c u m pI n s t r u c t i oSnh e e t
A i r H y d r a u l iP
p si
{ O T OOO
Air Hydraulic Pump
ASSEMBLY & OPERATION
INSTRUGTIONS
-'____----l
T
I
-
u l i cP u m pl n s t r u c t i oSnh e e t
SAVETHESEiNSTFUcrloNS. Foryoursafety
and the safetyof othersaroundyou,
readcarefullybeforeattemptingto install,assemble,
serviceor use this air hydraulic
pump observe all safety and warning
information.
Failureto comply with the
information
containedwithincould resultin severe,even fatal injury
and/orpropeny
damage.
G E N E R A LD E S C R I P T I O N
Theairhydraulic
pumpscandeliverhydraulic
fluidpressure
up to 10,000psl. lt consists
of an in-lineairand hydraulic
cylinder.
lt hasan operating
pressure
of 10,000psl at 125
PSI air inletpressure'lt is suitedfor plantmaintenance,
fabrication,
bolting,vehicle
repairandanytaskthat requires
hydrauric
pressure
fromair input.
Specifications
Hydraulic
Capacity
pressure
AirOperating
Hydraulic
Ouilet
AirInlet
OilTankCapacity
OilCapacity
Useable
O i lF l o wa t 1 0 , 0 0 0p S l
O i lF l o wa t 1 0 0p S l
Operating
Noise
AirConsumption
at 100 psl
10,000
P S I ( 7 0 0 B a r)
2 5 - 1 4 5 P S t( 1 . 7 - 1 0 B a r )
3 / 8 "- 1 8N P T( f e m a t e)
Rc 114"-19 ( femate)
2 . 5L ( 1 5 0c u .I n )
2 . 1L ( 1 2 8c u . i n)
0 . 1 1 U m i(n7 c u . i n/ m i n . )
O . B /Lm i n( 4 B . Bc u . i n/ m i n .)
70 dBA
pSl
340L I min.at '10,000
Technical Features
1.
2.
3
4.
Heavy-duty
aruminum
reservoir
for durabirity
and rightin werght.
Equipped
withmuffrer
to reduceworkingnoiseand operator
fatigue
Threeposition
treadleeasilyprovides
pressure,
holdand retease
operation
Internalpressurereliefvalveprovidesoverloadprotection
t wARNINGT
It is the responsibility
of the ownerand / or operatorto readthis instruction
manual
carefullybefore using your air hydraulicpump. proper
use and care of the
airlhydraulic
pumpswill helpassureyou of continuous,safe,
troublefreeperformance.
Failureto followany of these instructionsmay result property
in
damageor personal
injury.
Page 2
A i r H y d r a u l iP
c u m pI n s t r u c t i oSnh e e t
Whenusingpneumaticequipment,basicsafetyprecaution
shouldalwaysbe followedto
reducethe riskof personalinjuryand hazardsdue to overpressurization.
= = ; Z : . = ? " - ' ; = z : ' : ' : . ' ." , : : - z 1
. 1 - : - . : ::.:.: : . .
SafetyWarnings
'1. To preventpersonal
injury,alwaystakingproperprotective
wear when operating
h y d r a u l iecq u i p m e n t .
2. Pumpreservoir
mustbe vented.Failureto do so maycausethe rapidformation
of
vaporpockets,
whichcandamagethe pump.
3. All hosesand components
usedwiththesepumpsmusthavea workingpressure
ratinghigherthanor equalto the maximumpressure
ratingof the pump
4. Beforeusing,makesurethatallthe hosesandcomponents
are properly
connected
in accordance
withthisinstruction.
5 . O n l yp r o p e r ltyr a i n e d
w o r k e r cs a nu s et h i sA i rH y d r a u l p
i cu m p s .
6. Do not operatewith pressureover 145 PSl, whichmay causedamageand void
warranty.
7. Whentransferthe pumpor in anyverticalposition,
be sureto fastenthefillscrew.
B. Do notuse if youdetectstructure
failureduringuse.
9. Do not use if anycomponent
is foundmissingor damaged
' 1 0T. h e
a i r l h y d r a u l i cp u m pi s c a p a b l e
o f g e n e r a t i nf g
l u l dp r e s s u ruep t o 1 0 , 0 0 0P S l .
Makecerlainthe toolin useis heldsecurelyand is in properworkingcondition.
Do
notcontinue
to operatethepumponcetheworkis completed.
11.Stayclearof loadssupported
by hydraulics.
A cylinder,
whenusedas a loadlifting
device,shouldneverbe usedas a load holdingdevice.Afterthe loadhas been
raisedor lowered,it mustalwaysbe blockedmechanically.
12.To avoidpersonalinjurykeephandsand feet awayfrom cylinderand work-prece
duringoperation.
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A i r H y d r a u l iP
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13.Useonly rigidpiecesto holdloads.Carefully
selectsteelor woodblocksthat are
capableof supporting
the load.Neveruse hydraulic
cylinder
as a shimor spacerIn
anyliftingor pressingapplication.
14.Do not exceedequipment
ratings.Neverattemptto lifi a loadweighingmorethan
the capacityof the cylinder.Overloading
causesequipment
failureand possible
personal
injury.The cylinders
aredesigned
for a max.pressure
of 700 bar ( 10,000
P S t) .
15.Neverset the reliefvalveto a higherpressure
thatthe maximumratedpressureof
the pump.Highersettingsmayresultin equipment
damageandI or personalinjury.
16.The systemoperatingpressuremustnot exceedthe pressureratingof the lowest
ratedcomponentin the system.lnstallpressuregaugesin the systemto monitor
pressure.
operating
17.Avoid damaginghydraulichose. Avoid sharp bends and kinks when routing
hydraulichoses.Usinga bent or kinkedhose will causesevereback-pressure.
Sharpbendsand kinkswill internally
damagethe hoseleadingto premature
hose
failure.
'18.Do
not dropheavyobjectson hose.A sharpimpactmaycauseinternaldamageto
hosewirestrands.
Applyingpressure
to a damagedhosemaycauseit to rupture.
'19.Do
not lift hydraulicequipment
by the hoseor swivelcouplers.
Use the carrying
handleor othermeansof safetransoort.
20. KeepHydraulic
equipment
awayfromflamesand heat.Excessive
heatwill soften
packings
and seals,resulting
in fluidleaks,Heatalsoweakenshosematerials
and
packings,
Foroptimumpefformance
do notexposeequipment
to temperature
of 650
(
C 1500F )or higher,Protecthoseandcylinders
fromweldspatter.
21. Do nothandlepressured
hoses.Escaping
oil underpressure
canpenetrate
theskin,
causingseriousinjury, lf oil is injected
undertheskin,seea doctorimmediately.
22. Only use hydrauliccylindersin a coupledsystem,Never use a cylinderwith
unconnected
couplers.lf the cylinderbecomesextremely
overloaded,
components
canfailcatastrophically
causingserverpersonal
injury.
23. Hydraulic
equipment
mustbe onlybe serviced
by a qualified
hydraulic
technician.
To
protectyourwarranty,
useonlyhigh-grade
oil.
24. lmmediately
replacewornor damaged
parts.
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A i r H y d r a u l iP
c u m pI n s t r u c t i oSnh e e t
lnstallation
Beforeinstallation,
checkall the itemswiththe packinglistprovided
to makesurethatno
partsare missing.
Visuallyinspectallcomponents
for shipping
damage.Shipping
damage
is not coveredby warranty. lf shippingdamageis found,notifycarrierat once.The
carrieris responsible
for all repairand replacement
costs resultingfrom damagein
shipment.
'1. AIR
S U P P L YP. u m po p e r a t ew i t h2 5 - 1 4 5P S I a i r a n d a m i n r m u m
o f 3 4 0 U m i na, i r
pressureis requiredto obtain68.9Mpahydraulicpressure.A regulatorI filterI
lubricator
shouldbe installed
upstream
frompumpto provide
clean,lubricated
air and
allowfor air oressure
adiustment.
2 . A I R C O N N E C T I O NA
St.t a c ha i r s u p p l yt o t h e R c 1 1 4 " - ' 1c9o n n e c t i oonn t h e e n d o f
the pump.UseTeflontapeor similarthreadsealant.
Torqueto 20-25ft.lbs.( 27 - 34
N m) .
A CAUTION
Do not operatewith air pressureabove1.0Mpaor damagemay occur
which could void your warranty
4 . H Y D R A U L IC O N N E C T I O N S .
Threadhoseintooutletportof pump.Use1-112
wrapsof Teflontapethe NPThosefittings
only,leavingthe firstcompletethreadfree of tapeto ensurethat piecesof tapedo not
breakoff and enterthe system.Torquehosefittingsto 65 - 75 ft lbs (BB -102Nm).The
outletporlis locatedon the opposite
of pumpfromthe air inletconnection.
Valveblockor
treadleshouldbe restrained
when torquingfittings.The reservoirbaseshouldnot be
Page 5
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A i r H y d r a u l iP
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bolteddown or restrainedto compensatefor the fittinqsinstallation
toroue
5.
V E N T I N GT
. h i s p u m p m u s ta l w a y sb e v e n t e dp r i o rt o u s e .
a)
VENT SCREW. The vent screw should be screwed on to vent the reservorr
when the pump is operated in the horizontalposition.lt is located near the
hydraulicoutletport on the top of the reservoir.To use this screw,take off the Fill
Screw ( in Black ) and screwedVent Screw ( in Brass )on. The vent screw can
N O T b e u s e d w h e n t h i sp u m pi s m o u n t e dv e r l i c a l l yW
! h e n m o u n t i n gi n t h e v e r t i c a l
positionor for shippingpurpose,use the fill screw.See picturebelow.
b) FILL SCREW.The fill screwis locatedon the sameposrtion
of the vent screw.
This screwserversonly for shipping.
To use as a fill port,removethe vent/fill
screwfromthe reservoir.
Oil levelshouldbe to bottomof oort.
* cAUTroN!!
When the pump in the verticalposition,the fill screw must be screwedfast.
6 . OIL LEVEL.Alwayscheckoil levelw i t ha l l c y l i n d e rosr toolsin the fully retracted
position.
lf theyare advanced
whent h ep u m pi s f i l l e dt.h e reservoir
willbe over-filled
whentheyare retracted.
Pagc 6
!.!Itq!ionsnu"t
Operation
1 . OfL LEVEL.
Checktheoil
levelof pump
and
addoilif necessary
2. VENT|NGpUMp.
Makesurethe
pumpreservorr
rs vented
3 TREADLE
OPERATION.
a) TO ADAVNCE
"PREssuRE'
pumpwil .,"nt,^":t]tDER' Depre
'
ropump
end of treadle
nuo,.*ii",::^t:"
r to the system.
and the
o) TO HOLD
THE
Posrr The
when
the,,.""o;?l:rljDER
tnerreezne-urr]ot pumpwillI
"pnEssuRa,
":,,'::
ton
r RELEAsE
;;#:'os i;ffi,:[::i#?"::jiilTil::
c) To RETRACTC
cylinder.,o .,oo'll'NDER Depress1
.vri,o",.
,,.".0,e
ii,il:,::;;ffTl::"
rhe
toretract
ho,dins
o".,,,jll
il: ,".11:
readleand return
it to
A rvore
TlProiongrneusffi
PR|II4,NG.primino
of rho x..-,
pump
pum
is;,; #;"",:,lfi
fvo'auric
-,-terv
our
or
";,;;;;";":::jHI
f:::::l;ill l"fift,l;
steps:
rernove
- - prace
and
P'quett
iton
onthe
;:iff:vertica'v,
r horizontatsurrace
fl set
:iinffi
air;;;;,"i:'::'::'^
:]
d)
wrl.ir"
i"rorg ;^t::'t-
^o'27s
Mpa
press
,he
e);:l*;"*Yilf:i:ifi;fflfe o.s,.n
cvnder
d.e;
fi ilfiJ:,:;l**?#,:'
mm*I5"J;,.,,*
PRESSURE
ADJUSTMENT
ro obtainless
thann
he systemor
";,;;;;,n']l}'
hvdrautic
pr
rimit
enher
#ilil,H':Hr,:ssure,
- ""-'ort pr€ssUre
insl
L"^y',"
rrso
rerier
relief
down
oown
o"*r
//hen
when
varve
valve
and
and
limiting
limiting,;.;;"::1'stable
stail
stall
in
in
,llll",,",i;;;ffi:;Tn1:,'#ll,l'lli:.i,srabre
,
as
the
the hvrjr.,,t:^
i
11so
,:,1:.:
rpressure
pump
in"'u'.J.
wi,
;:;ff"::";i:;ti=Hril:ffiTg:x:r.n:iii;:il'i:f
;J;ffffi
il:;ff,:'
#;.'.T;
<ssure un,
; f'a a starr-out
ano
;:1;ffi:""n';*:'l'iliil,ff;J;';i':
increase
pressure
.*,1.berow
theairpres";
,n"-ol"lo"'
;#TJTI
fr:tii:!:::
<ireorrvorau,,",i,]l.,'"ohydraulicpreSSUre.
is reached.
Repeat
#re 7
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A i r H y d r a u l iP
c u m pI n s t r u c t i oSnh e e t
pumpoperation
to verifythe stall-out
pressure.
A NOTE
Thesepumpswere not designedfor stallto restartapplications.
The sealson the
pump will not ensurethe pressuredrop accuracyrequiredfor effectivestall to
restartoperation.
Maintenance
1. MAINTAINING
P R O P E RO I L L E V E L
Check the oil level of the pump priorto starl-up,and add hydraulicoil, if necessary,Dy
removingthe vent/fillscrew ,
-I-HE
2. CLAENING
MUFFLER.
Clean the mufflerevery
, o r m o r e f r e q u e n c yi f p u m p i s u s e d i n d i t l y
environment.
To exposethe muffler,
remove2 screwsholdingdownmufflerplate Wash
mufflerelementin soapwater,dry,and reassemble,
installing
screwshandtight.
3 . C H A N G I NT
GH EO I L .
change the oil every
The venvfillplug servesas a drainplug used for
c h a n g i nogi l .R e f i lpl u m pw i t hh y d r a u l o
i ci l .D i s p o soef u s e do i lp r o p e r l y .
Page8
A i r H y d r a u l iP
c u m pI n s t r u c t i oSnh e e t
Nipple: R c 1 / 4 "- ' 1 9
Air Disconnect
Hydraulic
OutputPort: 3/8"- 1B NPT Female
Coupleras follows:
OptionalHydraulic
l/8-18NPr
Page 9
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A i r H y d r a u l iP
c u m pI n s t r u c t i oSnh e e t
"\ssl*
ItemNo.
0 1*
02*
03
04
Description
O Ring
BackupRing
Oil OutletScrew
Spring
Quantity
2
SteelBall
1
06
07"
0B*
09
10
Oil Feedback
Screw
BackupRing
O Ring
DowelPin
1
1
Oil Feedbackvalve
1
1'1
SteelBall
1
tz
1e
14
16
SteelBallBase
Spring
AllenScrew
Spring
Foot Pedal
Page10
I
z
1
1
1
1
I
'l
1
1
I
17
1B
19
20
21
22
23*
24
25
26
2728
29
30
J I
32
33
34
aR
36
37*
3B
39
40
41
42
43
AllenBoltScrew
SpringWasher
Washer
SpringClip
Block
Retaining
ActuatorButton
O-Ring
AllenBoltScrew
Air InletFitting
IntakeAir ValveBody
z
2
2
1
1
,l
I
I
b
1
'l
SealWasher
Air ValvePoppet
AllenBoltScrew
Spring
1
O-Ring
2
2
2
Ring
Retaining
Muffler
ReleaseValveBody
Mesh
Oil Filtration
Ring
Retaining
O-Ring
ReleaseValveButton
Pin
Snap-Ring
ConeSpring
Cap Screw
CopperWasher
I
'1
I
1
2
2
'l
1
'l
2
1
10
10
1
44*
O-Ring
45
CoverPlate
Screw
Washer
SealGasket
PressureSettingScrew
SafetySpring
ValvePin
Release
SealGasket
ReleaseValveScrew
1
SealWasher
AllenBoltFixingScrew
SteelBall
EndBlack
Oil IntakeScrew
Reservoir
e
46
47
48
49
50
51
52
53
54
55
56
57
5B
59
Page ll
'l
{
I
'l
1
1
1
1
1
1
2
1
1
1
A i r H y d r a u l iP
c u m pl n s t r u c t i oSnh e e t
bU
Seal Gasket
61
Hexcylinder
U-Cap
B a c k - UR
p ing
BrassSleeve
HexBoltNut
SpringBase
62
63
o4
6B
69
T
P l u n g eAr s s ' y
PistonAss'y
I
A i rC y l i n d e r
72
/.t
SealGasket
Allen BoltScrew
T R O U B L ES H O O T I N G
only qualifiedhydraulictechnicians
shouldservicethe pumpor systemcomponents.
A
systemfailuremay or may not be the resultof a pumpmalfunction.
To determine
the
causeof the problem,
thecomplete
systemmustbe included
in anydiagnostic
proceoure.
Thefollowing
information
is intended
to be usedonlyas an aid in determining
if a problem
exists Do NoT disassemble
the pump.For repairservice,contactAuthorized
Service
Centersin Vourarea.
Symptoms
Pumpdoesnotstart
2) Pumpdoesnot rectprocare
3 ) A i rm o t o rf a i l st o b u r l dp r e s s u r e
4) Pumpreciprocates
but no pressure
5 ) P u m pb u i l d sl e s st h a nf u l lp r e s s u r e
ProbableCause
. Airsupply
turnedoffor air lineblocked:
. Airpiston
stuck.
1 ) C h e c k c y l i n d e rb o r e o f p u m p l o r
contamination
or lackof lubrication.
2) Pistonpoppetnotsealing. Replace.
* External
leakin system;
- Internal
l e a ki n p u m p ;
" Internal
leakin systemcomponent;
. Low
oil level
Checkprime.Depressboth air valveand
hydraulic
releasevalveat thesametime.
" Check
airsupply.lowairpressure;
* Internal
reliefvalvesetlow:
Page12
Air HydraulicPumpInstruction
Sheet
. Externalsystemleak;
. Inletcheckballnotseating
properly;
"
6) Pumpwillnot holdsystempressure
properly;
Outletcheckballnotsealing
* Releasevalve mechanismnot
sealing
properly.Checkpin, ball, releasepoppet
and poppetretainer.
pressure,
7) Pumpbuild
but the loaddoes * loadgreaterthancylinder
capacityat full
pressure;
not move
" Flowto cylinder
blocked;
8) Pumpwill not buildmaximumpressure. . Check piston sub-assembly;
Replace
Visualsign of leakagethroughair exhaust copper gasket and assemblein verlical
muffler
position.
pistonpacking.
Replace
willnot return
9) Cylinder
'10)Low
oil flow rate
Returnflow or couplerrestricted/locked;
No loadon a " loadreturn"cylinder;return
springbrokenon cylinder,Releasevalve
malfunction;
. Reservoirnot vented; Inadequate
air
supply;Dirtyairfilter;Cloggedinletfilter;
Page 13