Operating instruction

Hydraulic unit LHP 2500

AKER WIRTH GmbH

Kölner Str. 71 - 73
41812 Erkelenz

Purchase Order No.: 4500110135-20

GHT – Giessbach Hydraulic Tools GmbH

Zum Kämpen 34
D – 41812 Erkelenz

Phone: (+49 2431) 972861

Fax: (+49 2431) 972862

Consignment No. P000232.001

Serial number: 076

Page 1 of 12
 Index

1. SAFETY INFORMATION ............................................................................................................3

2. Operating instruction Hydraulic power unit LHP 2500 ..............................................................4
2.1. General .......................................................................................................................................4
2.2. Technical specifications .............................................................................................................4
2.3. Preparation before taking into operation....................................................................................5
2.3.1. Check oil level in the oiler 3 ...............................................................................................5
2.3.2. Checking the oil level in the tank .......................................................................................5
2.3.3. Venting the installation.......................................................................................................5
2.4. Operating instruction .................................................................................................................5
2.4.1. Operating elements on the installation ...............................................................................5
2.5. Service manual ...........................................................................................................................6
2.5.1. Oil level in the tank is to be checked before each use ........................................................6
2.5.2. Oil level in the air control unit - is to be checked before each use .....................................6
2.5.3. Cleanliness of the hydraulic oil every 6 months ................................................................6
-

2.6. Possible defects ..........................................................................................................................7

2.6.1. Leakage ...............................................................................................................................7
2.6.2. Inspection of the high pressure pump .................................................................................7
2.6.3. Inspection of the high pressure valve .................................................................................7
2.6.4. Oil is leaking out of the sound absorber .............................................................................7
3. Installation and operating instruction for air hydraulic pump type SC 10 – 500 – 25 .............8
3.1. General .......................................................................................................................................8
3.2. Connection to the air supply ......................................................................................................8
3.3. Lubrication .................................................................................................................................8
3.4. Compressed air - outlet ..............................................................................................................9
3.5. Connection to the liquid - feeding conduct ................................................................................9
3.6. Connection to the pressure outlet ...............................................................................................9
3.7. Start - up of the pump ..............................................................................................................10
3.8. Possible defects ........................................................................................................................11
3.9. Guarantee .................................................................................................................................12
4. List of spare parts LHP 2500 .............................................................................. 600055
5. Hydraulics – schematic ....................................................................................... 600055

Page 2 of 12
1. SAFETY INFORMATION

SAFETY INFORMATION
READ CAREFULLY BEFORE PUTTING INTO OPERATION!

ATTENTION - HIGH PRESSURE HYDRAULICS

1. In the case of any leakage during the pressure application, the pressure is in
principle to be let off immediately. The leakage spot is to be sealed or the
defective parts are to be replaced, respectively.

2. In the case of connecting any high pressure connections, it must in principle be

observed that the latter are established excellently.

Before each putting into operation, it must be observed that the aforesaid condition is
ensured.

If the high pressure elements are connected improperly, there exists

ACCIDENT HAZARD

Page 3 of 12
2. Operating instruction Hydraulic power unit LHP 2500
Reference drawing 600055

2.1. General
The Hydraulic power unit serves to generate pressures of up to 2500 bar. The
pressure is generated by the pneumatic pump 27. The pump works according to the
differential piston - principle.

The surface of the pneumatic piston of the SC 10-500-25 pump is 440 times the size
of the surface of the hydraulic piston.

1 bar of compressed air pressure generates 440 bar of hydraulic pressure. One gets
2500 bar of statistical hydraulic pressure by 5,7 bar of compressed air pressure.

The differential piston is changed over by a reversing valve into its respective final
position, so that an oscillating effect is created. The maximum frequency should not
exceed 1 stroke/sec..

The final pressure can be adjusted by the pressure control valve 3. The pump works
audibly more slowly when the pressure increases, and it stops automatically as soon
as the manual valve 6 is closed.

See description of the pump in chapter 3, as well.

The set is equipped with a 10 L oil tank. It has a suction filter 16 on the inside. The
oil level is shown by an oil level indicator. The working pressure is indicated by the
high pressure gauge 24 and can be drained by the drain valve 23. The connection to
the device is established by a connecting nipple 20.

2.2. Technical specifications

Maximum working pressure 2500 bar
Hydraulic oil ISO VG 10, DIN 51 519
Maximum compressed air pressure 5.9 bar
Maximum amount of compressed air required 0.6 m3 / min.
Volumetric capacity of the oil tank 10 liter
Oil recommendation ISO VG 10, DIN 51519 hydraulic oil
Filling on the part of the plant Shell Morlina 10
Discharge capacity 13 l / h at 700 bar

Page 4 of 12
2.3. Preparation before taking into operation

2.3.1. Check oil level in the oiler 3

The oiler can be filled with the same oil as specified in section 2.2. In the case of
normal stroke speed, 1 drop of oil/min. should be added to the compressed air!

2.3.2. Checking the oil level in the tank

The pump may never suck in air and may never run idle!
Please always make sure to have at least a minimum amount of oil in the tank.
If possible, never drain the oil completely.

2.3.3. Venting the installation

Make sure the oil cannot leak out through the connecting pieces. Open the drain
valve 23. Connect the pump with compressed air and open the inlet valve for
compressed air 6 slowly. When the pressure reducing valve 3 is screwed in, the
pump starts to work slowly. Let the pump run at a low stroke speed for 2 - 3 minutes.
The set is ready for operation, if it builds up pressure as soon as the drain valve 23
is closed.

2.4. Operating instruction

2.4.1. Operating elements on the installation

10 air supply pressure gauge

3 air pressure controller
24 high pressure gauge
23 high pressure drain valve
20 HP connecting nipple G ¼”
6 compressed air inlet valve
26.1 oil level indicator
26 oil tank
33/34 air inlet quick connecting nipple with hose connection
32 compressed air outlet connecting coupling, spout
Pos. 24 Pos.10 Pos.6

Pos.26.1 Pos.23 Pos.20 Pos. 32 Pos. 33,34 Pos.3 Pos. 26

Page 5 of 12
2.5. Service manual
The maintenance of this installation includes a regular inspection of the following
elements:

2.5.1. Oil level in the tank is to be checked before each use

At least 2/3 of the tank should be filled in pressureless condition, in order to prevent
the installation from sucking in air in operating state.

2.5.2. Oil level in the air control unit - is to be checked before each use

The oiler of the service unit must always be filled with oil, since otherwise there is a
risk that the pump wears out early. The oiler must be adjusted in such a way that 1
drop of oil/min. is taken.

2.5.3. Cleanliness of the hydraulic oil every 6 months

-

The hydraulic oil must be checked for cleanliness and condensation water from time
to time. The oil should be changed all two years latest. At this occasion, the whole
system should be rinsed thoroughly with clean oil, and be cleaned thoroughly
afterwards.

Page 6 of 12
2.6. Possible defects

2.6.1. Leakage

In case a pressure drop occurs in the installation, the high pressure screw joints in
the installation are to be visually checked for tightness first. Before tighten, the high
pressure has to be drained off. Accident Hazard!

In case a high pressure screw joint cannot be tightened by retightening it slightly, the
screw joint is to be unscrewed and checked whether the thrust collar is located in its
right place at the end of the thread.

2.6.2. Inspection of the high pressure pump

See operating instruction of the high pressure pump, chapter 3.

2.6.3. Inspection of the high pressure valve

The screw joint is to be unscrewed on the pressureless side and it is to be checked

whether oil leaks out there when pressure is built up. If the valve is defective, it is to
be replaced.

Attention
Valves are nearly always damaged because of too strong tightening!

2.6.4. Oil is leaking out of the sound absorber

Possible reason: The oiler is adjusted too heavily, pump seal is defective
(see operating instruction of the pump, pos.8).

Page 7 of 12
3. Installation and operating instruction for air hydraulic
pump type SC 10 – 500 – 25

3.1. General
The pump is designed in such a way that the pump head can be displaced in 45°
sections in relation to the high-pressure end. This can be easily done after removal
of the 8 bolts holding the pneumatic cylinder. Before screwing down the bolts again,
one must make sure the head is in the right position and the bore holes of the two
flanges are aligned.

If this work is not carried out carefully, the pump housing will probably be damaged.
The bolts are to be tightened slowly and evenly.

3.2. Connection to the air supply

a) A service unit is to be placed as closely as possible in front of the pump. The
inlet for compressed air on the pump is equipped with a 1/2 NPT female
thread and marked with “AIR IN“.

In general, it is recommendable to work with oiled compressed air. The oiler

should be adjusted in such a way that approximately 1 drop of oil/min. is
added to the compressed air.

The pump reaches its full discharge capacity at 7 bar of the compressed air
and with a feeding pipe for the compressed air of at least 12.5 mm in inside
diameter.

b) Attention: In case a compressed air pressure of more than 7 bar up to 10 bar

is applied during the operation, one absolutely has to place a safety valve in
the compressed air line, since even short-time pressures of more than 10 bar
could damage the pump.

3.3. Lubrication

A good lubricating oil, such as SAE 10 W, should be used for the lubrication. As
mentioned in Pos. 2, approximately 1 to 2 drops of oil/min. should be added to the
compressed air.
Working with too dry compressed air leads to early wear of the packings.

Page 8 of 12
3.4. Compressed air - outlet
The compressed air-outlet has a 3/4“ fitting and is marked with “AIR OUT“. A
sound absorber should be placed on the air outlet in any case. If no sound absorber
can be used, the compressed air should be carried away through a tube with at least
20 mm in nominal diameter.

3.5. Connection to the liquid - feeding conduct

The size of the connecting thread is listed on the list of parts of the pump concerned,
and the connecting branch is marked with “FLUID IN “ on the pump.

It is extremely important that the liquid is clean. Dirt leads to increased wear and
destroys the non-return valves and the high pressure cylinder. A filter of sufficient
size, the connecting branches of which are not smaller than the inlet fittings of the
pump, should be placed ahead of the hydraulic - suction line in any case.

3.6. Connection to the pressure outlet

Size and type of the outlet are listed on the list of parts belonging to your pump. The
outlet is marked with “FLUID OUT“ on the pump.

Due to the high pressures applied during the operation, greatest care must be taken
over the manufacture of the high pressure connection.

Make sure the threads of your tube - fittings fit exactly into those of the valves. In the
case of NPT - connecting pieces, the external thread is to be taped with teflon-tape.
The threads are to be screwed down rapidly, but not too tightly.

Page 9 of 12
3.7. Start - up of the pump

Attention: Test aggregate only in coupled state with the HP tube!

a) Fill oil into the oil tank pos. 26.

b) The oiler of the service unit of pos. 3 is to be filled with oil and to be adjusted
according to the description in section 3.

c) Close compressed air inlet valve pos. 6.

d) Put the pressure reducing valve onto 1 bar. ( indication on air supply pressure
gauge pos. 10 )

e) Open the high pressure drain valve pos. 23 at the hydraulic site, so that the
pump can run idle for a short time during start – up.

f) Open compressed air inlet valve pos. 6. ( HP pump starts running )

g) Close high pressure drain valve at the hydraulic site. ( pressure rises up,
indication on high pressure gauge pos. 24 )

h) Put the pressure reducing valve pos. 3 in the position until you can read the
pressure at the high pressure gauge pos. 24 you want to have.

i) Close compressed air inlet valve pos. 6.

j) Open high pressure drain valve pos. 23 at the hydraulic site. ( pressure starts
reducing, indication on high pressure gauge pos. 24 )

k) Repeat steps e to j.

Page 10 of 12
 Attention: Please make sure there is liquid on the suction valve at the first start-up, in
order to prevent the pump from dry running. Any dry run of the hydraulic part
causes damages to the piston and the cylinder.

a) Screw in the pressure-reducing valve slowly, until the pump starts to work.
This is the case at ca 1 bar of compressed air pressure under normal
conditions. Increase the compressed air pressure up to ca 3 bar and let the
pump run until you have the impression that the system is deaerated. Usually
this is the case after 1 to 2 minutes. It is not good for the pump if it runs idle for
a longer time.

b) Check during the normal operation whether the oiler delivers the prescribed
amount of oil. The drain valve can be closed now, but only after all prior steps
have been carried out. Afterwards the required pressure is adjusted by means
of the pressure-reducing valve.

Attention: All pump types are designed for a working pressure of 1 to 7 bar.
Pneumatic pressures of up to 10 bar may be applied for a short time, but they may
never be higher!

Working with compressed air pressures of more than 10 bar is not recommended for
continuous operation. The pump of the SC 10 - 500 - 25 type should not be used for
hydraulic pressures of more than 2500 bar. Higher pressures would shorten the
service life of the pump.

3.8. Possible defects

The pump was tested in our plant and has passed the final examination in every
respect. If the pump does not operate for whatever reason, please do not try to
repair it on your own, but contact your supplier. However, before you do so, please
check the following points:

a) In case the pump works, but does not deliver any hydraulic fluid, there may be
the following reasons for it:

1. A filter or any other component part offers too much resistance inside
the suction line.

2. The pressure line is not fully open, so that the pump cannot run freely
during idle running.

Page 11 of 12
3.9. Guarantee

Guarantee on defective material and workmanship.

This guarantee shall be granted only under the following conditions:

a) The pump has been lubricated in accordance with the regulations and
pursuant to paragraph 3.3.

b) The maximum air pressure, as described in paragraph 2.1, has not been
exceeded.

c) The air and liquid supplied have been clean at any time. (The guarantee shall
not apply in case of early wear due to dirt)

d) Only appropriate liquids have been pumped.

The packings and seals are not subject to the guarantee, since their life depends
to a large extent on the cleanliness of the liquid and the compressed air.

Attention: The manufacturing plant recommends the installation of an oiler in the

compressed air line, as described in paragraph 3.2, in order to reach a
maximum service life of the packings and pumps. However, the pump
can also work without oiler, since the compressed air system has been
lubricated with a Molykote - valve grease in the manufacturing plant.

If the pump is operated without oiler, it must be regreased with Molykote - valve
grease at regular intervals. Such an interval depends to a large extent on the
working conditions. If the pump is operated with clean air, relatively free of water
and any other contaminations, up to 3 million strokes and even more can be
reached, until the pump must be regreased again.

Page 12 of 12
 page 1 of 2

Drawing No..
Parts List 600055

Assembly:
High Pressure Unit LHP 2500

Item Description Qt’y Dwg No. Material

ID

01 High Pressure Unit LHP 2000 1 600055

02 Fitting EW12 ZLREDA3C 11

03 Air control unit Typ AC30-F03 DE 1

04 Fitting ET12ZLREDA3C 2

05 Fitting EVW12LA3C 2

06 Ball valve G 3/8“ 1

07 Fitting GE12L1/2NPTA3C 1

08 Air operated hydraulic pump typ SC 10-5 1

09 Noice dampener 1

10 Pressure gauge 0 - 10 bar D = 63 1

11 Fitting MAV12ZLRA3C 1

13 Fitting GE12ZLREDA3C 1

14 Fitting GE12L3/8NPTA3C 1

15 Double nippel G ½“ AG – G 3/8“ AG 1

16 Suction filter, typ, S16 1

17 Fill- & Ventingfilter. EF 1 1

17.1 Hex nut G 1“ 1

18 HP Adapter 3/8“ NPT – ¼“, 1

900089
20 Adapter G ¼“ IG – M 16x1,5 IG 1
900090

21 Nut ¼“ 4

22 Collar ¼“ 4

23 HP – Valve Type 3 – ¼“, 1 800064

24 High pressure NG 160 – 0-2500 bar, 1

 page 2 of 2
Drawing No..
Parts List 600055

Assembly:
High Pressure Unit LHP 2500

Item Description Qt’y Dwg No. Material

ID

25 Housing 1 600054

26 Tank 1 700016

27 Protection cover 1 900091

28 Spacer AD x ID x L – 12 x 7 x 12 4

29 Labelling 1 800068

30 Roller, D = 80mm 2

31 Guide roller with stopper 2

32 Plug VSTI3/8EDA3C 1

33 Quick connect nipple G 3/8“ AG 1

34 Quick connect coupling with hose conection 9mm 1

35 Screw EN ISO 2009 – M6 x 25 - NIROSTA 4

36 Head cap screw EN ISO 4762 – M8 x 12 - NIROSTA 16

37 Screw EN ISO 1207 – M5 x 10 - NIROSTA 3

38 Head cap screw DIN 7984 – M6 x 12 - NIROSTA 6

39 Head cap screw DIN 7984 – M6 x 12 - NIROSTA 4

40 Hex nut EN ISO 10511 – M 6 - NIROSTA 4

41 Hex screw 3/8“ – 24 UNF x ¾“ lang - NIROSTA 2

42 Washer DIN 125 T1 -

43 Sleeve 12x10 – E1215/10X 14

44 Pipe 12x1

45 HP Pipe 6,35x 2mm

46 Plug VSTI1/2EDA3C 1

47 Plug VSTI1/4EDA3C 1

48 Dobble nipple G ¼“ male x M 14x1,5 male 1