REL-GB-10 Manual 03-10

REL-GB-10 Manual 03-10
OPERATORS’ GUIDE
REL-GB-10
SINGLE / DOUBLE ACTING
10,000 PSI CONTIUOUS DUTY
GAS / HYDRAULIC PUMP
The REL-GB-10 single and double
acting hydraulic pumps feature
manual lever operation, continuous
duty performance, and a two stage
pumping system, to ensure rapid
tool advance.
The manual lever control valve, and
factory installed couplers are ready
to run your single or double acting
crimping, cutting and
spearing tools.
NO
TICE
NOTICE
Sizes, weights and tool specifications listed in
this manual are subject to change without notice.
Consult factory for information and updates.
WARNING
All information found in this guide
m u s t b e read and understood
before use or testing of this tool.
Failure to read and understand these warnings
and safe handling instructions could result
in severe personal injury and or death.
RELIABLE EQUIPMENT & SERVICE CO., INC.
92 Steamwhistle Drive • Ivyland, PA 18974 • USA
Phone: 215-357-3500 • Fax: 215-357-9193
REL-GB-10
MODEL: _________________________________________
SERIAL NO.: _____________________________________
YEAR: __________________________________________
1
REL-GB-10 Manual
02-10
2
DISTRIB
UTED BY
DISTRIBUTED
REGISTRATION
UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.
COMPANY ____________________________________________________
ADDRESS ____________________________________________________
_____________________________________________________________
PHONE ___________________ FAX _______________________________
SERIAL NUMBER ______________________________________________
DATE OF PURCHASE ___________________________________________
DEALER NAME ________________________________________________
3
TABLE OF CONTENTS
Registration
.................................................................................................................. 3
Table of Contents & Safety Reference Information ........................................................ 4
Tool Quick Reference ......................................................................................................... 5
General Safety Issues ..................................................................................................... 6-8
SAFETY - System Installation, Operation and Removal .................................................... 9-11
Hose Connections and Installation ................................................................................... 9
Pre-Operation of Tool, Disconnecting Hoses ................................................................ 10
SPECIFICATIONS
Hydraulic Fluid ................................................................................................................ 11
Tool & Motor Specifications ............................................................................................ 11
Visual References ....................................................................................................... 12-15
Scheduled Maintenance ............................................................................................... 13
Operation (Single Acting) ................................................................................................... 16
Operation (Double Acting) .................................................................................................. 17
MAINTENANCE
Troubleshooting ............................................................................................................ 18
Before Disassembly, Reservoir Clean & Fill ................................................................... 19
DRAWINGS
Major Components (Fig. 1) ................................................................... 20
Inner Pump Assembly (Fig. 2).............................................................. 21
PARTS LISTS Major Components & Inner Pump ....................................................... 22
Valve Block Assembly .......................................................................... 23
DRAWING
Valve Block Assembly (Fig. 3) .............................................................. 24
High Pressure Pump Block (Fig. 4 ), Manifold Outlet Block (Fig. 5) .. 25
PARTS LISTS High Pressure Pump Block, Manifold Outlet Block
Low Pressure Pump Assembly ........................................................... 26
DRAWING
Low Pressure Pump Assembly (Fig. 6) ............................................... 27
Maintenance Record ........................................................................................................ 28
User Notes, Contact Information & Visual Warnings..................................................... 28
THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.
Safety of user and others may be in jeopardy if these instructions
are not read and understood.
Operation/Safety methods may vary in accordance with the working
guidelines established by each utility or contractor
WARNING
For your own safety, ensure that you fully comply with all safe operation
guidelines required by your employer.
4
REL-GB-10 or REL-EP-____
REL-EP-115 - 1.5 hp electric
115V (14.2A) continuous duty motor.
REL-EP-230 - 230V (7.1A) continuous duty.
4 CYCLE GASOLINE or ELECTRIC
SINGLE AND DOUBLE ACTING
10,000 PSI HYDRAULIC PUMPS
REL-GB-10 - 8.75 ft./lb. torque,190cc
Briggs & Stratton OHV 4 stroke engine.
FEATURES:
10,000 PSI high pressure pump.
Fast, two stage pumping system.
Factory filled 2 gallon fluid reservoir
with recessed sight glass.
High-pressure relief valve.
The REL-GB-10 and REL-EP-115 single
and double acting hydraulic pumps feature
manual lever operation, continuous duty
performance, and a two stage pumping
system, to ensure rapid tool advance.
The manual lever control valve, and factory
installed couplers are ready to run your
single or double acting crimping, cutting
and spearing tools.
NO CONVERSION NECESSARY
Single/Double selector knob.
Integral manual lever control valve.
Designed for use with high pressure
single & double-acting, hydraulic tools.
REL-GB-10 has a steel support frame.
REL-EP-___ has a balanced carry handle.
RELIABLE EQUIPMENT & SERVICE CO., INC.
92 Steamwhistle Drive • Ivyland, PA 18974
Call: 800-966-3530 • FAX: 215-357-9193
Visit our web sight: www.Reliable-Equip.com
5
WARNING
BEFORE USING THIS TOOL, READ THE WARNINGS
and the recommended practices described in this manual.
Failure by the operator to read and fully understand these
warnings will leave this person unqualified to use and
operate this tool. Property damage, severe personal injury,
and/or death could result by not following these warnings.
These warnings will appear in appropriate locations when they are pertinent to the
particular subject being shown. Read each one carefully and follow them strictly.
Eye Protection
WARNING
Dust Mask
Always wear eye
protection to avoid
WARNING
injury from flying debris or hydraulic
oil leaks. Failure to do so can result
in serious personal injury.
Always wear a Mask.
Failure to observe this warning
may result in serious health issues
and/or breathing difficulty.
Foot
Protection
Hard Hat
WARNING
WARNING
Always wear a hard hat to avoid injury
from falling debris. Failure to do so
can result in serious personal injury.
Always wear foot protection.
Failure to do so can result in serious
personal injury.
Protective
Gloves
Hearing
Protection
WARNING
WARNING
Always wear hearing protection, to
avoid hearing loss due to long term
exposure to high noise levels.
Always wear protective gloves.
Failure to do so can result in serious
personal injury.
6
Safe Operation & Care
WARNING
USE THIS TOOL FOR ITS INTENDED PURPOSE ONLY
Any other use can result in injury or property damage.
INSPECT TOOL BEFORE USE. Replace any worn, damaged
or missing parts. A damaged or improperly assembled tool
may malfunction, injuring operator and/or nearby personnel.
INSPECT HYDRAULIC HOSES AND COUPLINGS before each
use. Repair or replace if any cracking, leakage, wear or
damage is is found. Worn or damaged hoses may fail
resulting in personal injury or property damage.
CLEAR WORK AREA of all bystanders and unnecessary
personnel before operating this tool.
KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.
Failure to observe this warning could result in serious
injury.
Safety
DO NOT attempt to make any changes to any of the component
parts or accessories when connected to the power source.
WARNING
DO NOT adjust, inspect, or clean tool while the tool is connected
to the power source. The tool could accidentally start up and
cause serious injury.
DO NOT lock the tool in the On Position. In an emergency,
serious damage or injury could occur during the time
required to stop the tool.
Oil Injection Injury
WARNING
Hydraulic oil or fluid under the skin is a serious injury. Oil
under pressure can penetrate the skin and may cause
dismemberment or loss of life. Seek medical assistance
immediately if such an injury should occur.
Always wear safety gloves, eye protection and all required
safety equipment when operating or handling this tool.
DO NOT use fingers or hands to attempt to locate a leak.
DO NOT handle hoses or couplers while system is pressurized.
NEVER open or service the system before depressurizing.
7
Burn Hazard
WARNING
Do Not connect or disconnect tool, hoses or fittings while
power source is running or while hydraulic fluid is hot.
Hot hydraulic fluid may cause serious burns.
Failure to observe this warning could result in serious
injury.
Electrical Shock Hazard
WARNING
Use only certified nonconductive hoses and fittings. Always
wear and use the necessary clothing, equipment and safety
practices to protect against electrical shock. Failure to follow
these rules can result in serious personal injury or death.
Safe Handling
HYDRAULIC FLUID MAY CAUSE SKIN IRRITATION.
Prevent hydraulic fluid from making contact with skin.
CAUTION
IN THE EVENT OF SKIN CONTACT immediately wash thoroughly.
Failure to observe this warning could result in injury.
General Safety
CAUTION
Ensure that all fellow employees and bystanders are clear and
protected from possible injury caused by this tool or the
operations being performed. Persons in close proximity could
be injured and property damaged if the tool were to malfunction.
This tool should always be used within the limits and purposes
stated by the product manufacturer. Abuse or usage beyond the
manufacturers’ intended purposes could cause damage to the
tool and severe injury to the operator.
NOTICE
If you have any questions regarding the information found in this
manual please contact RELIABLE EQUIPMENT before continuing.
Phone: 215-357-3500 Toll Free: 800-966-3530 Fax: 215-357-9193
8
HOSES AND FITTINGS
WARNING
There exists the potential for shock in using anything other
than certified nonconductive hoses and hydraulic oil with
dielectric properties, when using system components near
energized electrical lines. Failure to recognize these conditions
could cause electrocution.
Hoses and fittings used with this tool must comply with S.A.E. J1273 which covers
recommended practice for selection, installation, and maintenance of hose and hose
assemblies. The correct hoses and fittings are available from your supplier.
WARNING: Failure to comply with these warnings could result in severe bodily injury.
UNIT/HOSE CONNECTIONS
WARNING
ALWAYS DISCONNECT pump/power source and move toggle switch
to OFF before connecting or disconnecting any components.
ALWAYS DEPRESSURIZE hydraulic system, before slowly
disconnecting this unit or any of the systems components.
ALWAYS TIGHTEN couplings completely. Loose or improperly
tightened couplings will not allow fluid to pass through the
hose creating a blockage in the supply or return line.
ALWAYS INSPECT HOSES AND CONNECTORS b e f o r e
connection to tool. Replace or repair if any leakage is evident.
Leakage is a sign of deterioration in component parts. Worn or
leaking parts must be repaired or replaced, or tool damage or
severe injury could result.
HOSE INSTALLATION
CAUTION
ALWAYS ENSURE CONNECTORS ARE CLEAN
SINGLE ACTING - Connect the hose to the pressure port on the
power source, then connect to the port on the tool.
DOUBLE ACTING - Care must be taken to assure the correct
connection of the hoses to the pressure and return (tank) ports.
Connect the return hose to the return (tank) port on the power
source, then to the return port on the tool.
Connect the pressure hose to the pressure port on the tool, then
to the “P” pressure port on the power source.
Operation with hydraulic flow reversed can cause malfunction.
Failure to fully comply can result in severe injury or death.
9
PRE-OPERA
TION OF TOOL
PRE-OPERATION
WARNING
DO NOT connect hoses or fittings to pump before completing
all of the instructions in this Manual.
Ensure power source is OFF, and hydraulic flow is turned OFF.
Failure to comply with warnings can result in severe injury or death.
Before attempting to run or use the REL-SERIES pump, check all connections, including
hoses, and couplings. (See WARNINGS on page 8)
Wear all safety items required and make sure that the working area is clear of
obstructions and non-essential personnel.
WARNING: DO NOT disconnect the tool, hoses, or fittings while the
tool is running, hot, or under pressure. Serious injury or burns could result.
DISCONNECTING HOSES
WARNING
Turn pump OFF and disconnect from power source.
NOTE: It is adivised that controll valves be cycled with the power off to relieve
any residual pressure trapped within the line before disconnecting the hoses.
Ensure that valve lever is in the RIGHT (RET.) position and remove hose(s).
Disconnect the pressure hose from the pressure “P” port on the pump, then
disconnect the hose from the pressure port on the tool.
Disconnect the return hose from the return “T” port on the tool, then disconnect the
hose from the return (tank) port on the pump.
Install dust caps on all connectors to prevent dirt and contaminents from entering
the hydraulic system.
Refer to photos and diagrams on the following pages as needed
NOTICE
If you have any questions regarding the information found in this
manual please contact RELIABLE EQUIPMENT before continuing.
Phone: 215-357-3500 Toll Free: 800-966-3530 Fax: 215-357-9193
10
REL-GB-10
TOOL SPECIFICATIONS
Height ...................................................................................................... 24 in.
Depth ....................................................................................................... 26 in.
Width ....................................................................................................
18 in.
Weight .............................................................................................. 116 lbs.
Gasoline Motor (190 cc) .......................................... 8.75 ft. lbs. Torque
Pump System .......................................... 4 High Pressure Piston Style
Tool Operation .................................................. Single or Double Acting
Operating Pressure................................................. 10,000 psi (700 Bar)
Relief Setting (factory pre-set) .................................................. 3,500 psi
Oil Reservoir ................................................................................ 2 Gallons
Oil Delivery Per Minute ........................... 160 cubic inches at 100 psi
................................................................... 60 cubic inches at 10,000 psi
IMPOR
TANT
IMPORT
ANT:: The greatest cause of hydraulic pump failure is dirt.
Prevent the introduction of foreign matter into the unit via hydraulic fluid,
dirty connections or accumulation of sediment.
HYDRAULIC FLUIDS
All hydraulic fluids that meet these listed specifications or the listed HTMA
specifications may be used for this tool.
S. U. S.
@ 100O F (38O C) ......................................................................... 140 TO 225
@ 210O F (99O C) ........................................................................ 40 minimum
FLASH POINT ...................................................... 340O F min. (170O C min.)
POUR POINT........... ...................................................-30O F min. (-34O C min.)
11
Single Acting - Connect to FWD (left) female coupler.
Double Acting - Connect Pressure to FWD (L) & Return
to REV (R). (or S.A. when a Control Valve is used)
Check sight glass to ensure that the pump has
proper fluid volume as shown.
Remove vent valve to add proper fluid as needed.
Turn dial to S.A. for single acting applications.
Note: For ALL Single Acting and Double Acting
Remote Valve Applications set selector to S.A.
Turn dial to D.A. for double acting applications.
Valve will control both forward and reverse action
of the tool virtually eliminating hang-up.
Lift vent lever before operating.
Close vent lever after use and prior to transportation.
12
VALVE OPERATION
ADV. - ADVANCE / FORWARD
HOLD / NEUTRAL
RET. - RETRACT / RETURN
SCHEDULED MAINTENANCE
DAILY MAINTENANCE - The life, reliability, and safety of the tool is dependent on
proper maintenance.
Refere to and perform all ENGINE maintenance requirements as recommended by this
manual and the Briggs & Stratton Engine Operator’s Manual (Supplied with unit).
Clean all surfaces including, hand control, fittings, hoses and housing.
Inspect tool for wear and damage. Worn or damaged parts can cause malfunction.
Inspect for cracked hoses and leaking fittings.
Check fluid level of the power source reservoir frequently.
Remove Vent to add hydraulic fluid as needed. Replace vent immediately. (see page 12)
All the above items must be replaced with new parts if signs of wear are evident.
IMPOR
TANT
IMPORT
ANT:: The greatest cause of hydraulic pump failure is dirt. Prevent the
introduction of foreign matter into the unit via hydraulic fluid, dirty connections or
accumulation of sediment.
FLUID CONTAMINATION: Cover the ends of fittings with a dust cap when disconnected.
This will help keep the fluid from contamination. (See Reservoir Clean & Fill on pg 15)
MONTHLY MAINTENANCE: Inspect per Appendix A, SAE Standard J1273, 5/86 for
hose or fitting damage such as wear, cracks or leakage; replace the necessary parts.
NOTE: Keep Label Set clean and legible. Replace decals when necessary.
13
BRIGG & STRATTON
AIR FILTER
COVER RELEASE
190 cc 8.75 ft. lb. torque GASOLINE ENGINE
See power rating information on next page.
FUEL CAP
Unleaded Fuel
PULL
START
DO NOT
Mix Oil with Gas
See warnings on
next page and in
engine manual
OIL FILL
CHECK OIL
before
each use.
PRE-USE ENGINE CHECKLIST
Before attempting to run or use this pump, check & understand these basic engine requirements.
Refer to Briggs & Stratton Operator’s Manual for detailed safety, operation and maintenance instructions.
Wear all safety items required and make sure that all connections have been checked, the valve
is in the Neutral position, and the working area is clear of obstructions and non-essential personnel.
Move lever to FAST before starting.
Read and observe all warning
labels and operating instructions.
Move lever to SLOW to stop engine.
Remove cover to check air filter.
DO NOT increase governor tension
as this may cause damage to pump.
Replace Air Filter as needed to
improve engine performance.
14
STARTER
CORD HANDLE
FINGER GUARD
DO NOT OPERATE WITHOUT THIS GUARD IN PLACE
AIR FILTER
COVER
MUFFLER
CAUTION
DO NOT TOUCH
Severe BURN
Injury will result.
THROTTLE
CONTROL
Refer to previous
page for instruction
SPARK PLUG
Refer to engine
manual for
maintenance
Engine Power Rating Infor mation
ST
AR
TING THE ENGINE
STAR
ARTING
The gross power rating for individual gas
engine models is labeled in accordance with
SAE (Society of Automotive Engineers) code
J19400 (Small Engine Power and Torque
Rating Procedure), and rating performance has
been obtained and corrected in accordance with
SAE J1995 (Revision 2002-05). Torque values
are derived at 3060 RPM; horsepower values
are derived at 3600 RPM. Actual gross engine
power will be lower and is affected by, among
other things, ambient operating conditions and
engine to engine variability. Given both the
wide array of products on which engines are
placed and the variety of environmental issues
applicable to operating the equipment, the
gas engine will not develope the rated gross
power when used in a given power equipment
(actual “on-ste” or power). This difference is
due to a variety of factors including, but not
limited to, accessories (air cleaner, exhaust,
charging, cooling, carburetor, fuel pump, etc.)
application limitations, ambient operating
conditions (temperature, humidity, altitude),
and engine-to-engine variability.
Due to manufacturing and capacity limitations,
Briggs & Stratton or Reliable Equipment &
Service Co., Inc. may substitute an engine
of higher rated power for this Series engine.
Ensure Pump Valve is in the neutral position,
connections are correct and secure, and
resevoir vent is open. Refer to instructions
on the following pages for pump operation.
Check Oil Level refer to instructions in
the engine manual as needed.
Fill Gasoline Tank with proper fuel as
recommended in the engine manual.
NO
TE: Allow engine to cool before opening
NOTE:
or refilling fuel tank.
Turn the Fuel Shut OFF Valve (if equiped)
to the ON position.
Move the Throttle Control to the FAST
position to START.
NOTE: Operate engine in FAST position.
Firmly hold the sarter cord handle. Pull
the Starter Cord Handle slowly until
resistance is felt, then pull rapidly.
Ignition may require more than one pull,
NOTE: If engine does not start after multiple
attempts go to BRIGGSandStratton.com
or call1-8000-233-3723 (in USA).
Move Throttle Control to the SLOW position
to STOP the engine.
Contact RELIABLE EQUIPMENT at
800-966-3530 for maintenance of your
high pressure pump and tooling componets
15
SINGLE ACTING PUMP OPERATION
NOTE: This is a 10,000 psi hydraulic power source.
DO NOT USE with standard low pressure hydraulic tools. (i.e. Impact Wrench, Tamper,
Ground Rod Diver, etc. . .) Consult Reliable or the tool manufacturer if you have questions.
There are a number of safety items that need to be addressed when using the tool.
Seek out the supervisor for basic instruction in handling the tool. Some basic problems
are easily overcome by knowing the rules of operation.
Inspect, set-up and connect the tool as described on the previous pages.
Refer to photos and diagrams on the previous pages as needed.
1) Open reservoir vent. (Lift Lever
^ Vertical)
2) Connect tool Pressure hose to the LEFT (Female) FWD valve block coupling.
A Single Acting In-line Control Valve may also be used for remote applications.
Connect Connect Return (Tank) hose to RIGHT (Male) REV valve block coupling.
ENSURE THAT ALL CONNECTIONS ARE TIGHT AND SECURE
3) Set D.A./S.A. selector knob to the S.A. position.
NOTE: D.A./S.A. selector knob is located on the right side of the lever valve block.
4) Ensure that the valve lever is in the RETURN (RET.) position.
7) Turn motor on when ready to begin tool operation.
6) Move lever to the left to advance the tool ram, blade or spear.
Once the crimp/cut has been completed, an audible “POP” will be heard.
This signals that the full pressure/tonnage has been achieved.
NOTE: A 4-way valve may also be used for added control options.
Move lever to the left to advance.
Operate the control valve to advance the tool ram, blade or spear.
7) Move lever to the RIGHT to allow the ram to retract.
NOTE: Lever can be moved to the CENTER (HOLD) position at any time during
the Advance or Retract cycle.
REPEAT OPERATION AS REQUIRED BY THE CONNECTION OR APPLICATION.
8) Once task has been completed: Turn motor OFF.
NOTE: It is adivised that control valves be cycled with the power OFF to relieve
any residual pressure trapped within the line before disconnecting the hoses.
10) Ensure that valve lever is in the RIGHT (RET.) position and remove hose(s).
See Disconnecting Hoses.
11) Close Reservoir Vent (Turn Lever Clockwise) and secure pump for future use.
If you have any questions regarding the information found in this manual
please contact RELIABLE EQUIPMENT at 800-966-3530 or 215-357-3500.
16
DOUBLE ACTING PUMP OPERATION
There are a number of safety items that need to be addressed when using the tool.
Seek out the supervisor for basic instruction in handling the tool. Some basic problems
are easily overcome by knowing the rules of operation.
Inspect, set-up and connect the tool as described on the previous pages.
Refer to photos and diagrams on the following pages as needed.
1) Open reservoir vent. (Lift Lever vertical)
2) Connect tool hose(s) to the valve block couplings.
NOTE: A Double Acting In-line Control Valve may also be used for remote applications.
Connect ADVANCE (Forward) hose from tool to the LEFT (female) coupling.
Connect the RETRACT (Reverse) hose to the RIGHT (Male) coupling.
^
ENSURE THAT ALL CONNECTIONS ARE TIGHT AND SECURE
3) Set D.A./S.A. selector knob to the D.A. position for your tool assembly.
Set D.A./S.A. selector knob to the S.A. position if an In-line Control Valve is to be used.
NOTE: D.A./S.A. selector knob is located on the right side of the lever valve block.
4) Ensure that the valve lever is in the RETURN (RET.) position.
5) Start motor when ready to begin tool operation.
6) Move the valve lever to the Left (ADV.) to advance the tool ram, blade or spear.
Once the crimp/cut has been completed an audible “POP” will be heard.
This signals that the full pressure (tonnage) has been reached.
NOTE: If a 4-way valve is used for added control options. Move lever to the left to advance.
Operate the control valve to advance or retract the tool ram, blade or spear.
7) Move lever to the RIGHT (RET.) to retract the tool ram.
NOTE: Lever can be moved to the CENTER (HOLD) position at any
time during the Advance or Retract cycle.
REPEAT OPERATION AS REQUIRED BY THE CONNECTION OR APPLICATION.
8) Once task has been completed: Turn motor OFF.
NOTE: It is adivised that control valves be cycled with the power off to relieve
any residual pressure trapped within the line before disconnecting the hoses.
9) Ensure that valve lever is in the RIGHT (RET.) position. Remove hose(s).
See Disconnecting Hoses.
10) Close Reservoir Vent (Turn Lever Clockwise) and secure pump for future use.
WARNING: DO NOT disconnect the tool, hoses, or fittings while the
tool is running, hot, or under pressure. Serious injury or burns could result.
IF YOU HAVE QUESTIONS REGARDING THE USE AND/OR OPERATION
OF THIS TOOL CONTACT RELIABLE EQUIPMENT AT 800-966-3530
17
TROUBLESHOOTING
Determine the source (i.e. tool or hydraulic system) of the problem before trouble shooting.
Will not run
Improper power source (REL-EP-115) .............................. Verify power source meets specifications 115V AC
Motor runs but pump will not operate
Low hydraulic fluid ............................................................ Check fluid level
Incorrect viscosity .............................................................
Pump damaged ................................................................
Hoses incorrectly connected .............................................
Dirt in pump ......................................................................
Use recommended fluid
Repair by authorized technician
Switch hoses (see hose connection in this manual)
Disassemble, clean and repair
Pump runs slow
Power supply not functioning correctly .............................. Reset to operator manual specs.
Fluid not warmed to correct temp ...................................... Allow a warm-up period
Fluid viscosity too high ..................................................... See recommended viscosity
Air in hydraulic system ..................................................... Check hoses for breaks, leaks, or loose connections
Hydraulic fluid level low ..................................................... Fill to level. Check for leaks
Worn or damaged components ......................................... Replace worn or damaged components
Pump operation is erratic
Hydraulic fluid not warm .................................................... Allow oil to warm up
Dirt or contaminants in tool ............................................... Clean and reassemble
Air in system .................................................................... Check hoses for breaks, leaks, or loose connections
Pump runs continuously
Tool locked in “ON” position .............................................. Release toggle switch
Pump runs hot
Low fluid level .................................................................... Fill pump reservoir to correct level
Fluid viscosity incorrect .................................................... Use recommended fluid
Fluid dirty ......................................................................... Drain tank, flush, and replace fluid
Worn or damaged O-rings or gaskets ............................... Replace worn or damaged components
Pump leaks hydraulic fluid
Worn or damaged seals .................................................... Disassemble and replace worn or damaged seals
Components loose ............................................................ Tighten component hardware
Pump lacks power
Control valve leaking ......................................................... Worn part or seal rings
NOTICE
If you have any questions regarding the information found in this
manual please contact RELIABLE EQUIPMENT before continuing.
Phone: 215-357-3500 Toll Free: 800-966-3530 Fax: 215-357-9193
18
READ BEFORE DISASSEMBLY
Safety
DO NOT attempt to make any changes to any of the component
parts or accessories when connected to the power source.
WARNING
WARNING
DO NOT adjust, inspect, or clean tool while the tool is connected
to the power source. The tool could accidentally start up and
cause serious injury.
Before disassembly, disconnect hoses as described in this manual.
Any residual pressure within the unit can and will spray at
high velocity, injuring the person doing the disassembly. Hot or
pressurized hydraulic fluid will cause serious injury or death.
Complete disassembly is not recommended. Return the unit
to an authorized dealer for total disassembly and/or repair.
All maintenance or disassembly should take place on a flat, clean work surface covered
with towels or wipers so as to have a clean space for the disassembled parts.
Inspect each part during disassembly for wear, scratches, and cuts. Discard the worn or
damaged parts and replace with new factory authorized parts.
O-rings are sensitive to sharp edges. Inspect closely for cuts or damage. A small cut will
cause a leak. When assembling or disassembling O-rings, use hydraulic fluid as a
lubricant to help disassembly or installation.
RESER
VOIR CLEAN AND FILL
RESERV
ALWAYS disconnect pump/power source and move toggle switch to OFF before
connecting or disconnecting system components.
ALWAYS DEPRESSURIZE hydraulic system before slowly disconnecting this unit or
any of the system’s components.
Disconnect pump from any hoses or tools.
Remove the screws holding the motor housing and pump assembly to reservoir.
Carefully lift assembly out of reservoir, taking care not to damage gasket.
Dump out old oil from reservoir, clean out ALL sludge and sediment. DO NOT RUN DRY
Clean inlet screen of dirt and debris.
Fill with CLEAN HYDRAULIC FLUID as specified.
Reference hydraulic fluid sight glass for appropriate level, as shown on page 12.
Check gasket for damage, replace if necessary. Re-assemble completely.
Test thoroughly prior to field use.
19
FIGURE 1
MAJOR COMPONENTS
GASOLINE PUMP
BRIGG & STRATTON
GASOLINE ENGINE
AIR FILLTER
COVER RELEASE
75
PULL
START
FUEL CAP
OIL FILL
92 93
VALVE
BLOCK
ASSY.
3
58
48 49
1
68
76
BRIGGS & STRA
TT
ON 8.75 ENGINE
STRATT
TTON
Refer to the manufacturers (supplied) Operators Manual
for Operation, Care and Maintenance information.
20
FIGURE 2
VALVE BLOCK
ASSEMBLY
7
21
FIGURE 1
1
2
3
43
49
58
59
60
61
68
74
75
76
77
78
92
97
98
99
R40001
R40002
R40003
R40043
R40049*
R40058
R40059
R40060
R40061
R40205
R40074
R40075
R40076
R40077
R40078
R22103
R40097
R40098
R40099
FIGURE 2
3
4
11
12
13
14
15
16
17
18
20
25
26
31
33
34
41
43
44
47
49
51
59
62
79
95
96
97
98
99
R40003
R40004
R40011
R40012
R40013
R40014
R40015
R40016
R12769
R12774
R13427
R40025
R40026
R40031*
R40033
R40034
R40041
R40043
R40044
R40047*
R40049*
R40051*
R40059
R40062
R40079
R40095
R40096
R40097
R40098
R40099
MAJOR COMPONENTS, GASOLINE PUMP
TANK
MOTOR MOUNT
COVER
SCREW
O-RING
SIGHTGLASS TUBE
SCREW 5/16X24
STUD
NUT
COUPLER SET (3050-3/3005-3 FEM., 3010-3/3009-3 MALE)
WASHER, RUBBER
CAGE
FOOT ASSEMBLY
BOLT
WASHER
VENT VALVE ASSEMBLY (Includes # 22103 & #22107)
ELEC. MOTOR COUPLER
SCREW
5/16 LOCKWASHER
1
1
1
16
16
1
4
1
1
1
4
1
4
4
4
1
1
2
6
INNER PUMP ASSEMBLY
COVER
MANIFOLD PLATE
BEARING
CENTER BLOCK
DRIVESHAFT
RETAINING RING
HOUSING RETAINING RING
CAM BEARING ASSY
THRUST WASHER
THRUST BEARING
KEY
BYPASS TUBE
OUTLET BLOCK
O-RING
SCREW (OUTLET BLOCK)
1/16 PIPE PLUG
LARGE BAYONET
SCREW
DOWEL
V-SEAL
O-RING
O-RING
SCREW
SET SCREW
KEY 3/16 SQ X 3/4
PUMP COUPLER
SPIDER
ELEC. MOTOR COUPLER
SCREW
5/16 LOCKWASHER
22
1
1
1
1
1
1
1
1
2
1
1
1
1
9
1
8
1
10
6
1
16
1
4
2
4
1
1
1
2
6
FIGURE 3
31
55
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
R40031*
R40055
R40102
R40103
R35017
R40105
R40106
R40107
R40108
R40109
R40110*
R24542
R40112*
R35008
R40114*
R40115
R40116
R40117
R40118
R40119
R40120
R12251
R40122
R35018
R35019
R35020
R40126*
R40127*
R40128
R40129
R40130
VALVE BLOCK ASSEMBLY
O-RING
BALL 1/4"
CAP
SHAFT
TOP BLOCK
ROTOR
GROMMET
WAVE SPRING
BEARING
WASHER
O-RING
SPRING PIN 3/16 X 1.25
V-SEAL
SPRING
VALVE GASKET
STEM
RETAINING NUT
SELECTOR KNOB
SPRING
REGULATOR SCREW
PINTLE
REGULATOR SPRING
BALL 1/8
STUD
PLASTIC BALL
SCREW
O-RING
B/U RING
3/32 X 3/4 SPRING PIN
SET SCREW
SPRING PIN 1/4 X 1/2
9
3
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
3
1
1
1
It is highly recommended that this unit be returned to RELIABLE EQUIPMENT or
a factory trained and authorized service center for all repair and maintenance.
Complete disassembly is not recommended.
Gasoline Engine - Refer to the manufacturers (supplied) Operators Manual for Engine
Operation, Care & Maintenance information.
All maintenance or disassembly should take place on a flat, clean work surface covered with
towels or wipers so as to have a clean space for the disassembled parts.
Inspect each part during disassembly for wear, scratches, and cuts. Discard the worn or
damaged parts and replace with new factory authorized parts.
O-rings are sensitive to sharp edges. Inspect closely for cuts or damage. A small cut will
cause a leak. When assembling or disassembling O-rings, use hydraulic fluid as a
lubricant to help disassembly or installation.
23
FIGURE 3
VALVE BLOCK
ASSEMBLY
24
FIGURE 4
HIGH PRESSURE
PUMP BLOCK
FIGURE 5
MANIFOLD
OUTLET BLOCK
25
FIGURE 4
5
6
7
8
9
10
31
39
40
46
49
50
84
R40005
R40006
R40007
R40008
R40009
R40010*
R40031*
R40039
R40040*
R40046
R40049*
R40050
R40084
FIGURE 5
27
28
29
30
31
32
35
36
38
64
80
R40027
R40028*
R40029
R40030
R40031*
R40032
R40035
R40036
R40038*
R40064
R40080
FIGURE 6
19
21
22
23
24
31
44
45
48
52
53
54
55
70
71
72
R13426
R40021
R40022
R40023
R12736
R40031*
R40044
R40045
R40048
R40052
R18204
R40054
R40055
R40070
R40071
12795
HIGH PRESSURE PUMP BLOCK
PRESSURE BLOCK
CHECK PLUG
SPRING
BALL 9/32
PISTON + BUSHING SET
O-RING
O-RING
SMALL BAYONET
O-RING
LOCKWASHER
O-RING
SCREW
SPRING (HP SIDE)
4
8
8
8
4
8
9
4
8
20
16
8
4
MANIFOLD OUTLET BLOCK
TRANSFER BUSHING
O-RING
SPRING
BALL 3/8 DIA
O-RING
TRANSFER TUBE
VALVE CLAMP
SCREW
B/U RING
SCREW
VALVE TUBE
1
2
1
1
9
1
1
2
2
2
1
LOW PRESSURE PUMP ASSEMBLY
GEAR
PUMP BLOCK
INTAKE BLOCK
IDLER SHAFT
NEEDLE BEARING
O-RING
DOWEL
SCREW
SCREW
ADJUSTING SCREW
SPRING
PINTLE
BALL 1/4"
FILTER
ADAPTER
DRIVE PIN
26
2
1
1
1
4
9
6
4
16
1
1
1
3
1
1
1
FIGURE 6
LOW PRESSURE
PUMP ASSEMBLY
WARNING
BEFORE USING THIS PRODUCT
READ THE SAFETY WARNINGS
and recommended practices described
in the manual. Failure by the operator to
read and fully understand the warnings
will leave this person unqualified to use
and operate the tool.
REL-SM
Failure to observe all warnings and instructions could result
in property damage, severe personal injury, and/or death.
EXPLOSION HAZARD
DO NOT operate motor where explosive vapors or
flammable materials exist. Death or serious injury
will result.Check NEC and local codes before installing.
CAUTION
CH-1800-EH
2 PERSON LIFT
WARNING
ELECTROCUTION
HAZARD
ENGINE SPEED IS FACTORY
PRESET AT 3000 RPM
Increasing engine speed by increasing governor tension
and WILL VOID ALL WARRANTIES and may damage pump.
The user should be properly
trained in the correct procedures
required for work on or around
electrical lines.
OPEN VENT VALVE
BEFORE OPERATING.
CLOSE AFTER
USE.
1915-V
27
MAINTENANCE RECORD
If you have any questions regarding the information
in this manual please contact RELIABLE EQUIPMENT
at the address, phone or fax numbers shown below.
92 Steamwhistle Drive Ivyland, PA 18974
Phone: 800-966-3530 Fax: 215-357-9193
Visit us on the web at www.Reliable-Equip.com
28
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