BVA Hydraulics HD1010 User manual

Printed in Taiwan
MODELS: HD1010, HD1012 - 10 Ton Capacity
HD2506 - 25 Ton Capacity
HD3008, HD3014 - 30 Ton Capacity
HD5506, HD5513, HD5520 - 55 Ton Capacity
HD7506, HD7513 - 75 Ton Capacity
HD10006, HD10010, HD10013, HD10018 - 100 Ton Capacity
Maximum Operating Pressure 10,000 PSI
Double Acting Cylinders
Instruction Manual
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
!
HD1010-M0_062014

WARNING: NEVER use hydraulic cylinder as a support
device.
WARNING: Always check connections before using.
Alteration of these products is strictly prohibited. Use only
those adapters and attachments provided and approved by
the manufacturer.
WARNING: To reduce the risk of personal injury and/or
property damage, ensure that the rated working pressure of
each pressurized attachment be equal to or greater than the
rated working pressure developed by the hydraulic pump.
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 hazards associated with its use.
2. Verify that the product and the application are compatible. If in
doubt, call BVA Hydraulics Technical Service [phone].
3. Inspect before each use. Do not use if bent, broken, leaking or
damaged components are noted.
4. Replace worn or damaged parts and assemblies with BVA
Hydraulics authorized replacement parts only. Lubricate as
instructed in Maintenance Section.
5. Ensure method of conrming load is accurate and working
properly.Havegaugeorloadcellaccuracyveriedbyqualied
personnel on a yearly basis.
2
SAFETY AND GENERAL INFORMATION
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. Instructions and safety
information shall be conveyed in the operator’s native language
before use of this product is authorized. 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
authorized manual, remove from service immediately.
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 out by a BVA Hydraulics authorized service center. Owners
and operators of this equipment shall be aware that the use and
subsequent repair of this equipment may require special training
and knowledge. It is recommended that an annual inspection be
done by qualied personnel and that any missing or damaged
parts, decals, warning/safety labels or signs be replaced with BVA
Hydraulics 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
BVA Hydraulics Double Acting Cylinder is designed for rated
capacity pushing, spreading and pressing jobs. Each cylinder
is equipped with a built-in safety relief valve in the return circuit
to prevent over-pressurizing. The valve is preset to 10,000 psi;
it will open as internal pressure exceeds the preset pressure.
A wide variety of applications exist for this category of product.
Special skill, knowledge and training may be required for a specic
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/dwellings in general, 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 therefore accept
responsibility for that decision. Immediately after lifting, loads must
be supported by appropriate mechanical means.
!
!
Figure 1 - Typical Cylinder Components
!
Saddle
Ram
Carrying Handle
(HD55XX~HD100XX)
Safety Relief
Valve
Dust Cap
Return Oil Port,
3/8”-18NPTF
(Female Coupler)
Collar Protective
Cap
Advance Oil Port ,
3/8”-18NPTF
(Female Coupler)
Cylinder

3
!WARNING
INSTALLATION
NOTICE: Use an approved, high-grade pipe sealant to seal all
hydraulic connections.
1. Remove the dust cover and rubber plug from coupler .
2. Inspectallthreadsandttingsforsignsofwearordamage,and
replaceasneeded.Cleanallthreadsandttings.
3. Connect hydraulic hose from hydraulic pump to the cylinder
coupler.Ensurethattherearenouidleaks.
4. Installin-linepressuregauge.
5. Check for leaks in system and have repaired by qualified
personnel.
NOTICE: The use of cylinder attachments or extensions reduces
the cylinder capacity by at least 50% per attachment/extension.
WARNING: Before operating the pump, tighten all
hose connections with proper tools. Do not overtighten.
Connections should only be tightened securely and leak-free.
Overtightening can cause premature thread failure or high
pressure ttings to burst.
WARNING: Before repairs are made, depressurize cylinder.
Tipsforhydraulichoses&uidtransmissionlines:
•Avoidshortrunsofstraightlinetubing.Straightlinerunsdonot
provideforexpansionandcontractionduetopressureand/or
temperature changes.
•Reduce stress in tube lines. Long tubing runs should be
supportedbybracketsorclips.
 Donotpull,positionormovecylindersetupbythe
 hose. Use carrying handle or other means of safe
transport.
 Do not handle pressurized hoses. Never attempt
 tograsp a leakingpressurized hose.Ensure to
 release the system pressure before disconnecting
 hydraulichoseorconnections.
 Hydraulicuidcan igniteandburn.Keep hydraulic
 equipmentawayfromamesandheat. Excessiveheat
 will soften seals, resulting in uid leaks. Heat also
 weakenshosematerials.
 Cylinder must be on a stable base which is able
 tosupporttheloadwhilepushingorlifting.Useshims,
 frictionmaterialorconstrainstopreventslippageofthe
 baseorload.Ensurecylinderisfullyengagedinto/
ontoadapters,extensionaccessories.
 Centerloadoncylinder.Distributeloadevenlyacross
 theentiresaddlesurface.Donotoff-centerloadson
 acylinder.Theloadcantiporthecylindercan“kick
out”.
 Nevertrytodisassembleahydrauliccylinder,refer
 repairstoqualied,authorizedpersonal.ContactBVA
 Hydraulicstechserviceforauthorizedservicecenter.
Do not subject hose to sharp objects or heavy
 impact.
 Hosematerialorsealsmustnotcomeincontactwith
 corrosivematerialssuch as batteryacid,creosote-
 impregnatedobjects and wet paint. Neverpaint a
coupler or hose.
• Noalterationshallbemadetothecylinder.
• Useonlyfactoryauthorizedfasteners,accessories
  andhydraulicuid.
Failuretocomplywiththefollowingwarningsmay
result in personal injury as well as property
damage.
• Study, understand, and follow all instructions
  providedwithandonthisdevicebeforeuse.
 • Theusermustbeaqualiedoperatorfamiliar
withthecorrectoperation,maintenance,anduseofcylinders.
 Wearprotectivegearwhenoperating
 hydraulicequipment.
 ThisdeviceisNOTsuitableforuseassupport
 device!As the load is lifted, use blocking and
 cribbingtoguardagainstafallingload. Stayclear
 ofaliftedloadbeforeitisproperly supported . Never
relyonhydraulicpressuretosupportaload.
Crush Hazard.Keephandsandfeet away
 fromcylinderand workpiece during
 operation.
Bothcouplersonthecylindermustbeconnected
 tothepump.Double-actingcylindermustbeused
 withapumpequippedwith4-wayvalve.
Donotadjustorremovethesafety reliefvalve.
 Highersettingthanratedpressurewillresultin
 equipmentdamageand/orpersonalinjury.
• Donotexceedratedcapacityofthecylinderor
any equipment in the system. The cylinder is
designedforamax.pressureof10,000psi.
  • Donotconnectacylindertoapumpwithhigher
 pressurerating.
•Donotsubjectcylindertoashockloads,aloaddropped
 suddenly,causingthesystempressuretoexceedrated
pressure.
 Thesystemoperatingpressuremustnotexceed
 thepressureratingofthelowestratedcomponent
the system. Install a pressure gauge or other load
measuringinstrumenttomonitortheoperatingpressure.Burst
hazardexistsifhose,connectionoranyothercomponentin
thesystemexceeditsratedpressure.
 Avoiddamaginghydraulichose.Donotallowhose
 tokink,twist,curl,crush,cutorbendsotightlythat
 uidowwithinthehoseisblockedorreduced.
 Periodicallyinspectthehoseforwear.
Heavy
 Eachdouble acting cylinder isequipped with a
 pressurereliefvalveinthereturncircuitwhichwill
 open as internal pressure exceeds10K psi.
Whenthisoccurs,oilwillbedirectedoutsideofthecylinder
wallsandontothecylinderbody.Thiswillcreateaslippery,
hazardousconditionintheimmediateworkarea.Clean up
oil immediately!
!
!

SPECIFICATIONS
Model
Number
Cylinder
Capacity
(tons) Stroke
(in)
Cylinder
Effective
Area
(in2)
Internal
Pressure at
Capacity
(psi)
Oil Capacity
(in3)
Push Pull Push Pull Push Pull Push Pull
HD1010 11.40 3.80 10.04 2.24 0.74 10179 10270 22.49 7.43
HD1012 11.97 2.24 0.74 26.81 8.86
HD2506 25.70 13.39 5.90 5.14 2.68 10000 9993 30.33 15.81
HD3008 32.90
16.20
8.15 6.49 3.19 10139
10157
52.89 26.00
HD3014 14.49 6.49 3.19 94.04 46.22
HD5506
55.70
6.18 10.99 3.19
10136
67.92 19.71
HD5513 13.19 10.99 3.19 144.96 42.08
HD5520 20.12 10.99 3.19 221.12 64.18
HD7506 81.70 25.90 6.10 16.09 5.12 10155 10117 98.15 31.23
HD7513 13.11 16.09 5.12 210.94 67.12
HD10006
104.40 48.60
6.57 20.57 9.58
10151 10146
135.14 62.94
HD10010 10.13 20.57 9.58 208.37 97.05
HD10013 13.11 20.57 9.58 269.67 125.59
HD10018 18.15 20.57 9.58 373.35 173.88
Model
Number
Collapsed
Height
(in)
Extended
Height
(in)
Weight
(lbs)
Cylinder
Dia.
(in)
Collar Thread
Mounting
Hole Dia.
(in.)
HD1010 16.12 26.19 26.7 2.87 2-1/4"-14 1.30
HD1012 18.03 30.00 30.0
HD2506 10.56 16.46 24.8 3.62
3-5/16"-12
2.30
HD3008 15.31 23.46 43.0 3.98 2.20
HD3014 21.65 36.14 60.6
HD5506 13.03 19.21 70.5
5.00 5"-12 3.70HD5513 20.04 33.23 104.0
HD5520 28.86 49.98 146.2
HD7506 13.70 19.80 93.7 5.75 5-3/4"-12 4.00
HD7513 20.71 33.82 136.8
HD10006 14.06 20.63 138.6
6.97 6-7/8"-12
5.47
HD10010 17.67 27.80 169.2 5.50
HD10013 20.63 33.74 193.6 5.47
HD10018 27.05 45.20 248.3
4

5
Storage
Cylinders should be stored vertically with ram plunger fully retracted
in a dry, protected area, not exposed to corrosive vapor, dust or
other harmful elements. When a 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, reducing the possibility of corrosion
and damage thereof.
How to remove faulty coupler:
If cylinder does not retract,
1. Secure load by other means.
2. Depressurize pump and hose.
3. Remove the cylinder from application.
4. Disconnect and replace with new coupler.
NOTICE: Do not attempt to grasp with pliers or wrench without
rst wrapping the jaws of such tool with rags or similar padding.
How to bleed air from system:
1. Place pump at a higher elevation than the hose and cylinder
as shown in Figure 2.
2. Operatepumptofullyextend and retractthecylinder2or 3 times.
The objective is to force the air bubbles up hill and back to the
pump reservoir.
3. Follow pump instruction manual to bleed the air from pump
reservoir. On most pumps, air can escape by opening the oil
ller plug/screw.
OPERATION
Operate the hydraulic pump to advance and retract the cylinder.
Do not continue pumping when cylinder is fully extended. Internal
pressure will build up and may damage the seal of the cylinder.
WARNING: NEVER rely on hydraulic pressure alone to
secure a load! NEVER allow personnel to work or pass
under a load until the load is secured by cribbing, blocking,
or other mechanical means.
WARNING: To help prevent material fatigue if the cylinder
is to be used in a continuous application, the load should
not exceed 85% of the rated capacity.
WARNING: Your cylinder, hose(s), couplings and pump all
must be rated for the same maximum operating pressure,
correctly connected and compatible with the hydraulic uid
used. An improperly matched system can cause the system
to fail.
WARNING: All personnel must be clear before lowering load.
MAINTENANCE
1. Inspect hoses and connections daily. Replace damaged
components immediately with BVA Hydraulics Replacement
Parts only.
2. Tighten connections as needed. Use pipe thread sealing
compound when servicing connections.
3. Always use clean, approved hydraulic uid and change as
recommended or sooner if the uid becomes contaminated
(never exceed 400 hours). Follow pump manufacturers
instructions for changing and adding hydraulic uid. Use only
good quality hydraulic uid. We recommend Mobil DTE13M
or equivalent when using with hand pump or air pump; BVA
Hydraulics Oil (F01) or equivalent when using with electric
pump. Never use brake uid, transmission uid, turbine oil,
motor oil, alcohol, glycerin etc. Use of other than good quality
hydraulic oil will void warranty and damage the cylinder, pump,
hose etc.
4. Use an approved, high-grade pipe thread sealant to seal all
hydraulic connections. Teon tape can be used if only one layer
of tape is used and it is applied carefully (two threads back) to
prevent the tape from being introduced into hydraulic system.
A piece of tape could travel through the system and obstruct
the ow of uid and adversely affect function.
Lubrication & Cleaning
Keep cylinder clean at all times.
1. Any exposed threads (male or female) must be cleaned and
lubricated regularly, and protected from damage. Lubricate with
light machine oil.
2. 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 immediately after exposure.
Daily clean exposed ram with clean cloth dampened with light
machine oil. Protect exposed ram from the elements at all times.
3. 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.
!
!
!
!
Figure 2 - Illustration to bleed air from system

6
TROUBLESHOOTING GUIDE
The following information is intended as an aid in determining if problem exists. Cylinders should be repaired only by authorized BVA
Service Center. For repair service, contact service center in your area.
Symptom Possible Causes Corrective Action
Erratic action
• Air in system or pump cavitation.
•Externalleakageincylinder.
•Cylinderstickingorbinding.
•Ventthesystem(refertogure2).
•Contactservicecenter.
•Contactservicecenter.
Cylinder will not extend, or
respondtopressurizeduid
• Overload condition.
•Loosecouplers.
•Faultycouplers.
•Impropervalveposition.
•Oillevelinpumpislow.
•Pumpnotoperating.
•Air-lockedpump.
•Remedyoverloadcondition.
•Tightencouplers.
•Replacebothfemaleandmalecouplers.
•Closereleasevalveorchangevalveposition.
•Fillandbleedthesystem.
•Checkpump’soperatinginstructions.
•Primepumpperpumpoperatinginstructions.
Cylinder extend only partially
•Oillevelinpumpislow.
• Overload condition.
•Cylinderisstickingorbinding.
•Fillandbleedthesystem.
•Remedyoverloadcondition.
•Contactservicecenter.
Cylinder move slower than normal
•Looseconnectionorcoupler.
• Restrictedhydrauliclineortting.
•Pumpnotworkingcorrectly.
•Cylindersealsleaking.
•Tightenconnectionorcoupler.
•Cleanandreplaceifdamaged.
•Checkpump’soperatinginstructions.
•Contactservicecenter.
Cylinder responds to pressurized
uid,butsystemdoesnotmaintain
pressure
•Overloadcondition.
•Pumporvalvemalfunctioning.
•Cylindersealsleaking.
•Remedyoverloadcondition.
•Checkpump’soperatinginstructions.
•Contact service center.
Oilleakingfromcylinder •Wornordamagedseals. •Contactservicecenter.
Cylinder will not retract or retracts
slower than normal
•Impropervalveposition.
•Malfunctioningcoupler,damaged
application.
•Pumpreservoiroverlled.
•Cylinderdamageinternally.
•Openreleasevalveorchangevalveposition.
•Secure load by other means. Depressurize
pump and hoses, remove application and
replace coupler.
•Secure load by other means. Depressurize
pump and hoses, remove application, then drain
uidtoproperlevel.
•Contactservicecenter.
Cylinder performs poorly •Oillevelinpumpislow.
•Airtrappedinsystem.
•Ensureproperoillevel.
•Ventthesystem(refertogure2).

7
8
9
11
12
11
10
13
14
15
16
17
18
7
5
4
3
2
1
1.1
19
20
6
Note: Not all components of the pump are replacement items, but are illustrated as a convenient reference of location and
position in the assembly sequence.
Double Acting Cylinder
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
MODEL: HD1010, HD1012, HD3008 & HD3014

8
Item Part No. for Model: Description Qty
HD1010 & HD1012 HD3008 & HD3014
1 SD10 SD25 Saddle Assy. 1
1.1 * O-ring 1
2 H10-6-2305-100 H25-6-2305-103 Collar Protective Cap 1
3 * Wiper Seal 1
4 F10-5-1804-109 F30-5-1804-105 Upper Bearing 1
5 * Back-up Ring 1
6 * U-cup 1
7 N/A Cylinder 1
8 N/A Ram 1
9 F10-5-1205-107 F30-5-1205-103 Ram Ring 1
10 F10-5-1204-105 F30-5-1204-101 Bearing 1
11 * Back-up ring 2
12 * O-ring 1
13 * O-ring 1
14 * Oil Seal 1
15 * O-ring 1
16 * Back-up Ring 1
17 F10-6-1601-101 F30-6-1601-107 Cylinder Base 1
18 F10-3-1610-104 Safety Relief Valve 1
19 CH38F Coupler 3/8” NPTF 2
20 H02-4-6003-108 Dust Cap 2
(*) F10-3-9901-105 F30-3-9901-101 Seal Kit -
Note: Not all components of the pump are replacement items, but are illustrated as a convenient reference of location and
position in the assembly sequence.
Double Acting Cylinder
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
MODEL: HD1010, HD1012, HD3008 & HD3014
Note: To ensure safe and reliable performance, replace worn or damaged parts with BVA Hydraulics Authorized
Replacement Parts only.
(*) - indicates items included in, and available only as part of Seal Kit
N/A - part is not available as replacement

9
8
9
10
13
10
11
12
15
14
16
17
7
5
4
3
2
1
1.1
18
6
Note: Not all components of the pump are replacement items, but are illustrated as a convenient reference of location and
position in the assembly sequence.
Double Acting Cylinder
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
MODEL: HD2506

10
Item Part Number Description Qty
1 SD25 Saddle Assy. 1
1.1 * O-ring 1
2 H25-6-2305-103 Collar Protective Cap 1
3 * Wiper Seal 1
4 F25-5-1804-102 Upper Bearing 1
5 * Back-up Ring 1
6 * U-cup 1
7 N/A Cylinder 1
8 N/A Ram 1
9 F25-5-1204-108 Bearing 1
10 * Back-up ring 2
11 * O-ring 1
12 * O-ring 1
13 * Oil Seal 1
14 * O-ring 1
15 * Back-up Ring 1
16 F10-3-1610-104 Safety Relief Valve 1
17 CH38F Coupler 3/8” NPTF 2
18 H02-4-6003-108 Dust Cap 2
(*) F25-3-9901-108 Seal Kit -
Note: Not all components of the pump are replacement items, but are illustrated as a convenient reference of location and
position in the assembly sequence.
Double Acting Cylinder
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
MODEL: HD2506
Note: To ensure safe and reliable performance, replace worn or damaged parts with BVA Hydraulics Authorized
Replacement Parts only.
(*) - indicates items included in, and available only as part of Seal Kit
N/A - part is not available as replacement