LARZEP, S.A. LARZEP AUSTRALIA PTY. LTD.

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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

(+34)943174166 e-mail: hydraulic@larzep.cm ; cmercial@larzep.cm www.larzep.cm LARZEP GB LTD. 3 Cmmerce Way- Leightn Buzzard BEDS LU7 4RW UNITED KINGDOM Tel. (+44)1525377819 - Fax.

1 HYDRAULIC PULLERS MODELS: FU FU FU FU FU5000 COMPLETE FV JAWS PULLER FX JAWS PULLER FT GROSS BEARING PULLER, SIMPLE FZ GROSS BEARING PULLER, COMPLETE LARZEP, S.A. Avenida Urtiaga, MALLABIA (Vizcaya). SPAIN Tel. (+34) Fax. (+34) hydraulic@larzep.cm ; cmercial@larzep.cm LARZEP GB LTD. 3 Cmmerce Way- Leightn Buzzard BEDS LU7 4RW UNITED KINGDOM Tel. (+44) Fax. (+44) sales-gb@larzep.cm LARZEP AUSTRALIA PTY. LTD. Unit19, Westpl Drive Hallam. VICTORIA 3803 AUSTRALIA Tel. (+613) Fax. (+613) sales@larzep.cm.au LARZEP HYDRAULICS (INDIA) PVT.LTD. 201, Vardhaman Chamber - 1, G-Blck, Cmmunity Center. VIKAS PURI.NEW DELHI INDIA Tel. (+91) Fax. (+91) inf@larzep.in

2 Instructin Manual INDEX 1. ESSENTIAL SAFETY REQUIREMENTS WARRANTY TECHNICAL FEATURES START UP MAINTENANCE DECLARATION OF CONFORMITY...6 ANNEX GENERAL DRAWING, PARTS AND DIMENSIONS 1. ESSENTIAL SAFETY REQUIREMENTS. The LARZEP hydraulic pullers has been designed and manufactured in cmpliance t ur quality standards and under the supervisin and cntrl that the ISO 9001 rules frces. An inadequate use f the equipment culd cause hard physical damages t the peratr, as well as the machine r the treated material. The use f the machine must be dne in perfect technical cnditins and in accrdance t the cnsideratins described in the present manual. The peratr must knw the inherent risk t the use f high pressure hydraulic elements and must be perfectly trained in the machine wrking. This equipment has been designed nly fr the applicatins described in this manual, ther kind f uses are nt freseen and s, LARZEP, S.A. will nt be respnsible in any case f the damages caused by an inadequate use. The instructins must be always available fr the peratr. In additin t the instructin manual, the peratr must be trained in the use f the machine, the rules and standards crrespnding t this kind f applicatins; such as: Accident preventin, envirnmental prtectin, etc. The expsed persnnel must use prtective devices such as: Bts, Gggles, Glves, Clthes, etc. depending n the applicatin. Bts Gggles Glves Clthes In every new use f the equipment, fllw the START UP chapter f the present manual. Never mdify the equipment r add elements that culd affect t the security withut the manufacturer authrizatin. The repairs, maintenance peratins, etc. nly will be dne by specialist persnnel and with riginal LARZEP spare parts. Replace peridically the hydraulic hses if they are part f the installatin althugh they d nt seem damaged. Make the maintenance peratins regularly as we explain in the manual, all this peratin must be dne with depressurized and discnnected equipments. Once the peratin is dne, discnnect the equipment, clean and stre it in a clean and safety place. In case f see a bad functin f the machine r any f the cmpnents f the installatin, stp the applicatin immediately, blck the system and if it is pssible, slve the prblem. Befre start the peratin assure that there is nt anybdy expsed in the dangerus zne. Check that the machine and the accessries has nt suffered damages during the transprt r installatin. Always use the equipment in well-lit areas. All the material f the installatin must be in stable zne and the peratr must fresee the mvements f the applicatin. Chse the mst suitable mdel fr the applicatin frm the wide range available, and make sure that it will nt exceed 80% f its nminal capacity during nrmal peratin. D nt expsure the equipment t intense heat surces (welding). Include cntrl elements (pressure gauges) in the installatin in rder t enable the peratr t mnitr the pressure in the system and ensure that the equipment s nminal capacity is never exceeded. Be prepared t use safety valves and accessries if the safety criteria s demand. The pump cntrls shuld be activated manually, as shuld the cnnectins between elements equipped with quick plugs. Clean the quick plugs befre cnnecting and make sure the cnnectins are perfect (first insert as far as the plug will g and then screw in by hand). A bad cnnectin may result in imprper functining and may even generate a safety hazard. Install the device in such a way as t ensure that the hses are nt subjected t sharp r frced bends r thrust actins that may cause them t break. D nt mdify the device (welded parts, lengthening drive levers, etc.) withut cnsulting the manufacturer. D nt use the hses fr transprting the device. Use the handles n the cylinders (when apprpriate) and set the pump lever t the transprtatin psitin. When filling the pump with il, always use LARZEP hydraulic il r anther il f similar characteristics. Fill nly t the indicated level and remember that the cylinder pistn shuld be retracted. BREAK PREVENTION: Check fr perfectly tightened extenders, nuts and guilltine. Keep spindle greased and extenders centred. When the pieces t be pulled are frced t wrk in bad cnditins, we must reduce the maximum lad applied t the puller. As standard, we ll reduce t half f the lad. The break will never be dangerus because there s n risk f element prjectin. (Puller s parts). This danger is fictitius; it always seems t be dangerus due t the nise and the cmmtin that a big puller prvkes when brken. The unique risk when brken; and this case is imprbably, is the falling dwn f the puller due t the lst f the supprting pint. (It desn t happen because generally an extender and the spindle are enugh t supprt it.) 2

3 Instructin Manual 2. WARRANTY. LARZEP, S.A. guarantees its prducts against all design and manufacturing defects fr the duratins f tw years frm the date f purchase. This guarantee des nt include the rdinary wear f bth metal and nn-metal parts, abuse, using the equipment beynd its rated capacity and any wear r damage incurred as a result f using a hydraulic fluid which is nt recmmended by LARZEP, S.A. Please nte that if the equipment is disassembled r serviced by anyne ther than an authrized service dealer r by LARZEP, S.A., this guarantee is rendered null and vid. In the event f a warranty claim, return the equipment, t LARZEP, S.A. r the authrized dealer which sld yu the hydraulic equipment, LARZEP, S.A. will repair r replace the faulty equipment, whichever is deemed mst apprpriate. LARZEP, S.A. shall nt be held liable fr any cnsequential damages r lsses, which may ccur as a result f 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 Hydraulic Part Mechanic Part PART FU0500 FU1000 FU2000 FU3000 FU5000 FV FX FZ FT Cylinder SM00518 SH01204 SH02205 SH03005 SH06008 * * * * Pump W00307 W00307 W00607 W02407 W02407 * * * * Hse AP2015 AP2015 AP2015 AP2015 AP2020 * * * * Gauge adaptr AZ1501 AZ1501 AZ1501 AZ1501 AZ1501 * * * * Gauge AV10008 AV10008 AV10008 AV10008 AV10008 * * * * Male cupling AZ3120 AZ3120 AZ3120 AZ3120 AZ3120 * * * * FU0500/M FU1000/M FU2000/M FU3000/M FU5000/M Jaws FU0507 (3) FU1007 (3) FU2007 (3) FU3007 (3) FU5007 (3) Jaw crsshead FU2008 FU3008 FU5008 (*) (*) 2 Jaw crsshead FU2009 FU3009 FU5009 (*) 2 and 3 jaw crsshead FU0508 FU1008 _ (*) (*) Arms FU0510 (6) FU1010 (6) FU2010 (6) FU3010 (6) FU5010 (6) 6 4 Jaw blts + nuts FU0511 (6) FU1011 (6) FU2011 (6) FU3011 (6) FU5011 (6) 6 4 Spindle + Handle _ FU1012 FU2012 FU3012 FU5012 * * * * Shrt blts _ 14A0330 (2) 14A0074 (2) 14A0075 (2) 14A0076 (2) * * Hllw saddle _ AZ0551 AZ0552 AZ0553 AZ0556 * * * * Bearing puller FR0500 FR1000 FR2000 FR3000 FR5000 * Grss crsshead 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) * * Shrt extenders FU0523 (2) FU1023 (2) FU2023 (2) FU3023 (2) FU5023 (2) * * Bearing cup puller _ FI1000 FI2000 FI3000 FI5000 * Pint prtectr FU0525 FU1025 FU2025 FU3025 FU5025 * * * * Cnnectin nuts 14B0030 (2) 14B0051 (2) 14B0029 (2) 14B0030 (2) 14B0031 (2) * * Lng blts _ 14A0331 (2) 14A0098 (2) 14A0099 (2) 14A0100 (2) * * Wden case CU1000 CU1000 CU2000 CU3000 CU5000 * * * * * Part included in set * Part included depending n the size: 2 and 3 jaw bdy fr 5 and 10 tn, and different bdies fr 2 and 3 jaws fr 20, 30 and 50 tn 3

Instructin Manual 4. START UP. All mdels Keep the spindle greased and cleaned. 1. Check the safety hle f the axle, if it hasn t the hle, use the shaft prtectr as supprting pint. 2.

4 Instructin Manual 4. START UP. All mdels Keep the spindle greased and cleaned. 1. Check the safety hle f the axle, if it hasn t the hle, use the shaft prtectr as supprting pint. 2. Hld jaws slightly by tightening clamps blts. 3. Place jaws in the lwest hle and centred respect the spindle. 4. Apply hydraulic frce. D nt exceed the 80% f the nminal capacity f the equipment. 5. When using the Bearing Cup puller, d nt exceed the 70% f the nminal capacity f the equipment. 6. When using the Bearing puller, d nt exceed the 50% f the nminal capacity f the equipment. 7. Never hit the spindle. The pullers can break due t: - Changed parts (emery stne...) - Blwlamp used whilst pulling. - Strikes. - Overlad. 1. The whle set delivered in a strng wden bx t prtect the equipment frm damages during the transprt. Once the applicatin is finished clean the equipment and stre it in the bx until the next use. 2. Unpack the equipment checking that all the pieces described in the spare part sheet are in; and that have nt suffered damages. 3. Cnnect the hse and the quick cupler, assure a perfect cnnectin. 4. Pump several times with the lever; check the screw is slightly pened (turn left) t purge the circuit. 5. Clse manually the screw (turn right). When we pump, the pistn will advance. If we pen the screw again, the pistn returns thanks t the spring. Mdels FV: 2 and 3 Jaw Puller: Supplied with cmmn 2 and 3 jaw bdy fr 5 and 10 tn mdels. Supplied with tw different bdies fr 2 jaws and 3 jaws in 20, 30 and 50 tn mdels. Keep the spindle greased and cleaned. Check the safety hle f the axle, if it hasn t the hle, use the shaft prtectr as supprting pint. Hld jaws slightly by tightening clamps blts. Place jaws in the lwest hle and centred respect the spindle. The Jaws wrks perfectly whit a maximum angle f 10º Set the puller crrectly, adjust better the first alignment. Tighten the spindle turning it. The jaws have t be supprted cmpletely. Tighten the screws f the links. Pump several times t pull the piece. Mdels FX: 2 Jaw Puller: As same as FV series, but with nly 2 jaws. Mdels FZ: Grss Bearing Cmplete Puller: Grss Bearing Cmplete Puller includes: 2 sets f extenders f different lengths and jining nuts. The cmplete set als includes bearing puller (FR) and Bearing Cup puller (FI). Fr cnstructive reasns, the 5 tn mdel desn't include the FI bearing cup puller accessry. Keep the spindle greased and cleaned. Check the safety hle f the axle, if it hasn t the hle, use the shaft prtectr as supprting pint. Keep extenders centred and the crsshead fully hrizntal. Use hydraulic pump t get pulling pwer. The Bearing Puller must be used always placing the piece t be pulled, in the flat face f the puller. NEVER THE OTHER WAY ROUND. Mdels FT Grss Bearing Simple Puller: Extender puller: supplied with tw different lengths and jining nuts. Used fr munting and dismantling As same as mdels FZ. It DOESN T include Bearing and Bearing Cup Pullers. OPERATION T grip and pull a gear, bearing, wheel, pulley, etc. frm a shaft: 4

5 Instructin Manual In rder t perfrm a prper pull, make sure yu firmly grip the gear, bearing, wheel, etc. and apply frce t shaft. Depending n the jb we ffer a cmplete range f hydraulic pullers. T grip and pull an internal bearing: Place the (FI) Bearing Cup Puller inside the bearing t be pulled, check the puller is centred. Use the internal puller FI in cmbinatin with the FZ FT mdels. T grip and pull a shaft frm husing: Fasten t the threaded male end f the shaft t pull while pushing against the husing. Use the thread f the shaft t tighten the puller and this way pull while pushing against the husing. Hw t chse the capacity f a puller Fr hydraulic pullers, the maximum frce exerted in tns shuld be 7 times the diameter f the shaft in inches. Shaft diam. in inches Shaft diam. in mm Cap. Puller in Tns 0" - 2" " - 3 1/2" /2" - 5 1/2" MAINTENANCE. All the maintenance peratins must be dne with depressurized equipment and discnnected hydraulic and electrically. Always use LARZEP riginal spare parts. In every use f the equipment make a visual inspectin; check the il level, damages in hydraulic part (scratched pistn, thread, leaks, etc.), the cnditin f the accessries.(hses, cuplers, etc.) Clean the equipment after each use and keep grease critical areas: threads, shafts, inside the rller, pistn, etc. befre stre the equipment in the bx. In case f frequent use, replace peridically the hses and cuplers althugh they d nt seem damaged. Peridically (at least nce t the year), replace the hydraulic il f the tank by clean il. The il filling it s made thrugh the plug. Check the level with the dipstick placing the pump head dwn in vertical psitin. Use LARZEP AZ8901 il. The maintenance peratins r repairs that suppse the dismantling f the mechanical parts f the equipment (jack, cylinder r pump) must be dne by specialist persnnel. PROBLEM DIAGNOSIS SOLUTION 1 The pistn f the cylinder des nt advance. 1.1 Excess r lack f il in the tank. 1.1 Check the level and refill. 1.2 Clgged filter. 1.2 Dismantle the pump and clean it. 1.3 Oil leak by the admissin ball f the pump. 1.3 Repair the ball seat and replace the ball. 1.4 Pressure cllar f the cylinder damaged. 1.4 Replace the detent. 1.5 Cup f the pump damaged. 1.5 Replace the cllar. 1.6 Pressure relief valve f the pump unrated. 1.6 Rate the valve. 1.7 A bad cnnectin f the hse. 1.7 Check the cnnectin. 2 The cylinder des nt reach pressure. 2.1 Pressure cllar f the cylinder damaged. 2.1 Replace the detent. 2.2 Leak by the ball f the actin screw. 2.2 Repair the ball seat and replace the ball. 2.3 Oil leak by the admissin ball f the pump. 2.3 Repair the ball seat and replace the ball. 3 The pistn des nt return. 3.1 Ball f the actin screw pasted. 3.1 Release the screw and mve the ball. 3.2 Jamming r twisted pistn in the cylinder. 3.2 Repair r replace the pistn. 3.3 Damaged spring in the cylinder. 3.3 Replace the spring. 3.4 Excess f il in the tank. 3.4 Check the level. 5

6 The slutins in black must be carried ut by specialist persnnel. Instructin Manual 6. DECLARATION OF CONFORMITY. 6

Instructin Manual DRAWINGS, PARTS AND DIMENSIONS.

5 185 170 40 10 240 230 35 20 250 330 135 30 270 440 180 50 400 580 230 FV &

mm 5 240 230 10 350 240 20 305 350 30 393 580 50 690 920 FI Bearing cup puller

7 Instructin Manual DRAWINGS, PARTS AND DIMENSIONS. FZ & FT Extender Puller Capacity (tn) A max. mm. B max. mm. B min. mm FV & FX Jaw puller Capacity (tn) A max. mm B max. mm FI Bearing cup puller Capacity (tn) A max. mm B max. mm B min. mm FR Bearing puller Capacity (tn) A max. mm B max. mm B min. mm D /8" UNF /8" UNF /8" UNF " UNF /4 " UNF

8 Instructin Manual Optinal blank heads (mm) LARZEP A B C tn AZ M28x1, AZ /16" AZ /16" AZ /4" Extenders Capacity (tn) LARZEP A B F G H I 5 FU /2" UNF-20 5/8" UNF-18 5 FU /2" UNF-20 5/8" UNF FU , /8" UNF-18 3/4" UNF FU , /8" UNF-18 3/4" UNF FU , /8" UNF-18 3/4" UNF FU , /8" UNF-18 3/4" UNF FU , " UNF-14 1" UNF FU , " UNF-14 1" UNF FU , /4" UNF /4" UNF FU , /4" UNF /4" UNF-12 Grss crsshead LARZEP Capacity (tn) A B C D FU FU FU FU ,5 77,5 26 FU ,5 Jaws LARZEP Capacity (tn) A B C D F G H FU ,5 44, FU , FU , FU , , FU ,

Technical Documentation

Technical Documentation Quality f the future. Technical Dcumentatin Manual Black Bx Light Order-N.: 0255-004 Sparkasse Pfrzheim Calw (BLZ 666 500 85) Kt.-Nr. 791326 UniCredit Bank AG Karlsruhe (BLZ 660 202 86) Kt.-Nr. 15653957