Holmatro PPU 15 User manual

OWNER’S MANUAL
PPU 15 Personal Power Unit
This pump complies with NFPA-1936, standard on powered rescue tool systems, 1999 edition.
918.269.011

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All rights reserved. You are prohibited from copying or reproducing this manual, any
materials contained herein or any portion hereof in any manner whatsoever without the
express prior written consent of Holmatro.
Holmatro reserves the right to change the contents of this manual at any time
without prior notice. Holmatro also reserves the right to change any part or component of
any machine referenced in this manual at any time without prior notice.
This manual is intended for use solely with the basic version of each piece of
equipment and each product referenced and should not be used in connection with any
modified, altered or adapted version of any piece of equipment without the express prior
written consent of Holmatro.
Additional information on adjustments, maintenance and repair of any product
contained herein will be provided upon written request of the technical department of
your supplier. If not provided, contact Holmatro directly.
EXCEPT AS EXPRESSLY SET FORTH ON THE ENCLOSED
WARRANTY CARD, HOLMATRO MAKES NO OTHER WARRANTY OR
REPRESENTATION, EITHER EXPRESS OR IMPLIED, WITH RESPECT TO
THE STATEMENTS CONTAINED HEREIN. HOLMATRO HEREBY
EXCLUDES ANY AND ALL IMPLIED WARRANTIES, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
IN NO EVENT WILL HOLMATRO BE LIABLE FOR DIRECT,
INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
ARISING OUT OF USE OF THIS MANUAL OR ANY STATEMENTS
CONTAINED THEREIN.
SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED
WARRANTIES OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT
APPLY TO YOU.
IF ANY PROVISION CONTAINED HEREIN SHALL BE UNLAWFUL, VOID
OR FOR ANY REASON UNENFORCEABLE, THEN THAT PROVISION SHALL
BE SEVERED FROM THE STATEMENT AND SHALL NOT EFFECT THE
VALIDITY AND ENFORCEABILITY OF THE REMAINING STATEMENTS
CONTAINED HEREIN.
1. Introduction

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We congratulate you on this purchase. Be sure to read and understand this user manual before using the
pump. The user manual covers all relevant aspects for safe and optimal use of this pump.
First of all check that your equipment is complete and undamaged. If it is not, notify your dealer immediately
and do not use the equipment.
This equipment is designed for use by professional, fully trained fire and rescue personnel.
This pump is suitable only for driving double-acting hydraulic rescue equipment operating with mineral oil
and designed for an allowable pressure of 720 bar. The pump allows two tool connection –one tool
operation.
Follow these instructions to ensure your safety and to keep your equipment in good condition.
2. Safety Instructions
*Study these operating instructions carefully before operating this equipment.
*Use this equipment only for jobs for which it is designed. If in doubt or not clear, be sure to consult your
supplier.
*Always carry personal protection equipment such as safety goggles, helmet, gloves, protective clothing
and safety shoes. Keep spectators at sufficient distance.
*In the event of oil leakage, stop immediately and consult the troubleshooting list.
*In the event of unfamiliar noise, vibration or other unusual behaviour, stop immediately and consult your
dealer.
*Never disconnect the quick-action couplings when the pump is in operation and when the directional
valve of the pump is in either of the "Operation" positions –1 or 2.
*Use only original Holmatro accessories and parts.
*Observe the maintenance instructions.
*Only trained service technicians certified by Holmatro are allowed to repair this equipment.
*Replace safety symbols/pictograms and/or information labels if illegible, damaged or removed.
*Always place the pump on a stable firm base which is free of protrusions or loose matter (gravel, dust)
*Use the pump at a minimum distance of 3 feet (1 metre) from buildings/structures.
*Never use the pump in an enclosed space and always ensure sufficient ventilation.
* Never inhale exhaust gas. It contains Carbon Monoxide, a colorless and odorless gas which can cause
loss of consciousness or death.
*Keep the exhaust discharge free of foreign objects.
*Never refill fuel when the engine is running.
*Never refill or even use near open fire.
*Fill the fuel tank to the sight glass level. Never overfill.
*Remove fuel spillage before starting the engine.
*Never lift the pump with chains or steel wire ropes on the carrying handle.
*The vehicle or object must be stabilized before beginning any extrication technique.
*Never use the relief device tool on pressurized hoses, valve blocks, or rescue tools that are attached to an
operating power unit. The pressure relief device is designed for use only on hoses that are disconnected
from the pump unit. (See section 5.2.3)

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3. Description
3.1 Product identification
A. Hydraulic oil fill cap H. Choke lever
B. Hydraulic oil level indicator J. Engine oil fill port
C. Directional valve K. Engine oil drain pipe
D. Valve block w/ couplings L. Fuel shutoff valve
E. Hydraulic oil drain M. Starter recoil
F. Fuel level indicator N. Engine stop button
G. Fuel cap P. Spark plug
3.2 Specifications
Power unit, model: PPU-15
Allowable operating pressure :10,500 psi (720 bar)
Fuel tank capacity :1.32 qt. (1250 cc)
Hydraulic oil contents :2.43 qt (2300 cc)
Usable hydraulic oil contents :2.1 qt. (2000 cc)
Dimensions (LxWxH) :17 ¾” x 12” x 15” (451 x 305 x 381 mm)
Weight, ready for use :35 lbs. (15.9 kg)

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4. Operation
The engine drives a two-stage radial piston pump which is able to deliver the allowable pressure given in the
table at a specific oil volume.
5. Use
5.1 Initial use (first time only)
Check the equipment for damage. Do not use the equipment if it is not in good condition. Notify the
supplier. Check whether the guarantee registration card has been supplied and filled in. This must be sent
back to Holmatro to register your warranty.
When you receive the pump it must first be made ready for operation. Perform the following actions:
*Remove the red shipping cap from the hydraulic tank and replace it with the orange breather cap.
Note: Keep the red cap and label for future shipping.
*Check the pump for external damage.
*Check whether the bottle with engine oil has been supplied.
*Fill the crankcase with the specified amount of engine oil –0.26qt (0.25 L)
*Fill the fuel tank with lead-free gasoline up to the required level in the sight glass.
*Switch the directional valve to its “Neutral –0” position.
*Switch the choke lever to its CHOKE position.
*Turn fuel shutoff valve to the “OPEN” position.
*Pull the cord until resistance is felt, let the cord be retracted and then pull fast. Repeat this if the engine
does not start the first time. This unit may require 10 to 12 pulls to start the engine when it is received
new from the factory. After the initial start-up the engine should start after 2 –3 pulls of the recoil.
*Guide the starting cord back after starting.
Switch the choke lever to “RUN” when the engine has warmed up after approx. 20 -30 sec. (begins to run
irregularly).
After verifying that the equipment operates, turn off the engine by pressing the “ENGINE STOP” button
and holding for 2-3 seconds. Turn the fuel shutoff valve to “CLOSED”.
The pump is now ready for use.
5.2 Connecting hoses and rescue equipment/use of pump.
5.2.1Checklist:
Check the engine oil level every time before use.
*Remove the dipstick and check the level. See Honda Owner’s Manual. Refill if the level is too
low. Use only the recommended engine oil described in the Honda manual.
*Check the fuel level. Fill to sight glass level if low.
*Use only lead-free gasoline.
*Do not overfill the tank.
*Immediately remove any gasoline that spills.
Caution: Check the level only when the pump is in horizontal position and the engine is switched off.
Ensure sufficient ventilation. Do not check near open fire or sparks.

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5.2.2 Coupling:
The unit is equipped with different quick-action couplings, i.e. "male" and "female".
Caution: Never connect or disconnect the quick-action coupling when the pump is in operation. Set the pump
relief valve to its "neutral" position before coupling or uncoupling hoses and/or tools.
To couple the hoses using the flat face coupler:
1. Remove the dust caps from both the male and female couplers.
2. Insert the male coupler into the female coupler and push.
3. The coupler’s locking ring (A) will move forward to show the coupler is locked.
4. Check to make sure the connection is made by pulling on the two couplers.
To uncouple the hoses using the flat face coupler:
1. Turn the locking ring (A) of the coupler ¼ turn counterclockwise when holding it in your hand
pointing away from you (direction of large arrow on coupler) and pull back on the locking ring
(direction of small arrow on coupler).
2. Remove the male coupler from the female coupler if it has not released completely.
3. Make sure you put the dust caps back onto the couplers when not in use. This is an important step to
keep dirt and foreign objects from getting into the coupler.
Clean the female coupler by removing any dirt, oil, etc. with a clean dry rag. To ensure the automatic locking
capability of the coupler, the coupler should be checked periodically and cleaned by following the simple steps
below:
1. Rinse the coupler with lukewarm water and a soft soap solution.
2. When the coupling is dry and free from water, lubricate the flat end of the coupling (B) with hydraulic oil or
by spraying WD-40 onto the end.
3. Lubricate the locking sleeve by spraying WD-40 carefully in the area (C) between the back part and the
locking sleeve.
4. Connect the nipple into the coupling and see if the locking sleeve easily turns itself to the lock position. Check
by pulling the locking sleeve straight back. The nipple should not disconnect.
5. To disconnect the nipple, turn the locking sleeve and pull it backward.
6. Repeat steps 4 and 5 a few times to assist internal lubrication of the locking sleeve.
A
B
C

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5.2.3 Pressure relief device
A pressure relief device is provided for relieving pressure in the hydraulic hose. The pressure relief
device is only used to relieve pressure in hoses caused by elevated temperatures (i.e. if the hoses are left
lying in the hot sun). Follow the operation instructions below for proper use of the relief device and
observe all warnings

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5.2.4 Starting:
*Switch the directional valve to its “Neutral –0” position.
*Switch the choke lever to its “CHOKE” position.
*Turn fuel shutoff valve to the “OPEN” position.
*Pull the cord until resistance is felt, let the cord be retracted and then pull fast. Repeat this if the
engine does not start the first time.
*Guide the starting cord back after starting.
Switch the choke lever to “RUN” when the engine has warmed up after approx. 20 -30 sec. (begins to run
irregularly).
NOTE: Start in the “RUN” position if the engine is still warm. Start in the “CHOKE” position if the engine
is cold or runs out of gasoline during operation.
5.2.5 Operating:
The directional valve can be set to either of the OPERATION positions –1 or 2 as soon as the engine is
running regularly and a tool is connected. Use the tool selector handle to choose the position for the tool
that is required to be used. The oil now flows through the discharge hose to the tool and back to the pump.
The tool can perform its function by operating the tool’s dead-man control. The pump automatically
supplies the required pressure.
5.2.6 Shutting Down:

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The pump can be shut down after completion of the work.
*Close the tool(s) being operated with the pump. (Partially re-open the tool to relieve any
pressure)
*Check that the pump relief valve is in its "neutral" position. (before uncoupling hoses).
*Press the “ENGINE STOP” button to stop the engine.
*Close the fuel valve.
*Remove any dirt from the couplings and the dust caps to prevent penetration into the hydraulic
system.
*Take the dust caps apart and place them on the power unit’s couplings.
5.2.7 Cleaning and storage
Clean the unit and any accessories used before storage.
*Clean all quick-action couplings. Ensure that the dust caps are installed
*Check the pump for external damage and/or oil leakage.
*Always store the pump in a horizontal position.
*Ensure that the pump cannot tilt during transport. This can cause leakage of hydraulic oil or gas.
5.3 Important additional user information

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Hoses
The hydraulic hoses belonging to the hydraulic system need attention. Observe the following points:
1. Do not use hoses without proper anti-kink devices and prevent kinking behind the attachment.
2. Prevent kinking of the hoses and never bend the hoses beyond their minimum bending radius -89 mm (3
½”).
3. Do not pull the hoses to move tools or pumps.
4. Prevent torsion of the hose.
5. Do not use the hoses to keep the equipment in position and especially not if the hoses are pressurized.