Curtiss-Wright POP-A-PLUG SYSTEM Operating Instructions Manual Download Page 6

EST GROUP  

 

DC4042 06/18 

 

 

PAGE 6 OF 6 

 

Questions? 

Contact EST Group Customer Service at any of the following locations. 

 

 

 

www.cw-estgroup.com 

 

North, Central & South America 

EST Group Corporate Office 

2701 Township Line Road 
Hatfield, PA 19440-1770 USA 
P: +1.215.721.1100  
    +1.800.355.7044 
F: +1.215.721.1101 

[email protected]

 

 

Europe / Middle East / Africa 

EST Group B.V.

 

Hoorn 312a 
2404 HL Alphen aan den Rijn 
The Netherlands 
P: +31.172.418841 
F: +31.172.418849 

[email protected]

 

 

China

 

P +86.400.636.5077 

[email protected]

 

 
 

Singapore

 

 

P +65.3158.5052 

[email protected]

 

 

 

©2018 Curtiss-Wright

 

 

WARNING 

 

3. TESTING 

3.1. Test Ram/Pump set-up   

To verify Ram/Pump set-up, step on the end of the 

pump pedal marked "PUMP"   

 while watching 

the Hydraulic Ram.  Within a few seconds, the Ram 
should begin to stroke.  Note that the piston strokes out 
of the back of the hydraulic Ram.  If the Ram does not 
stroke, check all connections, the oil level and repeat 
this step. 

Proper operation will be indicated by cylinder of the ram 
extending 1” – 3” (25.4 to 76.2 mm) (model dependent) 
followed by the pressurization indicated on the gauge 
increasing to 7500 PSIG (517 BARG).   

 

3.2. Release Pump pressure  

While holding the Ram handle step on end of the Pump 

Pedal marked "

RELEASE

".   

 This will allow 

the piston of the Ram to retract. 
 
To remove the pneumatic power to the equipment, 
disconnect the pneumatic quick connect.   

 

4. OPERATION 

Assemble the ram head with the pullrod assembly in accordance with 

DC1220

 or 

DC4000

: Pop-A-Plug installation 

instructions.  Follow Pop-A-Plug installation instructions.  

 

 

DURING RAM OPERATION, THE SAFETY CABLE MUST ALWAYS 
BE ATTACHED TO THE PULLROD.   

 

NEVER LEAVE THE EQUIPMENT UNATTENDED WHILE 
CONNECTED TO A PNEUMATIC PRESSURE SUPPLY.   

 

NEVER DISCONNECT THE HOSE FROM THE RAM OR PUMP 
WHEN THE EQUIPMENT IS PRESSURIZED.

 

5.  CLEANING AND MAINTENANCE 

The Ram system should be cleaned of all dirt and oils after ever use.  Keeping the Ram Kit components wiped free of 
debris before and after use will lessen the chances of foreign materials entering the hydraulic or pneumatic system 
and extend the life of the equipment.  Change hydraulic oil every 300 hours of use approximately; use Power-Team 
AW Hydraulic Oil ISO-46.   

There are no serviceable parts on the Ram Kit. Contact EST Group for any repair or replacements of components.     

 

HERE

STEP

STROKES

PISTON

FRONT

 

Summary of Contents for POP-A-PLUG SYSTEM

Page 1: ...n Air Activated Hydraulic Pump a High Pressure Hydraulic Hose with quick connects and a Hydraulic Ram EST Group Ram Kits are used for installation and removal of Pop A Plug Heat Exchanger Tube Plugs manufactured by Curtiss Wright EST Group Operating Instructions for Part Number Description Components Description PAP 6600 SIL Small Ram Package PAP 6605 5 Ton Ram Assembly PAP 1010 Hose Assembly PAP ...

Page 2: ...MBOLS AND DEFINITIONS Safety symbols are used to identify any action or lack of actions that can cause personal injury DANGER Danger is used only when actions or lack of actions will cause serious human injury or death WARNING Warning is used to describe and action or lack of action where serious injury can occur READ INSTRUCTIONS Read all instruction prior to operating equipment EYE PROTECTION We...

Page 3: ... protection to protect against hearing loss or damage Possible Kickback and Parts Ejection Hazard Keep body head face and all extremities clear from rear of hydraulic ram during operation Tools and components listed in this instruction are designed for the sole purpose of installing and removing P2 and CPI PERMA plug heat exchanger tube plugs The equipment is not designed or intended to be used fo...

Page 4: ...5 7044 F 1 215 721 1101 est info curtisswright com Europe Middle East Africa EST Group B V Hoorn 312a 2404 HL Alphen aan den Rijn The Netherlands P 31 172 418841 F 31 172 418849 est emea curtisswright com China P 86 400 636 5077 est china curtisswright cn Singapore P 65 3158 5052 est asia curtisswright com 2018 Curtiss Wright Small Ram PAP 6605 Medium Ram PAP 123 RA Large Ram PAP 1755 Pump Assembl...

Page 5: ... and at least after every 10 hours of use Follow the safety and handling instructions with regards to the hydraulic oil in accordance with the provided SDS 1 2 Hose Ensure the hose is free of cracks kinks or any visible damage Inspect all threads and fittings for signs of wear or damage 1 3 Ram Visually inspect for cylinder damage leaking fluid and excessive wear or damage Ensure the safety cables...

Page 6: ... the pressurization indicated on the gauge increasing to 7500 PSIG 517 BARG 3 2 Release Pump pressure While holding the Ram handle step on end of the Pump Pedal marked RELEASE This will allow the piston of the Ram to retract To remove the pneumatic power to the equipment disconnect the pneumatic quick connect 4 OPERATION Assemble the ram head with the pullrod assembly in accordance with DC1220 or ...

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