Lifton LP 8 E User manual
LP 8 E ELECTRO-PACK
HYDRAULIC POWERPACK
OPERATING MANUAL
Serial Nos. N01561-
Issued 10/1990
Revised 01/02-02
•Introduction and Description
•Technical Data
•Instruments
•Parts Identification
•Hydraulic Settings
•Operation
•Recommended Hydraulic Oil
•Safety Precautions
•Maintenance
•Fault Location
•Spare Parts List
•EC Declaration of Conformity
•Warranty Conditions
Dealer:
BREAKERS A/S Anker Engelundsvej 3, 9200 Aalborg SV, Denmark
Introduction and Description
This manual is intended to provide operation and service information necessary for safe
and efficient use of the hydraulic powerpack LIFTON LP 8 E Electro-Pack.
Hydraulic powerpacks are of course subject to wear with service life dependent on
maintenance and severity of operation. It is therefore important to observe the following
before attempting to use the LIFTON powerpack.
Operation and service other than in accordance with the instructions given may subject
the powerpack to conditions beyond the design capability, which may result in system
failure or personal injury.
1. Before attempting to use the powerpack, carefully read the entire operating
manual and warranty conditions.
Special attention should be paid to the section “Safety Precautions”.
2. Read the operating manual for the powerpack engine.
3. Read the operating manual for the connected tools.
4. Make sure that the powerpack is correctly sized for the tool.
LIFTON LP 8 E is a hydraulic powerpack designed for the operation of LIFTON hand-
held breakers and other hydraulic tools with an oil flow of 20 l.p.m. (EHTMA Category C).
Year of manufacture: See the ID-tag.
Technical Data LIFTON LP 8 E
Measures (HxWxL)....................................................................... 585x525x680 mm
Weight Incl. oil .............................................................................................70 kg
Noise Sound pressure level 1 m (ISO 11203) ................................ LPA = 81 dB
Emission Measured sound power level (2000/14/EC)...........................LWA = 91 dB
Guaranteed sound power level (2000/14/EC)......................LWA = 104 dB
Construction Chassis/tank ........................................... Combined welded steel section
with integrated fan housing, epoxy powder coated
Frame .........................Welded stainless steel tube with foldable handles
Wheels............................................................ 230 mm solid rubber tyres
Hydraulics Flow............................................................................................20 l.p.m.
Variable by means of internal by-pass valve
Pressure relief valve ........................................Set at 140 bar, adjustable
Nominal pressure ........................................................................ 120 bar
Type .....................................................................................Open centre
Pump ................. Gear pump, directly driven from the engine crank shaft
by means of flexible coupling
Oil tank capacity ............................................................................ 5 litres
Oil level gauge.................................... Automatic low-level engine cut-off
Filtration........................................................... 25 Micron return line filter
Return line filter by-pass in valve block
Filter indicator .......................................................Return line filter gauge
Cooling system ................. Thermostatically controlled air blast oil cooler
Motor ......... Three-phase asynchronous a.c. motor, bipolar, 3 x 400 V, 5.5 kW
Instruments
Automatic Low Level Cut-Out Switch
operating on hydraulic oil level prevents motor starting if the level is too low. Correct oil
level is the top position of the sight glass.
Filter Condition Gauge
The filter condition gauge, which is mounted in the cowl, indicates the condition of the
return line filter. The filter element should be changed when the needle is in the red
sector (at working temperature).
By-Pass Valve
The by-pass valve allows change of tool during operation. Move the valve to the OFF
position for change of tool or motor start. The by-pass valve can also be used to adjust
the oil flow to the tool (setting part way between OFF and ON), if less than 20 l.p.m. is
required.
Automatic Hydraulic Oil Thermostat
The thermostat ensures that the hydraulic oil has the correct temperature under all
weather conditions.
Thermal Relay
prevents the electric motor from overheating. If the powerpack stops due to overheating,
it can be started again after a few minutes by pressing the blue button on the thermal
relay.
Parts Identification
(1) Electric motor (8) Thermal relay
(2) Filler cap, hydraulic oil (9) Oil cooler
(3) Sight glass, hydraulic oil level (10) Pump
(4) Filter condition gauge (11) Pressure relief valve
(5) Hydraulic oil filter (13) Foldable handles
(6) Electro-box (14) By-pass valve
(7) Starting switch 0, 1 and 2 (15) Hydraulic oil drain
513
Hydraulic Settings
Once correctly set, the powerpack will maintain its performance for a long time. The oil
flow and the pressure relief valve should, however, be checked once a year.
To set the oil flow and the pressure we recommend using LIFTON test equipment or
similar test equipment.
LIFTON Test Equipment Test Set-Up
(1) Connect the test equipment to the quick-release couplings ”OUT” and ”IN” on the
powerpack, ensuring that the loading valve of the test equipment is fully open.
(2) Carry out the starting procedure.
(3) Move the by-pass valve on the powerpack to ”ON”.
(4) Turn the loading valve, until the gauge shows approx. 70 bar and allow the unit to
warm up for 3-4 minutes.
(5) Slowly close the loading valve.
(6) Adjustment of the pressure relief valve (mounted to the right on the valve block be-
hind the hose connections) is carried out as follows:
(a) Use two spanners: 9/16” (15 mm) for the lock nut and 1/2” (13 mm) to adjust
the setting (”IN” to increase pressure – ”OUT” to decrease pressure).
(b) Retighten the lock nut.
5-46 l.p.m.
0-250 bar
(A)
(B)
Order No. 1801154
Powerpack
OUT IN
(7) After having adjusted to correct pressure slowly close the loading valve. The flow
indicator should not start to drop (the valve starts opening) until the pressure is
approx. 20 bar below the setting of the pressure relief valve in order to secure full
performance of the unit.
(8) After having checked and adjusted the pressure relief valve check that the flow is
correct according to the technical data. The filter condition gauge should be in the
green sector.
Operation
Starting
1. Check power supply.
2. Check hydraulic oil level (the sight glass at the side of the hydraulic tank should be
filled to its top position).
3. Clean quick-release couplings if necessary and connect the tail-hoses to the power-
pack and the tool (refer to operating manual).
4. Check that the by-pass valve is in the OFF position.
5. Turn the starting switch to position 1. If the motor does not start after approx. 5 se-
conds, turn the switch to position 2.
6. Allow the engine to warm up for 3-4 minutes.
7. The powerpack is now ready for use, and the by-pass valve can be moved to the ON
position.
Stopping
1. Turn the by-pass valve to OFF.
2. Turn starting switch to 0.
Recommended Hydraulic Oil
To protect the environment, LIFTON recommends the use of biodegradable oil.
Viscosity (ideal).................................................................................................... 20-40 cSt
Viscosity (allowable)......................................................................................... 15-1000 cSt
Viscosity index .......................................................................................................Min. 100
Standard mineral or synthetic oil can be used.
When the tool works continuously, the oil temperature will steady at a certain level called
the oil working temperature. This will, depending on the nature of the job and the cooling
capacity of the system, be 20-40°C above the air temperature. At working temperature,
the oil viscosity must be within the ideal area. The tool may not be operated, if the oil
viscosity is not within the allowable area, or if the temperature is not within ÷20°→+70°C.
The viscosity index expresses the dependence of the viscosity on the temperature. That
is the reason why a high viscosity index is preferable, so that the oil can be used within a
wide temperature interval.
Applicable oil types
-20°C -10°C 0°C 10°C 20°C 30°C 40°C 50°C 60°C 70°C
TYPE OF OIL
Viscosity
at 40°C
BP Biohyd 32 36.0 cSt
BP Biohyd 46 44.0 cSt
BP Biohyd SE 46 46.0 cSt
BP Biohyd SE 68 72.2 cSt
CASTROL Biotech HTG 32 36.8 cSt
MOBIL EAL 224 H 36.0 cSt
Q8 Holbein 46 48.4 cSt
SHELL Naturelle HF 35.0 cSt
STATOIL M 32-68 47.4 cSt
SHELL Tellus oil T46 46.0 cSt
ESSO Univis N46 45.7 cSt
TEXACO Rando oil HDZ46 51.0 cSt
MOBIL DTE 15 44.9 cSt
Permitted oil temperature
Recommended oil temperature
430
Safety Precautions
The design of the LIFTON powerpack guarantees maximum operator safety, and the
noise level has been kept as low as possible.
The following safety precautions must be taken:
1. Do not use the powerpack longer than prescribed in your local environmental work-
ing regulations. The noise load from extensive daily use may result in hearing de-
fects.
2. Always use protective earplugs, goggles, gloves, shoes and hard hat.
3. Always disconnect the hydraulic circuit before dismounting hoses or servicing the
powerpack.
3. Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fin-
gers to check for hydraulic oil leaks. Do not put your face close to suspected leaks.
Hold a piece of cardboard close to suspected leaks and then inspect the cardboard
for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help
quickly.
4. Never leave the powerpack turned on.
5. Avoid lifting the powerpack more than allowed according to your local environmental
working regulations.
6. Operation without tool may lead to damage of hydraulic parts due to development of
heat.
7. In case of oil spill, cleaning must be done according to local regulations.
8. If the powerpack is connected with new hoses, or if a new tool is being used for the
first time, the hydraulic oil level will drop and requires topping up.
9. Never add oil while motor is running.
Maintenance
Service interval
Before
starting
Every 300 hours
or yearly
Hydraulic oil A B
Hydraulic filter A B
A = Inspection, adjustment or refilling
B = Replacement
Motor
Refer to technical data in the motor manual.
Hydraulic Oil Filter
When the filter gauge needle remains in the red sector (while the powerpack is running
and the oil is warm), the filter must be replaced. The old filter is removed by turning it
clockwise (use a filter strap wrench if necessary). Tilting the powerpack rearwards will
minimise oil spill. Before mounting the new filter, it is recommended to grease the sur-
face of the seal with oil in order to ease correct tightening of the filter.
Hydraulic Oil
It is recommended to exchange the hydraulic oil after one year of operation or if the oil
becomes contaminated with water (the oil has a milky appearance). Drain off the oil by
disconnecting the drain plug from below the oil tank.
Fault Location
SYMPTOM POSSIBLE CAUSE ACTION
Insufficient power supply Check power supply
Starting switch in position 0 Turn switch to 1
Thermal relay disconnected Activate relay
Motor does not
start
Low hydraulic oil Top up
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/
defects
Poor tool
performance
Worn hydraulic pump Replace pump
Check for loose connections
on line to pump
Make sure that filler cap on 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 powerpack causing
warm air to recirculate
Resite powerpack 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
Low hydraulic oil - tripping float
switch
Add hydraulic oil
Insufficient power supply Check power supply
Pack stops
suddenly
Thermal relay disconnected Activate relay
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 1 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 1
17000040 Frame 1
27104010 Washer 3/8x35 2
37120010 Screw M10x50 4
41805507 Plastic pipe plug 4
Only for frames w/hose rack
57005307 Handle 2
67100010 Washer ø10 6
190 1807747 Loctite 495
191 1807737 Loctite 245 50 ml
Fig 2
10 7000050 Cowl 1
11 7005259 Filler cap 1
12 7100006 Washer ø6 8
13 7000401 Screw M5x16 3
14 7000400 Screw M6x12 8
15 7000402 Gauge hose L=210 mm 1
16 7000403 Seal 2
17 7005080 Filter gauge clamp + ring 1
18 7000404 Fitting 04 1
191 1807737 Loctite 245 50 ml
192 7000453 Labels 1
193 1807746 Sealing tape 1
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 2 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 3
20 7000027 Cooler guard 1
21 7123206 Screw M6x12 8
22 7005068 Oil cooler 1
23 7000405 Rubber feet 2
24 7000572 Tank/chassis 1
25 7005612 Wheel 2
Only available in pairs
26 7000505 Seal 1
27 7000221 Washer ø32/ø22/10 2
28 7000028 Seal 1
29 7000437 Float switch 1
29 a7000253 Seal f/float switch 1
30 7005087 Rubber grommet 2
32 7005072 Sight glass 1
39 7000407 Washer ø6 16
40 7110006 Nut M6 8
41 7100010 Washer ø10 4
42 7000406 Screw M10x14 2
44 1803707 Fitting 06 1
45 7016375 Seal ring 3/8" 1
46 1803047 ID-tag 1
191 1807737 Loctite 245 50 ml
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 3 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 4
50 7003387 Pump plate 1
51 7001438 Fan inlet ring 1
52 7000573 Fan 1
53 7000574 Spacer ring 1
54 8001304 Electro-Motor 1
55 1806702 Nut M10 2
56 7100010 Washer ø10 2
57 7000436 Screw M10x70 4
58 1820721 Screw M8x20 4
59 7000415 Screw M8x10 1
60 7000575 Engine half coupling 1
61 7005169 Coupling spider 1
62 7005170 Pump half coupling 1
63 7111008 Nut M8 4
64 7000469 Washer ø8 4
65 7000477 Screw M8x35 4
66 7000581 Pump 7.9 CC 1
Seal kit, woodruff key, lock washer (pos. 80) and
nut (pos. 81) are available as spares for the
hydraulic pump. Please state serial No. of the
powerpack and make of the pump.
67 7000469 Washer ø8 4
68 7121508 Screw M8x16 4
69 7100010 Washer ø10 4
70 7000576 Electro-box complete 1
71 1817726 Screw M6x15 4
72 7000577 Rear plate 1
73 7000469 Washer ø8 4
74 7000580 Spacer 2
75 7000582 Distance bushing 1
76 7000413 Screw M4x4 1
191 1807737 Loctite 245 50 ml
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 4 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 5
80 7222311 Adaptor 12-06 2
81 7016019 Seal ring ø19 2
82 1817740 Fitting 02 w/seal 1
83 7016125 Seal ring 1/8" 1
84 7001189 Valve block 1
84 7001198 *Valve block 1
85 7005075 Filter 25 Mikron 1
86 7005082 Thermostat complete 1
87 7100016 Washer 5/8 1
89 7005263 Filter adaptor 1
91 7004084 Thermostat end cap 1
92 7005128 Locking ring M36x1.5 1
93 7122008 Screw M8x30 3
94 7111008 Nut M8 3
96 7004050 Clamp plate 1
97 7004051 Seal 1
98 7004134 Handle 1
99 7000416 O-Ring ø9.6x2.4 1
100 7013604 Roll pin ø4x16 2
101 7013604 Roll pin ø4x16 1
102 7001190 Spool 1
103 7005172 Pressure relief valve 1
104 7005113 Seal ring ø5/ø9x1 1
105 7121005 Screw M5x10 1
106 7016375 Seal ring 3/8" 2
107 1805137 Q.R. coupling 06 female 1
108 1805733 Protective cap 1/2" female 1
109 1805138 Q.R. coupling 06 male 1
110 1805728 Protective cap 3/8" male 1
111 7000418 Screw M5x8 1
112 7000433 *Coupling 08-08 Hitrak 1
113 1805714 *Seal ring 1/2" 1
115 7005113 Seal ring ø5/ø9x1 1
116 7000435 Fitting 02 1
117 7004747 By-pass valve 1
118 7000588 Filter washer 1
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 5 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
119 7001191 Valve block complete 1
Pos. 80-93/98-116
191 1807737 Loctite 245 50 ml
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 6 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 6
170 7000789 Hose clip ø19/12 4
171 7000426 Cooler return line 1
172 7000432 Adaptor 08-06 1
173 1805714 Seal ring 1/2" 2
174 7000429 Cooler feed line 1
175 7000433 Coupling 08-08 Hitrak 1
176 7000430 Suction hose L=185 mm 1
177 7000427 Coupling 08-08 Hitrak 2
178 7000431 High pressure hose 1
179 7016019 Seal ring ø19 1
180 7000790 Hose clip ø21/15 2
191 1807737 Loctite 245 50 ml
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Spare Parts List LIFTON LP 8 E Electro-Pack Powerpack Page 7 of 7
23 29-08-2000 Serial-No. N01561-
* Only from serial No. N15918
Pos. Part No. Description Quantity
Fig 7
120 7000608 Thermal relay 1
121 7000609 Automatic cutout 1
122 7000610 Phase control 1
123 7000612 Auxiliary relay 1
124 7000611 Contactor 1
125 7000613 1-0-2 switch 1
126 7000614 Transformer 1
127 7000615 Tap 1
128 7000616 Box bottom 1
129 7000617 Cover 1
130 7000618 Mounting plate 1
131 7000620 Cable 2
132 7000621 Screw 4
133 7000622 Socket 1
134 7000497 Seal kit 1
Subject to alterations without further notice
Breakers A/S * P.O. Box 7010 * DK-9200 Aalborg SV * Tel: +45 98 18 17 22 * Fax: + 45 98 18 89
Breakers A/S Denmark Phone: +45 98 181722 Fax: +45 98 188922
LP 8 E Electro-Pack drivstation Fig. 1 + 2 23 4-7800007
LP 8 E Electro-Pack Powerpack 4-7800065b
LP 8 E Electro-Pack Kraftstation
Breakers A/S Denmark Phone: +45 98 181722 Fax: +45 98 188922
LP 8 E Electro-Pack drivstation Fig. 3 23 4-7800066a
LP 8 E Electro-Pack Powerpack
LP 8 E Electro-Pack Kraftstation
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