics unit operation. For this, the lever must be
vertical. (Fig. 6) Close the bleed valve only for unit transport; for this, place the lever horizontal. (Fig. 7)

Fig. 6 – Bleed valve open Fig. 7 – Bleed valve closed

When the unit is connected to the power supply, there are three signal sounds (device self-test).
Before screwing, the desired oil pressure must be set at the pressure setting (3) when the manual
control (LHU-M) is used. (Fig. 8) (see 5.1 Manual Control)

Fig. 8

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Correct Suspension

4.0 TECHNICAL NOTES

4.1 General

Check the GEDORE hydraulic unit for any possible damage before each use. Also carry out a functional
check.
When using a GEDORE hydraulic wrench, compliance with the operating manual for the wrench takes
equal priority.
When making bolted connections, comply with the manufacturer’s instructions or the design
specifications!
For safety reasons and to avoid unnecessary temperature increases, the hydraulic unit automatically
switches off after around 7 seconds when the pump is idling.
After use, keep all the screw connector system dry and clean.

4.2 Bleed valve

Close the bleed valve when transporting = lever horizontal!

Reopen the bleed valve before using = lever vertical!
( Fig. 6/7)

4.3 Transport

Do not tilt the hydraulic unit, to ensure that the hydraulic oil cannot run out.

4.4 High-Pressure Hoses

The useful life of high-pressure hoses is subject to legislation. Irrespective of the external condition, the
life for
hydraulic high-pressure hoses is a maximum 4 – 6 years. This includes a storage time of 2 years.
Before each use, high-pressure hoses and all couplings, fittings and connections must be checked to
ensure they are undamaged and in good condition.
The plug-in couplings must be checked for dirt and contamination and, if necessary, cleaned before
each use.
Dirt particles in the hydraulic system lead to faults, malfunctions and operational failure!
The high-pressure hoses must be laid in a wide curve to ensure that no accident risk is posed by
tripping, etc.
They must not be kinked, stood on or mechanically damaged.

A hydraulic hose laid in a tight curve will stretch under high-pressure. The forces generated by this
can cause damage to sensitive adjacent components. The operator must therefore take care to
ensure that the hydraulic hoses are always unencumbered, even when under pressure

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4.5 Maintenance

Fuse replacement
Loosen hexagon socket screws in the housing cover and remove housing.
Open the hexagon socket screws at the control housing cover. (Fig. 9)

Fig. 9 – Control Housing Fig. 10 – Fuse

Remove fuse (Fig. 10) carefully with pliers and replace it. (Fig. 11)

Fig. 11

Venting the hoses

At frequent dismounting / mounting of the hoses small amounts of air might enter the hoses. In order
to safeguard the correct settings of the torque function we advise to flush the hoses at every new start
as follows:
Mount the hoses according the instruction manual to the hydraulic pressure unit. Connect the free
ends of the hoses. (fig. 12) Press start-button (manual pic. 13 – 13.2; automatic pic. 16.1 – 16.2) for
about 5 seconds to start flushing the hoses. Disconnect the hoses. Start work process again according
to instruction manual.

Fig. 12

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Hydraulic oil and oil level

When the hydraulic unit is in frequent use, we recommend an annual oil change.
(For oil type and volume, see technical data 2.0 - fig. 1)
The oil level must always be between “min” (10.2) and “max.” (10.1). (Fig. 13)
If the oil level falls below the “min” mark, hydraulic oil (for type, see 2.0) must be immediately refilled.

Fig. 13 – Sight Glass – oil level

An oil change is recommended when the oil has a cloudy, milky appearance (by too much water
inclusion) or is too black (by component wear).
To change the oil, first remove the housing fixing screws and remove the cover.
Remove the bleed valve (attention! In the open position) with an open-end wrench. (Fig. 14.1/14.2)

Fig. 14.1 Fig. 14.2

Fill oil into the opening until the correct oil level is achieved, then screw in the bleed valve again.
Used hydraulic oil must be professionally disposed of. It must not be allowed to seep into the earth or
enter the sewerage system.
Immediately soak up any spilled oil with absorbent material.
Remove the plug from the mains before carrying out any maintenance on the GEDORE hydraulic unit.

GEDORE Hydraulic Units are extremely low maintenance.

We recommend having the oil change performed in the original plant if required.

Repairs

Repairs to the GEDORE hydraulic unit must be carried out only by GEDORE or by a GEDORE-authorized
service partner.

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4.6 Troubleshooting

Motor does not start

Remedy: Check the power supply, check fuses in the control case!
Motor F1 = T 8.0 A / 500V, 6.3 x 32 mm
(Spare Fuse F1 is in the control box fig. 4.5)

Hydraulic wrench activates incorrectly

The high-pressure plug-in couplings and/or high-pressure nipples on the hydraulic unit, on the
hydraulic wrench or on the hydraulic hoses are reversed.
Remedy: check the connections as per fig. 2-4 and install correctly!
Even-numbered high-pressure hose pairs must be coupled in sequence with an
intermediate connector (fig. 4).
Therefore work with odd numbers of hose pairs!

Hydraulic oil leaking from the swivel coupler of the hydraulic wrench
See “hydraulic wrench activates incorrectly”
The high-pressure couplings in the return flow are incorrectly connected, causing an impact pressure
at the
piston-rod side of the wrench.
Remedy: check the connections and secure the couplings with locking sockets!

High-pressure plug-in couplings cannot be removed

The hydraulic unit has not been relieved of the pressure after standstill.
Remedy: Press ventilation button (5) of the solenoid valve. (Fig. 15)
The valve is used to relieve the hydraulics circuit!

Fig. 15

High-pressure plug-in couplings cannot be connected

Refer to “high-pressure plug-in couplings cannot be removed”
Excess pressure in the high-pressure hose due to heating of the high-pressure hose by the sun or due
to an indoors/outdoors temperature variation.
Remedy: cool the high-pressure hoses by spraying with or immersing in water.

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5.0 REMOTE CONTROL

5.1 Manual Control (M)

After connection of the remote control to the hydraulic unit, the light diode (13.1) lights up orange.
After pressing the start button (13.2), the diode lights up green - screwing can now start.
After pressing the start button, the unit switches into forward flow - if the button is released into return
flow.
The pump runs during forward flow and switches off automatically 7 s after the start button is released.

If the light diode at the remote control lights up red, the oil temperature has risen to about
80° C. Then the unit should cool off again

Fig. 16

5.2 Automatic Control (A)

If the Automatic Control is used please read following instruction (fig. 16.1)

Fig. 16.1

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Mode of Operation:
Press and release push-button (16.2) = Motor starts
Control lamp (16.3) becomes orange

Press push-button for 5s (16.4). Control lamp (16.3) flashes = system ready for
calibration

Hold green button (16.5) until control lamp (16.3) becomes = Calibration procedure is
orange. finished

Release green button (16.5). Control lamp becomes green (16.3). = bolting operation can be
started

Hold green button (16.5) until control lamp (16.3) flashes green = required torque is
reached

Torque settings via operating pressure

The respective operating pressure for the desired torque is determined from the included torque
settings table of the respective hydraulics wrench and, as described above, set at the hydraulic unit.

Drehmomenteinstellung
The determined operating pressure must be set at the GEDORE hydraulic unit.
For this, switch on the motor, keep the start button (13.2) pressed and turn the pressure setting (3)
until the desired operating pressure is indicated at the manometer (2).

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6.0 APPENDIX

6.1 General Image LHU-30

1.1
1.2

4 5
9

6
10
7

1 Hydraulic Connection (1.1 return flow, 1.2 forward flow) 6 Remote Control connection
2 Manometer 7 Power supply connection
3 Pressure setting 8 Fan
4 Label 9 Bleed valve
5 venting button for magnetic valve 10 Sight glass for oil level

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6.2 General Image LHU-35, LHU-40, LHU-60

1.1

1.2

9
3
5

10 7

1 Hydraulic Connection (1.1 return flow, 1.2 forward flow) 6 Remote Control connection
2 Manometer 7 Power supply connection
3 Pressure ssetting 8 Fan
4 Label 9 Bleed valve
5 venting button for magnetic valve 10 Sight glass for oil level

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