HYDHPUMP Operation & Maintenance
Contents
1. 5 gallon 5 sight gauge ALGST 29902 3 2 Gallons 184 NOTE Cover Plate ordered as separate item see below 22203 2 Calon Zi Sight Gauge shipped loose inside reservoir 29905 16 5 Gallons 28 Filler Breather included with cover plate Weight does not include covers COVER PLATES Vescor Vari Pak Reservoirs allow you to choose the style cover plate for your individual needs Reservoir and Cover Plate must be ordered as separate items Please use part number when ordering mat aso e ef o E uton Number ADAPTER CUTOUT cutout for 56 145TC 10 s 5 16 17 16 She adapter j e style 1 1A 1B All covers include 1 PMB07 10 Mini Breather F Cutout 321 32 cutout for 182 256TC adapter only style 7 F Cutout F Cutout A ine B os gt gt FB Cutout Style A Cover Plate Style B Cover Plate Style C Cover Plate Style D Cover Plate Style E Cover Plate Blank Cover with Breather Cutout with Breather Cutout and with Breather Cutout and 182 256TC Adapter Cutout Part Number 99908 Part Number 99909 56C 145TC Adapter Cutout 56C 145TC Adapter Cutout Part Number 99907 Part Number 99910 1 2 NPT Connection Part Number 99911 27 NOTE WITH VESCORS POLICY OF CONSTANTLY IMPROVING ITS PRODUCTS SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 1 JULY 03 PARTNO HYDHPUMP QTY DESCRIPTION 1 PUMP RESERVOIR 52. Gravity 29 Flash 234 F Fire 380 F Viscosity at 100 F 80 S U S Viscosity at 210 F 37 4 S U S Average Viscosity Index 15 Pour Minus 55 60 F Neutralization No 03 Conradson Carbon Less than 01 Rust and Oxidation Inhibited Incorporated Foam Depressant Aniline Point 185 230 Approved Sources Mobile DTE 11M Product Number 603100 0 Lubriplate Special low pour hydraulic oil 76762 pour 75 F Emergency Sources SAE 5 Motor Oil Viscosity 60 S U S Automatic transmission fluid SPECIAL HYDRAULIC CYLINDERS AND HAND PUMPS 2727 Clinton St River Grove IL 60171 1598 gt 1 708 453 3238 Fax 1 708 453 0297 Web Site address www starhyd com E mail address starhyd starhyd com VARI PAK RESERVOIRS 2 3 and 5 Gallon Capacity 3 8 16 Mounting Nut 9 1 4 9 1 4 La 10 95 8 Square Body Wea 7 16 Dia 4 Holes m 4 11 16 r Each Vari Pak Reservoir Includes 1 1 Oil Level amp Temp Gauge 2 1 1 2 NPT Drain 3 Channel Gasket for Top Plate Seal 4 Steel Construction with Customer Choice of Top Plate 5 Exterior of reservoir prime painted 6 Interior of reservoir coated with rust preventive oil Sight Gauge Vescor Shipping a Part Number height Capacity Weight 2 3 to
3. Valves If the pump fails to supply pressure or if the pump piston is under pressure at all times the pump valves may need cleaning Stand pump in an upright position Remove the valve plug and seal Tilt the pump to remove valve springs and balls Allow oil to drain from the reservoir through these valve holes to wash foreign matter from the valve cavity Lay pump on its side to clean and inspect valve chamber Be careful not to mar or nick the ball valve seats Clean the valve balls and springs in solvent Replace rusted or corroded balls Do not stretch the ball springs To reassemble insert in sequence the small ball small spring large ball and large spring into the cleaned chamber Finally screw in valve seal plug Note that the seal kit contains the new style valve plug and seal This procedure should be carried out in all ball valve circuits If the valves fail to operate properly after they have been cleaned it may be necessary to reseat the valve balls Remove the springs and tap each ball lightly in its respective seat using the Y ball seating tool CP13 42 for the small ball and the 3 8 ball seating tool CP13 43 for the large ball Remove balls to make sure they are not stuck to the seats Reassemble pump valves as before See Air Bleeding instructions before attempting to operate the pump E i a of a Release Valve Cam Type REPAIR PARTS KIT SECAR PARTS KIT if the pump fails to lift or hold a load the release valve may
4. and inspect valve seat and screw A slight depression in the end of the screw is not harmful Screws with excessive deformation should be replaced Re seat the release ball using the Y ball seating tool CP13 42 To reassemble insert the release valve packing using inserting tool P1A 40 Reinstall the release screw See Air Bleeding instructions before attempting to operate the pump Overload Valve If the pump fails to lift or hold a load after the release valve and pump valves have been checked the overload valve may be dirty To clean the valve remove valve plug and valve plug seal Using a screwdriver remove the overload valve screw valve spring valve plunger and steel ball Clean and inspect valve cavity If the ball seat is marred re seat the overload ball by lightly tapping the ball on seat using tool CP13 45 Remove the ball to prevent sticking Reassemble the ball plunger spring and valve screw Connect a pressure gage to the pressure outlet Stroke the pump to obtain maximum desired pressure Turn the valve screw clockwise to increase the pressure reading and counter clockwise to reduce the maximum reading After valve is set properly replace valve plug Note that the seal kit contains the new style valve plug and seal See Air Bleeding instructions before attempting to operate the pump Large Piston Pump Relief Valve If the pump fails to lift faster under no load than it does under heavy load the large piston
5. unloading valve may be dirty This valve is covered with a sealing compound to prevent tampering Remove the sealing compound valve screw spring and plunger with seals Use threaded socket tool CP13 41 to remove plunger Clean and inspect the valve cavity Inspect the plunger packings and replace if necessary To reassemble lubricate the plunger seals with hydraulic fluid and carefully insert it back into the valve cavity taking care not to damage the seals Reassemble the spring and valve screw Tighten the screw to obtain the desired effort on lever bar at large piston change over point If the screw is tightened too far it will restrict the unloading valve movement and cause ARGE PISTON RELIEF VALVE excessive handle effort throughout the high pressure cycle SPECIAL TOOLS AVAILABLE FOR BELOW UNLOADING VALVE TOOL bd PART No CP13 41 O VER OAL ALVE BAI SEATING 1 4 BALL SEATING TOO TOOL PART No CP15 45 PAR CP13 42 NSERTING TOOL FOR P1A 4 RELEASE bp a SALL SEATING TOOL ALVE SEAL PART No P1A 40 PART Nor ACR S245 CP SERIES STAR Hi Lo Two Speed Pumps 1 V2 1 V2 1 5 16 Diameters Y 16 DE e FAT Piston MODELS CP15 CPS15 FCP15 Item No Part Name Part N
6. DUAL PISTON HYDRAULIC PUMPS SERVICE MANUAL Hi Lo Two Speed Hand or Foot Operated Th M C P Series without reservoirs STAR HYDRAULICS INC 2727 CLINTON STREET RIVER GROVE ILLINOIS 60171 708 453 3238 www starhyd starhyd com In servicing hydraulic units clean liness is of the utmost importance A clean work place and proper tools are necessary to insure efficient and effective repair Special tools can be furnished on request NOTE Please specify pump model number when ordering parts If you are not sure of your pump model number call the factory and request a pump model identification sheet be faxed or e mailed to your Pump parts lists are also available for your model CL ONLY ON O PRESSURE PORT A TD CP 15 C B_ D B Typical assembly drawing of two speed pump showing sectional view location TROUBLE POSSIBLE CAUSE CORRECTIVE REPAIR INSTRUCTIONS Pump will not hold pressure Pump fails to supply pressure Pump piston does not draw a full charge This is evident by a cushion effect at the top of the pump stroke Pump piston raises by itself under pressure Pump functions properly but will generate only a given pressure below its normal pressure maximum Pump fails to supply greater output at no load than under load gt No DA A Re
7. GAL WITH OIL LEVEL GAGE DRAIN PLUG amp CAP 1 DIRECTIONAL VALVE 2 TEE CONNECTOR 2 QUICK DISCONNECTPLUG ROTARY HANDLE PRESSURE OIL LEVEL GAUGE TU Frame Series Travel Suffix Bearing Weight Item Class Scale Unless Otherwise Specifled S N A N A N A N A N A 63 T4 UNK XXXXE Assembly Part Number Item Description HYD HAND PUMP E JMG 050403 5C WITH 5 GAL RESERVOIR NOTE OIL IS NOT SUPPLIED WITH PUMP TOP QUICK DISCONNECT SOCKETS BLIND END IN BOTTOM QUICK DISCONNECT PLUGS ROD END OUT DIRECTIONAL VALVE TOP QUICK DISCONNECT SOCKETS BLIND END IN TEE CONNECTORS 3 8 SAE BOTTOM QUICK DISCONNECT PLUGS ROD END OUT Precision Pulley amp Idler P O Box 287 Pella IA 50219 641 628 3115 By Dwg No HYD H PUMP EJA Date 11 25 03 Part No HYDHPUMP 7 19 07 JPM Temp No Revisioni N A ECO7225 PART NO MHOSE PARTNO LHOSE PARTNO XHOSE JMG 050403 10 12 JMG 050403 16 20 JMG 050403 24 QTY DESCRIPTION QTY DESCRIPTION QTY DESCRIPTION 3 HOSE 36 3 HOSE 36 3 HOSE 36 6 HOSE 72 6 HOSE 72 6 HOSE 72 12 HOSE 144 12 HOSE 144 12 HOSE 144 15 HOSE 180 15 HOSE 180 15 HOSE 180 SAE PORT 23 9 NOSE WITH COUPLINGS QUICK DISCONNECT ADAPTER PLUG MALE 36 HOSE 1 SWIVEL FITTING 72 HOSE 2 6 SAE STRAIGHT FITTING QUICK DISCONNECT SOCKET FEMALE QUICK DISCONNECT PLUG MALE 144 HOSE 3 JE QUICK DI
8. SCONNECT i SOCKET FEMALE TU Frame Series Travel Suffix Bearing Weight Item Class Scale ao Se TOST Precision Pulley amp idler E N A N A N A N A N A N A N A UNK AH P O Box 287 e Pella IA 50219 641 628 3115 eee Assembly Part Number Item Description Temp No Royision By EJA Dwg No HYDHOSE ANGULAR 1 HYD HOSE KITS N A ENPR3090 Date 11 25 03 PartNo SEE TABLE Tolerances Unless Otherwise Specifled HYDRAULIC ASSISTED TAKE UP IN PULL MODE Principal of Operation Hydraulic Cylinder movement is used to move the pulley The threaded rod is rotated to engage STOP NUT and lock pulley from movement Operations To Increase Belt Tension 1 Apply hydraulic pressure to the rod end of the cylinder to cause Take up pulley movement until desired belt tension is achieved Pressure gage on cylinder can be used to establish belt tension from cylinder area Force is equal to pressure times area 2 When finished adjusting tension rotate travel rod end nuts on the end opposite the cylinder moving the STOP NUTS toward and against the saddle until resistance is felt Hydraulic pressure can now be released The STOP NUT is on the end of the saddle opposite the cylinder when using Take up Frame in PULL MODE 3 If further movement is needed repeat step 1 amp 2 as needed Operations To Decrease Belt Tension 1 Apply hydraulic pressure to the rod end of cylinder 2 Rotate the travel rod end nuts on the end opposite the cylind
9. be ee oe E oe RP dirty From back of pump remove the release valve plug release Fl ava N ball spring and 3 8 release ball From the front remove the fo eS release lever pin release lever and release plunger and seal nea Clean release valve chamber and inspect the ball seat If a necessary re seat the release ball by tapping it lightly on the ball seat using the 3 8 ball seating tool CP13 43 Clean plunger and inspect the plunger packing and replace if necessary To reassemble insert the ball ball spring and release valve plug Lubricate the release plunger packing with hydraulic oil and carefully insert into the plunger chamber Re install the release lever and lever pin See Air Bleeding instructions before attempting to operate the pump pAr 7 SECTION B B RELEASE VALVE CAM TYPE p IODELS 4A MODELS SECTION Release Valve Screw Type If the pump fails to lift or hold a load the release valve may be dirty Remove the release screw release valve seal and 9 32 release valve ball Clean
10. er moving the STOP NUTS away from the saddle This will allow the saddle to move in the desired direction The STOP NUT is on the end of the saddle opposite the cylinder when using Take up Frame in PULL MODE 3 Actuate cylinder applying hydraulic pressure to the cylinder end of the cylinder or allow pressure to bleed off of the rod end of the cylinder This will cause Take up pulley movement BLIND until desired belt tension is achieved 2 END IN 3 If further movement is needed repeat up Q step 1 through 3 as needed 4 When finished adjusting tension rotate travel rod end nuts in opposite direction to step 2 until resistance is felt Hydraulic pressure can now be released ROD END RESERVOIR OUT NOTES 1 Hydraulic Take Up Frame and cylinder ship unassembled 2 The Pump Kit comes with a 5 gallon reservoir pressure gauge oil level gauge and valves 3 The Hose Kit comes with 3 8 hoses fittings and adapters ROD END IN TRAVEL ROD BLIND END a OUT STOP NUT CYLINDERS ARE SHOWN IN PULLING CONFIGURATION WITH STOP NUT POSITIONED TO PREVENT PULLEY MOVEMENT Decimal a Part La om a HYD TAKE UP FRAMES ANGULAR 11 WITH PUMP amp HOSE KITS pa ra To Su Gar are JPM Precision Pulley amp idler P O Box 287 Pella IA 50219 641 628 3115 a a 7 19 07
11. lease valve ball not seating properly Ball valves not seating properly Overload valve ball not seating properly Large piston unloading valve seal faulty Lack of oil Air bound pump Release valve ball not seating properly Small ball in valve circuit not seating properly Overload valve ball not seating properly Large piston unloading valve seal faulty Air bound system Lack of oil Large ball in ball valve circuit not seating properly Overload valve not properly set Large piston unloading valve not set properly Refer to Release Valve notes Refer to Pump Valve notes Refer to Overload Valve notes Refer to Large piston unloading valve Refer to Oil notes Refer to Air Bleeding notes Refer to Release Valve notes Refer to Pump Valve notes Refer to Overload Valve notes Refer to Large piston unloading valve Refer to Air Bleeding notes Refer to Oil notes Refer to Pump Valve notes Refer to Overload Valve notes Refer to Large piston unloading valve Air Bleeding Air accumulation in a hydraulic system will cause erratic action This may appear as pump failure to the inexperienced user For this reason it is advisable to air bleed each pump before attempting to operate To emove air from the pump open release valve with the pump in an upright position Operate the pump slowly through the full piston stroke about a dozen time
12. o Repair Kit incl parts with CP15 RK These models can be Large Pistons sss seeie e cater CP15 2 Small Piston incl pin CP13 4RP hand or foot operated Large Piston Packing ee e P6 4 screw or cam released Small Piston PackiNng CP13 5RP with reservoirs Pump Packing NUt ooooooooo CP15 7 base mounted Pump Piston WipOT ooooooo CPIS 4 Piston Pin incl Rings CP13 10RP Link Pin incl Rings ace CP13 10RP CP13 19RP CP13 13RP Pump Valve Complete incl 2 Overload Valve Complete Release Valve Complete P1 3RP Release Plunger Complete CP13 17RP Release Valve Complete PAC 18RP Lever Handlesi cisocsss e aso P13 23 Breather ScreWsawg esi sos so isa P1 16 Please give the following Se aaa es EE cae oe WET SERT Relief Valve Complete CP13 25RP Foot Loyo ensineresiers sem es oro FCP12 9 7 Foot Lever Return Spring FCP13 23 US eis Release Lever Cam amp Pin FCP13 13RP Model No of Pump Foot Release Leve oooom o FCP13 14 j Release Lever Pin incl Rings CP13 10RP Cam Release Lever cecesceccce CP13 14 Inserting Tool sseescoeees CP13 44 STAR HYDRAULICS INC 2727 CLINTON ST RIVER GROVE IL 60171 1598 708 453 3238 STAR HYDRAULICS INC Hydraulic oil recommendations for Star Hydraulic hand and foot pumps Typical test data
13. s Close the release valve Pump should be ready for use Oil If the pump fails to operate check the oil level before attempting any repairs The maximum fill level is 1 Y below the inside of the reservoir cover CAUTION Use only hydraulic oil when refilling NEVER USE BRAKE FLUID Pump Piston Leakage of oil around the pump piston may indicate worn or damaged piston packings To replace packings a Remove the piston actuating linkage b Remove the piston See piston section drawing A A c Remove all packings see piston section drawing A A d Clean all parts and dry with compressed air e Install new packings wipers and static seals making sure that packing seal lips are face down toward the pressure Lubricate each part into clean hydraulic oil before assembly f Open the release valve to allow air to bleed from the piston barrel back to the reservoir and insert the piston g Replace piston linkage NOTE With release valve open stroke pump about a dozen times to bleed air completely from the pump rq Py r 4 L 4 H 4 E F CP15 4 TENE KLN aras Me Uy AA Lk LPS CP13 CP14 GPUS CPO4 OLD STYLE PUMP VALVE PUMP PISTON FCTION A A ZECYPINOAT Do D KO sh f A NAZAN Ls D Pump
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