DOA KOLUBRA Benutzerhandbuch
KOLUBRA
HIGH PRESSURE HYDRAULIC POWER PACK
DOA s.r.l.
Via Cortiva 5 - 22060 NOVEDRATE (Como) ITALY
TEL +39 031 792040 FAX +39 031 791917
www.doa.it e-mail: [email protected]t
SAFETY MANUAL
USE AND MAINTENANCE
DECEM
BER 200
8
–
2
st
issue
editionISSUE
IMPO
RTANT
READ THIS MANUAL BEFORE
USING THE TOOL
KEEP ALWAYS FOR FUTURE
REFERENCES
2
CONTENTS OF THE MANUAL
Page
INTRODUCTION 3
SAFETY SYMBOLS 4
DESCRIPTION OF THE PRODUCT
Description 5
Typical applications 5
Accessories 5
Other configurations available 5
TECHNICAL CHARACTERISTICS
General view – main components and their functions 6
view of the control block 7
Weight and dimension 8
Hydraulic oil 9
Flexible hose 10
Quick couplers and use 10
SAFETY RULES 12
USE OF THE PRODUCT
General safety instructions 12
What not to do 14
Before working 15
Start and use or the power pack 15
Cold start 15
Positioning of the power pack 16
Engine starting 16
Connection of the hoses and tool to the power pack 16
End of operations 17
MAINTENANCE AND CARE
Maximum pressure regulation 18
Power pack cleaning 19
Periodical controls and substitution of wear out parts 20
Maintenance of the flexible hose 21
Disposal and scrapping 22
Repair 22
PROBLEM / CAUSE / SOLUTION / CHART 23
WARRANTY 25
PART LIST AND EXPLODED VIEW ARE ATTACHED TO THIS MANUAL IN A
SEPARATE SHEET
3
INTRODUCTION
Dear customer,
Congratulations for having purchased a DOA product. The machine you bought, was manufactured with
high quality materials to assure your maximum satisfaction and a long lasting service without problems.
For your safety and obtaining the best result, we recommend to read this manual and respect the simple
instructions contained, this will protect you from accidents and avoid damages to the equipment.
Keep it always available together with its enclosures, so that it can be consulted when necessary.
IMPORTANT
SOME ENCLOSURES CONTAINING INFORMATION ABOUT ACCESSORY PARTS OR
SAFETY MANUALS OF THE MANUFACTURERS OF ENGINES, ALTERNATORS OF
OTHER SUBCOMPONENTS OF DOA TOOLS, COULD HAVE BEEN SUPPLIED TOGETHER
WITH THIS MANUAL.
THESE ENCLOSURES ARE AN INTEGRAL PART OF THE MANUAL AND THEY MUST BE
KEPT TOGETHER WITH THE MANUAL ITSELF..
BE CAREFUL WHEN YOU CONNECT THE POWER PACK TO AN UNKNOWN HYDRAULIC TOOL OR
A TOOL WHICH WE DON’T KNOW THE HYDRAULIC MAXIMUM TOLERABLE VALUES OF
PRESSURE AND FLOW OF. FOR AVOIDING ACCIDENTS AND DAMAGES TO THE EQUIPMENT, BE
SURE THAT THE MAXIMUM VALUES OF PRESSURE AND FLOW OF THE TOOLS CONNECTED TO
THE POWER PACK ARE COMPATIBLE WITH THOSE ONE OF THE POWER PACK ITSELF.
NOTE
–
THE TEXT AND THE ILL
USTRATIONS IN
THIS MANUAL ARE AN
EXCLUSIVE PROPERTY OF DOA S.R.L. THE PERSON WHO USES THE TEXT OR
REPRODUCES, EVEN PARTIALLY, ILLUSTRATIONS OR PARAGRAPHS FOR NON-
AUTHORISED PURPOSES
CAN BE LEGALLY LIABL
E.
DATA, ILLUSTRATIONS
AND CHARACTERISTICS
OF THIS MANUAL ARE O
NLY
INFORMATIVE AND NOT BENDING. DOA RESERVES THE RIGHT TO MAKE
MODIFICATIONS AT ANY TIME AND WITHOUT PREVIOUS NOTICE.
4
SAFETY SYMBOLS
SAFETY SYMBOLS
This manual contains safety warnings represented by symbols indicating three different levels of
danger:
This symbol indicates an operation or situation extremely
dangerous which can cause serious accidents or death if
proper precautions are not respected
This symbol indicates a dangerous operation or situation
that can cause serious accidents or death
This symbol warns about generic danger that can cause
accidents and damages to the equipment or the properties.
This symbol indicates important information
WHEN THE EFFECTS OF A CERTAIN ACTION ARE NOT EXACTLY KNOWN, REMIND THAT
EVEN THE SIMPLEST OPERATION MAY HIDE DANGERS.
IN CASE OF DOUBTS DO NOT RISK – DO NOT MAKE EXPERIMENTS!
ASK YOUR DOA DEALER OR YOUR FOREMAN.
5
PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
KOLUBRA is a high pressure hydraulic power pack powered by gasoline engines.
The machine has been engineered to power high pressure tools or cylinders, the hydraulic pressure is up
to 700 Bar that can be easily reduced or adjusted by using the relief valve integrated with the machine.
The power packs is equipped with a high quality piston pump, all other hydraulic components have been
chosen are to assure the best performances, robustness and a long lasting use without problems.
The engine acceleration is manual .
TYPICAL APPLICATIONS
Powering of high pressure hydraulic tools or equipment like:
rescue tools, lifting cylinders, railroad maintenance tools, concrete crackers, demolition tools , hydraulic
rock splitting tools and all equipment that work with pressures up to 700 bar .
ACCESSORIES
- SET OF HYDRAULIC HIGH PRESSURE HOSES LENGTH 5 m . WITH QUICK COUPLERS
- HIGH PRESSURE MALE QUICK COUPLER THREAD 3/8” NPT
- HIGH PRESSURE FEMALE QUICK COUPLER 3/8” NPT
- COMPLETE HIGH PRESSURE MALE/FEMALE QUICK COUPLER SET 3/8” NPT
OTHER CONFIGURATIONS AVAILABLE
KOLUBRA is also available in the following versions :
- With electric motors single phase 230 Volt for INDOOR works or in applications where is not
possible use gasoline engines
- With hydraulic motor ( oil to oil intensifier ), in this version is possible to power the KOLUBRA
and obtaining high prerssure from a normal low pressure power pack or from the circuit of mini
excavators etc.
6
TECHNICAL CHARACTERISTICS
GENERAL VIEW – MAIN COMPONENTS AND THEIR FUNCTIONS
Fig. 1 - KOLUBRA HIGH PRESSURE HYDRAULIC POWER PACK
1 - CONTROL VALVE BLOCK is the group that includes all hydraulic control components , the part is
obtained working a laminated aluminium block
2 - PRESSURE CONTROL LEVER is the lever that deliver pressure to tools , depending on setting it
can have two or three positions ( see following paragraph )
3 - FRAME is made in robust stainless steel tubes with rubber feet and insulated handle
4 - ENGINE gasoline type can be of different brands HONDA or ROBIN SUBARU the power is 4,5 or 5
HP, starting is recoil start
5 - HYDRAULIC OIL TANK the oil capacity is 5 litres, tank is manufactured in steel sheet to resist to
heat and impacts.
6 - PISTON PUMP it is quality a three pistons pump to assure durability and the best performances
KOLUBRA is also available with electric motor and with hydraulic motor or equipped with oil cooler
7
VIEW OF THE CONTROL VALVE BLOCK
Fig. 2 THE CONTROL VALVE BLOCK is the group that includes all hydraulic control components ,
the part is obtained working a laminated aluminium block
1 - PRESSURE GAUGE depending on models installed is rated for a maximum pressure of 600 or 700
bar
2 - ON/OFF FLOW LEVER is the lever that controls the distribution valve that delivers oil to tools , the
central position in the illustration is the OFF position where the tools are still , the lever must be put in
this position before start and put off engine
THREE POSITION HYDRAULIC CONTROL VALVE
the control valve has two possibility of setting: A and B
A SETTING
The lever has three positions that allow to control in two directions the cylinders or the tool
- LEFT POSITION P1– Pressure out from the Male coupler
- CENTRAL POSITION OFF – Pressure in hold/stop/neutral it is the engine starting position (see
position in the picture )
- RIGHT POSITION P2– Pressure out from the Female coupler
B SETTING
The lever has only two positions ON /OFF that allow to give the flow to a tool or to take it away. Setting
B is for powering tools ( like the rescue tools ) that have on board its own a three way control valve ,
when the machine is on setting B the other position is blocked by a stop screw that prevents the lever
to engage the eliminated position
3 - PRESSURE RELIEF VALVE is the valve that adjust the maximum value of the pressure of power
pack. The valve regulation knob must be secured after regulation to avoid it to get loose and
consequently change the pressure regulation
4 - FEMALE QUICK COUPLER is installed on the right of the valve as shown in picture and has plastic
caps to protect from impacts and dirt
5 - MALE QUICK COUPLER is installed on the left of the valve as shown in picture and has plastic caps
to protect from impacts and dirt
6 - HYDRAULIC OIL FILTER CARTRIDGE it is “ spin on “ type it is not maintainable can only be
replaced
8
KOLUBRA HIGH PRESSURE HYDRAULIC POWER PACK
TECHNICAL CHARACTERISTICS
WEIGHT ( dry ) Kg 35
HEIGHT cm 40
LENGTH cm 50
WIDTH cm 40
PRESSURE min max 210 - 700 bar
PRESSURE CAN BE REGULATED BY THE PRESSURE RELIEF VALVE
FLOW max l/min 3
OIL TANK CAPACITY liters 5
CONTROL VALVE TYPE 3 position – at “H” configuration OPEN CENTER
PUMP TYPE ……………………………… 3 PISTONS
ENGINE CHARACTERISTICS
ENGINE CHARACTERISTICS
CHARACTERISTICS
HOSES DIMENSION THERMOPLASTIC TWIN HOSE SET - 1/4” - WORKING PRESSURE 700 BAR
LENGTH 5 m
TERMINAL THREADS 3/8”NPT
ENGINE TYPE SINGLE CYLINDER 4 STROKES
BRAND AND MODEL HONDA - ROBIN
POWER 5 HP HONDA – 4,5 HP ROBIN
STARTING RECOIL
ENGINE ACCELERATION MANUAL
FUEL UNLEADED PETROL
HYDRAULIC CHARACTERISTICS
WEIGHT AND DIMENSION
ENGINE CHARACTERISTICS
STANDARD HYDRAULIC HOSES CHARACTERISTICS
9
HYDRAULIC OIL
Viscosity at the lower expected ambient temperature: max 68 cSt ( 9° E )
Viscosity at the higher expected ambient temperature: min. 22 cSt ( 3.10° E )
( cSt = centistokes ° E = Engler degrees )
HYDRAULIC OILS CORRESPONDENCE CHART
The following chart indicates the most common hydraulic oils recommended for DOA hydraulic tools and
power packs. The oils in the chart are suggested for standard temperatures; the left column indicates oils
for Winter operations; the right column shows the Summer ones. HYDRAULIC OILS OF OTHER BRANDS
CAN ALSO BE USED BUT THEY SHOULD HAVE EQUIVALENT CHARACTERISTICS TO THOSE OF
THIS CHART.
HYDRAULIC OIL – CORRESPONDENCE
WINTER TEMPERATURES SUMMER TEMPERATURES
AGIP ARNICA 32 ARNICA 46
BP HLP HV 32 HLP HV 46
CASTROL HYSPIN AWH 32 HYSPIN AWH 46
ELF HYDRELF DS 32 HYDRELF DS 46
ESSO INVAROL EP 32 INVAROL EP 46
MOBIL DTE 13 DTE 15
Q8 HAENDEL 32 HAENDEL 46
SHELL TELLUS T 32 TELLUS T 46
If you use the hydraulic tools in extreme climatic conditions, please contact DOA for more information.
IN CERTAIN COUNTRIES OR IN SOME SPECIAL APPLICATIONS THE USE OF BIODEGRADABLE OIL IS
PRESCRIBED BY LAW, IN THIS EVENTUALITY CONTACT DOA FOR MORE INFORMATION.
NORMALLY THERE ARE NO PROBLEMS OF HYDRAULIC-OIL COMPATIBILITY ( MIXING DIFFERENT TYPES
OF OILS ) WHEN THE TOOL USED WAS CONNECTED BEFORE TO OTHER POWER PACKS THAT COULD
HAVE OTHER OILS, NORMALLY THERE ARE NO PROBLEMS IF THE OIL OF THESE MACHINES IS OF A GOOD
QUALITY AND REGULARLY FILTERED.
OIL FILTER AND HYDRAULIC OIL MUST BE COMPLETYELY CHANGED EVERY 250 HOURS, WHEN
CHANGING THE OIL IS BETTER CHANGE ALSO THE OIL IN THE FLEXIBLE HOSES
NEVER USE OILS CALLED ESTHERI FOSFORIC ! THESE OILS ARE EXTREMELY TOSSIC AND
AGGRESSIVE, BE CAREFUL NOT TO CONNECT THE POWER PACKS TO TOOLS THAT WERE WORKING
WITH THESE OILS , MIXTURES WITH THESE OILS CAN DAMAGE THE PACK OR THE TOOLS .
THE OIL LEVEL MUST ALLWAYS BE VISIBLE FROM THE LEVEL EYE
10
FLEXIBLE HOSES
THE POWER PACK CAN BE SUPPLIED WITH A COUPLE OF HIGH PRESSURE HYDRAULIC FLEXIBLE HOSES
OF 5 M. LENGTH COMPLETE WITH QUICK COUPLERS.
THE STANDARD FLEXIBLE HOSES SUPPLIED WITH KOLUBRA ARE OF THE BEST QUALITY AND RATED TO
RESIST TO A PRESSURE OF 700 BAR.
THE THREAD DIMENSION IS 3/8” NPT
DO NOT USE HOSES OR COUPLERS THAT ARE NOT RATED FOR 700 BAR , IF THIS IS NOT RESPECTED
THIS NEGLIGENCE CAN RESULT IN SERIOUS ACCIDENTS AND DAMAGE TO THE EQUIPMENT
THE FLEXIBLE HOSE ALWAYS REMAINS FULL OF OIL.
THE FIRST TIME A NEW HOSE IS USED, IT WILL GET FULL OF OIL TAKING IT AWAY FROM THE
HYDRAULIC CIRCUIT. IT WILL BE THEN NECESSARY TO RESTORE ADEQUATELY THE OIL LEVEL IN
THE TANK.
BE ABSOLUTELY SURE THAT IN CASE OF NEW HOSE ARE USED THEY HAVE TO BE RATED TO RESIST
AT 700 BAR
QUICK COUPLERS
THE STANDARD QUICK COUPLERS INSTALLED ON KOLUBRA ARE RATED TO RESISTS AT 700 BAR –
COUPLERS ARE SUPPLIED WITH PLASTIC CAPS THAT PROTECT FROM DIRT AND IMPACTS, IT IS ADVICED
TO ALLWAYS PUT THE PROTECTION ON THE COUPLERS AFTER USE.
I
FEMALE QUICK COUPLER MALE QUICK COUPLER
CEJN code 101151404 CEJN Code 101156404
DOA code A161103 DOA code A161104
DOA high pressure power packs and hydraulic tools are equipped with quick couplers made by CEJN like
those one shown in the picture.
Inhaltsverzeichnis
