Larzep FU0500 User manual

HYDRAULIC PULLERS
MODELS:
FU0500 - FU1000 - FU2000 - FU3000 - FU5000 COMPLETE
FV0500-1000-2000-3000-5000 3 JAWS PULLER
FX0500-1000-2000-3000-5000 2 JAWS PULLER
FT0500-1000-2000-3000-5000 GROSS BEARING PULLER, SIMPLE
FZ0500-1000-2000-3000-5000 GROSS BEARING PULLER, COMPLETE
LARZEP,S.A.   LARZEPAUSTRALIAPTY.LTD. LARZEPGBLTD.
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48269MALLABIA,SPAIN HALLAM,VIC.3803AUSTRALIA BEDSLU74RWUNITEDKINGDOM
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2
Instruction Manual
Hydraulic Pullers
INDEX
1. ESSENTIAL SAFETY REQUIREMENTS .................................................2
2. WARRANTY ..................................................................................................3
3. TECHNICAL FEATURES............................................................................3
4. START UP...................................................................................................4-5
5. MAINTENANCE............................................................................................5
6. DECLARATION OF CONFORMITY.........................................................6
ANNEX
GENERAL DRAWING, PARTS AND DIMENSIONS
1. ESSENTIAL SAFETY REQUIREMENTS.
The LARZEP hydraulic pullers has been designed and manufactured in compliance to our quality standards and under the supervision and control that the ISO 9001
rules forces.
An inadequate use of the equipment could cause hard physical damages to the operator, as well as the machine or the treated material.
The use of the machine must be done in perfect technical conditions and in accordance to the considerations described in the present manual. The operator must know
the inherent risk to the use of high pressure hydraulic elements and must be perfectly trained in the machine working.
This equipment has been designed only for the applications described in this manual, other kind of uses are not foreseen and so, LARZEP, S.A. will not be
responsible in any case of the damages caused by an inadequate use.
The instructions must be always available for the operator. In addition to the instruction manual, the operator must be trained in the use of the machine, the rules and
standards corresponding to this kind of applications; such as: Accident prevention, environmental protection, etc.
The exposed personnel must use protective devices such as: Boots, Goggles, Gloves, Clothes, etc. depending on the application.
Boots Goggles Gloves Clothes
In every new use of the equipment, follow the START UP chapter of the present manual.
Never modify the equipment or add elements that could affect to the security without the manufacturer authorization.
The repairs, maintenance operations, etc. only will be done by specialist personnel and with original LARZEP spare parts.
Replace periodically the hydraulic hoses if they are part of the installation although they do not seem damaged.
Make the maintenance operations regularly as we explain in the manual, all this operation must be done with depressurized and disconnected equipments.
Once the operation is done, disconnect the equipment, clean and store it in a clean and safety place.
In case of see a bad function of the machine or any of the components of the installation, stop the application immediately, block the system and
if it is possible, solve the problem.
Before start the operation assure that there is not anybody exposed in the dangerous zone. Check that the machine and the accessories has not suffered damages
during the transport or installation. Always use the equipment in well-lit areas.
All the material of the installation must be in stable zone and the operator must foresee the movements of the application.
Choose the most suitable model for the application from the wide range available, and make sure that it will not exceed 80% of its nominal
capacity during normal operation.
Do not exposure the equipment to intense heat sources (welding).
Include control elements (pressure gauges) in the installation in order to enable the operator to monitor the pressure in the system and ensure that the equipment’s
nominal capacity is never exceeded. Be prepared to use safety valves and accessories if the safety criteria so demand.
The pump controls should be activated manually, as should the connections between elements equipped with quick plugs.
Clean the quick plugs before connecting and make sure the connections are perfect (first insert as far as the plug will go and then screw in by hand). A bad
connection may result in improper functioning and may even generate a safety hazard.
Install the device in such a way as to ensure that the hoses are not subjected to sharp or forced bends or thrust actions that may cause them to break.
Do not modify the device (welded parts, lengthening drive levers, etc.) without consulting the manufacturer.
Do not use the hoses for transporting the device. Use the handles on the cylinders (when appropriate) and set the pump lever to the transportation position.
When filling the pump with oil, always use LARZEP hydraulic oil or another oil of similar characteristics. Fill only to the indicated level and remember that the
cylinder piston should be retracted.
BREAK PREVENTION:
Check for perfectly tightened extenders, nuts and guillotine. Keep spindle greased and extenders centred.
When the pieces to be pulled are forced to work in bad conditions, we must reduce the maximum load applied to the puller. As standard, we’ll
reduce to half of the load.
The break will never be dangerous because there’s no risk of element projection. (Puller’s parts). This danger is fictitious; it always seems to be
dangerous due to the noise and the commotion that a big puller provokes when broken.
The unique risk when broken; and this case is improbably, is the falling down of the puller due to the lost of the supporting point. (It doesn’t
happen because generally an extender and the spindle are enough to support it.)

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Instruction Manual
Hydraulic Pullers
2. WARRANTY.
LARZEP, S.A. guarantees its products against all design and manufacturing defects for the durations of two years from the date of purchase. This guarantee does not
include the ordinary wear of both metal and non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage incurred as a result of
using a hydraulic fluid which is not recommended by LARZEP, S.A.
Please note that if the equipment is disassembled or serviced by anyone other than an authorized service dealer or by LARZEP, S.A., this guarantee is rendered null
and void.
In the event of a warranty claim, return the equipment, to LARZEP, S.A. or the authorized dealer which sold you the hydraulic equipment, LARZEP, S.A. will
repair or replace the faulty equipment, whichever is deemed most appropriate. LARZEP, S.A. shall not be held liable for any consequential damages or losses, which
may occur as a result of faulty equipment
3. TECHNICAL FEATURES.
Full equip FU0500 FU1000 FU2000 FU3000 FU5000
Hydraulic Part JH00518/1 JH01204/1 JH02205/1 JH03005/1 JH06008/1
Mechanic Part FU0500/M FU1000/M FU2000/M FU3000/M FU5000/M
Packing CU1000 CU1000 CU2000 CU3000 CU5000
PART FU0500 FU1000 FU2000 FU3000 FU5000 FV FX FZ FT
Hydraulic
Part
Cylinder SM00518 SH01204 SH02205 SH03005 SH06008 * * * *
Pump W00307 W00307 W10707 W22307 W22307 * * * *
Hose AP2015 AP2015 AP2015 AP2015 AP2020 * * * *
Gauge adaptor AZ1501 AZ1501 AZ1501 AZ1501 AZ1501 * * * *
Gauge AV10008 AV10008 AV10008 AV10008 AV10008 * * * *
Male coupling AZ3120 AZ3120 AZ3120 AZ3120 AZ3120 * * * *
FU0500/M FU1000/M FU2000/M FU3000/M FU5000/M
Mechanic
Part
Jaws FU0507 (3) FU1007 (3) FU2007 (3) FU3007 (3) FU5007 (3) 3 2
3 Jaw crosshead _ _ FU2008 FU3008 FU5008 (*) (*)
2 Jaw crosshead _ _ FU2009 FU3009 FU5009 (*)
2 and 3 jaw crosshead FU0508 FU1008 _ _ _ (*) (*)
Arms FU0510 (6) FU1010 (6) FU2010 (6) FU3010 (6) FU5010 (6) 6 4
Jaw bolts + nuts FU0511 (6) FU1011 (6) FU2011 (6) FU3011 (6) FU5011 (6) 6 4
Spindle + Handle _ FU1012 FU2012 FU3012 FU5012 * * * *
Short bolts _ 14A0330 (2) 14A0074 (2) 14A0075 (2) 14A0076 (2
)
* *
Hollow saddle _ AZ0551 AZ0552 AZ0553 AZ0556 * * * *
Bearing puller FR0500 FR1000 FR2000 FR3000 FR5000 *
Gross crosshead FU0517 FU1017 FU2017 FU3017 FU5017 * *
Blank nuts FU0518 (2) FU1018 (2) FU2018 (2) FU3018 (2) FU5018 (2) * *
Washer FU0519 (2) FU1019 (2) FU2019 (2) FU3019 (2) FU5019 (2) * *
Slides FU0520 (2) FU1020 (2) FU2020 (2) FU3020 (2) FU5020 (2) * *
Fixing nuts FU0521 (2) FU1021 (2) FU2021 (2) FU3021 (2) FU5021 (2) * *
Large extenders FU0522 (2) FU1022 (2) FU2022 (2) FU3022 (2) FU5022 (2) * *
Short extenders FU0523 (2) FU1023 (2) FU2023 (2) FU3023 (2) FU5023 (2) * *
Bearing cup puller _ FI1000 FI2000 FI3000 FI5000 *
Point protector FU0525 FU1025 FU2025 FU3025 FU5025 * * * *
Connection nuts 14B0030 (2) 14B0051 (2) 14B0029 (2) 14B0030 (2) 14B0031 (2
)
* *
Long bolts _ 14A0331 (2) 14A0098 (2) 14A0099 (2) 14A0100 (2
)
* *
Wooden case CU1000 CU1000 CU2000 CU3000 CU5000 * * * *
* Part included in set
* Part included depending on the size: 2 and 3 jaw body for 5 and 10 ton, and different bodies for 2 and 3 jaws for 20, 30 and 50 ton

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Hydraulic Pullers
4. START UP.
All models
Keep the spindle greased and cleaned.
1. Check the safety hole of the axle, if it hasn’t the hole, use the shaft protector as supporting point.
2. Hold jaws slightly by tightening clamps bolts.
3. Place jaws in the lowest hole and centred respect the spindle.
4. Apply hydraulic force. Do not exceed the 80% of the nominal capacity of the equipment.
5. When using the Bearing Cup puller, do not exceed the 70% of the nominal capacity of the equipment.
6. When using the Bearing puller, do not exceed the 50% of the nominal capacity of the equipment.
7. Never hit the spindle.
The pullers can break due to:
- Changed parts (emery stone...)
- Blowlamp used whilst pulling.
- Strikes.
- Overload.
1. The whole set delivered in a strong wooden box to protect the equipment from damages during the transport. Once the application is finished clean the
equipment and store it in the box until the next use.
2. Unpack the equipment checking that all the pieces described in the spare part sheet are in; and that have not suffered damages.
3. Connect the hose and the quick coupler, assure a perfect connection.
4. Pump several times with the lever; check the screw is slightly opened (turn left) to purge the circuit.
5. Close manually the screw (turn right). When we pump, the piston will advance. If we open the screw again, the piston returns thanks to the spring.
Models FV: 2 and 3 Jaw Puller:
Supplied with common 2 and 3 jaw body for 5 and 10 ton models.
Supplied with two different bodies for 2 jaws and 3 jaws in 20, 30 and 50 ton models.
•Keep the spindle greased and cleaned.
•Check the safety hole of the axle, if it hasn’t the hole, use the shaft protector as supporting point.
•Hold jaws slightly by tightening clamps bolts.
•Place jaws in the lowest hole and centred respect the spindle.
•The Jaws works perfectly whit a maximum angle of 10º
•Set the puller correctly, adjust better the first alignment.
•Tighten the spindle turning it.
•The jaws have to be supported completely.
•Tighten the screws of the links.
•Pump several times to pull the piece.
Models FX: 2 Jaw Puller:
As same as FV series, but with only 2 jaws.
Models FZ: Gross Bearing Complete Puller:
Gross Bearing Complete Puller includes: 2 sets of extenders of different lengths and joining nuts. The complete set also includes bearing puller (FR) and Bearing Cup
puller (FI). For constructive reasons, the 5 ton model doesn't include the FI bearing cup puller accessory.
•Keep the spindle greased and cleaned.
•Check the safety hole of the axle, if it hasn’t the hole, use the shaft protector as supporting point.
•Keep extenders centred and the crosshead fully horizontal.
•Use hydraulic pump to get pulling power.
•The Bearing Puller must be used always placing the piece to be pulled, in the flat face of the puller. NEVER THE OTHER WAY ROUND.
Models FT Gross Bearing Simple Puller:
Extender puller: supplied with two different lengths and joining nuts. Used for mounting and dismantling
As same as models FZ. It DOESN’T include Bearing and Bearing Cup Pullers.
OPERATION
To grip and pull a gear, bearing, wheel, pulley, etc. from a shaft:
In order to perform a proper pull, make sure you firmly grip the gear, bearing, wheel, etc. and apply force to shaft.
Depending on the job we offer a complete range of hydraulic pullers.

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Instruction Manual
Hydraulic Pullers
To grip and pull an internal bearing:
Place the (FI) Bearing Cup Puller inside the bearing to be pulled, check the puller is centred.
Use the internal puller FI in combination with the FZ o FT models.
To grip and pull a shaft from housing:
Fasten to the threaded male end of the shaft to pull while pushing against the housing.
Use the thread of the shaft to tighten the puller and this way pull while pushing against the housing.
How to choose the capacity of a puller
For hydraulic pullers, the maximum force exerted in tons should be 7 times the diameter of the shaft in
inches.
Shaft diam. in inches Shaft diam. in mm Cap. Puller in Tons
0" - 2" 0 - 50 20
2" - 3 1/2" 50 - 87 30
3 1/2" - 5 1/2" 87 - 136 50
5. MAINTENANCE.
oAll the maintenance operations must be done with depressurized equipment and disconnected hydraulic and electrically.
oAlways use LARZEP original spare parts.
oIn every use of the equipment make a visual inspection; check the oil level, damages in hydraulic part (scratched piston, thread, leaks, etc.), the condition
of the accessories.(hoses, couplers, etc.)
oClean the equipment after each use and keep grease critical areas: threads, shafts, inside the roller, piston, etc. before store the equipment in the box.
oIn case of frequent use, replace periodically the hoses and couplers although they do not seem damaged.
oPeriodically (at least once to the year), replace the hydraulic oil of the tank by clean oil.
oThe oil filling it’s made through the plug. Check the level with the dipstick placing the pump head down in vertical position. Use LARZEP AZ8901 oil.
oThe maintenance operations or repairs that suppose the dismantling of the mechanical parts of the equipment (jack, cylinder or pump) must be done by
specialist personnel.
PROBLEM DIAGNOSIS SOLUTION
1 The piston of the cylinder does not advance. 1.1 Excess or lack of oil in the tank. 1.1 Check the level and refill.
1.2 Clogged filter. 1.2 Dismantle the pump and clean it.
1.3 Oil leak by the admission ball of the pump. 1.3 Repair the ball seat and replace the ball.
1.4 Pressure collar of the cylinder damaged. 1.4 Replace the detent.
1.5 Cup of the pump damaged. 1.5 Replace the collar.
1.6 Pressure relief valve of the pump unrated. 1.6 Rate the valve.
1.7 A bad connection of the hose. 1.7 Check the connection.
2 The cylinder does not reach pressure. 2.1 Pressure collar of the cylinder damaged. 2.1 Replace the detent.
2.2 Leak by the ball of the action screw. 2.2 Repair the ball seat and replace the ball.
2.3
Oil leak by the admission ball of the pump. 2.3 Repair the ball seat and replace the ball.
3 The piston does not return. 3.1 Ball of the action screw pasted. 3.1 Release the screw and move the ball.
3.2 Jamming or twisted piston in the cylinder. 3.2 Repair or replace the piston.
3.3 Damaged spring in the cylinder. 3.3 Replace the spring.
3.4 Excess of oil in the tank. 3.4 Check the level.
The solutions in black must be carried out by specialist personnel.

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Instruction Manual
Hydraulic Pullers
6. DECLARATION OF CONFORMITY.

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Instruction Manual
Hydraulic Pullers
DRAWINGS, PARTS AND DIMENSIONS.
FZ & FT
FV & FX
FI
FR
Extender Puller
Capacity (Tn) A max. mm A min. mm B max. mm
5 185 40 170
10 240 35 230
20 250 135 330
30 270 180 440
50 400 230 580
Jaw puller
Capacity (Tn) A max. mm B max. mm
5 230 240
10 350 305
20 480 350
30 580 393
50 920 690
Bearing cup puller
Capacity (Tn) A max. mm B max. mm B min. mm
10 115 145 40
20 115 145 40
30 150 240 60
50 150 240 60
Bearing puller
Capacity (Tn) A max. mm A min. mm B mm D
5 110 10 130 5/8" UNF - 18
10 110 10 130 5/8" UNF - 18
20 130 25 150 5/8" UNF - 18
30 250 35 260 1" UNF - 14
50 330 50 300 1 1/4 " UNF - 12

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Instruction Manual
Hydraulic Pullers
Optional blank heads (mm)
LARZEP A B C Tn
AZ0571 34 M28x1,5 7 10
AZ0572 48 1 9/16" - 16 8 20
AZ0573 55 1 13/16"-16 9 30
AZ0575 80 2 3/4"-16 12 50
Extenders
Capacity (Tn) LARZEP A B F G H I
5 FU0522
230 16 25 20 1/2" UNF-20 5/8" UNF-18
5 FU0523
180 16 25 20 1/2" UNF-20 5/8" UNF-18
10 FU1022
460 19,5 27 25 5/8" UNF-18 3/4" UNF-18
10 FU1023
210 19,5 27 25 5/8" UNF-18 3/4" UNF-18
20 FU2022
515 19,5 30 25 5/8" UNF-18 3/4" UNF-16
20 FU2023
336 19,5 30 25 5/8" UNF-18 3/4" UNF-16
30 FU3022
592 25,4 35 40 1" UNF-14 1" UNF-14
30 FU3023
328 25,4 35 40 1" UNF-14 1" UNF-14
50 FU5022
820 31,6 43 45 1 1/4" UNF-12 1 1/4" UNF-12
50 FU5023
504 31,6 43 45 1 1/4" UNF-12 1 1/4" UNF-12
Gross crosshead
LARZEP Capacity (ton) A B C D
FU0517 5 210 35 35 15
FU1017 10 280 40 40 20
FU2017 20 370 57 57 20
FU3017 30 480 77,5 77,5 26
FU5017 50 615 97 97 32,5
Jaws
LARZEP Capacity (ton) A B C D F G H
FU0507 5 261 9 10,5 44,5 107 13 25
FU1007 10 438 14 10,5 83 156 16 26
FU2007 20 535 21 14,5 115 150 20 32
FU3007 30 680 27 18,5 125 215,5 25 42
FU5007 50 1055 34 24,5 150 500 32 51