Larzep Z12101 User manual

Operating Instructions Instrucciones de uso
Hydraulic Pumps pneumatically operated
Bombas hidroneumáticas
GB E
Read carefully this manual before installing and using the pump.
Lea atentamente este manual antes de la instalación y el uso de la bomba.
Z12101
Z12102/H
Z12103
Z12104 - Z12104/H
Z12107
Z12110
Z14007
Z14010
Z17007
Z19107
Z19207
193552102 - v.1 - UPD 300817

2193552102 - v.1 - UPD 300817
Fig. 3a
Fig. 1 Fig. 2
Fig. 3b

3
193552102 - v.1 - UPD 300817
AB
C
Fig.4
Fig.6Fig.5
Fig. 7 Fig. 8
Fig. 9 Fig. 10

4193552102 - v.1 - UPD 300817
Fig.11

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193552102 - v.1 - UPD 300817
INDEX
GENERAL PRECAUTIONS ........................................................................................................................................................................................6
1 TRANSPORT, STORAGE AND UNPACKING............................................................................................................................................................6
2 DESCRIPTION.............................................................................................................................................................................................................7
3 SAFETY.......................................................................................................................................................................................................................8
4 TECHNICAL SPECIFICATIONS..................................................................................................................................................................................9
5 INSTALLATION AND START-UP..............................................................................................................................................................................10
5.1 Filling the reservoir (if the pump is supplied without oil) .................................................................................................................................. 10
5.2 Start-up ............................................................................................................................................................................................................10
5.3 Connecting the oil return line (use with a double acting cylinder)....................................................................................................................10
5.4 Connecting the compressed air line.................................................................................................................................................................10
6 OPERATION..............................................................................................................................................................................................................11
7 MAINTENANCE.........................................................................................................................................................................................................12
7.1 Checking connections......................................................................................................................................................................................12
7.2 Cleaning the air filter........................................................................................................................................................................................ 12
7.3 Checking level and change of the hydraulic oil................................................................................................................................................12
7.3.1 Checking the hydraulic oil...........................................................................................................................................................................12
7.3.2 Hydraulic oil change ................................................................................................................................................................................... 12
7.4 Pump cleaning .................................................................................................................................................................................................12
7.5 Troubleshooting ...............................................................................................................................................................................................13
8 SCRAPPING AND DISPOSING OF THE PUMP.......................................................................................................................................................13
OPERATION DIAGRAM............................................................................................................................................................................................14
WARRANTY ..............................................................................................................................................................................................................14
SPARE PARTS..........................................................................................................................................................................................................14
ÍNDICE
ADVERTENCIAS GENERALES ...............................................................................................................................................................................15
1 TRANSPORTE, ALMACENAMIENTO Y DESEMBALAJE.......................................................................................................................................15
2 DESCRIPCIÓN..........................................................................................................................................................................................................16
3 SEGURIDAD..............................................................................................................................................................................................................17
4 CARACTERÍSTICAS TÉCNICAS .............................................................................................................................................................................18
5 INSTALACIÓN Y PUESTA EN FUNCIÓN.................................................................................................................................................................19
5.1 Llenado del depósito del aceite (si la bomba se suministra vacía)..................................................................................................................19
5.2 Puesta en función de la bomba ....................................................................................................................................................................... 19
5.3 Conexión del tubo de recuperación de aceite (para uso de doble efecto).......................................................................................................19
5.4 Conexión del aire comprimido ......................................................................................................................................................................... 19
6 USO .........................................................................................................................................................................................................................20
7 MANTENIMIENTO.....................................................................................................................................................................................................21
7.1 Verificación de las conexiones.........................................................................................................................................................................21
7.2 Limpieza del filtro del aire ................................................................................................................................................................................ 21
7.3 Control del nivel y sustitución del aceite hidráulico..........................................................................................................................................21
7.3.1 Control del nivel del aceite hidráulico .........................................................................................................................................................21
7.3.2 Sustitución del aceite hidráulico ................................................................................................................................................................. 21
7.4 Limpieza de la bomba......................................................................................................................................................................................21
7.5 Problemas y soluciones................................................................................................................................................................................... 22
8 DESTRUCCIÓN Y ELIMINACIÓN DE LA BOMBA...................................................................................................................................................22
ESQUEMA DE FUNCIONAMIENTO.........................................................................................................................................................................23
GARANTÍA................................................................................................................................................................................................................23
PIEZAS DE REPUESTO ...........................................................................................................................................................................................23

6193552102 - v.1 - UPD 300817
ORIGINAL INSTRUCTIONS
GENERAL PRECAUTIONS
This manual contains important safety information: read carefully before installing and using the pump.
Carefully follow the installation instructions contained in this manual.
NOTE: Most of problems with new equipment results from inappropriate operations or installations.
This manual must always accompany both the pump and the machine on which the pump is installed, even when pump and machine
or the pump alone is sold, loaned or otherwise transferred to other premises.
Before installing the pump and setting it up for operation make sure it has not been damaged during transportation: check that there are
no cracks or dents on the body and that there are no traces of oil leaks. If damage is noticed, inform the carrier of the problem imme-
diately. DO NOT INSTALL THE PUMP. Ask the manufacturer for instructions.
THE MANUFACTURER SHALL NOT BE HELD LIABLE FOR INJURY TO PEOPLE OR ANIMALS OR DAMAGE
TO PROPERTY CAUSED BY INSTALLATION AND OPERATION OF A DAMAGED PUMP.
1 - TRANSPORT, STORAGE AND UNPACKING
Given the modest weight of the pump and the type and size of the packaging, no particular transport precautions are necessary.
Is the pump set aside to be used some time after purchasing, it must be stored in a place adequately protected against weather condi-
tions at a temperature between 10° and 50° C.
Do not stack more than four single boxes containing pumps. If the pumps are delivered packed on pallets, they should be left in their
original packing and unpacked immediately prior to use.
Dispose of packing materials in accordance with the laws of the country where the pump is unpacked.

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193552102 - v.1 - UPD 300817
2 - DESCRIPTION
The device supplied is an air-powered hydraulic pump that converts a compressed air supply into a pressurized hydraulic flow (see
“Technical specifications” Chapter 4).
The pump can be utilized to power single and double acting hydraulic actuators; in the latter case a directional control valve must be
interposed between pump and user.
THE USE OF THE PUMP IN POTENTIALLY EXPLOSIVE ENVIRONMENTS, IF NOT DULY PROTECTED (PRO-
TECTION NOT SUPPLIED) IS STRICTLY FORBIDDEN. POSSIBLE ACCUMULATION OF ELECTROSTATIC
CHARGES.
All other uses of the pump shall be considered improper and can cause serious accidents. The manufac-
turer declines all liability for damages resulting from improper use of the pump.
Ask the manufacturer if in doubt about the correct installation and use of the pump.
Figure 12 shows the main components of the pump.
Fig.12a - 2.4 litres model.
Fig.12b - 5 litres model.
Treadle
(RELEASE side)
Pump body/reservoir 2.4 litres
Compressed air inlet
connection
Sight glass
Treadle
(PUMP side)
Oil pressure port
Filler plug.
Double acting cylinder connection (oil return)
Breather screw
Pump body/reservoir 5 litres
Compressed air inlet
connection
Sight glass
Treadle
(PUMP side)
Treadle
(RELEASE side)
Oil pressure port
Filler plug.
Double acting cylinder connection (oil return)
Breather screw

8193552102 - v.1 - UPD 300817
3 - SAFETY
Observe all the following safety rules. They are of the maximum importance for your own safety and the safety of others. In addition to
the indications in this chapter, observe also the prescriptions in all other sections of the manual.
DO NOT TAMPER WITH THE PROTECTIONS AND SAFETY DEVICES AND DO NOT MODIFY THE PUMP IN ANY WAY TO AVOID
CREATING POTENTIALLY HAZARDOUS SITUATIONS FOR WHICH THE OPERATOR OR THE SERVICE TECHNICIAN IS UNPRE-
PARED.
REMOVING OR TAMPERING WITH ANY OF THE SAFETY DEVICES ON THE PUMP AUTOMATICALLY INVALIDATES THE WAR-
RANTY AND ABSOLVES THE MANUFACTURER FROM ALL LIABILITY.
●The pump and the machine on which the pump is installed must be used exclusively by people over 18 years of age who have read
this manual and have a thorough knowledge of the machine and the pump.
●The pump may be used by people over the age of 16 provided they are supervised by an adult.
●Keep the pump well clear of heat sources, naked flames and sparks. Maximum operating temperature of the pump is 50° C.
●The pump may be operated with hands and feet, as long as you only press the "PUMP" and "RELEASE" zones indicated on the
pedal board.
●Work clothes must be close fitting and buttoned up. Wear the protective clothing stipulated in the place where the pump is installed.
●Do not attempt to operate the pump by standing on the treadle, use only light foot pressure to operate the pump mechanism.
●Do not arbitrarily move the pump to different locations. The pump must be used in the position designated by the manufacturer of
the machine to which it is connected.
●When connecting the pump follow the prescriptions in chapter 5 “Installation and start-up” and always use certified hoses and couplings.
For the choice of hoses and coupling, as well as hydraulic cylinders, remember that these components must be fit to safely
support the max. pump pressure.
●Before operating the pump, ensure that all connections with pipes are clamped with appropriate tools. Do not tighten exces-
sively. Connections need to be clamped safely only and without leakage. Excessive tightening may cause an early thread
breakage or the breakage of high-pressure systems already with pressures lower than the capacities declared.
●Do not exceed the hydraulic pressure indicated on the pump label and do not tamper with the internal safety valve. Working with a
higher pressure than the stated capacity may cause damage to persons or objects.
●The work area must be kept clear of obstructions so that the pump can be operated in safe conditions.
Pay attention to falling objects which could strike the pump treadle and set the pump into operation.
●The work area must be kept clean and the floor must bear no traces of oil, grease or any other slippery or corrosive substances.
●If it were necessary to disconnect the air supply hose or the hydraulic oil hose, ensure that there is no pressure by disconnecting the
pneumatic power supply and by draining the hydraulic system.
●If a hydraulic pipe breaks or needs to be disconnected, immediately cut the supply to the pump and operate the RELEASE control
valve twice in order to release all pressure. Never try to grasp with your hands a leaking pipe under pressure. The power of hydraulic
liquid jets under pressure may cause serious damage.
●Do not expose the pipe to potential dangers, such as: fire, extreme hot or cold temperatures, cutting surfaces or heavy weights. Do
not twist, turn, fold or bend the pipe to an extent that the oil flow in the pipe blocks or decreases. As one of these conditions may
cause damage to persons or objects, periodically inspect the pipe.
●Do not use the pipe to remove the equipment connected to it. This kind of stress may cause damage to the pipe, as well as persons
or objects.
●WARNING: the mechanical features of the pipe and the seal fittings must be compatible with the hydraulic liquid used and
must be fit to safely support the max. pump pressure.
The pipes must not come into contact with corrosive substances. Never paint pipes or fittings: the deterioration due to corrosion may
damage their efficiency causing unexpected breaks and damage to persons or objects.
If the pipes are uncovered and the operator is nearby them, they should be inserted into appropriate sheaths they have to
be fixed in order to protect also the fittings. In event of break, the sheath prevents oil jets under pressure.
●If the pump develops a fault, do not attempt to repair it unassisted. Disconnect the compressed air supply, switch off the machine to
which the pump is connected and call a maintenance technician.
●Before restoring the oil level, ensure that the connected cylinders are in a pulled-back position.
The oil volume that is discharged into the tank from the cylinders when are retracted, must bring the oil to the maximum level allowed.
Excessive filling or topping up, without taking this factor into account, may cause the exceeding of the tank capacity, put the tank
even under pressure and result in breaks with damage and consequent risks to persons.
●When the pump is not being used and before interrupting any hydraulic connection or working on the system in any way, turn off and
disconnect the pneumatic supply.

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193552102 - v.1 - UPD 300817
4 - TECHNICAL SPECIFICATIONS
Dimensions (mm) Pump dimensions are shown on page 2, figs. 1 & 2
Noise level 75 dB(A) / 1m
Recommended oil types SHELLTELLUS S2 V22/32 - MOBIL DTE 22/24 - CASTROLHYSPINAWS 22/32 - or equivalent
(•) With 8 bar compressed air supply pressure - (*) Different connection types are available on request
Model Z12101 Z12102/H Z12103 Z12104 Z12104/H Z12107 Z12110
Air inlet pressure (bar•) 2.8 ÷ 10
Maximum working pressure (bar•) 700 250 700 700 700 700 1000
Maximum rated flow (l/min•) 1.1 2.6 1.1 1.1 1.1 1.1 0.85
Relief valve setting (bar•) 100 200 300 400 450 700 1000
Air connection (standard*) 1/4" G
Oil connection (standard*) 3/8" NPTF
Max. weight (kg) ~ 4.65
Reservoir capacity / usable capacity (l) ~ 2.4 / 2.1
Model Z14007 Z14010 Z17007 Z19107 Z19207
Air inlet pressure (bar•) 2.8 ÷ 10
Maximum working pressure (bar•) 700 1000 700 700 700
Maximum rated flow (l/min•) 1.1 0.85 1.1 1.1 1.1
Relief valve setting (bar•) 700 1000 700 700 700
Air connection (standard*) 1/4" G
Oil connection (standard*) 3/8" NPTF
Max. weight (kg) ~ 10.2 ~ 15.9 ~ 19 ~ 36
Reservoir capacity / usable capacity (l) ~ 5 / 4.2 ~ 7 / 6.8 ~ 10 / 9.5 ~ 20 / 18.7
(•) With 8 bar compressed air supply pressure - (*) Different connection types are available on request

10 193552102 - v.1 - UPD 300817
5 - INSTALLATION AND START-UP
This chapter describes the methods of installation of the pump. The method here recommended will give excellent results. The purchaser
of the pump, i.e. the manufacturer of the machine on which the pump will be installed, may opt for different types of installation, using
brackets or any other types of accessories considered to be necessary. HOWEVER, THE ORIGINAL SHAPE AND ATTACHMENT OF
THE PUMP MUST NOT BE MODIFIED, THE PROTECTIONS APPLIED TO THE PUMP MUST NOT BE TAMPERED WITH AND NO
ACTION MUST BE TAKEN THAT COULD MAKE THE PUMP POTENTIALLY DANGEROUS. If these instructions are disregarded, the
person who is responsible for the modifications automatically assumes full liability for any accidents that may occur during use of the pump.
THE PUMP MAY BE USED IN HORIZONTAL POSITION ONLY. Ask the manufacturer about the use in vertical position.
Figure 3 on page 2 shows the drilling template to use when designing the pump baseplate (fig.3a -> 2.4 Lt. pump / fig.3b -> 5 - 7 - 10 - 20
Lt. pump).
IMPORTANT: the fixing hole depth for pump with 2.4 litre reservoir is 20 mm. This length must not be exceeded.
The fixing screws must be self-tapping type for plastic - Ø 5 - UNI 9707.
WARNING
IF THE PUMP’S CONTROLS ARE EXPOSED TO FALLING OBJECTS OR SOMETHING OTHER THAT COULD
ACCIDENTALLY HIT THEM AND CAUSE AN UNEXPECTED START-UP, IT IS NECESSARY TO INSTALL AN
APPROPRIATE PROTECTION IN ORDER TOAVOID THIS HAZARD AND RESTORE THE SYSTEM SECURITY.
THE PROTECTION MUST STAND ON TO THE CONTROL MECHANISM.
5.1 - Filling the reservoir (if the pump is supplied without oil)
The table "TECHNICAL SPECIFICATIONS" (page 9) shows the oil quantities required to fill the pump reservoir. The same table shows
the actual usable oil capacities also. Use the oil types specified in the table. The use of oil with different characteristics can result in
serious damage to the pump and render it unsuitable for use.
THE MANUFACTURER SHALL NOT BE HELD RESPONSIBLE FOR INJURY TO PEOPLE OR DAMAGE TO
PROPERTY CAUSED BY THE USE OF UNSUITABLE OR EXHAUST OIL.
DAMAGE TO THE PUMP RESULTING FROM THE ABOVE MENTIONED CAUSES IS NOT COVERED BY
WARRANTY.
●Use a slotted tip screwdriver to remove the filler plug (fig.12, page 7)
●Pour the correct quantity of oil into the reservoir (refer to the table "TECHNICAL SPECIFICATIONS", page 9)
●Clean the edges of the filler opening with a clean cloth and refit the plug, pressing it down fully.
5.2 - Start-up
THE INSTALLATION OF A DEVICE THAT INTERCEPTS THE PNEUMATIC AIR SUPPLY IS RECOMMENDED
TO RAPIDLY DISCONNECT THE PUMP FROM PNEUMATIC CIRCUIT IN CASE OF NEED OR MAINTENANCE.
BEFORE CARRYING OUT ANY CONNECTIONS, VERIFY THE CONDITION OF FITTINGS AND SEALS AND
ENSURE THREADS AND PIPES ARE CLEAN AND INTACT.
●Connect the hydraulic pressure hose (fig.12, page 7). The hose must be fitted with a 3/8" NPTF coupling after binding the thread
with Teflon tape.
●Unscrew the breather screw (fig.5, page 3) by three or four turns using an appropriate screwdriver
5.3 - Connecting the oil return line (use with a double acting cylinder)
●If the filler plug is in its extracted position (B in fig.4, page 3), press it fully down to position “A” (fig.4, page 3).
●Unscrew the threaded insert from the centre of the filler plug (C in fig.6, page 3) and connect a hose with a 3/8" NPTF fitting after
binding the thread with Teflon tape.
5.4 - Connecting the compressed air line
●Select a quick coupler that is suitable for your air line, bind the thread with Teflon tape, and then screw it into the compressed air
inlet connection (fig.12, page 7)
●The quick coupler must be connected to an air line supplying compressed air at between 2.8 and 10 bar (see "TECHNICAL SPE-
CIFICATIONS", page 9).
WARNING:
BEFORE OPERATING THE PUMP, ENSURE THATALL HYDRAULIC PIPES CONNECTIONSARE CORRECTLY
TIGHTENED . THIS OPERATION MUST BE CARRIED OUT WITH APPROPRIATE EQUIPMENT