Product Manual

– 2 –
Specifications (Continued)
2-Stage, High/Low Pump Dimensions (Tabular)
General Safety Information
DISCONNECT POWER BEFORE SERVICING THIS EQUIPMENT.
1. Follow all local electrical and safety codes, as well as the
National Electrical Code (NEC) and the Occupa tional Safety and
Health Act (OSHA).
2. Never exceed the maximum operating speed and pressure of
the pump.
3. If using AC motors, ground the motor properly by wiring with
a grounded, metal-clad raceway system, using a separate
ground wire connected to bare metal of the motor frame, or
other suitable means.
4. Guard all moving parts.
RELEASE SYSTEM PRESSURE BEFORE SERVICING THIS
EQUIPMENT.
5. Drain all liquids from the system before servicing.
6. Check hoses and connections for security before each use.
7. Periodically check the pump and system components.
8. Provide a means of pressure relief for pumps whose discharge
line can be shut off or obstructed.
9. Wear safety glasses at all times when working with pumps.
10. Keep work area clean, uncluttered and properly lighted;
replace all unused tools and equipment.
11. Keep visitors at a safe distance from the work area.
12. Make the workshop child-proof with padlocks, master switch-
es, and by removing starter keys.
13. Do not operate an engine in an enclosed area.
14. Do not spill gasoline on hot engine surfaces.
15. Store gasoline only in an approved container.
16. Keep dirty and oily cleaning rags in a tightly closed metal con-
tainer.
17. Check engine oil level before operating the engine.
18. Familiarize yourself with the controls and emergency shut-
down procedures.
19. Never operate the equipment when you are fatigued.
20. All system components pressure ratings should be greater
than maximum system pressure.
21. Put safety guards on all moving parts.
22. Keep all guards in place.
Installation
Do not overtighten fittings and bolts – this can damage the
pump.
1. Assemble one coupling half to the engine/motor and tighten
the set screw.
2. Assemble the other coupling half loosely to the pump shaft.
Note drive key dimensions in Specification section of this
manual.
Do not force coupling onto pump shaft. A snap ring inside
pump may be damaged by forcing coupling.
3. Insert the rubber spider into engine/motor coupling half.
4. Bolt the pump and mounting gasket “A” loosely to 4-bolt foot-
mounted pump adaptor.
5. Align the shafts to make sure they are on center with each
other.
Misalignment with shafts may result in premature shaft seal
failure.
6. Tighten the mounting bolts.
7. Mate the coupling halves together, allowing 1/16” gap
between halves.
8. Check shaft alignment again.
The gap in the coupling halves is to prevent end loading of the
pump shaft.
9. Tighten the set screw in the pump coupling half.
10. Remove plastic port protectors from the inlet and outlet ports.
11. Squirt oil into the pump for pre-lubrication for start-up.
12. Turn shaft coupling slowly to ensure proper shaft alignment
and coupling installation.
13. Connect inlet line by slipping inlet hose over inlet tube and
fasten with hose clamp.
NOTE: A few drops of oil on inlet tube beaded section will
help ease the installation.
14. Keep inlet hose short and of adequate size to avoid pump cavi-
tation.
NOTE: Cavitation is recognized by excessive pump noise.
Provide cooling for the hydraulic oil based on: duty cycle,
pres sure/flow, ambient temperature, oil and component max-
i mum temperature specifications, and reservoir capacity.
15. Use a 1/2” NPTF, high pressure fitting for the outlet port.
Use a good quality pipe joint compound (pipe dope) on all
NPTF hydraulic fittings.
Flush all lines to ensure contaminants have been removed.
2690165 MODELS 1012, 1053 AND 1056
WARNING!
WARNING!
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
MODEL A B C
1012 4.906” 4.031” 2.531”
1053 5.468” 4.594” 3.094”
1056 5.468” 4.594” 3.094”
2690165 hilo.indd 2 8/17/11 9:20 AM
Installation (Continued)
Do not use Teflon tape on NPTF hydraulic fittings.
Do not overtighten NPTF pressure fitting in pump. This could
distort or crack the pump gear housing.
Never run pump without hydraulic oil.
16. At initial start-up, turn the pump several times by hand to
prime the pump.
17. Bleed all air from the system to prevent erratic pump operation.
18. After several cycles, check the reservoir oil level and refill as
necessary.
NOTE: When the ambient temperature is below 32°F, allow the
pump to operate at low pressure for several minutes to warm the
oil in the reservoir.
Operation
1. Check oil level before each use.
2. Follow operating instructions for engine or motor.
DO NOT EXCEED THE PRESSURE RATINGS OF THE SYS-
TEM COMPONENTS. A HYDRAULIC PRESSURE GAUGE IS
RECOMMENDED IN THE HYDRAULIC CIRCUIT.
3. The unloading valve is adjustable up to 600 PSI by turning the
adjusting screw clockwise.
Pressure gauge required when adjusting unload valve.
NOTE: Increasing the unloading valve pressure will require increas-
ing the pump drive horsepower. Factory preset, with a 400-900
PSI adjustment range. Maximum recommended loading for 3 HP
electric motors and 5 HP engines is 550 PSI.
If pump has not operated for an extended period of time,
manually rotate pump shaft to prime and lubricate pump.
Maintenance
1. Keep the reservoir filled with hydraulic fluid.
NOTE: Use a good quality automatic transmission fluid
(ATF) for year round operation.
2. Make frequent inspections of hydraulic oil and change if con-
taminated.
3. To fill the reservoir with clean oil. Use a clean funnel fitted with
a fine mesh wire screen. Do not use a cloth strainer. Most
pump failures, valve malfunctions, and short unit life can be
traced directly or indirectly to dirt or other foreign material
(water, chips, lint, etc.) entering or already in the hydraulic sys-
tem.
4. Keep the unit clean of dirt and foreign materials.
5. Keep electrical connections clean.
2690165 MODELS 1012, 1053 AND 1056
– 3 –
WARNING!
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
Pump does not develop full
pressure
Motor won’t start
Will not pump oil (Motor runs
but cylinder does not move,
or moves slowly)
Pump motor unit is noisy
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
1. System relief valve set too low or leaking
2. Oil temp. is too high
3. Pump is worn out
4. Double acting cylinder piston seals are cut or
worn out
1. Loose connection
2. Circuit breaker tripped
3. Voltage drop
4. Seized pump
1. No oil in reservoir
2. Motor operating wrong rotation
3. Oil level low
4. Suction strainer is clogged
5. Double acting cylinder piston seals are cut or
worn out
6. Reservoir breather is dirty or clogged
1. Low oil level
2. Air in system
3. Suction strainer or in-line filter is clogged
1. Check system relief valve for proper setting
with pressure gauge in outlet line
2. Let oil cool below 140°F
3. Replace worn parts or pump
4. Replace or repair cylinder
1. Check wiring
2. Reset circuit breaker
3. Use heavier gauge wire
4. Replace pump
1. Check oil level, refill
2. Change rotation of prime mover
3. Add oil as needed
4. Clean suction strainer
5. Replace or repair cylinder
6. Clean reservoir breather and reinstall
1. Add oil as needed
2. Bleed air from highest fitting in system
by loosening fitting very slightly and
operating unit until bubbling of air
stops, then tighten
3. Clean suction strainer or in-line filter
Troubleshooting Chart
2690165 hilo.indd 3 8/17/11 9:20 AM