BVA Hydraulics HP0205 User manual

Printed in Taiwan
MODELS: HP0205, HP0505 & HP1006
Maximum Operating Pressure 10,000 PSI
HP0205-M0 rev 12/07
Single Acting,
Pull 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.
!
! ADVERTENCIA
• Leer, comprender, y seguir las instrucciónes antes de utilizar el aparato.
• El manual de instrucciónes y la información de seguridad deben estar comunicado en lengua del operador
antes del uso.
• No seguir estas indicaciónes puede causar daños personales o materiales.

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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 qualified 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 Single Acting Pull Cylinder is designed for
rated capacity pulling jobs. A wide variety 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/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 pulling, loads must be supported
by appropriate mechanical means.
NEVER use hydraulic cylinder as a support device!
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.
SPECIFICATIONS
Model
Number
Cylinder
Capacity
(ton)
Stroke
(in)
Cylinder
Effective
Area
(in2)
Oil
Capacity
(in3)
Collapsed
Height
(in)
Extended
Height
(in)
Weight
(lb.)
Internal
Pressure
at
Capacity
(psi)
Ram
Plunger
Thread
(mm)
Adapter
Thread
(in)
Collar
Thread
HP0205 2.5 5.00 0.56 2.78 10.55 15.55 6.4 8,930 M16x1.5 3/4”-14 NPTF 1 1/2”-16
HP0505 5 5.55 1.14 6.34 11.95 17.48 9.3 8,770 M2x1.5 1 1/4”-11.5 NPTF 2 1/4”-14
HP1006 10 5.95 2.44 14.48 11.75 17.70 20.9 8,200 M30x2 N/A M85X2
Figure 1 - Typical Single Acting Cylinder Components
Threaded Adapter
Collar Protecting Cap
Cylinder Housing
Female Coupler,
3/8”-18NPTF
Dust Cover
Ram Plunger
Base Mounting Hole (not shown)
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! WARNING
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 qualified 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.
• 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 fluid flow within the hose is blocked or
reduced. Periodically inspect the hose for wear.
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 fluid can ignite and burn. Keep
hydraulic equipment away from flames and
heat. Excessive heat will soften seals, resulting in
fluid 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 qualified, 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 fluid.
Heavy
INSTALLATION
IMPORTANT! 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 fittings for signs of wear or damage,
and replace as needed. Clean all threads and fittings.
3. Connect hydraulic hose from hydraulic pump to the cylinder
coupler. Ensure that there are no fluid leaks.
4. Install in-line pressure gauge.
5. Check for leaks in system and have repaired by qualified
personnel.
Note: The use of cylinder attachments or extensions reduces
the cylinder capacity by at least 50% per attachment/
extension.
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 fittings to burst.
Before repairs are made, depressurize cylinder.
Tips for hydraulic hoses & fluid 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.
!
!

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 (888)
332-6419.
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 confirming load is accurate and working
properly. Have gauge or load cell accuracy verified by
qualified personnel on a yearly basis.
OPERATION
Operate the hydraulic pump to retract and advance the
cylinder. Do not continue pumping when cylinder is fully
retracted. Internal pressure will build up and may damage
the seal of the cylinder.
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.
Your cylinder, hose(s), couplings and pump all must
be rated for the same maximum operating pressure,
correctly connected and compatible with the hydraulic fluid
used. An improperly matched system can cause the system
to fail.
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 fluid and change as
recommended or sooner if the fluid becomes contaminated
(never exceed 400 hours). Follow pump manufacturers
instructions for changing and adding hydraulic fluid. Use
only good quality hydraulic fluid. 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 fluid, transmission
fluid, 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. Teflon 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 flow of fluid and adversely affect function.
Figure 2 - Illustration to bleed air from system
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.
Storage
Cylinders should be stored in vertical position and 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 retracted and then extended 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 extend/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.
Important: Do not attempt to grasp with pliers or wrench
without first 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 below.
2. Operate pump to fully retract and extend the cylinder 2 or
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 filler plug/screw.
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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 figure 2).
• Contact service center.
• Contact service center.
Cylinder will not retract, or
respond to pressurized fluid
• 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 retract 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 fitting.
• 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
fluid, 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 extend or extends
slower than normal
• Improper valve position.
• Malfunctioning coupler, damaged
application.
• Pump reservoir overfilled.
• 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 fluid to
proper level.
• Contact service center.
Poor performance • Oil level in pump is low.
• Air trapped in system.
• Ensure proper oil level.
• Vent the system (refer to figure 2).

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Note: Not all components of the cylinder are replacement items, but are illustrated as a
convenient reference of location and position in the assembly sequence.
HP0205-M0
rev 12/07
MODELS: HP0205, HP0505 & HP1006
Single Acting,
Pull Cylinders
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
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For Models HP0205 & HP0505:
For Model HP1006:

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Note: To ensure safe and reliable performance, replace worn or damaged parts with BVA
Hydraulics Authorized Replacement Parts only.
Parts List
(*) - indicates items included in, and available only as part of Seal Kit
N/A - part is not available as replacement
Item Part Number for Model: Description Qty.
HP0205 HP0505 HP1006
1 N/A N/A N/A Ram Plunger 1
2 H29-6-1804-104 H21-6-1804-108 H20-5-1804-105 Upper Bearing 1
3 * * * Dust Seal 1
4 N/A N/A N/A Cylinder Housing 1
5 * * * Back-up Ring 1
6 * * * U-cup 1
7 * * * U-cup 1
8 * * * Back-up Ring 1
9 H05-6-1204-106 H10-5-1204-109 H20-6-1214-100 Bearing 1
10 H29-3-1403-108 H21-3-1403-102 H20-3-1413-108 Guide Rod 1
11 511-2-0069-118 511-2-0125-103 511-2-0125-103 Compression Spring 1
12 511-2-0125-112 511-2-0200-101 511-2-0200-101 Compression Spring 1
13 H29-6-1204-100 H21-5-1204-108 - Lower Bearing 1
14 CH38F CH38F CH38F Coupler, Female 3/8”-18NPTF 1
15 H02-4-6003-108 H02-4-6003-108 H02-6-6003-108 Dust Cover 1
16 H02-6-1008-105 H02-6-1008-105 H02-6-1008-105 Rubber Plug 1
17 H05-6-2305-107 H21-5-2305-109 H20-6-2306-100 Protecting Cap 1
18 H29-6-2808-107 H21-6-2812-102 - Threaded Adapter 1
19 - - * O-ring 1
20 - - * Back-up Ring 1
21 - - 511-2-0069-109 Compression Spring 1
(*) H29-3-9901-104 H21-3-9910-109 H20-3-9910-102 Seal Kit -
Note: Not all components of the cylinder are replacement items, but are illustrated as a
convenient reference of location and position in the assembly sequence.
HP0205-M0
rev 12/07
MODELS: HP0205, HP0505 & HP1006
Single Acting,
Pull Cylinders
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com

LIMITED LIFETIME WARRANTY
BVA Hydraulics®, represented in the United States by SFA Companies [“SFA”] warrants this product to be free from defects in
material and workmanship for the life of the product as long as the original purchaser owns the product. The warranty is non-
transferable and is subject to the terms, exclusions, and limitations described below:
• Damaged components, including but not limited to bent rams, dented or crushed cylinder walls, broken welds or couplers as
well as worn out seals, o-rings and springs are the result of misuse and not covered by warranty and BVA Hydraulics will not
provide any warranty credit for such damaged components.
• This warranty does not cover ordinary wear and tear, overloading, alterations (including repairs or attempted repairs not
performed by BVA Hydraulics or one of its authorized personnel), improper fluid use, or use of the product in any manner for
which the product was not intended or the use of which is not in accordance with the instructions or warnings provided with
the product.
• In the unlikely event that a BVA Hydraulics product fails due to material defect in workmanship, you may contact SFA for
disposition. In such cases, the customer’s sole and exclusive remedy for any breach or alleged breach of warranty is limited
to the repair or replacement of the defective product.
• Under no circumstances is BVA Hydraulics liable for any consequential or incidental damage or loss whatsoever.
• THIS WARRANTY IS LIMITED TO NEW PRODUCTS SOLD THROUGH AUTHORIZED DISTRIBUTORS AND OTHER
CHANNELS DESIGNATED BY BVA HYDRAULICS. NO AGENT, EMPLOYEE OR OTHER REPRESENTATIVE OF BVA
HYDRAULICS IS AUTHORIZED TO MODIFY THIS WARRANTY.
• THE FOREGOING IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING
BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FOR A FITNESS FOR A PARTICULAR
PURPOSE.
• Components not manufactured by BVA Hydraulics including certain motor systems, gasoline engines, and other are not
covered by this warranty and instead are covered by the manufacturer’s separate manufacturer’s warranty provided in the
package.
• BVA Hydraulics’ liability in all cases is limited to, and will not exceed the purchase price paid for the product.
SFA Companies
10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone]
E-mail: [email protected]
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