PW-E1S 5,000 psi 5HP ELECTRIC POWER UNIT OPERATION MANUAL

Transcription

1 PW-E1S 5,000 psi 5HP ELECTRIC POWER UNIT OPERATION MANUAL ON/OFF Switch High Pressure Supply Hydraulic Power Unit Shutoff Valves Low Pressure Return Breather Cap 5 HP Motor Optional Pump Hydraulic Fluid Reservoir High Pressure Supply Typical Hydraulic Power Unit Please read this manual before operation to ensure the proper installation and operations. Thank you for purchasing the PW-E1S Hydraulic Power Unit. The PW-E1S Pump is configured for 5,000 PSI and Mineral Oil. The provided MSDS sheet will only pertain to this specific power unit. Your fluid is. The simultaneous manifold and twin valve pump can operate 2 tools at full power at the same time. Dependable and hardworking, you can operate our electric power units

2 5,000 psi all day long and year after year. Champion builds pumps to operate with most fluids and industry compatible connections. All Champion s pumps are single stage units, this means NO lag time, full power all the time. This power unit will only attach to hoses that have compatible couplings. Your couplers are,. The motor is a 5 horsepower (HP), 208/230 Volt single phase, Omni directional electric motor. The motor is ready to be hard wired to your power source with the standard 6 foot lead wire. (Please see motor plate or electrical wire data sheet with this manual for wiring configuration to your source) The pump used on the Electric Hydraulic Power Unit is designed to be self-priming and will come shipped with hydraulic fluid already in reservoir. The Hydraulic Power Unit reservoir has a 2.5-gallon capacity. The suction for the pump is taken about 1 above the floor of the reservoir and is equipped with a screen to prevent pump ingestion of debris. A red plug is installed on the reservoir at the factory (used for shipment). Upon receipt of your Hydraulic Power Unit, the RED PLUG on the reservoir tank will need to be removed and the breather cap installed. (Breather Cap is shipped with pump) Red Plug Breather Cap The breather cap allows the reservoir tank to breath when fluid is transferred from the tool through the return hose. Never remove breather when pump is running. A reservoir sight glass is included to ensure proper oil level. The reservoir contains approximately 1.9 gallons of hydraulic fluid when the fluid level is in the center of the sight glass. When fluid cannot be seen in the sight glass, the fluid level is low and hydraulic fluid needs to be added. To add fluid remove that breather cap and pour the recommended fluid into the fill spout until filed to the proper level. (See MSDS for recommended fluid for your pump). Remember that the reservoir has the maximum amount of fluid in it when any piston driven tool(s) are fully retracted so that the piston is drawn to the back of the cylinder; this is because that fluid in the tool cylinder has emptied into the reservoir tank from the

3 tool cylinder. When the cylinder rod is extended to its fullest length, the maximum amount of fluid is used. In that condition, the piston shaft is displacing the maximum amount of hydraulic fluid from the piston, thus filling the reservoir. Naturally, this will also cause a slight change in the level during normal operation. The Hydraulic Power Unit is manufactured for dual port operation. Both ports (Red Handled and Blue Handled Hydraulic Power Unit Shutoff Valves) are set to approximately 5,000 psi to allow operation. The Hydraulic Power Unit can supply and operate two tools at the same time. The maximum pressure output for the Hydraulic Power Unit is approximately 5,000 PSI. If the pump discharge pressure in the Hydraulic Power Unit exceeds approximately 5,000 PSI, an internal pressure relief valve opens and bypasses the fluid to the reservoir. There are internal pressure reliefs installed on the hydraulic system so that the system will never exceed the reported output pressure. Two internal pressure reliefs are installed on the discharge manifold of the pump (one on each Hydraulic Power Unit on/off valves). The spring-loaded internal reliefs will lift or open at approximately 5,000 psi. Operating the hydraulic system in a deadheaded condition will cause overheating of the hydraulic oil if allowed to continue unabated. A typical reason for this condition to exist would be if one of the Hydraulic Power Unit Shutoff Valves on the Hydraulic Power Unit were left in the ON position for any amount of time without a hose and tool connected. This causes the pump to "Deadhead" If this happens, shut off the power unit and cycle the valve or valves on and off a few times to clear the pressure and put the valve to the OFF position before starting the power unit once again. The Hydraulic Power Unit Shutoff Valve has three positions (ON, OFF and NEUTRAL) but only two positions are identified on the Hydraulic Power Unit. The two identified positions on the Hydraulic Power Unit are ON and OFF. When the Hydraulic Power Unit Shutoff Valve is in the OFF position, hydraulic fluid is re-circulated, internal to the Hydraulic Power Unit. When the Hydraulic Power Unit Shutoff Valve is in the ON position, hydraulic fluid flows to the equipment. Even though it is not identified on the Hydraulic Power Unit, there is a position (detent) at the midpoint between the OFF and ON position. This position is the NEUTRAL position and operates the same as the OFF position (re-circulates hydraulic fluid internal to the Hydraulic Power Unit).

4 When the Hydraulic Power Unit Shutoff Valve is in the OFF position, the hydraulic fluid is cycling through the Hydraulic Power Unit and will not build up pressure. When the Hydraulic Power Unit Shutoff Valve is in the ON position, and the hoses and tool(s) are connected, the hydraulic fluid will cycle through the Hydraulic Power Unit and Tools. When the Hydraulic Power Unit Shutoff Valve is in the ON position and NO tools are connected, the pressure will build up due to deadheading the Hydraulic Power Unit and cause the internal relief valve(s) to open. This will cause the hydraulic fluid temperature to increase. The normal operating temperature for the hydraulic fluid is between 110 F and 150 F. Power Unit Care: 1. Check fluid levels routinely Always remember not to over fill the reservoir, as the tools may be in the retracted position when last disconnected. 2. Keep water and debris off the electric motor and from around the on/off switching box. 3. Drain and replace hydraulic fluid every 50 hours of run time or if a noticeable difference in color to the fluid is apparent. 4. Periodically check for hydraulic leaks around the valves, tank or motor connection to the pump. If a leak is detected please shut the system down, clean around area and identify where the leak is coming from and call Champion Rescue Tools or your dealer for technical help. 5. Periodically check for hydraulic leaks around couplers and fittings. If a leak is detected please shut the system down, clean around area and identify where the leak is coming from and call Champion Rescue Tools or your dealer for technical help.

5 Manufacturer's Specifications: Model: PW-E1S5HP - Single Phase Electric Motor Weight: 149 lbs/wet - Dimensions: 26 L x 23 W x 18 D (with Standard Frame) Operating Pressure: 5,000 psi, Support Should you require technical help, service, training, or any other type of support, please contact our Corporate Offices at: Champion Rescue Tools 814 Berry Court Upland, California USA Phone: (909) Fax: ( Toll Free: (888) Champion Rescue Tools

6 PW-E1S 10,500 psi 5HP ELECTRIC POWER UNIT OPERATION MANUAL ON/OFF Switch High Pressure Supply Hydraulic Power Unit Shutoff Valves Low Pressure Return Breather Cap 5 HP Motor Optional Pump Hydraulic Fluid Reservoir High Pressure Supply Typical Hydraulic Power Unit Please read this manual before operation to ensure the proper installation and operations. Thank you for purchasing the PW-E1S Hydraulic Power Unit. The PW-E1S Pump is configured for 10,500 PSI and Mineral Oil. The provided MSDS sheet will only pertain to this specific power unit. Your fluid is. The simultaneous manifold and twin valve pump can operate 2 tools at full power at the same time. Dependable and hardworking, you can operate our electric power units

7 10,500 psi all day long and year after year. Champion builds pumps to operate with most fluids and industry compatible connections. All Champion s pumps are single stage units, this means NO lag time, full power all the time. This power unit will only attach to hoses that have compatible couplings. Your couplers are,. The motor is a 5 horsepower (HP), 208/230 Volt single phase, Omni directional electric motor. The motor is ready to be hard wired to your power source with the standard 6 foot lead wire. (Please see motor plate or electrical wire data sheet with this manual for wiring configuration to your source) The pump used on the Electric Hydraulic Power Unit is designed to be self-priming and will come shipped with hydraulic fluid already in reservoir. The Hydraulic Power Unit reservoir has a 2.5-gallon capacity. The suction for the pump is taken about 1 above the floor of the reservoir and is equipped with a screen to prevent pump ingestion of debris. A red plug is installed on the reservoir at the factory (used for shipment). Upon receipt of your Hydraulic Power Unit, the RED PLUG on the reservoir tank will need to be removed and the breather cap installed. (Breather Cap is shipped with pump) Red Plug Breather Cap The breather cap allows the reservoir tank to breath when fluid is transferred from the tool through the return hose. Never remove breather when pump is running. A reservoir sight glass is included to ensure proper oil level. The reservoir contains approximately 1.9 gallons of hydraulic fluid when the fluid level is in the center of the sight glass. When fluid cannot be seen in the sight glass, the fluid level is low and hydraulic fluid needs to be added. To add fluid remove that breather cap and pour the recommended fluid into the fill spout until filed to the proper level. (see MSDS for recommended fluid for your pump). Remember that the reservoir has the maximum amount of fluid in it when any piston driven tool(s) are fully retracted so that the piston is drawn to the back of the cylinder; this is because that fluid in the tool cylinder has emptied into the reservoir tank from the

8 tool cylinder. When the cylinder rod is extended to its fullest length, the maximum amount of fluid is used. In that condition, the piston shaft is displacing the maximum amount of hydraulic fluid from the piston, thus filling the reservoir. Naturally, this will also cause a slight change in the level during normal operation. The Hydraulic Power Unit is manufactured for dual port operation. Both ports (Red Handled and Blue Handled Hydraulic Power Unit Shutoff Valves) are set to approximately 10,500 psi to allow operation. The Hydraulic Power Unit can supply and operate two tools at the same time. The maximum pressure output for the Hydraulic Power Unit is approximately 10,500 PSI. If the pump discharge pressure in the Hydraulic Power Unit exceeds approximately 10,500 PSIG, an internal pressure relief valve opens and bypasses the fluid to the reservoir. There are internal pressure reliefs installed on the hydraulic system so that the system will never exceed the reported output pressure. Two internal pressure reliefs are installed on the discharge manifold of the pump (one on each Hydraulic Power Unit on/off valves). The spring-loaded internal reliefs will lift or open at approximately 10,500 psi. Operating the hydraulic system in a deadheaded condition will cause overheating of the hydraulic oil if allowed to continue unabated. A typical reason for this condition to exist would be if one of the Hydraulic Power Unit Shutoff Valves on the Hydraulic Power Unit were left in the ON position for any amount of time without a hose and tool connected. This causes the pump to "Deadhead" If this happens, shut off the power unit and cycle the valve or valves on and off a few times to clear the pressure and put the valve to the OFF position before starting the power unit once again. The Hydraulic Power Unit Shutoff Valve has three positions (ON, OFF and NEUTRAL) but only two positions are identified on the Hydraulic Power Unit. The two identified positions on the Hydraulic Power Unit are ON and OFF. When the Hydraulic Power Unit Shutoff Valve is in the OFF position, hydraulic fluid is re-circulated, internal to the Hydraulic Power Unit. When the Hydraulic Power Unit Shutoff Valve is in the ON position, hydraulic fluid flows to the equipment. Even though it is not identified on the Hydraulic Power Unit, there is a position (detent) at the midpoint between the OFF and ON position. This position is the NEUTRAL position and operates the same as the OFF position (re-circulates hydraulic fluid internal to the Hydraulic Power Unit).

9 When the Hydraulic Power Unit Shutoff Valve is in the OFF position, the hydraulic fluid is cycling through the Hydraulic Power Unit and will not build up pressure. When the Hydraulic Power Unit Shutoff Valve is in the ON position, and the hoses and tool(s) are connected, the hydraulic fluid will cycle through the Hydraulic Power Unit and Tools. When the Hydraulic Power Unit Shutoff Valve is in the ON position and NO tools are connected, the pressure will build up due to deadheading the Hydraulic Power Unit and cause the internal relief valve(s) to open. This will cause the hydraulic fluid temperature to increase. The normal operating temperature for the hydraulic fluid is between 110 F and 150 F. Power Unit Care: 1. Check fluid levels routinely Always remember not to over fill the reservoir, as the tools may be in the retracted position when last disconnected. 2. Keep water and debris off the electric motor and from around the on/off switching box. 3. Drain and replace hydraulic fluid every 50 hours of run time or if a noticeable difference in color to the fluid is apparent. 4. Periodically check for hydraulic leaks around the valves, tank or motor connection to the pump. If a leak is detected please shut the system down, clean around area and identify where the leak is coming from and call Champion Rescue Tools or your dealer for technical help. 5. Periodically check for hydraulic leaks around couplers and fittings. If a leak is detected please shut the system down, clean around area and identify where the leak is coming from and call Champion Rescue Tools or your dealer for technical help.

10 Manufacturer's Specifications: Model: PW-E1S5HP - Single Phase Electric Motor Weight: 149 lbs/wet - Dimensions: 26 L x 23 W x 18 D (with Standard Frame) Operating Pressure: 10,500 psi, Support Should you require technical help, service, training, or any other type of support, please contact our Corporate Offices at: Champion Rescue Tools 814 Berry Court Upland, California USA Phone: (909) Fax: ( Toll Free: (888) Champion Rescue Tools