Atlas Copco LP 13-20 DEL PAC Maintenance and service guide

LP 13-20 DEL PAC
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 
 
ATLAS COPCO CONSTRUCTION TOOLS AB 2007-03
NACKA • SWEDEN No. 3392 5146 01
www.atlascopco.com

1 English
!"!"
INTRODUCTION ....................................................................................................................... 2
SAFETY INSTRUCTIONS ........................................................................................................ 2
Introduction to safety ....................................................................................................... 2
Safety symbols used ........................................................................................................ 2
General safety rules.......................................................................................................... 3
Protective equipment........................................................................................................ 3
MARKINGS ............................................................................................................................... 4
Identification ...................................................................................................................... 4
CE ....................................................................................................................................... 4
Safety signs on the Power Pack...................................................................................... 4
GENERAL INFORMATION....................................................................................................... 4
Parts identification ............................................................................................................ 5
OPERATING INSTRUCTIONS ................................................................................................. 6
Preparation before starting.............................................................................................. 6
Starting the engine (electric start)................................................................................... 7
Starting the engine (recoil start)...................................................................................... 7
Stopping the engine.......................................................................................................... 7
Hydraulic control and connectors................................................................................... 8
Connecting/disconnecting hoses ................................................................................... 8
How to check the hydraulic system ................................................................................ 9
Service schedules............................................................................................................. 9
Scrapping and waste disposal ...................................................................................... 10
TROUBLESHOOTING ............................................................................................................ 11
TECHNICAL DATA................................................................................................................. 12

English 2
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These operating and safety instructions must be read before operating the machine. Instruc-
tions for operation and basic maintenance are included. The purpose of this booklet is to give
the machine user an understanding of how to safely and efficiently use and maintain the ma-
chine.
%"&!"#$"!
 
To reduce the risk of serious injury to yourself or others, read these safety instructions before
using the Power Pack. Post these safety instructions at work locations, provide copies to em-
ployees, and make sure that everyone reads the safety instructions before using the Power
Pack. Comply with all safety regulations.
These instructions have been compiled from international safety standards and form part of
the operating instructions. Signs and decals that are important for your safety and the care of
the Power Pack are included with each power pack. Make sure that they are legible. New
decals can be ordered using the spare parts list.
' () 
The indications DANGER, WARNING and CAUTION, as used in the safety instructions, have
the following meanings:
SAFETY INSTRUCTIONS
•Before starting, read all instructions
carefully
•Special attention must be
paid to information
alongside this symbol
•Only use Atlas Copco genuine parts
DANGER Immediate hazard which
WILL result in serious or
fatal injury if the warning is
not observed
WARNING Hazard or hazardous
procedure which COULD
result in serious or fatal
injury if the warning is not
observed
CAUTION Hazard or hazardous
procedure which COULD
result in injury or damaged
equipment if the warning is
not observed

3 English
*) )
•The Power Pack and accessories must only be used for their purpose
•Learn how the Power Pack is switched off in the event of an emergency
•Only qualified and trained persons may operate or maintain the Power Pack
•Keep the Power Pack in a safe place out of the reach of children, locked up
•Pay attention and look at what you are doing
•Use your common sense
•Do not use the Power Pack when you are tired or under influence of drugs, alcohol or
anything else that may influence your vision, reaction or judgement
•Never leave the Power Pack turned on
•Avoid lifting a higher weight than that allowed according to your local environmental work-
ing regulations
•Regular maintenance is prerequisite for machine safety. Carefully follow the operating
instructions. Replace damaged and worn components in good time. For major service to
the Power Pack, contact your nearest authorized workshop. When cleaning mechanical
parts with solvent, make sure to comply with current health and safety regulations and
ensure sufficient ventilation
•Breathing the Power Pack’s exhaust gases can harm and possibly kill you. Do not start or
run the Power Pack in enclosed areas, even if the doors and windows are open. Start and
run the Power Pack outdoors.
•Explosions and fire can be caused by sparks from the exhaust or the electrical system.
Do not use the machine in closed areas with flammable material, vapour or dust.
+, ' 
Always use approved personal protective equipment. Operators and other staff in the prox-
imity areas where work is in progress must as a minimum use the following approved protec-
tive equipment:
•Hearing protection
When the Power Pack is used as a power source for breakers, cut-off saws and similar tools,
use the following personal protective equipment:
•Protective helmet
•Safety glass with side protection
•Respiratory protection when appropriate
•Protective gloves
•Protective boots
WARNING
The engine exhaust from this prod-
uct contains chemicals. These
chemicals could cause cancer, birth
defects or other reproductive harm.
Start and run the Power Pack out-
doors.

English 4
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

The Atlas Copco LP 13-20 DEL PAC fulfils all safety regulations in the Directive 98/37/EC.
The Atlas Copco LP 13-20 DEL PAC does not comply with the regulations in the Directive
2000/14/EC with regard to noise. The Atlas Copco LP 13-20 DEL PAC has therefore no CE
marking. The Atlas Copco LP 13-20 DEL PAC is therefore not approved for use on the EU
market.
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*!#!%#- "!
The Atlas Copco LP 13-20 DEL PAC is a hydraulic Power Pack designed for operating Atlas
Copco hydraulic breakers and other tools.
The Power Pack is fitted with a 10 HP Lombardini, air cooled, 1 cylinder 4-stroke diesel
engine with electric start. The flow of the LP 13-20 DEL PAC is 20 l.p.m.

5 English
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1 Filler cap, fuel 11 Hydraulic pump
2 Filler cap, hydraulic oil 12 Recoil start
3 Sight glass, hydraulic oil level 13 Pressure relief valve
4 Filter condition gauge 14 Foldable handles
5 Hydraulic oil filter 15 By-pass valve
6 Engine oil, dipstick 16 Air filter
7 Starting switch 17 Drain plug
8 Ignition switch OFF and ON 18 Battery
9 Stop lever 19 Throttle lever
10 Oil cooler

English 6
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The following checks should be made each time you return to the Power Pack after leaving it
for a period of time. All these checks concern the serviceability of the Power Pack. Some
concern your safety.
•Remove dirt and debris especially from around the linkage and hydraulic oil cooler
•Clean all safety decals. Replace any that are missing or cannot be read
•Inspect the Power Pack and hoses generally for signs of damaged and missing parts
•Check for fluid and fuel leakages beneath the Power Pack
•Check the security of the hinged frame
•Make sure the fuel filler cap is tightly closed
•Check the hydraulic oil level and add as necessary
•Position the Power Pack in a safe position
•Ensure that the hydraulic couplings are clean and fully serviceable
•Ensure that any hydraulic tool you plan to use is compatible with the model of the Power
Pack you are using. See the section Flow rates
•Check the engine oil level and add oil as necessary
•Ensure that you have adequate fuel for the job. Top up as necessary, taking care not to
overfill
WARNING
•Diesel and its vapours are flammable and explosive. Fire or explosion can
cause severe burns or death
•Keep naked flames away from the Power Pack
•Do not smoke while refuelling the Power Pack or working with the engine
•Do not refuel with the engine running. Turn off the engine and let the engine
cool before refuelling
•Do not overfill the tank beyond the top of the red plug inside the fuel tank filter

7 English
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)
1. Set the hydraulic by-pass valve (A)
in the OFF position
2. Set the engine speed lever (C) in the
START position
3. Turn the starting key (D) clockwise
to the START position
4. Push the start button (E) for a few
seconds
5. Remove your hand from the button,
as soon as the engine starts
6. Let the engine warm up without load
for about 3 minutes
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1. Set the hydraulic by-pass valve (A)
in the OFF position
2. Set the engine speed lever (C) in the
START position
3. Take the recoil handle (12) and pull
the rope softly until it is extended to
its full limit.
4. Let the rope rewind completely.
5. Start the engine by pulling the rope
strongly
.
6. Let the engine warm up without load
for about 3 minutes
/
1. Turn the hydraulic by-pass valve (A)
to the OFF position
2. Move the throttle lever (C) to the low
speed position and let the engine
run for about 3 minutes without load
3. Move the throttle lever (H) to the
STOP position
4. Turn the ignition key (D) counter
clockwise to the OFF position
5. Slowly pull out the recoil starting
handle (12) until resistance is felt
and leave the handle in this position.
This prevents rust from forming
while the engine is not in use
CAUTION
In order not to damage the starter,
do not activate the starter for more
than 10 seconds. Wait for about 15
seconds before the next try.
CAUTION
Do not allow the recoil starting
handle (12) to snap back against the
engine. Return it gently to prevent
damage to the starter.
WARNING
Never use any cold-starting aids
such as ether, gasoline, paint thin-
ner or other volatile liquid or gas.
H
C
A
D
E

English 8
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
The by-pass valve (F) shall be in the OFF
position when starting and in the ON
position when using the tool.
Connectors (G) and (H) are used to
connect the Power Pack to the tool as
follows:
•Connector (G) Return (female)
•Connector (H) Feed (male)
2
/
Connecting hoses
1. Prepare the Power Pack
a) Turn the by-pass valve to the
OFF position
b) Stop the engine
2. Inspect the couplings
a) Ensure that the couplings are
clean and serviceable
3. Connect the hoses
a) Attach the return line
b) Attach the feed line
c) Rotate the collar on the female
coupling to secure the coupling
4. Check the hydraulic oil level
a) Start the engine and run the
Power Pack to fill up the hy-
draulic circuit
b) Check the hydraulic oil level
Disconnecting hoses
1. Prepare the Power Pack
a) Turn the by-pass valve to the
OFF position
b) Stop the engine
2. Remove the hoses
a) Rotate the collar on the female
coupling
b) Release the return line
c) Release the feed line
Note: The couplings are unlocked by mov-
ing the collar back on the coupling
CAUTION
When stopping the engine, reduce
the load slowly. Do not stop the
engine suddenly since it may cause
the temperature to rise abnormally.
CAUTION
Ensure that any tool you plan to use
is compatible with the model of the
Power Pack you are using.
Non-compatible tools might harm
both the Power Pack and the tools.
Check the section Flow rates in this
instruction book and compare the
flow rate with the technical specifi-
cations in the instruction book for
the tool.
WARNING
Do not disconnect the hoses when
the Power Pack is running or if the
hydraulic oil is hot.
Hot hydraulic oil might cause seri-
ous burns.
Off
On
F
H
G
pressure fuel pipe

9 English

1 /// )
' 
To set or check the oil flow and the pres-
sure relief valve we recommend using the
Atlas Copco test equipment or similar test
equipment.
Part number 3371 8011 54
How to check
1. Stop the engine (see the section
Stopping the engine)
2. Connect the test equipment to the
Power Pack. Male (B) to the return
connection and female (A) to the
feed connection on the Power Pack.
Make sure that the loading valve of
the test equipment is fully open
3. Start the engine (see the section
Starting the engine – electric
start)
4. Move the by-pass valve on the
Power Pack to the ON position
5. Turn the loading valve, until the
gauge shows approx. 70 bar (1000
psi) and allow the Power Pack to
warm up for 3-4 minutes
6. Slowly close the loading valve until
the pressure gauge shows the
nominal pressure according to the
technical specifications
7. Check that the flow is according to
the flow rate in the technical specifi-
cations
Note: The inaccuracy of the reading on the
flow meter is ±2 l.p.m. (±0.5
gal/min). If the performance is not in
accordance with the technical speci-
fications for the Power Pack, please
see the section TROUBLE
SHOOTING
+/ )
A poorly maintained Power Pack is a haz-
ard. Doing regular maintenance and lubri-
cation jobs as listed in these schedules will
help keep the Power Pack in a safe work-
ing condition.
Apart from the daily jobs, the schedules
are based on the operation hours of the
Power Pack. Keep a regular check of
hours in use. Do not use a Power Pack
that is due for regular service. Rectify any
defects found during regular maintenance
before clearing the Power Pack for use.
Daily
1. Clean the Power Pack in general
2. Check fuel lines, tank, fuel cap and
fittings for cracks or leaks. Replace if
necessary
3. Check for damages
4. Check hydraulic fluid level
5. Check engine oil level
6. Check hydraulic couplings
7. Check hydraulic hoses
8. Check hydraulic oil filter
5-46 l/min. (1-12 gal/min.)
0-250 bar (0-3600 psi)
WARNING
Maintenance must be done only by
suitably qualified and competent
persons.
Before doing any maintenance,
make sure that the Power Pack is
safe and correctly sited on level
ground.

English 10
Note: Check tightness of nuts, bolts,
screws and hose fittings after the
first days of operation and thereafter
in accordance with the maintenance
schedule
Note: The engine oil should be replaced
after the first 8 hours of operation
and thereafter in accordance with
the maintenance schedule in the
engine manufacturer’s operating and
maintenance instructions
Every 3 months
1. Do the daily jobs
2. Check tightness of nuts, bolts,
screws and hose fittings
3. Clean the air cleaner element (see
engine manufacturer’s handbook)
Every 300 hours or every year
1. Do the daily jobs and jobs every 3
months
2. Change the hydraulic oil
3. Change the hydraulic oil filter
 )
Used and worn out parts must be treated
and disposed of in such a way that the
greatest possible part of them can be re-
cycled and the influence on the environ-
ment kept as low as possible
IMPORTANT
When the filter gauge needle re-
mains in the red sector (while the
engine is running idle and the oil is
service warm), the filter must be
replaced. The old filter is removed
by turning it clockwise (use a filter
strap wrench if necessary). Tilting
the Power Pack rearwards will
minimise oil spilling.
Before mounting the new filter, it is
recommended to grease the surface
of the seal with oil in order to ease
correct tightening of the filter.
WARNING
Fine jets of hydraulic oil at high
pressure can penetrate the skin. Do
not use your fingers to check for
hydraulic oil leaks. Do not put your
face close to suspected leaks. Hold
a piece of cardboard close to sus-
pected leaks and then inspect the
cardboard for signs of hydraulic oil.
If hydraulic oil penetrates your skin,
get medical help quickly.

11 English
"#$31"!*
Problem Cause Solution
No fuel Top up tank
Fuel line blocked Clear line
Fuel filter is taped Change the fuel filter
Engine turns over but does
not start
Engine malfunction Refer to engine manual
By-pass valve in the ON
position Turn valve to OFF
Engine malfunction Refer to engine manual
Engine does not turn over
or is difficult to turn
Battery uncharged Start engine with recoil start
or recharge battery
Damaged hoses Check and replace if needed
Leaking connections Check for tightness/leaks
Low hydraulic oil level
Defect hose couplings Replace couplings
Low pressure relief valve
setting Adjust valve
High back pressure Check hose system for
blockage
Poor tool performance
Worn hydraulic pump Replace pump
WARNING
Maintenance must be done only by suitably qualified and competent persons.

English 12
Problem Cause Solution
Check for loose connections
on line to pump
Make sure that the filler cap
on the tank is not loose
Frothy or creamy coloured
hydraulic oil Air or water in oil
Check that oil level is at the
top of the sight glass
Poor siting of Power Pack
causing warm air to
recirculate
Resite Power Pack for free
air circulation
Blocked oil cooler Blow cooler clean. NEVER
use a wire brush
Defect fan Replace fan
Back pressure too high Check hose system
Tool runs hot
Tool defect Check and service tool
Power Pack stops suddenly Out of fuel Top up tank
"1!"
Dimensions
Height (A) 705 mm (27.7”)
Width (B) 600 mm (23.6”)
Length (C) 745 mm (29.3”)
Weight with oil 116 kg (256 lbs)
Engine type
Engine Lombardini, air cooled, 1
cylinder 4-stroke diesel
engine with electric start
Performance 10 HP (7.5 kW) at 3600 rpm
Fuel Diesel
Starter Electric start and recoil hand
start
Hydraulic system
Circuit type Open centre
Pump type Gear pump, directly driven
from the engine crankshaft
by means of a flexible
coupling
Filtration 25µ filter in return line. Filter
by-pass valve in valve block
Cooling Thermostatically controlled
system air blast oil cooler

13 English
Fluids, lubricants, capacity and
specification
Item Capacity Fluid/lubricant
Litres (gal,US)
Engine (oil) Refer to manufacturer’s operating
and maintenance instructions.
Fuel tank 5 (1) Diesel, cetan value
more than 45
Hydraulic fluid 7 (1.85) Mobil EAL 224
or similar
Flow rates
The European Hydraulic Tool Manufactur-
ers Association (E.H.T.M.A.) has catego-
rised hydraulic power packs and tools in
terms of flow rate and working pressure.
Our LP 13-20 DEL PAC is categorised by
the E.H.T.M.A. as below:
Flow rate, l.p.m. (gal,US) 20 (5)
Nominal pressure, bar (psi) 120 (1800)
Max. pressure, bar (psi) 140 (2000)
E.H.T.M.A. category C
Note: Atlas Copco hydraulic power
packs are clearly marked with
E.H.T.M.A. categories. It is im-
portant that any tool used with the
Power Pack is of a compatible
category. If any doubt, consult
your Atlas Copco dealer.
Hose length
1 In normal ambient temperature, 0-
40°C (32-104°F), the maximum hose
length should not exceed 25 m (82 ft)
2 Normally, 7 m of Twin hoses are to be
used for the Power Pack.
Twin hose and other accessories are
shown in the spare parts list.
WARNING
The setting of the pressure relief
valve on the Power Pack can in
some cases be higher than the pre-
scribed max. pressure according to
the E.H.T.M.A. category.
A too high pressure relief valve set-
ting can harm the tool.
Readjust the pressure relief valve
on the Power Pack if the technical
specifications of the tool prescribe
a lower pressure relief valve setting
than the standard setting of the
Power Pack.
IMPORTANT
The torque of the engine is reduced
when reducing the rpm. The Power
Pack can therefore not in all cases
deliver the maximum pressure at
low rpm.