Chicago Pneumatic PAC P13 Maintenance and service guide

WARNING HYDRAULIC POWER PACK
Any piece of equipment can be dangerous if not operated properly. YOU are responsible for the safe operation
of this equipment. The operator must carefully read and follow any warnings, safety signs and instructions
provided with or located on the equipment. Do not remove, defeat, deface or render inoperable any of the safety
devices or warnings on this equipment. IF any safety devices or warnings have been removed, defeated,
defaced or rendered inoperable, DO NOT USE THIS EQUIPMENT!!!
IMPORTANT SAFETY RULES TO FOLLOW.
Post this Safety and operating instruction at work locations, provide copies to employees, and make sure that
everyone reads the Safety and operating instruction before operating or servicing the machine.
In addition, the operator or the operator's employer must assess the specific risks that may be present as a result
of each use of the machine.
Safety signal words: The safety signal words Danger, Warning and Caution have the following meanings:
DANGER: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
CAUTION: Personal precautions and qualifications only qualified and trained persons may operate or maintain
the machine. They must be physically able to handle the bulk, weight, and power of the tool. Always use your
common sense and good judgment.
PERSONAL PROTECTIVE EQUIPMENT
Always use approved protective equipment. Operators and all other persons in the working area must wear
protective equipment, including at a minimum: Protective helmet, Hearing protection, Impact resistant eye
protection with side protection, Respiratory protection when appropriate, Protective gloves, Proper
protective boots, Appropriate work overall or similar clothing (not loose-fitting) that covers your arms
and legs.
WARNING Drugs, alcohol or medication Drugs, alcohol or medication may impair your judgment and powers
of concentration. Poor reactions and incorrect assessments can lead to severe accidents or death.
► Never use the machine when you are tired or under the influence of drugs, alcohol or medication.
► No person who is under the influence of drugs, alcohol or medication may operate the machine.
WARNING Hydraulic oil at high pressure Thin jets of hydraulic oil under high pressure can penetrate the skin
and cause permanent injury. Immediately consult a doctor if hydraulic oil has penetrated the skin. Never use
your fingers to check for hydraulic fluid leaks. Keep your face away from any possible leaks.
WARNING Hydraulic oil Spilled hydraulic oil can cause burns, accidents due to slippery conditions and will
also harm the environment. Take care of all spilled oil and handle it according to your safety and environmental
regulations. Never dismount the hydraulic machine when the hydraulic oil is hot.
CAUTION Skin eczema Hydraulic oil can cause eczema if it comes in contact with the skin. Avoid getting
hydraulic oil on your hands. Always use protective gloves when working with hydraulic oil. Wash hands after
contact with hydraulic oil.
CAUTION Moving parts Risk for crushed hands and fingers. Never check bores or passages with hands or
fingers. Never operate the machine when adjusting the choke control or fuel valve.
WARNING Whipping hydraulic hose Hydraulic hoses under pressure can whip uncontrollably if screws
loosen or are loosened. A whipping hydraulic hose can cause severe injuries. Depressurize the hydraulic system
before loosening the connection of a hydraulic hose. Tighten the nuts on the connections of the hydraulic hoses
to the required torque. Check that the hydraulic hose and the connections are not damaged.
If the person receiving this handout will not be the user of the equipment, forward these instructions to the
operator. IF there is any doubt as to the operation or safety of the equipment, DO NOT USE!!! CALL A
TOOL SHED IMMEDIATELY!!! FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN INJURY OR DEATH

Operation, precautions
DANGER Explosion hazard
When working on certain materials and when using
certain materials in machine parts, sparks and
ignition can occur. Explosions will lead to severe
injuries or death.
►Never operate the machine in any explosive
environment.
►Never use the machine near flammable materials,
fumes or dust.
►Make sure that there are no undetected sources
of gas or explosives.
DANGER Fuel hazard
The fuel (petrol and oil) is extremely flammable and
petrol fumes can explode when ignited, causing
serious injury or death.
►Protect your skin from contact with the fuel. If fuel
has penetrated the skin, consult a qualified health
professional.
►Never remove the filler cap, and never fill the fuel
tank when the machine is hot.
►Release the filler cap slowly to let pressure escape.
►Never overfill the fuel tank.
►Make sure the filler cap is screwed on when the
machine is used.
►Avoid spilling fuel on the machine, wipe off any
spilled fuel.
►Check regularly for fuel leaks. Never use the
machine if it is leaking fuel.
►Never use the machine in the proximity of material
that can generate sparks. Remove all hot or
spark-generating devices before starting the
machine.
►Never smoke when filling the fuel tank or when
working with the machine or servicing it.
►Only store fuel in a container that is specially
constructed and approved for the purpose.
►Consumed petrol and oil containers must be taken
care of and returned to the retailer.
►Never use your fingers to check for fluid leaks.
DANGER Exhaust gas hazard
The exhaust gas from the machine’s combustion
engine contains carbon monoxide which is
poisonous, and chemicals known to the State of
California and other authorities to cause cancer, birth
defects, or other reproductive harm. Inhalation of
exhaust fumes can cause serious injury, illness, or
death.
►Never inhale exhaust fumes.
►Never operate the machine indoors or in a poorly
ventilated area.
►Never stand in a deep hole, ditch, or similar
surrounding during operating.
73392 5183 01b | Original instructions
Safety and operating instructionsPAC P13

WARNING Dust and fume hazard
Dusts and/or fumes generated or dispersed when
using the machine may cause serious and permanent
respiratory disease, illness, or other bodily injury (for
example, silicosis or other irreversible lung disease
that can be fatal, cancer, birth defects, and/or skin
inflammation).
Some dusts and fumes created by drilling, breaking,
hammering, sawing, grinding and other construction
activities contain substances known to the State of
California and other authorities to cause respiratory
disease, cancer, birth defects, or other reproductive
harm. Some examples of such substances are:
>Crystalline silica, cement, and other masonry
products.
>Arsenic and chromium from chemically-treated
rubber.
>Lead from lead-based paints.
Dust and fumes in the air can be invisible to the
naked eye, so do not rely on eye sight to determine
if there is dust or fumes in the air.
To reduce the risk of exposure to dust and fumes,
do all of the following:
►Perform site-specific risk assessment. The risk
assessment should include dust and fumes created
by the use of the machine and the potential for
disturbing existing dust.
►Use proper engineering controls to minimize the
amount of dust and fumes in the air and to
minimize build-up on equipment, surfaces,
clothing, and body parts. Examples of controls
include: exhaust ventilation and dust collection
systems, water sprays, and wet drilling. Control
dusts and fumes at the source where possible.
Make sure that controls are properly installed,
maintained and correctly used.
►Wear, maintain and correctly use respiratory
protection as instructed by your employer and as
required by occupational health and safety
regulations. The respiratory protection must be
effective for the type of substance at issue (and if
applicable, approved by relevant governmental
authority).
►Work in a well ventilated area.
►If the machine has an exhaust, direct the exhaust
so as to reduce disturbance of dust in a dust filled
environment.
►Operate and maintain the machine as
recommended in the operating and safety
instructions
►Select, maintain and replace consumables/
inserted tools/ other accessory as recommended
in the operating and safety instructions. Incorrect
selection or lack of maintenance of consumables/
inserted tools/ other accessories may cause an
unnecessary increase in dust or fumes.
►Wear washable or disposable protective clothes
at the worksite, and shower and change into clean
clothes before leaving the worksite to reduce
exposure of dust and fumes to yourself, other
persons, cars, homes, and other areas.
►Avoid eating, drinking, and using tobacco
products in areas where there is dust or fumes.
►Wash your hands and face thoroughly as soon as
possible upon leaving the exposure area, and
always before eating, drinking, using tobacco
products, or making contact with other persons.
►Comply with all applicable laws and regulations,
including occupational health and safety
regulations.
►Participate in air monitoring, medical examination
programs, and health and safety training
programs provided by your employer or trade
organizations and in accordance with
occupational health and safety regulations and
recommendations. Consult with physicians
experienced with relevant occupational medicine.
►Work with your employer and trade organization
to reduce dust and fume exposure at the worksite
and to reduce the risks. Effective health and safety
programs, policies and procedures for protecting
workers and others against harmful exposure to
dust and fumes should be established and
implemented based on advice from health and
safety experts. Consult with experts.
►Residues of hazardous substances on the machine
can be a risk. Before undertaking any maintenance
on the machine clean it thoroughly.
WARNING Overheated power pack
The power pack can become overheated and cause
burns.
►Never close the cooler in order to warm up the
power pack quicker.
►Never run the power pack without a fan.
3392 5183 01b | Original instructions8
PAC P13Safety and operating instructions

WARNING Slipping, tripping and
falling hazards
There is a risk of slipping or tripping or falling, for
example tripping on the hoses or on other objects.
Slipping or tripping or falling can cause injury. To
reduce this risk:
►Always make sure that no hose or other object is
in your way or in any other person's way.
►Always make sure you are in a stable position with
your feet as far apart as your shoulders width and
keeping a balanced body weight.
DANGER Electrical hazard
The machine is not electrically insulated. If the
machine comes into contact with electricity, serious
injuries or death may result.
►Never operate the machine near any electric wire
or other source of electricity.
►Make sure that there are no concealed wires or
other sources of electricity in the working area.
WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the event
of an emergency.
►Stop the machine immediately in all cases of
power supply interruption.
WARNING Noise hazard
High noise levels can cause permanent and disabling
hearing loss and other problems such as tinnitus
(ringing, buzzing, whistling, or humming in the
ears). To reduce risks and prevent an unnecessary
increase in noise levels:
►Risk assessment of these hazards and
implementation of appropriate controls is
essential.
►Operate and maintain the machine as
recommended in these instructions.
►Select, maintain and replace the insertion tool as
recommended in these instructions.
►If the machine has a silencer, check that it is in
place and in good working condition.
►Always use hearing protection.
►Use damping material to prevent work pieces
from 'ringing'.
WARNING Nominal pressure
If the maximum nominal pressure for the hydraulic
machine is exceeded, it can result in material damage
and personal injury.
►Always run the hydraulic machine with a tool that
does not require a continuously higher pressure
than the stated nominal pressure. See section
"Technical data".
Maintenance, precautions
WARNING Machine modification
Any machine modification may result in bodily
injuries to yourself or others.
►Never modify the machine. Modified machines
are not covered by warranty or product liability.
►Always use original parts, insertion tools, and
accessories.
►Change damaged parts immediately.
►Replace worn components in good time.
WARNING Hot components
Under normal working conditions the engine
components, particularly the exhaust system, will
get hot. The hydraulic oil, pump, valve, and tank
can also reach high temperatures that can cause
burns.
►Never touch a hot exhaust system, hydraulic oil,
pump, valve or tank.
WARNING Accessory hazards
Accidental engagement of accessories during
maintenance or installation can cause serious
injuries, when the power source is connected.
►Never inspect, clean, install, or remove accessories
while the power source is connected.
Storage, precautions
♦Keep the machine and tools in a safe place, out
of the reach of children and locked up.
93392 5183 01b | Original instructions
Safety and operating instructionsPAC P13

Overview
To reduce the risk of serious injury or death
to yourself or others, read the Safety
instructions section found on the previous
pages of this manual before operating the
machine.
Design and function
PAC P13 is a hydraulic power pack designed for
operating hydraulic breakers and other hydraulic
machines. No other use is permitted.
PAC P13 is fitted with an 13 HP HONDA air cooled
petrol engine with a hydraulic POD system (power
on demand).
The oil flow is 20-30 ± 2 l.p.m continuous (5-8 US
gal/min).
Main parts
ABCDEF G H
I
J
K
L
M
N
O
P
Q
A. Filter condition gauge
B. Oil cooler
C. Engine oil, dipstick
D. By-pass valve
E. Filler cap, hydraulic oil
F. Filler cap, fuel
G. Ignition switch OFF and ON
H. Recoil start
I. Air filter
J. Choke control
K. Fuel tap
L. Sight glass, hydraulic oil level
M. Pressure relief valve
N. Hydraulic oil filter
O. Drain plug
P. Hydraulic pump
Q. Foldable handles
Labels
The machine is fitted with labels containing
important information about personal safety and
machine maintenance. The labels must be in such
condition that they are easy to read. New labels can
be ordered from the spare parts list.
Data plate
Made in Bulgaria
F
D
CA
B
G
E
H
A. Maximum permitted hydraulic oil flow
B. Machine type
C. Maximum relief valve setting
D. The warning symbol together with the book
symbol means that the user must read the
safety and operating instructions before the
machine is used for the first time.
E. Serial number (is also stamped in the valve
housing).
F. The CE symbol means that the machine is
EC-approved. See the EC declaration which is
delivered with the machine for more
information.
G. Year of manufacture.
H. Maximum nominal operating pressure
3392 5183 01b | Original instructions10
PAC P13Safety and operating instructions

Noise level label
WA
xxx
dB
The label indicates the guaranteed noise level
corresponding to EC-directive 2000/14/EC. See
"Technical data" for accurate noise level.
EHTMA
The European Hydraulic Tool Manufacturers
Association (EHTMA) has categorised hydraulic
power packs and tools in terms of flow rate and
working pressure.
PAC P9
20 l.p.m. (5 US gal/min)Flow rate
125 bar (1,810 psi)Nominal pressure
150 bar (2,175 psi)Max pressure
CEHTMA category
EHTMA category
The machine is clearly marked with EHTMA
categories. It is important that any power source
used is in a compatible category. If any doubt,
consult an authorised supervisor.
Safety label
Fuel label
Lifting point label
Installation
WARNING Whipping hydraulic hose
Hydraulic hoses under pressure can whip
uncontrollably if screws loosen or are loosened. A
whipping hydraulic hose can cause severe injuries.
►Depressurise the hydraulic system before
loosening the connection of a hydraulic hose.
►Tighten the nuts on the connections of the
hydraulic hoses to the required torque.
►Check that the hydraulic hose and the connections
are not damaged.
Quick-release couplings
The original hydraulic hoses are fitted with Flat-Face
quick-release couplings that are strong and easy to
clean. The quick-release couplings are fitted so that
the male connection supplies oil and the female
connection receives oil.
NOTICE Wipe all couplings clean before
connecting. Ensure that couplings are clean and
correctly engaged before operation. Failure to do so
may result in damage to the quick couplings and
cause overheating and cause foreign matter to enter
the hydraulic system.
113392 5183 01b | Original instructions
Safety and operating instructionsPAC P13

Hydraulic oil
In order to protect the environment, use of
biologically degradable hydraulic oil is
recommended. No other fluids must be used.
♦Viscosity (preferred) 20-40 cSt.
♦Viscosity (permitted) 15-100 cSt.
♦Viscosity index minimum 100.
Standard mineral or synthetic oil can be used. Make
sure to only use clean oil and filling equipment.
When the machine is used continuously, the oil
temperature will stabilise at a level which is called
the working temperature. This will, depending on
the type of work and the cooling capacity of the
hydraulic system, be between 20-40°C (68-104°F)
above the ambient temperature. At working
temperature, the oil viscosity must be within the
preferred limits. The viscosity index indicates the
connection between viscosity and temperature. A
high viscosity is therefore preferred, because the oil
can then be used within a wider temperature range.
The machine must not be used, if oil viscosity fails
to remain within the permitted area, or if the
working temperature of the oil does not fall between
20°C (68°F) and 70°C (158°F).
NOTICE The setting of the pressure relief valve on
the machine can in some cases be higher than the
prescribed maximum setting according to the
EHTMA category, see "EHTMA category". A too high
pressure relief valve setting can harm the machine
to be used. Readjust the pressure relief valve, if the
technical specifications of the machine prescribe a
lower pressure relief valve setting than the standard
setting of the machine.
Hydraulic control and
connectors
C
HG
The by-pass valve (C) must be in the OFF position
when starting and in the ON position when using
the machine.
Connectors (G) and (H) are used to connect the
power pack to the machine as follows:
♦Connector (G) = Return (female quick-release
coupling).
♦Connector (H) = Feed (male quick-release
coupling).
Hoses and connections
Ensure that the machine you plan to use is
compatible with the model of power pack being
used. Otherwise, both the power pack and the
machine might be harmed. Check the "Technical
data" in this instruction book and compare the flow
rate with the technical specifications in the
instruction book for the machine.
Connecting hoses
♦Turn the by-pass valve to the OFF position and
stop the engine/motor.
♦Make sure the couplings are clean and serviceable.
♦Attach the return line hose and the feed line hose.
♦Start the engine/motor and run the power pack
to fill up the hydraulic circuit. Check the hydraulic
oil level.
Disconnecting hoses
♦Turn the by-pass valve to the OFF position and
stop the engine/motor.
♦Remove the feed line hose and the return line
hose.
The couplings are unlocked by moving the collar
back on the coupling.
Hose length
For power packs giving a flow of 20 l.p.m. (5 US
gal/min), a maximum hose length of 21 m (69 ft) is
recommended. For power packs giving a higher
flow, a maximum hose length of 14 m (46 ft) is
recommended.
Normally, 7 m (23 ft) of Twin hose is used for the
power pack.
Twin hoses and other accessories are shown in the
spare parts list.
3392 5183 01b | Original instructions12
PAC P13Safety and operating instructions

Checking the hydraulic
system
To set or check the hydraulic oil flow and the
pressure relief valve we recommend using Chicago
Pneumatic or similar test equipment.
♦0-250 bar (0-3,600 psi)
♦5-46 l.p.m. (1-12 US gal/min)
1. Stop the engine.
2. Connect the test equipment to the power pack.
Male (B) to the return connector and female (A)
to the feed connector on the power pack.
3. Make sure that the test equipment loading valve
is fully open.
4. Start the engine/motor.
5. Move the by-pass valve on the power pack to
the on position.
6. Turn the loading valve, until the gauge shows
approximately 70 bar (1,000 psi) and allow the
power pack to warm up for 3-4 minutes.
7. Slowly close the loading valve, until the pressure
gauge shows a pressure of 100 bar (1,400 psi).
8. Check that the flow is according to the flow rate
in the technical specifications.
9. The accuracy of the reading on the flow meter
is ±2 l.p.m. (±0.5 US gal/min). If the performance
is not in accordance with the technical
specifications for the power pack, see section
"Troubleshooting".
Transport
During transport make sure the power pack is
secured. Ensure that the power pack is upright
during transportation and lifted with approved lifting
equipment.
Operation
WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the event
of an emergency.
►Stop the machine immediately in all cases of
power supply interruption.
Operating
Preparation before starting
The following checks must be made each time you
start to use the power pack. All these checks concern
the serviceability of the power pack. Some concern
your safety:
♦Clean all safety labels. Replace any that are
missing or cannot be read.
♦Inspect the power pack and hoses generally for
signs of damage.
♦Remove dirt and debris especially from the
linkages and hydraulic oil cooler.
♦Check for oil and fuel leakages beneath the power
pack.
♦Ensure that the hydraulic couplings are clean and
fully serviceable.
♦Check all fastenings.
♦Check the hydraulic oil level and add as necessary.
133392 5183 01b | Original instructions
Safety and operating instructionsPAC P13

♦Check the engine oil level and add oil as
necessary.
♦Make sure the fuel filler cap is tightly closed.
♦Place the power pack in a safe position, to prevent
tilting during operation.
♦Ensure that any machines you plan to use are
compatible with the power pack model used.
♦Ensure that you have adequate fuel for the job.
Top up as necessary, taking care not to overfill.
♦If the power pack has a recoil starter for starting
the engine, the cord must not be wound around
the operator's hand when starting the engine.
The first time the power pack is started with new
hoses, these will take approx 1.5 litres (0.4 US gal)
of oil to fill up. Add this amount of oil after the first
start-up.
Start and stop
Changing flow rate
The flow rate can be changed from 20 l.p.m (5 US
gal/min) to 30 l.p.m (8 US gal/min).
1. Loosen the screw (A).
A
2. Move the POD cylinder to the alternative mark.
3. Retighten the screw (A).
Starting the engine
1. Turn the engine switch (A) to position ON.
2. Turn on the fuel by setting the fuel control (B)
to the ON position.
3. Move the choke control (C) to the CLOSE
position. If the engine is warm, or the air
temperature is high, move the choke control to
the OPEN position.
3392 5183 01b | Original instructions14
PAC P13Safety and operating instructions

4. Set the hydraulic by-pass valve (D) to the OFF
position.
D
5. Pull out the starter cord (E) until it resists. Release
the handle so the starter cord goes back again,
and then pull the starter cord until the engine
starts.
E
6. As the engine warms up, gradually move the
choke control (C) to the OPEN position.
Before usage, the power pack must be allowed to
warm up to its working temperature for several
minutes.
Stopping the engine
1. Turn the engine switch (A) to position OFF.
2. Turn off the fuel by setting the fuel control (B)
to the OFF position.
When taking a break
♦During all breaks you must place the machine in
such a way that there is no risk for it to be
unintentionally started. Make sure to place the
machine on the ground, so that it can not fall.
♦In the event of a longer break or when leaving the
workplace: Switch off the power supply and then
bleed the machine by activating the start and stop
device.
Maintenance
Regular maintenance is a basic requirement for the
continued safe and efficient use of the machine.
Follow the maintenance instructions carefully.
♦Before starting maintenance on the machine,
clean it in order to avoid exposure to hazardous
substances. See “Dust and fume hazards”
♦Use only authorised parts. Any damage or
malfunction caused by the use of unauthorised
parts is not covered by warranty or product
liability.
♦When cleaning mechanical parts with solvent,
comply with appropriate health and safety
regulations and ensure there is satisfactory
ventilation.
♦For major service of the machine, contact the
nearest authorised workshop.
♦After each service, check that the machine's
vibration level is normal. If not, contact the nearest
authorised workshop.
Every day
Never perform maintenance when the power pack
is running.
♦Clean and inspect the machine and its functions
each day before start working.
♦Conduct a general inspection for leaks and
damage and wear.
♦Change damaged parts immediately.
♦Replace worn components in good time.
♦Never use the equipment if you suspect that it is
damaged.
♦Never strike or abuse the equipment.
♦Make sure that all the attached and related
equipment, such as hoses and POD (power on
demand) are in good condition.
153392 5183 01b | Original instructions
Safety and operating instructionsPAC P13