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KEN-503-7170K_8960K_Instructions_KEN-503-7170K_8960K_Instructions.qxd 11/07/2012 13:10 Page 4
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.
SETTING UP
9. Bent or damaged couplers or port threads.
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
OPERATING
have to be used - See REPAIRS on page 6 for further information). Tighten securely but do not over tighten.
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.
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
APPLICATIONS AND LOAD CAPACITY
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
100% of ram capacity
capacity will be reduced by
a further 50% and each
additional single extension will
reduce the capacity by
50% of ram capacity
a further 50%. If connecting
more than two extensions
together, ensure that the short
extension is positioned the
furthest away from the
hydraulic ram.
4
25% of ram capacity
Pressure Release Valve
50% of ram capacity
25% of ram capacity
6% 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.
TROUBLE SHOOTING - PUMPS
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.
FAULT
POSSIBLE CAUSE
Pump loses pressure.
1.System components leaking.
Pump not delivering oil.
1. Low oil level in reservoir.
2. Seats are worn.
Pump does not reach
1. Low oil level in reservoir.
rated capacity.
2. System components leaking.
3. Fluid leaking past inlet or outlet
check valves.
Pump handle has
1. Air trapped in system.
'spongy' feel.
2. Too much oil in reservoir.
TROUBLE SHOOTING - RAMS
FAULT
POSSIBLE CAUSE
Ram piston will not
1. Loose couplers.
extend.
2. Low oil level in pump reservoir.
3. Ram seals leaking.
Ram system extends
1. Low oil level in pump reservoir.
only partially.
2. The load exceeds the capacity of the
system.
Filler plug
screw
Filler plug
screw positioned
here on HPT035
SOLUTION
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.
SOLUTION
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.
5
Continued on page 6
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