User Manual - Hydraulic Cylinders
Contents
1. 16 12 10 8 18 1 5 2 5 6 6 14 12 8 8 22 1 5 4 6 10 14 10 8 6 26 2 5 6 10 12 10 8 6 30 2 5 10 16 12 10 6 4 Table 2 Minimum Recommended Gauge Table Bleeding Air from the System After all connections are made the hydraulic system must be bled of any trapped air Refer to Figure 3 With no load on the system and the pump vented and positioned higher than the hydraulic device cycle the system several times If you are in doubt about venting your pump read the operating instructions for your pump Check the reservoir fluid level and fill to proper level with the hydraulic fluid as necessary If there is a problem contact the authorized dealers Figure 3 System Bleeding IMPORTANT Some spring return cylinders or rams have a cavity in the rod which forms an air pocket This type of cylinder or ram should be bled when positioned upside down or lying on its side with the port facing upward Page 10 Operating Instructions Bleeding Air from the System 1 Cycle the hydraulic system until operation is smooth and consistent 2 Check the pump reservoir level Add the hydraulic fluid as needed Electric Motor Control Operation 1 Connect the power cord to an appropriate power source 2 Place the motor control switch in the ON position 3 Depending on system requirements Refer to Figure 7 This remote will start and run the pump motor as long as the button is pressed Switch will automatically return to OFF position when2. Apply tape carefully two threads back to prevent it from being pinched by the coupler and broken off inside the system Loose pieces of sealant could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts Electric Motor Operation Motor voltages are not changeable They are 12 VDC 11 14 VDC 120 VAC 90 130 VAC 50 60 Hz 220 VAC 190 240 VAC 50 60 Hz 1 Verify the valve is in the neutral or hold position 2 Connect the motor to a power supply Caution e The correct voltage is required for the pump to operate Verify the voltage rating on the pump motor name plate matches the outlet or power source you are using Low voltage may cause an overheated motor a motor that fails to start under load motor surging when trying to Page 9 Initial Setup continued start or a stalled motor before maximum pressure is reached e Check the voltage at the motor with the pump running at full pressure Never run the motor on long light gauge extension cords Refer to Table 2 Minimum Recommended Gauge Table 3 Start the pump and shift as required 4 Turn off the pump when not in use AMPS AT Maximum Electrical Cord Size AWG mm 3 2 Volt Drop Length of Electrical Cord Hyd Pressure mm AWG 0 8 m 8 15m 15 30 m 30 46 m 0 25 ft 25 50 ft 50 100 ft 100 150 ft 6 0 75 1 1 5 2 5 18 16 14 12 10 0 75 1 5 2 5 4 18 14 12 10 14 1 2 5 4 6
3. DANGER Do not exceed rated capacities of the cylinders Excess pressure may result in personal injury Avoid off center loads that could damage the cylinder and or cause loss of the load Read and understand all safety and warning decals and instructions for devices attached Inspect each cylinder and coupler before each shift or usage to prevent unsafe conditions from developing Do not use cylinders if they are damaged altered or in poor condition Do not use cylinders with bent or damaged couplers or damaged port threads Under certain conditions the use of an extension with a hydraulic cylinder may not be advisable and could present a dangerous condition Avoid pinch points or crush points that can be created by the load or parts of the cylinder To help prevent material fatigue if the cylinder is to be used in a continuous application the load should not exceed 85 of the rated capacity or stroke Cylinder must be on a stable base which is able to support the load while pushing or lifting To help prevent personal injury use shims friction material or constraints to prevent slippage of the base or load Do not set poorly balanced or off center loads on a cylinder The load can tip or the cylinder can kick out and cause personal injury Do not use the locking collar on a threaded piston as a stop The threads may shear resulting in loss of the load If this component is used to lift or lower loads be certain that t
4. button is released and pump motor will turn off as expected during operation Figure 7 Push Button Remote Motor Control Performance Specifications The information in the following charts can be used as a basis to determine if the system is performing Amp Draw at Amp Draw at dB A at Idle 690 Bar 1 0 000 690 Bar 10 000 and 690 Bar Pune bali PSI 115V PSI 230V 10 000PS EP18 Series 2 860 9 6 4 8 67 81 EP211 Series 2 880 226 11 3 67 81 Table 3 Drive Unit Requirements Pump Max Pressure Output Bar oy E PSI Fluid Delivery cc min 0 Bar 0 PSI 7 Bar 100 50 Bar 700 70 Bar 345 Bar 690 Bar PSI PSI 1 000 PSI 5 000 PSI 10 000 PSI EP18 690 Bar 4200 2800 330 300 EP211 690 Bar 8200 7400 840 750 Typical delivery Actual flow varies with field conditions Table 4 Fluid Pressure Chart Page 11 General Maintenance WARNING e Disconnect the unit from the power supply before performing maintenance or repair procedures e Repairs and maintenance are to be performed in a dust free area by a qualified technician System Evaluation The components of your hydraulic system cylinders pumps hoses and couplings all must be Rated for the same maximum operating pressure e Correctly connected e Compatible with the hydraulic fluid used A system that does not meet these requirements can fail possibly resulting in serious injur
5. Do not connect a pump that may draw 25 amps to a 20 amp fused electrical circuit Never use an ungrounded power supply with this unit Changing the voltage is an involved and if incorrectly performed hazardous procedure Consult the manufacturer for specific information before attempting rewiring Wire pump motors for counterclockwise rotation when viewed from the shaft end of the motor Do not attempt to increase the power line capacity by replacing a fuse with another fuse of higher value Overheating the power line may result in fire Exposing electric pumps to rain or water could result in an electrical hazard Avoid conditions that can cause damage to the power cord such as abrasion crushing sharp cutting edges or corrosive environment Damage to the power cord can cause an electrical hazard WARNING Before operating the pump tighten all hose connections using the correct tools Do not overtighten Connections should be only secure 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 rupture burst or need to be disconnected immediately shut off the pump and shift the control valve twice to release pressure Never attempt to grasp a leaking hose under pressure 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 surf
6. POWERRAM HYDRAULIC TOOLS User Manual for EP18 Series EP211 Series Electric Powered EP18 amp EP211 Series Two Stage Hydraulic Pump Rev 0 May 2014 Table of Contents Description aria add AAA ar ae 2 PE18 211 Series Electric Hydraulic Pumps ooooooooooooo nooo 2 Control Vales ciar iaa EEN Cee SES 3 Safety Symbols and Definitions ooooooooooroor orar 5 Safety PTE CUOTA AE AREA AR 5 Mare dd IEA 9 Operating INSEMICHIONS daria aaa iaa 12 Performance Specifications s sa saas nan dd eee eee ee A ii 14 General Maintenances rra e e ee ee ee Re AER 15 Troubleshooting GUIde caido EA a EE de e 18 Page 2 Description The EP18 series hydraulic pumps are designed to have a maximum of 690 bar 10 000 psi at a flow rate of 260 cc min 16 cu in min A pump can be valved for use with either single or double acting cylinders The EP211 series pump all the same features as the EP18 series The EP211series is equipped with a 1 12 kW HP 2 880 RPM electric motor where the EP18 series is equipped with a 0 37 kW HP 2860 RPM electric motor All pumps come fully assembled less fluid and ready for work EP18 211 Series Electric Hydraulic Pumps The 17 series uses an induction motor Refer to the Performance section of this manual for motor ratings Electric Motor The EP18 series pumps are equipped with 0 37 kW 1 2 hp 2860 rpm single phase Brushless induction motor 3M remote control co
7. aces heavy impact or extreme heat or cold Do not allow the hose to kink twist curl 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 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 material such as creosote impregnated objects and some paints Consult the manufacturer before painting a hose Never paint the couplers Hose deterioration due to corrosive materials may result in personal injury Page 6 Safety Precautions continued e 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 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 e Carefully inspect all hoses and fittings prior to use Before each use check entire hose for cuts leaks abrasion or bulging of cover or damage or movement of couplings If any of these conditions exist replace the hose immediately NEVER attempt to repair the hose Cylinder
8. d level should be 1 3 3 8 cm 0 5 1 5 in from the top of the fill hole when all cylinders are retracted 2 Drain flush and refill the reservoir with an approved Powerram hydraulic fluid after every 300 hours of use The frequency of fluid changes depends upon general working conditions severity of use the overall cleanliness and care given to the pump Fluid should be changed more frequently when the system is not operated regularly indoors Page 12 General Maintenance continued Adding Hydraulic Fluid To The Reservoir 1 Retract the cylinder s devices 2 Disconnect the power supply 3 Clean the entire area around the filler plug 4 Remove the filler plug and install a clean funnel with a filter 5 Use only Powerram hydraulic fluid rated at AW 46 47 cSt 38 C 215 SUS 100 F If low temperature requirements are needed use hydraulic fluid 5 1 cSt 100 C 451 cSt 40 C Sound Reduction Electrically Powered Motor The electrically powered hydraulic pump operates in the 67 81 dBA range If further sound reduction is desired any of the following options will help reduce the sound level 1 Install a pressure switch to automatically shut off the motor when maximum pressure is reached holding cycle 2 Contact Powerram Authorized Dealers support for products more suitable to your application Hose Connections CAUTION To prevent personal injury from leaking hydraulic fluid seal all hydraulic connections wit
9. ed will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor CAUTION Used without the safety alert symbol indicates a potentially hazardous situation which if not or moderate injury avoided may result in property damage IMPORTANT Important is used when action or lack of action can cause equipment failure either immediate or over a long period of time Safety Precautions WARNING The following procedures must be performed by qualified trained personnel who are familiar with this equipment Operators must read and understand all safety precautions and operating instructions included with the pump If the operator cannot read these instructions operating instructions and safety precautions must be read and discussed in the operator s native language These products are designed for general use in normal environments These products are not designed for lifting and moving people agri food machinery certain types of mobile machinery or in special work environments such as explosive flammable or corrosive Only the user can decide the suitability of this product in these conditions or extreme environments Power Team will supply information necessary to help make these decisions Consult your nearest Authorized Dealersy Saf
10. ety glasses must be worn at all time by the operator and anyone within sight of the unit Additional personal protection equipment may include face shield goggles gloves apron hard hat safety shoes and hearing protection The owner of this tool must ensure that safety related decals are installed maintained and replaced if they become hard to read Shut OFF the motor before opening any connections in the system The guide cannot cover every hazard or situation so always do the job with SAFETY FIRST Pump WARNING 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 Retract the system before adding fluid to prevent overfilling the pump reservoir An overfill can cause personal injury due to excess reservoir pressure created when cylinders are retracted The load must be under operator control at all times Page 5 Safety Precautions continued e Do not connect pump to hydraulic system powered by another pump Electric Motor WARNING Hoses Electrical work must be performed and tested by a qualified electrician per local directives and standards Disconnect the pump from the power supply and relieve pressure before removing the motor case cover or performing maintenance or repair Check the total amperage draw for the electrical circuit you will be using For example
11. h a high quality non hardening pipe thread sealant IMPORTANT Sealant tape or non hardening sealer tape can be used to seal hydraulic connections if only one layer of tape is used Apply tape carefully two threads back to prevent it from being pinched by the coupler and broken off inside the system Loose pieces of sealant could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts Storage Store the unit in a dry well protected area where it will not be exposed to corrosive vapors dust or other harmful elements If a unit has been stored for an extended period of time it must be thoroughly inspected before it is used Page 13 WARNING Troubleshooting Guide Repair work or troubleshooting must be performed by qualified personnel who are familiar with this equipment e Disconnect the power supply before removing the electrical cover Electrical work should be performed by a qualified electrician e Check for system leaks by using a hand pump to apply pressure to the suspect area Watch for leaking fluid and follow it back to its source Never use your hand or other body parts to check for a possible leak Notes Fora detailed parts list or to locate a Powerram Authorized Hydraulic Service Center contact your nearest Powerram Authorized Dealers Plug the outlet ports of the pump when checking for leakage to determine if the leakage is in the pump in the cylinder or i
12. he load is under operator control at all times and that others are clear of the load Do not drop the load As the load is lifted use blocking and cribbing to guard against a falling load To help prevent personal injury do not allow personnel to go under or work on a load before it is properly cribbed or blocked All personnel must be clear of the load before lowering Page 7 Safety Precautions continued Never use extreme heat to disassemble a hydraulic cylinder or ram Metal fatigue and or seal damage will result and can lead to unsafe operating conditions IMPORTANT e Keep the cylinder clean at all times e While at a job site when the cylinder is not in use keep the piston rod fully retracted and upside down Always use protective covers on disconnected quick couplers When mounting cylinders or rams using the internal piston rod threads collar threads threaded tie rods or base mounting holes the threads must be fully engaged Always use SAE grade 8 or better fasteners when attaching components to cylinders or rams and tighten securely e Limiting the stroke and pressure on all cylinders will prolong their life Page 8 Initial Setup 1 Remove all packing materials from the assembled unit 2 Inspect the unit upon arrival The carrier not the manufacturer is responsible for any damage resulting from shipment Filling the Pump Reservoir Most pumps are shipped without hydraulic fluid in the reserv
13. kage 3 Same procedure as above but for leaks around the entire inner mechanism If there are no visible leaks the low to high pressure ball check may be leaking Remove all parts Inspect the check body for any damage to the seat areas Clean and reseat if necessary Inspect the ball for damages and replace if necessary then reassemble 4 Sheared key s 4 Replace 5 High pressure pump inlet or outlet ball checks in the pump are leaking 5 Reseat or replace valve head Automatic valve will not build full pressure 1 Unloading pressure is too low 1 Increase unloading pressure per chart sheet 3 of 4 2 Defective or oversize seat on utomatic valve 2 Replace ball and seat Electric motor cuts out 1 Extension cord is too long and or not of sufficient gauge 1 Replace 2 Faulty motor 2 Replace and repair 3 Overheated motor can trip circuit breaker in shop power panel 3 Allow motor to cool reset circuit breaker located in shop power panel Foaming hydraulic fluid 1 Hydraulic fluid being splashed by counter weight 1 Lower hydraulic fluid level to approximately 38 mm 1 5 inches below the cover plate Cylinder s will not retract 1 Check the system pressure if the pressure is zero the control valve is releasing pressure and the problem may be in the cylinder s mechanical linkage connected to cylinder s or quick disconnect cou
14. n the tool Problem Cause Solution Electric motor does not run 1 Unit is not plugged in 1 Plug in unit 2 No voltage supply 2 Check line voltage 3 Broken lead wire or defective power cord plug 3 Replace defective parts 4 Defective motor 4 Replace or repair motor Pump is not delivering hydraulic fluid or delivers only enough hydraulic fluid to advance cylinder s partially or erratically 1 Hydraulic fluid level too low 1 Fill reservoir to 1 1 2 below the cover plate maximum 2 Air in system 2 Bleed the system 3 Debris is in pump or filter is plugged 3 Pump filter should be cleaned and if necessary pump should be dismantled and all parts inspected and cleaned 4 Cold hydraulic fluid or hydraulic fluid is too heavy hydraulic fluid is of a higher viscosity than necessary 4 Change to lighter hydraulic fluid 5 Relief valve or low pressure unloading valve out of adjustment 5 Readjust as needed 6 Sheared drive shaft key s 6 Replace 7 Motor rotating in wrong direction 7 Reverse rotation Page 14 Troubleshooting Guide continued Problem Cause Solution Pump will not build full pressure 1 Faulty pressure gauge 1 Calibrate gauge 2 Check for external leakage 2 Seal any faulty pipe fittings with Pipe sealant 3 Inspect the pump for internal lea
15. oir Hydraulic fluid may have been shipped in a separate container but if hydraulic fluid is needed use only approved Powerram hydraulic fluid rated at AW 46 47 cSt O 38 C 215 SUS 100 P If low temperature requirements are needed use hydraulic fluid 5 1 cSt 100 C 451 cSt 40 C 1 Clean the area around the filler cap to remove debris Debris in the hydraulic fluid can damage the polished surfaces and precision fit components of this pump 2 Remove the filler cap and insert a clean funnel with a filter 3 Fill the reservoir with hydraulic fluid to 8 L and 11 L from the cover plate 4 Replace the filler cap Verify the breather hole is open if applicable NOTE If hydraulic fluid foaming becomes a problem reduce the hydraulic fluid level to 2 below the cover plate Hydraulic Connections 1 Clean the areas around the fluid ports of the pump and cylinders 2 Inspect all threads and fittings for signs of wear or damage replace as needed 3 Clean all hose ends couplers or union ends 4 Remove the thread protectors from the hydraulic fluid outlets 5 Connect the hose assembly to the hydraulic fluid outlet and couple the hose to the cylinder CAUTION To prevent personal injury from leaking hydraulic fluid seal all hydraulic connections with a high quality non hardening pipe thread sealant IMPORTANT Sealant tape or non hardening sealer tape can be used to seal hydraulic connections if only one layer of tape is used
16. plings 1 Check the cylinders for broken return springs and check couplers to ensure that they are completely coupled Occasionally couplers have to be replaced because one check does not stay open in the coupled position Pump delivers excess hydraulic fluid pressure 1 Pressure gauge is not accurate 1 Calibrate gauge 2 Relief valve not properly set 2 Reset the relief valve Page 15 Troubleshooting Guide continued Problem Cause Solution Automatic valve will not release pressure 1 Sticking piston 1 Remove clean and polish 2 High pressure hydraulic fluid is leaking past the low to high pressure check This hydraulic fluid leaks back to the piston in the automatic valve keeping the piston closed 2 Seat the ball check Inspect and replace any faulty components Page 16
17. rd Low amperage draw small generators and low amperage circuits can be used as power source Extremely quiet noise level 67 81 dBA The EP211 series pumps are equipped with 1 12 kW 2880 rpm single phase Brushless induction motor Figure 1 EP18D Figure 2 EP211D Page 3 Control Valves Max Capacity 690 Bar 10 000 PSI Valve Function Use with Valve No Cylinder EP18D Type EP211D Single amp BP423 4 way 3 CENTER double Position pump POSITION A POSITION POSITION B acting mounted manual detented A y Diagrams Port A n Port B Port A AZ GY Yl 1e T T A Cy Pump Valve Function Use with Valve No Cylinder Type EP18S Single B1014 2 way 2 EP2119 7 lt Ma MR 8 acting position pump gt a mounted manual A y detented Diagrams D Q Valve Function Use with Valve No Cylinder Siapa i Type 18 471 217 3 RETURN Single 4 1 5 EP211SS ar near PUMP OFF ies way 2 position DE EMERGIZED DE EMERGIZED EMERGIZED 8 pump mounted solenoid operated normally closed Diagrams Table 1 Pump Configurations Page 4 Safety Symbols and Definitions The safety signal word designates the degree or level of hazard seriousness DANGER Indicates an imminently hazardous situation which if not avoid
18. y If you are in doubt about the components of your hydraulic system contact Powerram Technical Support Inspection Keep a dated and signed inspection record of the equipment An inspection checklist is available on request from your nearest Authorized Dealers Before each use the operator or other designated personnel should visually inspect for the following conditions e Cracked or damaged cylinder Excessive wear bending damage or insufficient thread engagement e Leaking hydraulic fluid Scored or damaged piston rod e Incorrectly functioning or damaged heads and caps Loose bolts or cap screws Damaged or incorrectly assembled accessory equipment e Modified welded or altered equipment Bent or damaged couplers or port threads Periodic cleaning WARNING Contamination of the hydraulic fluid could cause the valve to malfunction Loss of the load or personal injury could result Establish a routine to keep the hydraulic system as free from debris as possible e Seal unused couplers with dust covers Keep hose connections free of debris Equipment attached to a cylinder must be kept clean Keep the breather hole in the filler cap clean and unobstructed Use only Powerram hydraulic fluid Replace hydraulic fluid as recommended or sooner if the fluid becomes contaminated Never exceed 300 hours of use between fluid changes Hydraulic Fluid Level 1 Check the fluid level in the reservoir after each 10 hours of use The flui
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