OTC Tools 4000 User's Manual
Contents
1. pressure piston seal Check for dirt and or reseat valve seats Replace piston assembly and or piston seals Position cylinder lower than pump Extend and return cylinder several times Follow bleeding instructions Check fluid level per instructions OTC recommends these hand pump repairs be performed by an Authorized Hydraulic Service Center2. see Figure 2 appropriate view depends on model of pump A For models with Reservoir Type C Remove the filler cap The fluid level should be 1 2 inch 12 7 mm from the cover plate when the pump is level and resting horizontally on its base and the cylinders are retracted Figure 2 Draining And Flushing The Reservoir Drain clean and replenish the reservoir with high grade approved hydraulic fluid yearly or more often if necessary The frequency of fluid change will depend upon the general working conditions severity of use and overall cleanliness and care given the pump IMPORTANT Clean the exterior of the pump first After draining and flushing the reservoir drain and clean the other hydraulic system components hoses cylinders etc before connecting them to the pump again This will help prevent contaminated fluid from entering the pump Refer to Table 1 for your reservoir type For models with Reservoir Type A 1 Unthread and separate the pump head from the reservoir Drain the reservoir of the used hydraulic fluid 2 Flush out reservoir with a small amount of clean hydraulic fluid Clean the pump intake filter IMPORTANT Removing the filter from the pump assembly could result in its breakage Attempt to clean it as well as possible with it installed 3 Refill the reservoir and reassemble the pump head to the reservoir Tighten securely Check for leaks For models with Reservoir Type B 1 Remove the filler c
3. to split at pressures lower than their rated capacities Should a hydraulic hose ever rupture burst or need to be disconnected immediately shut off the pump and shift the control valve twice to release all 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 any potential hazard such as fire extreme heat or cold sharp surfaces heavy impact 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 result in personal injury Do not use the hose to move attached equipment Stress may damage the hose and 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 Never paint the couplers Hose deterioration due to corrosive materials may result in personal injury All components in the hydraulic system must match the maximum pressure rating of the pump Pump Do not exceed the PSI rating noted on the pump nameplate or tamper with internal high pressure relief valve Creating pressure beyond rated capacities may result in personal injury Before ad
4. Form No 102841 SPX Corporation CICS 0 Liventower drive Operating Instructions for Owatonna MN 55060 0995 USA Phone 507 455 7000 1U 5230 4008 61821 See 4016 gcse ot lorena See 4002 4009 61869 See 4016 Fax 800 955 8329 Order Entry 800 533 6127 4000 4012 61871 See 4016 Fax 800 283 8665 4002 4016 61872 See 4016 International Sales 507 455 7223 4002 ER 4017 JTO5845 Hae OAs See 4002 61522 See 4002 See 4016 SINGLE STAGE AND TWO STAGE HYDRAULIC HAND PUMP Max Pressure See Pump Data Plate Definition A hydraulic hand pump delivers hydraulic fluid under pressure by directly applied manual effort Note Illustrations depict general pump configurations JTO5945 61821 61871 61872 61869 61522 Maximum j Usable Oil Pressure Capacity i bar In 3 3 8 NPTF oil port s on all pumps Table 1 Sheet No 1of3 SPX Corporation Rev 4 Date 23 Jan 2001 Operating Instructions Form No 102841 Back sheet 1 of 3 SAFETY EXPLANATIONS Two safety symbols are used to identify any action or lack of action that can cause personal injury Your reading and understanding of these safety symbols is very important A DANGER Danger is used only when your action or lack of action will cause serious human injury or death A WARNING Warning is used to describe any action or lack of action where a serious injury can occur IMPORTANT Important is used when action
5. ap Drain the hydraulic fluid through filler hole 2 Remove the nut from the tie rod Separate the reservoir from the pump body Clean the reservoir and filter IMPORTANT Removing the filter from the pump assembly could result in its breakage Attempt to clean it as well as possible with it installed 3 Reassemble and fill the reservoir with hydraulic fluid Replace the filler cap For models with Reservoir Type C 1 Remove the ten screws fastening the reservoir cover to the reservoir and lift the pump and valve assemblies off 2 Drain all hydraulic fluid and flush reservoir with a small amount of clean hydraulic fluid 3 Remove the pump assembly filter rinse it clean and reassemble 4 Refill the reservoir with hydraulic fluid Place the pump and valve assembly with gasket on the reservoir and thread the ten screws Tighten securely and evenly Sheet No 3of3 Rev 4 Date 23 Jan 2001 Operating Instructions Form No 102841 Back sheet 3 of 3 TROUBLE SHOOTING A WARNING To help prevent personal injury always release pump pressure and disconnect hoses s from pump before making repairs Refer to the appropriate pump parts list during trouble shooting Repairs must be performed in a dirt free environment by qualified personnel familiar with this equipment PROBLEM Pump losing pressure Handle rises after each stroke Pump not delivering fluid Pump does not reach full pressure Pump handle can be pushed down slowly
6. ding hydraulic fluid retract the system to prevent overfilling the pump reservoir An overfill may cause personal injury due to excess reservoir pressure created when cylinders are retracted The load must be under operator control at all times Cylinder Do not exceed rated capacities of the cylinders Excess pressure may result in personal injury Do not set poorly balanced or off center loads on a cylinder The load may tip and cause personal injury Stay clear of lifted loads and keep others away e Extensions are not recommended for lifting applications SET UP Hydraulic Connections IMPORTANT Seal all hydraulic connections with a high grade nonhardening thread sealant Teflon tape may also be used to seal hydraulic connections if 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 pipe end Any loose pieces of tape could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts 1 Clean all areas around the fluid ports of the pump and cylinder Clean all hose ends couplers and union ends Remove thread protectors from the hydraulic fluid outlets and connect the hose assembly Couple hose to cylinder 2 The use of a hydraulic pressure or tonnage gauge not included is strongly recommended Remove the pipe plug from the gauge port of the valve thread the gauge into this port and s
7. e control knob counterclockwise CCW and operate the pump handle up and down approximately twenty times Turn the pressure control knob clockwise CW to its full stop position The pump should now be bled of air and ready to use Note Shaded areas reflect last revision s made to this form Operating Instructions Form No 102841 Q Hydraulic Fluid Level WARNING Cylinder s must be fully retracted before checking the fluid level Release all system pressure before breaking any hydraulic connection in the system Check the hydraulic fluid level in the reservoir periodically Use a funnel with a filter to add hydraulic fluid if needed Refer to Table 1 for your reservoir type For models with Reservoir Type A Place the pump in a vertical position with the pump head facing upward Unscrew and remove the pump head from the reservoir The fluid level within the reservoir should come to the fluid level mark Note Refer indicated on the reservoir body decal Before replacing the to appro pump head visually inspect the o ring which seals the pump Priate end head reservoir assembly Replace this o ring if it is worn or ei aa damaged Reinstall pump head to reservoir and tighten Lb P securely Check for leaks For models with Reservoir Type B Remove the filler cap The fluid level should come to the bottom edge of the filler hole when the pump is level and resting horizontally on its base and the cylinders are retracted
8. eal as noted above a WARNING To help prevent personal injury The gauge must have the same pressure rating as the pump and cylinder Personal injury can result if the wrong gauge is used Release hydraulic pressure BEFORE removing Sheet No 20f3 or tightening hose couplings oo Rev 4 Date 23 Jan 2001 Operating Instructions Form No 102841 Back sheet 2 of 3 OPERATION The 4008 can be operated only in the horizontal position All other hand pumps can be operated in a horizontal position or in a vertical position with head pointing downward Refer to Table 1 and your pump name plate to determine your style of pump IMPORTANT Figure 1 illustrates the 7orma drop of handle effort experienced when all except 4072 g g two stage pumps shift from F S low pressure stage to a lt eo 2 2 er high pressure stage E aS I S Pressure Unloading Pressure Figure 1 Two way Valve Pumps with a two way valve are for use with single acting cylinders 1 To extend the cylinder turn the valve knob clockwise to a closed seated position Note Hand tight only Work the pump handle up and down to build pressure 2 To release pressure open the valve slowly by turning the knob counterclockwise to control the load Four way Valve Pumps with a three position four way valve are for use with double acting cylinders The hose connection for extending a cylinder can be made to either port With the handle in the f
9. or lack of action can cause equipment failure either immediate or over a long period of time Pictogram Definition Do not remove this component For service only Pressure must be released A WARNING Itis the operator s responsibility to read and understand the following safety statements e Only qualified operators should install operate adjust maintain clean repair or transport this machinery e 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 OTC will supply information necessary to help make these decisions These instructions are intended for end user application needs Most problems with new equipment are caused by improper operation or installation Detailed service repair instructions or parts lists can be obtained from your nearest OTC facility Operating Instructions Form No 102841 SAFETY PRECAUTIONS A WARNING To help prevent personal injury Before operating the pump all hose connections must be tightened with the proper tools Do not overtighten Connections need only be tightened securely and leak free Overtightening may cause premature thread failure or high pressure fittings
10. orward position the fluid is directed to the top fluid port To maintain hold pressure stop the pumping action When the valve handle is in the center position fluid flow is blocked to both ports A WARNING The operator should always release the pressure slowly PREVENTIVE MAINTENANCE IMPORTANT Any repair or servicing that requires dismantling the pump must be performed in a dirt free environment by a qualified technician Lubrication Apply lubricant regularly to all pivot and rubbing points Use a good grade of No 10 motor oil or grease Do not use dry lubricants Bleeding Air From the System Air can accumulate in the hydraulic system during the initial set up or after prolonged use causing the cylinder to respond slowly or in an unstable manner To remove the air 1 Position the cylinder at a lower level than the pump and turn the cylinder rod end down 2 Extend and retract the cylinder several times without putting a load on the system Air will be released into the pump reservoir Follow the fluid level instructions for your reservoir type release the air from the reservoir and top off the fluid supply Bleeding Air From The Pump When the pump is first put into use or after refilling the pump s reservoir it may be necessary to bleed any trapped air from the pump If this is not done the pump will not function properly will not build pressure or has very spongy operation To bleed air from the pump turn the pressur
11. without raising the load Pump handle operates with a spongy action Pump handle effort drops significantly after some pressure has been obtained N Np CAUSE System components leaking Directional control valve leaks or not adjusted properly Fluid leaking past outlet check seat s Fluid leaking past outlet check seat s Low fluid level in reservoir Intake filter is dirty Seats worn and not seating properly Low fluid level in reservoir System components leaking Directional control valve leaks or not adjusted properly Improperly adjusted relief valve Fluid leaking past inlet or outlet checks or high pressure piston seal damaged Inlet checks are not seating Damaged piston assembly or piston seals leaking Air trapped in system Too much fluid in reservoir This is normal operation on most two stage hand pumps E 4 5 7 SOLUTION Repair or replace as necessary Reseat repair or replace directional control assembly and correctly adjust Check for dirt Reseat pump body and or replace poppet s or ball s Check for dirt Reseat pump body and or replace poppet s or ball s Check fluid level per instructions Remove reservoir and clean Repair seats or replace pump body Check fluid level per instructions Repair or replace as necessary Reseat repair or replace directional control assembly and correctly adjust Readjust Reseat or repair inlet or outlet checks or replace high
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