4
5
OPERATING
APPLICATIONS AND LOAD CAPACITY
USE:
To pressurise the hydraulic hand pump, turn the release valve on
the side of the pump clockwise to close the valve. Then pump
the handle up and down.
To release pressure, open the valve by turning the release valve
anti-clockwise.
The hand pump can be used in any position. When using the
hand pump in a vertical position, always ensure that the hose
end is facing downwards.
Adding two extension rods to
the hydraulic ram will make
the capacity reduce by 50%.
When the load is off centre the
capacity will be reduced by
a further 50% and each
additional single extension will
reduce the capacity by
a further 50%. If connecting
more than two extensions
together, ensure that the short
extension is positioned the
furthest away from the
hydraulic ram.
Pressure Release Valve
100% of ram capacity
50% of ram capacity
25% of ram capacity
6% of ram capacity
50% of ram capacity
25% of ram capacity
CARE & MAINTENANCE
CHECKING & FILLING THE OIL RESERVOIR:
1.
Place the hydraulic hand pump on a level surface and disconnect any
attachment from the end.
2.
Always follow the precautions advised by the oil manufacturer.
3.
Open the pressure release valve.
4.
Remove the filler plug from the cylinder. The oil should be within
15mm from the top of the reservoir.
If necessary, fill with hydraulic oil
ISO VG.22.32
until the oil is within
15mm from the top of reservoir. DO NOT USE BRAKE FLUID.
5.
Pump the handle 5 or 6 times to expel air.
6.
Screw on the filler plug.
Avoid mixing different grades of oil. After long periods of use, the oil should be replaced with new oil.
LUBRICATING:
Use light oil on all moving parts.
WHEN NOT IN USE:
Wipe clean with a slightly oiled cloth.
Store the hand pumps with the release valve open.
Store the rams in a vertical position with the rod end down in a dry, well protected area, where they will not be
exposed to corrosive vapours, dust or other harmful elements.
When a ram has not been used for 3 months, it should be connected to a pump and be fully extended and then
retracted to lubricate the cylinder walls, thereby reducing the potential for rust formation.
Make sure that the threaded dust cap plugs are put on to the ends of any hose, hydraulic rams and
accessories, to avoid dirt from entering the system.
BLEEDING THE SYSTEM:
Air can accumulate in the hydraulic system during the initial setup or after prolonged use, causing the ram to
respond slowly or in an unstable manner. To remove the air, please follow these steps.
1.
Place the ram at a lower level than the pump, with the piston end pointing down.
2.
Extend and retract the ram several times without putting a load on the system. Air will be released into the
pump reservoir.
3.
With the ram fully retracted, the pump sitting level and no pressure in the hydraulic system, remove the
pump’s filler screw.
4.
Pump the handle 5 or 6 times to bleed air out of the system.
5.
Close the pressure release valve.
6.
Replace the filler plug screw.
SETTING UP
Remove the dust covers from the hydraulic ports. Clean the area around these ports if necessary. Clean all
hose ends, couplers and union ends. Connect all hose assemblies to the pump and cylinder (sealing tape may
have to be used - See REPAIRS on page 6 for further information). Tighten securely but do not over tighten.
Filler plug
screw
Filler plug
screw positioned
here on HPT035
TROUBLE SHOOTING - PUMPS
POSSIBLE CAUSE
SOLUTION
FAULT
1.System components leaking.
1. Low oil level in reservoir.
2. Seats are worn.
1. Low oil level in reservoir.
2. System components leaking.
3. Fluid leaking past inlet or outlet
check valves.
1. Air trapped in system.
2. Too much oil in reservoir.
1. Repair or replace as necessary.
1. Check oil level.
2. Repair seats or replace pump body.
1. Check oil level.
2. Repair or replace as necessary.
3. Repair inlet or outlet check valves,
or replace high pressure piston
seal.
1. Refer to ‘BLEEDING THE SYSTEM’
on page 4.
2. Check oil level.
Pump loses pressure.
Pump not delivering oil.
Pump does not reach
rated capacity.
Pump handle has
‘spongy’ feel.
1. Loose couplers.
2. Low oil level in pump reservoir.
3. Ram seals leaking.
1. Low oil level in pump reservoir.
2. The load exceeds the capacity of the
system.
1. Tighten couplers.
2. Fill and bleed the system.
3. Replace worn seals. Look for
excessive contamination or wear.
1. Fill and bleed the system.
2. Use correct equipment.
Ram piston will not
extend.
Ram system extends
only partially.
TROUBLE SHOOTING - RAMS
POSSIBLE CAUSE
SOLUTION
FAULT
Continued on page 6
INSPECTION
Before each use, please inspect the hydraulic equipment for the following:
1.
A cracked or damaged cylinder.
2.
Excessive wear, bending, damage or insufficient part engagement.
3.
Leaking hydraulic fluid.
4.
A scored or damaged piston rod.
5.
Swivel heads and caps not functioning correctly.
6.
Loose bolts.
7.
Damaged or incorrectly assembled accessory equipment.
8.
Modified, welded or altered equipment.
9.
Bent or damaged couplers or port threads.
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