Hydraulic Hand Pump
Troubleshooting
Page 35
ii.
If the connection between the Giant Buttonhead Coupler #17G and the Test Fitting is
leaking sealant, remove and reattach the Test Fitting and test again. If the leak continues,
replace the Giant Buttonhead Fitting #17G, and then retest the pump.
iii.
Check that the By-Pass Valve #7 is tight, it could also be damaged or obstructed, see
“By-pass Valve Repair and Replacement”
on page twenty-two (22).
iv.
The Hydraulic Relief Valve #8 could be loose, weak, damaged or obstructed, see
“Relief
Valve Replacement”
on page eighteen (18).
If the 15,000 PSI Gauge #17B reads zero (0) pressure and the indicator needle does not move,
check the Hydraulic Pump Hose Assembly #17 and Test Fitting connection for sealant leaks
.
i.
Check if you can remove the Giant Buttonhead Coupler #17G from the Test Fitting. If the
Test Fitting is difficult or impossible to remove it indicates there is pressure in the system
and the 15,000 PSI Gauge #17B has failed. Immediately open By-Pass Valve #7 to
relieve the pressure and replace the 15,000 PSI Gauge #17B. See
“Pressure Gauge
Replacement”
on page twenty-four (24)
.
ii.
If the Test Fitting removes easily, it indicates a leak in the system.
The By-Pass Valve #7 is not tight, or it is damaged or obstructed, see
“By-pass
Valve Repair and Replacement”
on page twenty-two (22).
The Hydraulic Relief Valve #8 is loose, damaged or obstructed, see
“Relief
Valve Replacement”
on page eighteen (18).
DANGER: never operate the Hydraulic Hand Pump with a failed 15,000 PSI
Gauge #17B.
13. Stroke the Handle #10 as required bringing the pressure on the 15,000 PSI Gauge #17B to approximately
5,000 PSI, then stop. Examine the Hydraulic Pump Hose Assembly #17 and Test Fitting connection for
sealant leaks. Closely examine the Extra High-Pressure Hose #17E for bulges forming under the rubber
casing.
If the Hydraulic Pump Hose Assembly #17 is leaking sealant, repair it as required then retest the
pump.
If the connection between the Giant Buttonhead Coupler #17G and the Test Fitting is leaking
sealant, replace the Giant Buttonhead Coupler #17G then retest the pump.
If bulges begin forming on the outside of the Extra High-Pressure Hose #17E, immediately open
By-Pass Valve #7 to relieve the pressure and replace the Extra High-Pressure Hose #17E then
retest the pump.
14. Wait a few minutes then check that the reading on the 15,000 PSI Gauge #17B has not dropped.
If the pressure on the 15,000 PSI Gauge #17B has dropped, it indicates a leak in the system.
Return to step twelve (12).
15. Repeat steps thirteen (13) and fourteen (14) but this time bring the pressure on the 15,000 PSI Gauge
#17B to approximately 8,000 PSI.
16. Continue stroking the Handle #10 and watch the 15,000 PSI Gauge #17B, pressure should build to
approximately 11,000 PSI before relieving back to approximately 9,500 PSI.
DANGER: never pressurize the pump more than 11,500 PSI.
If the pressure gets over 11,000 PSI and does not relieve, it indicates a failed Hydraulic Relief
Valve #8 and it must be replaced.
Immediately open By-Pass Valve #7 to relieve the pressure.
See
“Relief Valve Replacement”
on page eighteen (18).
