ATD Tools Atd-5825 User manual

Model Number
Atd-5825
OperatingInstructions&PartsManual
Capacity
5 Ton
Atd Tools Inc.
160 Enterprise Drive, Wentzville, MO 63385 OIPM#5825-10-03
Printed in Taiwan
Flat Body Cylinder Kit
Instruction Manual
Max. Operating Pressure 10,000 PSI (700 Bar)

Save these instructions. For your safety, read and understand the information contained within. The owner and
operator shall have an understanding of this product and safe operating procedures before attempting to use this
product. Make certain that the operator thoroughly understands the inherent dangers associated with the use and
misuse of the product. If any doubt exists as to the safe and proper use of this product as outlined in this factory
authorizedmanual,removefromserviceimmediately.
Inspect before each use. Do not use if leaking, broken, bent, cracked or otherwise damaged parts are noted. If the
cylinder has been or suspected to have been subjected to a shock load, (a load dropped suddenly, unexpectedly upon
it),discontinue use until checked outby an authorized factory servicecenter. Owners and operators ofthis equipment
shallbe aware that the use and subsequent repair ofthis equipment may require special training and knowledge. It is
recommended that an annual inspection be done by qualified personnel and that any missing or damaged parts,
decals, warning / safety labels or signs be replaced with factory authorized replacement parts only. Any cylinder that
appears to be damaged in any way, is worn or operates abnormally shall be removed from service immediately until
such time as repairs can be made.
PRODUCT DESCRIPTION
ATDHydraulicsFlatBodyCylinder isengineeredto meetorexceed ANSIB30.1Standards forPerformanceand Safety.
This cylinder is designed for rated capacity lifting, lowering, pushing, spreading and pressing jobs. ATD Flat Body
Cylinder Kit consists of a flat body cylinder, four magnetic adapters, owner's manual and a blow molded case.These
fourpieces of different height adapters ranges from0.25inchto1.25inch are provided to extend the workingheight.A
widevariety of applications exist for this category of product. Special skill, knowledge and training may be required for
a specific task and the product may not be suitable for all the jobs described above. Unsuitable applications would
include applications that call for a device to move, level or support persons, animals, hazardous materials, mobile
homes/dwellingsingeneral, mirrors and/or plate glass, and/or to connect/secure hatches, components, etc. between
bulkheads. The user ultimately must make the decision regarding suitability of the product for any given task and
thereforeaccept responsibility for that decision.
Note: Always check connections before using. Alteration of these products is strictly prohibited.
* Max. Working Pressure 10,000 PSI (700 Bar)SPECIFICATIONS
Model
Number
Cylinder
Capacity
(tons)
Stroke
(in)
CylinderEffec-
tiveArea(in²) Oil Capacity
(in³) Collapsed
Height(in) Extended
Height(in) Weight
(lbs)
50.24 1.10 0.26 1.26 1.50 1.30Atd-5825
2
Magnetic adapter's height
Adapter I: 0.25 in
AdapterII:0.50in
AdapterIII: 1.00in
Adapter IV: 1.25 in
female
coupler
saddle
(ram)
magnetic
adapter blowmolded
case
TYPICAL INSTALLATION
handpump
(notincluded)

3
BEFORE USE
1. Before using this product, read the owner's manual
completely and familiarize yourself thoroughly with
the product, its components and recognize the haz-
ards associated with its use.
2. Verify that the product and the application are com-
patible. Inspect before each use. Do not use if bent,
broken, leaking or damaged components are noted.
3. Carefully remove the dust cap and plug from hose
coupler and ram coupler.
4. Connect hose coupler to ram coupler, ensure that
there are no fluid leaks.
5.Checkforleaksinsystemandhaverepairedbyquali-
fied personnel as needed. Before repairs are made,
depressurize cylinder.
6. Replace worn or damaged parts and assemblies with
ATDHydraulicsAuthorizedReplacementPartsonly
(See Replacement Parts Section). Lubricate as in-
structed in Maintenance Section.
7.Use adequate eye protectionwhen operating or near
this equipment.
8. Ensure method of confirming load is accurate and
working properly. Have gauge or load cell accuracy
verifiedby qualified personnel on a yearly basis.
9. Cylinder should be stored where protected from the
elements,abrasive dust, and damage. Thiscylinder
should be stored in the vertical position.
• Ifoilleakage is detected, discontinue use of the cylin-
der immediately and contact your nearest ATD Hy-
draulicsAuthorized ServiceCenter.Thecylindercould
develop excessive pressure and cause the cylinder,
hose or coupler to burst which could cause serious
injury or death.
• When loading a cylinder, always insure that coupler,
port, and adapter threads have not been damaged.
Failure to do so could cause serious injury or death.
• Avoid off-center loads. Loading off center may dam-
age the cylinder and cause loss of load which may
cause serious injury or death.
• Control the load at all times. Do not drop the load.
Threadsmay shear and cause loss of the load, which
may cause serious injury or death.
• AllWARNING statements must be carefully observed
to help prevent personal injury. Do not exceed rated
cylinder pressure. Monitor pressure and load at all
times.Always verifyloadwith calibratedloadcell and
indicator, known good pressure gauge or equivalent
devices.Wear protective clothing and safety goggles
to reduce the risk of injection. Wear appropriate
shoes.Do notwearsandals whenoperatingthis equip-
ment.Do not wear jewelrywhen operating this equip-
ment.
Hydraulic Hoses and Fluid Transmission Lines
• Avoid short runs of straight line tubing. Straight line
runsdonotprovideforexpansion andcontractiondue
to pressure and/or temperature changes.
• Reduce stress in tube lines. Long tubing runs should
be supported by brackets or clips. Before operating
the pump, all hose connections must be tightened
with the proper tools. Do not overtighten. Connec-
tionsshouldonly be tightened securely and leak-free.
Overtighteningcancauseprematurethread failure or
high pressure fittings to burst.
• Shouldahydraulichoseeverrupture,burstorneed to
bedisconnected, immediatelyshutoff thepumpand
release all pressure. Never attempt to grasp a leak-
ing pressurized hose with your hands. The force of
escaping hydraulic fluid can inflict injury.
•Do not subject the hose to potential hazard such as
fire, sharp surfaces, extreme heat or cold, or heavy
impact.
WARNING
!
! DANGER !
!
WARNING
Wear protective clothing and safety gog-
gles to reduce the risk of injection.

•Do not allow the hose to kink, twist, curl, crush, cut
or bend so tightly that the fluid flow within the hose is
blockedorreduced. Periodically inspect the hose for
wear, because any of these conditions can damage
the hose and possibly result in personal injury.
•Do not pull, position or move setup by the hose. Do-
ingsocan damage the hose and possibly cause per-
sonal injury.
•Hose material and coupler seals must be compatible
with hydraulic fluid used. Hoses also must not come
in contact with corrosive materials such as battery
acid, creosote-impregnated objects and wet paint.
Hose deterioration due to corrosive material can re-
sultin personal injury. Never paint acoupler or hose.
•Theusermust be a qualified operator familiar with the
correctoperation, maintenance,anduseof cylinders.
Lack of knowledge in any of these areas can lead to
personalinjury.
•Read and understand all safety and warning decals
and instructions.
•Useonly approvedaccessoriesandapproved hydrau-
lic fluid. Hoses, seals and all components used in a
system must be compatible with the hydraulic fluid
used.
•Do not exceed the rated capacity of the cylinder. Ex-
cess pressure can result in personal injury.
•Inspecteachcylinderandcouplerbeforeeachuseto
preventunsafe conditionsfromdeveloping.
•Do not use cylinders if they are damaged, altered or
in poor condition.
•Donotusecylinderswith bent or damaged coupler or
damaged threads.
•Undercertainconditions,theuseofanextensionwith
a hydraulic cylinder may not be advisable and could
present a dangerous condition.
•Avoid pinch points or crush points that can be cre-
ated by the load or parts of cylinder.
•Tohelpprevent material
fatigue if the cylinder is to
be used in a continuous
application, the load
should not exceed 85% of
the rated capacity.
•Cylinder must be on a
stable base which is able
to support the load while
pushing or lifting.
•Ensure cylinder is fully
engagedinto/ontoadapt-
ers, extension accessories.
4
•Tohelpprevent personalinjury,useshims,frictionma-
terialor constraintstopreventslippage of thebaseor
load.
•Donotoff-centerloadsonacylinder.Theloadcantip
or the cylinder can "kick out" and cause personal in-
jury.
•Do not use the locking collar on threaded piston as a
stop. The threads may shear resulting in loss of the
load.
•Do not create an overload condition where force ex-
ertedby one cylinder will intensify downward forceon
another cylinder.
•If this component is used to lift or lower loads, be
certain that the load is under operator control at all
times and that others are clear of the load. Do not
drop the load.
•Asthe load islifted,useblocking and cribbing toguard
againstafallingload.
•Neverallow personnel to work on, under or around a
loadbeforeitisproperlysupported byappropriateme-
chanicalmeans.Neverrelyonhydraulicpressurealone
to support load.
•Allpersonnel must be clear beforelowering.
•Never try to disassemble a hydraulic cylinder, Refer
repairstoqualified, authorized personnel.
IMPORTANT
•Keep cylinder clean at all times.
•Whenthe cylinder is not is use, keep the ram(s) fully
retracted.
•Use an approved, high-grade pipe thread sealant to
sealallhydraulicconnections.Teflon tape can be used
ifonlyonelayerof tape is used and it is applied care-
fully(two threadsback)toprevent the tapefrombeing
introducedintohydraulicsystem.Apieceoftapecould
travelthrough thesystemandobstructthe flowoffluid
andadversely affectfunction.
•NeverattachANYcomponentnotauthorizedbymanu-
facturer.
•Neveruse other than factory provided and/or author-
ized fasteners.
KNOWYOUR SYSTEM
Your cylinder, hose(s), couplings and pump all must be
rated for the same maximum operating pressure, cor-
rectlyconnectedand compatible with the hydraulic fluid
used.Animproperlymatchedsystemcan causethesys-
temto fail and possibly causeseriousinjury.If you are in
doubt,consult your nearest ATD Hydraulics Dealer.
Center loads on cylinder
!
WARNING
!
WARNING

5
SET UP
Remove thread protectors (dust cap) from hydraulic con-
nections/ports. Clean the areas around the fluid ports of
the pump and cylinder. Inspect all threads and fittings for
signs of wear or damage, and replace as needed. Clean
all threads and fittings. Connect all hose assemblies to
the pump and cylinder. Use an approved, high-grade pipe
sealant to seal all hydraulic connections. Tighten se-
curely but do not overtighten.
MAINTENANCE
Due to superior materials and manufacturing proc-
esses, there is little maintenance required of this
product. This fact does not preclude operators re-
sponsibility to inspect each cylinder thoroughly be-
fore each use.
1. Always use clean, approved hydraulic fluid and change
as needed.
2. Any exposed threads (male or female) must be cleaned
and lubricated regularly, and protected from damage.
Lubricate w/light machine oil.
3. If a cylinder or ram has been exposed to rain, snow,
sand, airborne abrasive, or any corrosive environment
it must be cleaned, lubricated, and protected immedi-
ately after exposure. Daily clean exposed ram with
clean cloth dampened with light machine oil. Protect
exposed ram from the elements at all times.
Periodic Cleaning
Keep the hydraulic system as free of dirt as possible.
When not in use, couplers must be sealed with dust
covers. All hose connections must be free of dirt and
grime. Any equipment attached to the cylinder must be
kept clean. Use only Mobil DTE13M (hand pump) or
equivalent hydraulic fluid and change as recommended
or sooner if the fluid becomes contaminated (never ex-
ceed 400 hours). Follow pump manufacturers instruc-
tions for changing and adding hydraulic fluid.
Storage
Cylinder should be stored in a vertical position in the
blow molded case with the ram end down in a dry, pro-
tected area, not exposed to corrosive vapor, dust or other
harmful elements. When cylinder has not been used for
a period of 4 months it should be connected to a pump
and fully extended and then retracted a minimum of 5
times. This cycle will lubricate the cylinder wall, reduc-
ing the possibility of corrosion and damage there of.
How to remove faulty coupler
If cylinder does not retract, secure load by other means.
Open release valve of host pump to depressurize pump,
hose and coupler. Prevent cylinder ram from retracting
(do not attempt to grasp with pliers or wrench without
first wrapping the jaws of such tool with rags or similar
padding). Disconnect and renew or replace coupler.
ONE YEAR LIMITED WARRANTY
For a period of one (1) year from date of purchase, Atd Tools Inc. will repair or replace, at its option, without charge,
any of its products which fails due to a defect in material or workmanship, or which fails to conform to any implied
warranty not excluded hereby.
Performance of any obligation under this warranty may be obtained by contacting your point of sale and obtaining return
or repair information from your supplier.
Except where such limitations and exclusions are specifically prohibited by applicable law, (1) the CONSUMER'S
SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF DEFECTIVE PRODUCTS AS
DESCRIBED ABOVE, and (2) Atd Tools Inc. SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDEN-
TAL DAMAGE OR LOSS WHATSOEVER, and (3) THE DURATION OF ANY AND ALL EXPRESSED AND IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, ANY WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, IS LIMITED TO A PERIOD OF ONE (1) YEAR FROM DATE OF PURCHASE.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply
to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.

6
Troubleshooting Guide
Symptom Possible Causes Corrective Action
Erratic action • Air in system or pump cavitation
• External leakage in flat body cylinders
• Cylinder sticking or binding
• Follow pump instructions for bleeding
air
• Contact Service Center
• Contact Service Center
Cylinder does not move
• Loose couplers
• Faulty coupler
• Improper valve position
• Low or no hydraulic fluid in pump
reservoir
• Air-locked pump
• Pump not operating
• Load is above the capacity of the
system
•Tighten couplers
•Replace both female and male
couplers(see Page 7)
•Close release valve or change pump
position
•Fill and bleed the system
•Prime pump per pump operating
instructions
•Check pump's operating instructions
•Use the correct equipment
Cylinder extends only partially
•Pump reservoir is low on hydraulic
fluid
•Load is above the capacity of the
system
•Cylinder is sticking or binding
•Fill and bleed the system
•Use the correct equipment
•Contact Service Center
Cylinder moves slower than normal • Loose connection or coupler
• Restricted hydraulic line or fitting
• Pump not working correctly
• Cylinder seals leaking
• Tighten
• Clean and replace if damaged
• Check pump operating instructions
• Replace cylinder
Cylinder moves but does not maintain
pressure • Cylinder seals leaking
• Pump or valve malfunctioning • Replace cylinder • Check pump operating instructions
Cylinder leaks hydraulic fluid • Worn or damaged seals • Replace cylinder
Cylinder will not retract or retracts
slower than normal
• Pump release valve closed
• Loose couplers
• Weak or broken retraction springs
• Cylinder damaged internally
• Pump reservoir too full
• Open pump release valve
• Tighten couplers
• Replace cylinder
• Replace cylinder
• Drain hydraulic fluid to correct level

Note:
1. To ensure safe and reliable performance, replace worn or damaged parts with ATD Hydraulics Authorized Replace-
ment Parts only.
2. For best performance and long equipment life, replace the pump's fluid supply at least once per year. To protect
yourwarranty and ensure proper performance,use good quality hydraulic jack fluid, we recommend Mobil
DTE 13M.
REPLACEMENT PARTS
Available Parts: Please refer to the Parts drawing when ordering parts. Not all components of this kit are replacement
items, but are illustrated as a convenient reference of location and position in the assembly sequence. When ordering
parts, give Model number, serial number and description below.
13
1
2
3
4
5
67
8910
11
12
14
15
16
Model No. Atd-5825
Part No.DescriptionQuantity
1Dust Seal 1
2Plunger 1
3Bolt 1
4Return Spring 1
5Repair Kits (O-ring, Back-up ring, and special washer) 1
6Bolt 1
7Base (N/A) 1
8Bushing 1
9Nut 1
10 Female Coupler(1/4" NPT Black Zinc) 1
11 Dust Cap 1
12 Magnetic Adapter I 1
13 Magnetic Adapter II 1
14 Magnetic Adapter III 1
15 Magnetic Adapter IV 1
16 Blow Molded Case 1
N/A - Part is not available
7

Notes
Atd Tools Inc.
160EnterpriseDrive,Wentzville, MO63385
Tel: [phone] Fax: [phone] www.atdtools.com