Operating instructions Form no. 1000437 safety definitions safety symbols are used to identify any action or lack of action that can cause personal injury. Your reading and understanding of these safety symbols is very important. OPeRATOR s MisTAKe - danger is used only when your action or lack of action will cause serious human injury or death. OPeRATOR s AleRT - Warning is used to describe any action or lack of action where a serious injury can occur. important - important is used when action or lack of action can cause equipment failure, either immediate or over a long period of time. Caution Hot Surface Caution Prevent Failure Special Tools Operating Instructions Read Owner s Manual Pneumatic Energy Electrical Energy Hydraulic Energy Safety Device (mechanical) Against Overload Operator Alert Operator s Mistake Hydraulic Fluid Level Eye Protection Hearing Protection Hydraulic Injection * Attaching partially extended cylinders or tools can cause an overfill situation. Always attach fully retracted cyllinders or tools to the pump Page no. 2 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 HYdRAuliC HOses And Fluid TRAnsMissiOn lines Avoid straight line tubing connections in short runs. Straight line runs do not provide for expansion and contraction due to pressure and/or temperature changes. See diagrams in Set-up Instructions section of this form. Eliminate stress in the tube lines. Long tubing runs should be supported by brackets or clips. Tubes through bulkheads must have bulkhead fittings. This makes easy removal possible and helps support the tubing. Before operating the pump, all hose connections must be tightened with the proper tools. Do not overtighten. Connections should only be tightened securely and leak-free. Overtightening can cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities. Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the pump and release all pressure. Never attempt to grasp a leaking pressurized hose with your hands. The force of escaping hydraulic fluid could cause serious injury. Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold, or heavy impact. Do not allow the hose to kink, twist, curl, crush, cut, or bend so tightly that the fluid flow within the hose is blocked or reduced. Periodically inspect the hose for wear, because any of these conditions can damage the hose and possibly result in personal injury. Never repair with tape. Do not use the hose to move attached equipment. Stress can damage the hose and possibly cause personal injury. Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must not come in contact with corrosive materials such as creosote-impregnated objects and some paints. Hose deterioration due to corrosive materials can result in personal injury. Consult the manufacturer before painting a hose. Never paint a coupler. PuMP Do not exceed the hydraulic pressure rating noted on the pump nameplate or tamper with the internal high pressure relief valve. Creating pressure beyond rated capacities can result in personal injury. Before replenishing the fluid level, retract the system to prevent overfilling the pump reservoir. An overfill can cause personal injury due to excess reservoir pressure created when the cylinders are retracted. Always shut off the motor and relieve pressure before breaking any connections in the system. The motor or engine is the major part of the weight of the pump. Always take this into consideration when lifting or moving the pump. CYlindeR Do not exceed the rated capacities of the cylinders. Excess pressure can result in personal injury. Do not set poorly balanced or off-center loads on a cylinder. The load can tip and cause personal injury. Read and understand the cylinder operating instructions and warning decals before using the cylinder. Operator s Mistake: A double-acting cylinder or ram must have both hoses and all couplers securely connected to both ports. If one of the two ports is restricted or becomes disconnected, pressure will build and the cylinder, hose or coupler can burst, possibly causing serious injury or death. HYdRAuliC Fluids Properly dispose of all fluids, components, and assemblies at the end of their useful life. Refer to MSDS sheet. Hydraulic fluid should be compatible with all hydraulic components. Refer to hydraulic fluid MSDS Sheet for temperature range. When using a low temperature hydraulic fluid and moving to a non low temperature application, change the fluid to the appropriate temperature range. Consult the MSDS sheet for useable temperature range. Page no. 5 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 PuMP OPeRATiOn When operating the pump for the first time: 1. Valve and hose connections must be tight, and the reservoir must be filled to the proper fluid level. Start the motor. 2. Jog the pump several times to build pressure. 3. Run cylinder out to its full travel several times to eliminate air from the system. For more complete instructions, refer to the section titled Bleeding The System under Set-up Instructions. 4. With the cylinder(s) retracted completely, check the fluid level in the reservoir and add fluid if necessary. Refer to Filling The Pump Reservoir under Set-up Instructions. 5. The pump is now ready to be put into regular operation. danger: When lifting or lowering a load, the load must be under operator control at all times and others must be clear of the load. use blocking and cribbing to guard against a falling load. do not drop the load. The use of a load lowering or metering valve is recommended in addition to the pump directional control valve. AiR Rotary Air Motor: Remove the thread protectors from the air inlet, and install the air supply fittings (not supplied) as shown in Figure 1. Air supply must be minimum 2.26 L/min. (80 CFM) and 5,5 BAR (80 PSI), with 2.83 L/min. (100 CFM) At 7 BAR (100 PSI) maximum. 1. Place the valve in the neutral or hold position. 2. Couple the air pump to the air supply and turn on the supply valve (if provided). 3. Open (or turn on) the air supply control valve at the pump (hold-to-run hand control is provided). 4. Shift the pump as necessary. 5. Turn the pump off when not in use. Figure 1 Recommended Air line Hook-up Quick Coupler here Reducing Bushing Air Motor locate in system here or... Hose Hold-to-run Hand Control (provided) diagram shown is for base unit without F-R-l, control valve and hand pendant To air source or supply here Lubricator Filter 6. Use of an air filter/lubricator is recommended. Page no. 7 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 Priming The Pump When operating the pump for the first time: 1. Valve and hose connections must be tight, and the reservoir must be filled to the proper oil level. Start the motor. 2. Jog the pump several times to build pressure. If the pump doesn't build pressure, it may not be primed. Short ON time of a 1/4 to 1/2 second repeatedly should prime the pump. An alternate method would be to throttle down the incoming air supply and run the motor at very low RPM. 3. Run wrench several times to eliminate air from the system. For more complete instructions, refer to the section titled "Bleeding Air From The System." 4. The pump is ready to be put into regular operation. important: After eliminating trapped air from a system with long hoses, retract the wrenchs and refill the pump reservoir to indicated fill level. Adjusting The Pressure Regulating Valve note: For easy adjustment of the pressure regulating valve, always adjust the pressure by increasing to the desired pressure setting. 1. The pump must be completely connected. 2. Turn knob counter-clockwise to loosen and decrease the setting to a lower than desired pressure. 3. Slowly turn the adjusting knob (B) in a clockwise direction. This gradually increases the pressure setting until the desired pressure is reached. important: The pressure range is from 1,000 to 10,000 Psi (69 Bar to 690 Bar) depending on the pump model. Adjustment Knob FiguRe 1 Page no. 8 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 PReVenTiVe MAinTenAnCe To help prevent personal injury, disconnect the pump from the air supply before performing maintenance or repair procedures. Repairs and maintenance are to be performed in a dust-free area by a qualified technician. Bleeding Air From The system Air can accumulate in the hydraulic system if the reservoir oil level is too low. This air causes the wrench to respond in an unstable or slow manner. To remove the air: 1. The hydraulic wrench(s) must be positioned on their side(s) with the couplers located upward. 2. Remove any load from the wrench(s), and cycle the hydraulic system through several cycles (fully extend and retract the wrench(s). note: The wrench must be at a lower level than the pump to allow air to be released through the pump Reservoir Hydraulic Fluid level 1. Check the oil level in the reservoir after each 10 hours of use. Proper oil level is indicated by the fill line when all wrenches are retracted. This is typically 44.5-50.8mm (1.75-2.00") from top of fill hole, depending on tank geometry. 2. Drain, flush, and refill the reservoir with an approved, high-grade hydraulic oil after approximately every 300 hours of use. The frequency of oil changes will depend upon the general working conditions, severity of use, and overall cleanliness and care given the pump. 3. The Air Supply Lubricator in the Filter-Regulator-Lubricator requires servicing to replenish the oil level. Check fluid level every 200 hours or less based on usage. 4. Lubricator oil is GAST#AD220 or an SAE10w High Detergent oil. The consumption rate is 1 drop of oil for every 50 CFM (1.41 L/MIN) air: Typically, 2 drops/min. Do not overfeed or the exhaust air will become contaminated. Maintenance Cleaning 1. Keep the pump's outer surface as free from dirt as possible. 2. Seal all unused couplers with thread protectors. 3. Keep all hose connections free of dirt and grime. 4. The breather-hole in the filler cap must be clean and unobstructed at all times. 5. Equipment connected to the pump must be kept clean. 6. Use only an approved, high-grade hydraulic oil in this pump. Change as recommended (every 300 hours). 7. The Air supply lubricator in the Filter-Regulator-Lubricator requires inspection every 200 hours. Page no. 9 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 TROuBlesHOOTing guide To help prevent personal injury, any repair work or troubleshooting must be done by qualified personnel familiar with this equipment. Use the proper gauges and equipment when troubleshooting. note: depending on the type of pump, it is often best to check for leaks by using a hand pump and applying pressure to the suspect area without the air motor running. Watch for leaking oil and follow it back to its source. Plug the outlet ports of the pump when checking for leakage to determine if the leakage is in the pump or in the wrench or tool. Refer to the Parts list included with your particular pump when using this troubleshooting guide. PROBleM CAuse solution Air motor does not run To help prevent personal injury, disconnect power supply before removing components. 1. Pump not turned ON. 2. Air supply is not plugged in. 3. No air in the supply. 4. Broken air lines or leaks in air lines. 5. Defective switches. 6. Defective motor. 7. Defective remote switch. 8. Overheated motor 1. Push air supply button to "ON" position. 2. Plug in unit to air supply. 3. Check air supply 4. Replace defective parts. 5. Check switches. 6. Repair or replace motor. 7. Repair or replace remote controls. 8. Wait for motor to cool before restarting. Check oil content in air supply. Page no. 11 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 PROBleM CAuse solution Pump is not delivering oil or delivers only enough oil to advance wrench(s) partially or erratically. 1. Oil level too low. 2. Loose-fitting coupler to wrench. 3. Air in system. 4. Air leak in suction line. 5. Dirt in pump or filter plugged. 6. Oil is bypassing through the double-acting wrench. 7. Cold oil or oil too heavy (Hydraulic oil is of a higher viscosity than necessary). 8. Relief valve or low pressure unloading valve out of adjustment. 9. Reservoir capacity is too small for the size of the wrench(s) used. 10.Defective directional valve. 11. Sheared drive shaft key(s) 12. Motor rotating in wrong direction. 13. Vacuum in reservoir. 1. Fill reservoir to 44.5 50.8mm (1.75" - 2.00") from top of filler hole with wrench retracted. 2. Check quick-disconnect couplings to wrench. Inspect couplers to ensure that they are completely coupled. Occasionally couplers have to be replaced because the ball check does not stay open due to wear. 3. Bleed the system. 4. Check and tighten suction line. 5. Pump filter should be cleaned and, if necessary, pump cartridges should be dismantled and all parts inspected and cleaned. 6. By removing the wrench and capping the hoses, the pump and valve can be checked. Observe if pump holds pressure. 7. Change to a lighter oil. 8. Adjust as needed. 9. Use smaller wrench(s) or larger reservoir. 10. Inspect all parts carefully and replace if necessary. 11. Replace. 12. Air motor: Air line connected into wrong port. 13. Check for plugged vent in filler plug. Page no. 12 Rev 1, 2 May 2011
Operating instructions Form no. 1000437 PCH Air Hydraulic/Pneumatic schematic Page no. 15 Rev 1, 2 May 2011