User Manual - Abest Industrial Supply
Contents
1. oO eo eo 235 H FA 42 s 19 20 17 18 7 16 to A 9 Nd 92004008 ERINGE15 Part Description 92004025 SPRING 92004050 BUSHING 92004053 U WASHER 92004033 PIN 92004059 O RING 92004037 O RINGGES 920040 38 FILTER 920040 62 CHANGE PISTON 920040 39 ALUMINUM PUMP BASE 920040 63 PISTON A 920040 12 O RING P12 B OVRLD SPRING END CAP OVRLD SPRING ACKUP RING P14 920040 40 SILENCER 920040 64 920040 42 LOW SPRING 920040 66 O RING S70 920040 43 STEEL BALL 8MM 920040 67 TOP CAP 920040 44 HIGH SPRING 920040 68 AIR INLET VALVE 92004020 O RINGPS 92004023 BUSHING 92004069 SPRING 92004048 URING 92004041 sPRING 920040 65 SCREW M5 18L o ZINKO PO Box 4903 http www zinko com Phone 909 989 9526 Hydraulic Jack Ontario CA 91761 Toll Free 1 800 579 8088 Fax 909 989 17242. MODELS ZAP 40 amp ZAP 62 Hydraulic Jack Air Hydraulic Foot Hand Pump Toll Free 7 800 579 8088 Web www zinko com Operating Instructions amp Repair Parts List Operator Responsibilities It is the operator s responsibility to read and understand the following safety statements Only qualified operators should install operate adjust maintain clean repair or transport this machinery These components are designed for general use in normal environments These components are not specifically designed for lifting and moving people agri food machinery certain types of mobile machinery or special work environments such as explosive flammable or corrosive Only the user can decide the suitability of this machinery in these conditions or extreme environments ZINKO will supply information necessary to help make the decision These instructions are intended for end user application needs Most problems with new equipment are caused by improper operation or installation A detailed parts list can be obtained from ZINKO upon request AWARNING All Warning Statements must be carefully observed to help prevent personal injury 1 Before operating the pump all hose connections must be tightened with proper tools DO NOT OVER TIGHTEN Connections should only be tightened securely and leak free Over tightening can cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities Should a h
3. P DO NOT EXCEED THE HYDRAULIC PRESSURE RATING NOTED ON THE PUMP DATA PLATE OR TAMPER WITH THE INTERNAL HIGH PRESSURE RELIEF VALVE Creating pressure beyond the rated pressure 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 cylinders are retracted AIR SUPPLY 1 SHUT OFF AND DISCONNECT THE AIR SUPPLY WHEN THE PUMP IS NOT IN USE OR BEFORE BREAKING ANY CONNECTIONS IN THE SYSTEM Preparations amp Setup Air Supply Hook up Remove the thread protector from the air inlet of the pump Select and install the threaded fittings which are compatible with your air supply fittings The air supply should be 20 CFM 57 M3 mm and 100 psi 7 bar at the pump to obtain the rated hydraulic pressure Air pressure should be regulated to a maximum of 140 psi 9 bar Secure your pump fitting to the air supply f improperly used pressurized equipment can be potentially hazardous Therefore 1 Hydraulic connections must be securely fastened before building pressure in the system 2 Release all system pressure before loosening any hydraulic connection in the system Operating Instructions Hydraulic Connections Clean all the areas around the fluid ports of the pump and cylinder Inspect all threads and fittings for signs of damage and replace as needed Clean all hose ends couplers and u
4. air run the system through several cycles extending and retracting the cylinder free of any load The cylinder must be at a lower level than the pump to allow air to be released through the pump reservoir Inspecting the Hydraulic Fluid Level Check the fluid level in the bladder after every 10 hours of use Drain and replenish the bladder with approved hydraulic fluid after approximately 300 hours of use For pumps with a 67 cubic inch 1 0 L bladder capacity Follow the same inspection procedures as mentioned above Refilling the Bladder If additional fluid must be added to the bladder use only approved hydraulic fluid 215 SSU 100 F 38 C Clean the entire area around the filler plug before adding fluid to the bladder Remove the filler plug and insert a clean funnel with filter The cylinder must be fully retracted and the air supply disconnected when adding the fluid to the bladder Periodic Cleaning IMPORTANT The greatest single cause of failure in hydraulic pumps is dirt Keep the pump and attached equipment clean to prevent foreign matter from entering system A routine should be established to keep the pump as free from dirt as possible All unused couplers must be sealed with thread protectors All hose connections must be free of grit and grime Any equipment hooked up to the pump should also be kept clean Use only approved hydraulic fluid in this unit and change as recommended every 300 hours Accessories Gauges and acce
5. e valve after each adjustment before measuring actual hydraulic pressure 4 Shut off and disconnect air supply to the pump and shift pump valve if so equipped or remote valve if so equipped two times to release all system pressure Check fluid level with the hydraulic system retracted THE PUMP IS NOW READY FOR OPERATION Note The Hydraulic pressure is increased or decreased by adjusting the air inlet pressure at the regulator 2 Stage Pumps On two stage pumps the air pressure regulator that is mounted on the pump controls only the output from the high pressure stage The output of the low pressure stage of the pump is determined by the air line pressure coming from the remote regulator A remote regulator is required to control the air pressure from the line The independent functioning of the low and high pressure stages of this pump can be best described as follows At the minimum air line pressure of 40 psi 3 bar the low pressure stage of the pump will deliver 480 psi 33 bar hydraulic pressure with the pump regulator turned counterclockwise to prevent air pressure from activating the high stage of the pump At the minimum air line pressure of 40 psi 3 bar the high pressure stage of the pump will deliver 4 000 psi 275 bar hydraulic pressure with the pump regulator turned clockwise to allow air pressure to reach the high pressure stage Always remember that the pump regulator must be turned fully counterclockwise when the pump is used
6. fluid inlet filter for contamination b Air in hydraulic system Check the air supply Pressure regulator improperly adjusted if so equipped Check hydraulic connections and 3 Remove reservoir and clean intake filter and reinstall 1 a Should be 20 CFM 57 M3 min minimum b Clean and reassemble 2 a Remove reservoir and clean intake filter and reinstall b Bleed the system as described in the Preventive Maintenance section 1 100 psi 7 bar is required to obtain maximum pressure 2 Adjust according to instructions in Operation section 1 Refit or repair as needed But Will Not Hold System Pressure other system components for leakage including 3 way 4 way valve Zinko Hydraulic Jack REV 071107 Model ZAP 40 amp ZAP 62 Troubleshooting continued PROBLEM CAUSE SOLUTION 1 Output pressure equal or higher 1 Normal operation than relief valve setting 2 Defective 3 way 4 way valve or 2 Repair or replace other components leaking Excess Oil Spray From Muffler eager is set too rich if so 1 Set at one drop per minute If the above procedures do not correct the problem contact your nearest ZIAKO service facility When submitting any jack or equipment to be repaired be sure to state the nature of the problem and indicate whether an estimate of the repair cost is needed Pump Will Continue To Run Slowly Even After Desired Pressure Is Reached 33 sr Parts Breakdown 8
7. nion ends Remove the thread protectors from the hydraulic fluid outlets Connect the hose assembly to the hydraulic fluid outlet and couple the hose to the cylinder o Zinko Hydraulic Jack Models ZAP 40 amp ZAP 62 Operating Instructions continued IMPORTANT Seal all external pipe connections with high grade thread sealant Teflon tape may also be used to seal hydraulic connections provided only one layer of tape is used Apply the tape carefully two threads back to prevent it from being pinched by the coupler and broken off inside the system Any loose pieces of tape could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts Priming the Pump Unit Under certain circumstances it may be necessary to prime the pump unit To do so follow these instructions For Hand Foot Pumps 1 Press the release end of the pedal while holding down the air intake valve with a flattened screwdriver The air intake valve is located directly under the pedal in the area marked PUMP The air intake valve is depressed simultaneously with the RELEASE area of the pedal during priming Allow the pump to cycle for approximately 15 seconds Remove the screwdriver and press the PUMP end of the pedal once more If the cylinder extends or pressure builds the pump has been successfully primed If the pump does not respond repeat the procedure jogging the air intake valve while holding the pedal in the RELEASE
8. position PUMP m4 Activating the pump with the pedal end marked with Activating the pump with the pedal end marked with this picogram the fluid is directed out of the reservoir this picogram the fluid is directed back to the reservoir AUN Pump Operation For Hand Foot Operated Pumps 1 To extend the cylinder depress the pedal on the end marked PUMP 2 To hold the cylinder in position release the end of the foot pedal marked with PUMP to deactivate the pump 3 To retract the cylinder depress the pedal on the end marked RELEASE For Pumps With Air Regulators 1 Open the air shut off valve if so equipped or connect the air quick coupler if so equipped NOTE Under certain circumstances the pump may need to be primed before operation 2 Slowly turn the air regulator control on unit clockwise to increase pressure counterclockwise to decrease pressure As air is admitted to the pump unit it will begin to deliver fluid to the system Continue to slowly turn the air regulator control clockwise until the gauge reads the maximum hydraulic pressure rating as stated on the pump s data plate A maximum hydraulic pressure reading should be obtained is air pressure is approximately 100 psi 7 bar 3 Cycle the system several times by manually shifting the 3 way 4 way valve if so equipped or the remote valve if so equipped Set the air regulator to obtain the desired hydraulic pressure When decreasing air pressure shift th
9. ssories may not be included with the pump However a hydraulic gauge is strongly recommended whenever the pump is used 1 The gauge MUST BE of the proper rating for the pressure used 2 Use only ZINKO approved accessories hydraulic fluid and repair parts Installing An In line Air Pressure Gauge 1 Remove the male fitting from the air filter and install a tee adapter with gauge between the hose and air filter 2 Install male fitting into the tee adapter and securely clamp the hose to the male fitting Installing An In line Hydraulic Pressure Gauge 1 Remove the thread protector from the hydraulic outlet port and inspect the threads and fittings for signs of wear 2 Install a tee adapter with gauge between the hose coupling and the pump hydraulic outlet port 3 Tighten all connections securely DO NOT OVER TIGHTEN HOSE CONNECTIONS Troubleshooting PROBLEM CAUSE SOLUTION 1 Low fluid level 1 Add fluid as instructed in Preventive Maintenance section 2 Prime pump as instructed in Operation section Pump Reciprocates But No Fluid Delivery cylinder will not extend Pump not primed Low Fluid Delivery cylinder extends slowly Pump Will Not Build To Maximum Pressure no visible leakage Pump Builds Pressure Fluid intake filter contaminated Inadequate air supply a Check air input supply b Contamination check air side of pump plugged air inlet screen Hydraulic failure a Check the
10. to produce 1 200 psi 83 bar or less Preventive Maintenance IMPORTANT Any repair or servicing that requires dismantling that pump must be performed in a dirt free environment by a qualified technician Dispose of machine fluids properly Draining and Flushing the Reservoir IMPORTANT Wipe the pump exterior completely clean before attempting this procedure 1 Drain the bladder of all oil and refill half full with clean hydraulic oil Rinse the filter clean 2 Run the unit for several minutes 3 Drain and clean the bladder once more 4 Refill the bladder with hydraulic oil IMPORTANT Drain and clean the other hydraulic system components hoses cylinders etc before reconnecting them to the pump This will prevent contaminated fluid from entering the pump again Zinko Hydraulic Jack Models ZAP 40 amp ZAP 62 Preventive Maintenance continued Lubrication For Hand Foot Pumps If the pump is operated on a continuous duty cycle for extended periods the manufacturer recommends installing an automatic air line oiler in the air inlet as close to the pumping unit as possible Set the unit to feed approximately one drop of oil per minute into the system Use SAE No 10 Oil Bleeding Air From the System During the first moments of operation after prolonged use a significant amount of air may accumulate within the hydraulic system This entrapped air may cause the cylinder to respond slowly or behave in an unstable manner To remove the
11. ydraulic 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 hazards such as fire sharp surfaces extreme heat or cold or heavy impact Do not allow the hose to be altered or 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 DO NOT USE THE HOSE TO MOVE ATTACHED EQUIPMENT Stress can damage 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 Consult the manufacturer before painting a hose Hose deterioration due to corrosive materials can result in personal injury NEVER PAINT COUPLERS Inspect machine for wear damage and correct function before each use Do not use machinery that is not in proper working order but repair or replace it as necessary REPLACE WORN OR DAMAGED SAFETY DECALS MODIFICATION OF A PRODUCT REQUIRES WRITTEN ZINKO AUTHORIZATION Use only components with the same pressure rating when assembling a system or machine UM
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