BVA PG5505 User manual

Printed in Taiwan
MODELS: PG5505 & PG6505
Gas Engine Pumps
Instruction Manual
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
Maximum Operating Pressure 10,000 PSI
PG6505-M0 rev 09/07
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.
!
Model PG6505 (Briggs & Stratton Engine)Model PG5505 (Honda Engine)
! WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.

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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 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. It is recommended that, prior to each use, an 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 pump that appears to be damaged in any way, is worn, leaking or operates abnormally shall be removed from service
immediately until such time as repairs can be made. Any pump that has been or suspected to have been subject to a shock load
(a load dropped suddenly, causing the system pressure to exceed 10,000 PSI), shall be removed from service immediately until
checked by qualified personnel. Owners and operators of this equipment shall be aware that the use and subsequent repair of
this equipment may require special training and knowledge.
PRODUCT DESCRIPTION
BVA Hydraulics Gas Engine Pump is engineered to meet most industrial standards for Performance and Safety. These pumps
provide hydraulic power when electricity and air power are not available. The pumps supply compressed hydraulic fluid to compatible
applications i.e. rams, presses, spreaders, compactors and crimping machines, anywhere that 10,000 PSI of fluid pressure is
needed. 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 must make the decision regarding suitability of the product for any given task
and assume the responsibility of safety for himself and others in the work area.
Note: Please refer to gas engine owner's manual for engine information.
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.
Always check connections before using. Alteration of these products is strictly prohibited. Use only those adapters,
attachments and accessories provided and approved by the manufacturer.
SPECIFICATIONS
Model
Number
Usable Oil
Capacity
(gal)
Pressure Rating
(psi)
Output Flow Rate
(in3/min)
Valve Type Motor
Manufacturer
Motor
Size
(hp)
Output
Port
Threads
Weight
(lb)
1st Stage 2nd Stage 1st Stage 2nd Stage
PG5505
5
700
10,000
427 100
Manual, 4-way,
3-position
Honda 5.5 3/8"-
18NPT
121
PG6505 700 457 67 Briggs &
Stratton 6.5 97
!
!

Figure 2 - Model PG6505 Components
Control Valve Lever
Oil Dipstick Cap
Frame
Hydraulic Oil Cap
Control Valve
Oil Output Ports
3/8"-18NPTF
Carry Handle
Drain Plug
Hydraulic Oil Reservoir
Engine Starter Grip Fuel Cap
Gas Engine
Control Valve Lever
Oil Dipstick Cap
Frame
Hydraulic Oil Cap
(not shown, on reservoir)
Control Valve
Oil Output Ports
3/8"-18NPTF
Carry Handle
Drain Plug
Hydraulic Oil Reservoir
Engine Starter Grip
Fuel Cap
Gas Engine
Figure 1 - Model PG5505 Components
3

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• Read, understand, and follow all
instructions provided with and on this
device before use.
• All WARNING statements must be
carefully observed to help prevent
personal injury.
• No alteration shall be made to this
device.
• Always wear protective gear when
operating hydraulic equipment. Tie
up long hair, wear eye and ear
protection, and non slip foot wear.
• Keep hydraulic equipment away from
flames and heat. Hydraulic fluid can
ignite and burn. Do not operate if
leaks are detected.
• Crush Hazard. Keep hands and
feet away from loading area. Avoid
pinch points or crush points that can
be created by the load, cylinder, or
system components.
• To avoid crushing and related injuries:
NEVER work on, under or around
a lifted load before it is supported
by appropriate mechanical means.
Never rely on hydraulic pressure
alone to support load.
! WARNING
HYDRAULIC PUMPS
• The user must be a qualified operator familiar with the
correct operation, maintenance, and use of pumps. Lack of
knowledge in any of these areas can lead to personal injury.
• Do not exceed rated capacity of the pump or any equipment
in the system.
• Never attempt to lift a load weighing more than the capacity
of the output device (cylinder, spreader etc.)
• Do not subject pump and its components to shock loads.
• Burst hazard exists if hose or connection pressure exceeds
rated pressure.
• Inspect pump, cylinder, hoses and connections before each
use to prevent unsafe conditions from developing. Do not
use if they are damaged, altered or in poor condition. Do
not operate the system with bent or damaged coupler or
damaged threads.
• Never hold or stand directly in line with any hydraulic
connections while pressurizing.
• ALWAYS use gauge or other load measuring instrument to
verify load.
• Never attempt to disconnect hydraulic connections under
pressure. Release all line pressure before disconnecting
hoses.
• Do not operate this device in an extreme temperature,
explosive atmosphere or in the presence of conductive
liquids.
• Always inspect hoses and connections for damage prior
to use.
• Ensure the device is placed on a hard, level surface.
• Ensure that application is stable to work on and around.
• Use only approved accessories and approved hydraulic fluid.
• Never attach ANY component not authorized by manufacturer.
• Do not connect to application which can return more oil to
the reservoir than the pump reservoir can hold.
• Do not connect pump to hydraulic system powered by
another pump.
• This device is not suitable for use as support device! As
the system load is lifted, use blocking and cribbing to guard
against a falling load.
• All personnel must be clear before lowering load or
depressurizing the system.
• Never try to disassemble a hydraulic pump, refer repairs to
qualified, authorized personnel.
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 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.
• Should a hydraulic hose ever rupture, burst or need to be
disconnected, immediately shut off the pump and release
all pressure. Never attempt to grasp a leaking 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 objects, extreme heat or cold, or heavy impact.
• Do not allow the hose to kink, twist, curl, crush, cut or bend
so tightly that the fluid flow within the hose is blocked or
reduced. Periodically inspect the hose for wear.
• Do not pull, position or move setup by the hose.
• 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. Never paint a coupler
or hose.
• FAILURE TO HEED THESE WARNINGS MAY RESULT IN
PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
!
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.
!
There are hazards associated with the use of this equipment which can only be avoided by reading,
understanding and following all the printed materials provided by the manufacturer of the gasoline
engine which drives this hydraulic pump.
DANGER

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BEFORE USE
1. Most malfunctions in new equipment are the result of improper operation and/or improper set-up assembly.
2. Visually inspect all components for shipping damage. Do not use if any damage is found.
Note: Gas Pump is shipped without hydraulic oil. Add oil before operating.
3. Familiarize yourself with the specifications and illustrations in this owners manual. Know your pump, its limitations and how it
operates before attempting to use. Refer to specification chart and figure 1 on page 2 for details of oil port thread size, usable
oil capacity and more.
The pump's maximum working pressure is 10,000 PSI. Make sure that all hydraulic equipment such as cylinders, hoses,
couplers, etc. used with this pump are rated at 10,000 PSI operating pressure.
Hydraulic Connections:
1. Use only hydraulic oil specified by the manufacturer. Check and make sure the oil level in reservoir is at about 2" from top of
reservoir plate, with cylinder retracted and motor off.
2. Use of pressure gauge is strongly recommended. Attach pressure gauges between the pump and cylinder, these gauges permit
the operator to monitor pressure on cylinder.
3. Make sure couplers, hoses, valve and gauges are tighten securely to prevent accidental removal of components while in use.
Hoses shall not be kinked or twisted.
Note: Always secure threaded port connections with non-hardening pipe thread compound. Take care not to introduce compound
into port orifices.
4. Do not exceed the rated capacity of the equipment connected to the pump. Use larger capacity cylinders if necessary.
!

OPERATION
ALWAYS monitor pressure, load or position using suitable equipment. Pressure may be monitored by means of an optional
manifold and gauge (contact BVA Hydraulics). Load may be monitored by means of a load cell and digital indicator. Correct
application position can only be determined by the operator of the equipment.
1. Check all system fittings and connections to be sure they are tight and leak free.
2. Check the engine oil level. Please refer to engine owner's manual.
3. Before starting the pump, always place the control valve lever in the middle (Neutral/Hold) position to prevent accidental lifting
or moving of load.
4. To start engine, refer to engine owner's manual.
5. Let the pump idle for a few minutes prior to operation.
6. Use the control valve lever to control the direction of fluid flow. This gas engine pump is equipped with a 4-way 3-position valve.
Refer to figure 3(a) below for the flowpath.
Note: Do not continue to operate pump after cylinder plunger is fully extended or retracted.
7. To stop the engine, refer to engine owner's manual.
8. Depressurize all connections before disconnect.
Note: Control valve on this pump is 4-way, 3-position valve type, for use with double-acting cylinders. If your application requires
a 3-way setting for single-acting cylinder as shown in figure 3(b), it can be changed by an authorized BVA Service Center. If you
have any doubt, please contact BVA Technical Service 888-332-6419.
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!
Position 1: Pressurized
oil flows to port A, port B
returns flow to reservoir
Position 3: Pressurized
oil flows to port B, port A
returns flow to reservoir.
Position 2: Neutral,
ports A and B are
closed. Hold Position.
Port A Port B Port A Port B Port A Port B
P R P R P R
(a) 4-way, 3-position valve for Double Acting Cylinder
Position 1 (Advance):
Pressurized oil flows to
port A.
Position 3 (Retract):
Port A returns flow to
reservoir.
Position 2 (Hold):
Neutral, port A is closed.
Hold Position.
Port A Port A Port A
(b) 3-way, 3-position valve for Single Acting Cylinder
Port A Port B
1
2
3
P R P R P R
Figure 3 - Flowpath of the valve positions and operations.

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MAINTENANCE
1. For gas engine, please refer to engine owner's manual.
2. Inspect hoses and connections daily. Replace damaged components immediately with BVA Hydraulics replacement parts
only.
3. Tighten connections as needed. Use non-hardening pipe thread compound when servicing connections.
4. Check hydraulic oil level every 40 hours of operation. Add hydraulic oil if necessary.
5. Completely change the hydraulic oil every 300 hours of operation. Change the oil more frequently when pump is used in an
extremely dusty environment or when the oil has been overheated. Use only good quality hydraulic oil. We recommend BVA
Hydraulic oil, Mobil DTE 15M or equivalent.
Adding Hydraulic Fluid
1. Make sure engine is OFF.
2. Depressurize and disconnect from application.
3. Remove oil cap located on top plate of reservoir.
4. Use a funnel to fill reservoir to about 2" from top of reservoir plate.
5. Wipe up any spilled fluid and reinstall the oil cap.
Note: Never use brake fluid, transmission fluid, turbine oil, motor oil, alcohol, glycerin etc. Use of other than BVA Hydraulic oil,
Mobil DTE 15M or equivalent, will void warranty and damage the pump, hose, and application.
Changing Hydraulic Fluid
1. For best results, change fluid once a year.
2. Remove the drain plug, tilt the pump and pour used fluid into a sealable container.
3. Dispose of fluid in accordance with local regulations. Do not mix hydraulic fluid with engine oil if you are planning to have
these fluids recycled.
4. Fill with BVA Hydraulic oil, Mobil DTE 15M or equivalent as recommended above. Reinstall oil cap.
Cleaning
Clean oil filter screen periodically with nonflammable solvent, then blow dry before reassemble back to pump.
Storage
1. When not in use, depressurize and disconnect hydraulic hoses from application.
2. Wipe clean, thoroughly.
3. Store in clean, dry environment. Avoid temperature extremes.
4. For transportation or long storage, shield pump with a protective cover.
Check Your Engine !
Refer to the Gasoline Engine Owner's Manual provided within. Follow the maintenance schedule to keep the engine in operating
condition.

TROUBLESHOOTING GUIDE
The following information is intended as an aid in determining if problem exists. Pumps should be repaired only by authorized
BVA Service Center. For repair service, contact service center in your area.
Symptom Possible Causes Corrective Action
Application does not extend, move or
respond to pressurized fluid
• Overload condition
• Loose couplers
• Faulty couplers
• Pump malfunction
• Remedy overload condition
• Tighten couplers
• Replace couplers
• Contact service center
Pump fails to maintain pressure • External leak
• Internal hydraulic leak
• Tighten all connections
• Contact service center
Application responds to pressurized
fluid, but system does not maintain
pressure
• Overload condition
• Pump or valve malfunction
• Application/connection leaking
• Remedy overload condition
• Contact Service Center
• Replace application/connection
Application responds slower than
normal
• Loose connection or coupler
• Restricted hydraulic line or fitting
• Application/connection leaking
• Tighten connection or coupler
• Clean and replace if damaged
• Replace application/connection
Application does not return fluid to
pump (i.e. cylinder will not retract)
• Malfunctioning coupler, damaged
application
• Secure load by other means.
Depressurize pump and hose,
remove coupler and/or application,
then renew or replace
Application does not fully extend
(cylinder or spreader)
• Reservoir overfilled
• Fluid level in pump is low
• Secure load by other means.
Depressurize pump and hose,
remove application, then drain fluid to
proper level
• Secure load by other means.
Depressurize pump and hose,
remove application, then fill fluid to
proper level
Poor performance • Fluid level in pump is low • Ensure proper fluid level
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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 others 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]
9

10
PG6505-M0
rev 09/07
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.
MODEL: PG5505 (Honda Engine)
Gas Engine Pump
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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Item Part No. Description Qty
1E55-4-9000-101 5.5hp Gas Engine 1
2E55-3-3007-109 Adapter Flange 1
3649-1-0079-132 Socket Head Bolt 4
4E55-4-3011-106 Shaft Adapter 1
5E05-6-9002-107 Gasket, Motor 1
6E10-6-9003-102 Reservoir Plate 1
7E05-6-9004-101 Gasket, Reservoir 1
8E55-4-3000-101 Upper Plate Assy. 1
9649-1-0095-204 Socket Head Bolt 4
10 E30-6-9006-104 Shaft 7/8 1
11 622-6-0318-203 Bearing Needle 1
12 E05-6-9007-107 Bearing 1
13 511-7-0064-109 O-ring 2
14 *a E15-4-4000-104 Piston Block 4
15 E30-4-5000-100 Lower Plate Assy. 1
16 649-1-0063-403 Socket Head Screw 8
17 *b E55-4-6000-106 Gear Pump Assy. 1
18 H23-6-1000-102 Magnet 1
19 E10-4-2000-109 Oil Cap 1
20 E55-3-7005-105 Frame 1
21 E55-3-9005-105 Reservoir 1
22 *c PW4 4-way Valve 1
23 #a 649-1-0060-407 Socket Head Bolt 10
24 #a 601-3-0064-106 Washer 10
25 *d E05-4-8000-106 Safety Valve Block 1
26 E05-3-9901-103 Drain Plug 1
27 532-3-0160-104 Washer 1
28 #b 653-1-0100-078 Hex Bolt, M10x1.5x40L 4
29 #b 605-3-0100-203 Washer 8
30 #b 661-2-0100-014 Nut 8
31 E05-3-9910-104 Bolt Kit for Valve (4pc.) 1
(#a) E60-3-9902-108 Bolt Kit for Reservoir Plate -
(#b) E60-3-9990-101 Bolt Kit for Frame -
(*a) E05-3-9940-102 Repair Kit for Item# 14 -
(*b) E05-3-9960-109 Repair Kit for Item# 17 -
(*c) E05-3-9911-106 Repair Kit for Item# 22 -
(*d) E05-3-9980-105 Repair Kit for Item# 25 -
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11
PG6505-M0
rev 09/07
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.
MODEL: PG6505 (Briggs & Stratton Engine)
Gas Engine Pump
Service Parts
SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone] * Fax: [phone]
E-mail: [email protected] Website: www.bvahydraulics.com
Item Part No. Description Qty
1 E60-4-9000-104 6.5 hp Gas Engine 1
2 #a 653-1-0080-151 Socket Head Bolt 2
3 #a 605-3-0080-102 Spring Washer 4
4 E60-4-3005-104 Transition Plate 1
5 E05-6-9002-107 Gasket, Motor 1
6 E10-6-9003-102 Reservoir Plate 1
7 E05-6-9004-101 Gasket, Reservoir 1
8 E60-4-3000-104 Upper Plate Assy. 1
9 649-1-0095-204 Socket Head Screw 4
10 E60-6-9002-100 Key 1
11 E30-6-9006-104 Shaft, 5/8 1
12 622-6-0318-203 Bearing Needle 1
13 E05-6-9007-107 Bearing 1
14 511-7-0064-109 O-ring 2
15 *a E10-4-4000-109 Piston Block 2
16 E60-4-5000-104 Lower Plate Assy. 1
17 649-1-0063-403 Socket Head Bolt 4
18 *b E60-4-6000-109 Gear Pump Assy. 1
19 H23-6-1000-102 Magnet 1
20 E60-3-7000-108 Frame 1
21 E60-3-9005-108 Reservoir 1
22 #b 661-2-0100-014 Nut 8
23 #b 605-3-0100-203 Washer 8
24 #b 653-1-0100-078 Hex Bolt, M10x1.5x40L 4
25 661-2-0080-014 Nut 1
26 653-1-0080-234 Socket Head Bolt, M8x1.25x7.5L 1
27 #c 653-1-0060-328 Socket Head Botl, M6x1x25L 10
28 #c 601-3-0064-106 Washer 10
29 *c PW4 4-way Valve 1
30 *d E05-4-8000-106 Safety Valve Block 1
31 E10-4-2000-109 Oil Cap 1
32 E05-3-9901-103 Drain Plug 1
33 532-3-0160-104 Washer 1
34 E05-3-9910-104 Bolt Kit (4pc.) 1
(#a) E60-3-9991-103 Bolt Kit for Engine -
(#b) E60-3-9990-101 Bolt Kit for Frame -
(#c) E60-3-9902-108 Bolt Kit for Reservoir Plate -
(*a) E05-3-9940-102 Repair Kit for Item# 15 -
(*b) E15-3-9960-107 Repair Kit for Item# 18 -
(*c) E05-3-9911-106 Repair Kit for Item# 29 -
(*d) E05-3-9980-105 Repair Kit for Item# 30 -
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SFA Companies
10939 N. Pomona Ave. Kansas City, MO 64153
Tel: [phone]
E-mail: [email protected]