Durapac DPA-16 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] Phone: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Reciprocating Air Hydraulic Power Unit
Model –DPA-16

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 2 of 10
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –Reciprocating Air Hydraulic Power Units are engineered to meet Industrial Standards for
Performance and Safety. The DPA-16 model’s unique hydraulic circuit allows the quick displacement
of hydraulic fluid under no load conditions and easy pumping in loaded conditions. These air
actuated power units supply compressed hydraulic fluid to compatible applications i.e. cylinder,
presses, spreaders, compactors and crimping machines, anywhere that 700 bar of fluid pressure is
needed.
•1.6 L usable oil reservoir
•3 position treadle for adv/hold/retract functions
•Release detent function enhances productivity
•Recommended air pressure range 3-8 bar
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your power unit’s suitability for an application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any power unit that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any power unit that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.
3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should understand this product and safe operating procedures before
attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. 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 authorised
manual, remove from service immediately.
DANGER:
•To avoid personal injury, keep hands and feet away from work area during operation
•Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin
causing serious injury. If oil is injected under the skin, see a doctor immediately

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 3 of 10
•Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be supported mechanically
WARNING:
•The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install pressure gauges in the system to monitor
operating pressure. It is your window to what is happening in the system
•Always wear appropriate personal protective equipment (PPE) when operating
hydraulic equipment. The operator must take precaution against injury due to failure
of the tool or work piece(s)
•Do NOT hold or stand directly in line with any hydraulic connections while pressurising
•Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
•All personnel must be clear before lowering load or depressurising the system
•Do NOT attempt to lift a load weighing more than the capacity of the cylinder
IMPORTANT:
•If at any stage, the safety related decals become hard to read, these must be replaced
•Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
•Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
•Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high-quality hydraulic oil
CAUTION:
•KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
•No alteration should be made to this device
3.1 Hydraulic Power Units
•Do use a gauge or other load measuring instrument to verify load
•Do NOT exceed the rated capacity of the power unit or any equipment in the system.
Burst hazard exists if connection pressure exceeds rated pressure
•Do NOT operate the system with bent or damaged couplers or damaged threads

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 4 of 10
•Do NOT subject the power unit and its components to shock loads
•Use only Durapac approved accessories and components
•Do NOT connect to an application which can return more oil to the reservoir than the
power unit reservoir can hold
•Do NOT connect the power unit to a hydraulic system that is powered by another
pump
3.2 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 power unit, connections should be tightened securely and leak-
free. Over tightening 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 power unit and release all pressure. Never attempt to grasp a leaking
pressurised 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
•Hose material and coupler seals must be compatible with the 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.
4.0 Installation
IMPORTANT:
•Always secure threaded port connections with high grade, non-hardening pipe thread
sealant. 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, which could cause jamming of precision-fit parts
•To extend the life of your power unit, the air compressor should have a filter, regulator
and lubricator system that will provide clean, lubricated air to the power unit. Contact
a Durapac representative for the necessary accessories

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 5 of 10
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your power unit, its limitations and how it operates before attempting to use.
Refer to the specification chart below or if in doubt, contact a Durapac representative.
4.2 Air Connection - Remove plastic cap, connect suitable air supply to air input port. Air
input port is designed to fit the popular 1/4" NPT air nipple (not included). Ensure that
your air source can dedicate 7.8 cfm @ 3-8 bar/45-116 psi to each power unit being
operated.
4.3 Check all system fittings and connections to be sure they are tight and leak free.
4.4 Check oil level in reservoir before operating the power unit.
4.5 Remove air from the power unit –Air can accumulate in the hydraulic system during
the initial setup or after prolonged use, causing the cylinder to respond slowly or in an
unstable manner. Should removal of air from power unit be required, please follow the
steps in 6.2 –Bleeding Air from the System in the Maintenance Section.
5.0 Operation
IMPORTANT:
•Always monitor pressure, load or position using suitable equipment. Pressure may be
monitored by means of an optional manifold and gauge. 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
•Do NOT operate a power unit that is disconnected from the application. If operated in
this condition, the hose and connections will become pressurised. This increases the
chance of a burst hazard. Damage may also occur to the power unit and its
components
5.1 To extend the cylinder, depress on the foot pedal marked "Pump" (horizontal portion)
until desired pressure, load or position is reached.
5.2 To hold the cylinder in position, release the foot pedal to deactivate the power unit.
5.3 To retract the cylinder, depress the release valve by stepping on the foot pedal marked
"Release" (raised, stirrup shaped portion).
6.0 Maintenance
IMPORTANT:
•Check oil level regularly
No load Load
DPA-16 S/A 3/8"-NPTF 1,600 700 1,000 150 3-8 6.6
Model
Number
Used
with
Cylinder
Weight
(kg)
Output Flow Rate
(cm3/min)
Air
Pressure
Range (bar)
Usable Oil
Capacity
(cc)
Oil Port
Thread
Pressure
Rating
(bar)

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 6 of 10
•Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the power unit, hose, and application. We
recommend Durapac Hydraulic Oil or equivalent
•Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre
•Damage to hydraulic hoses may not be detected during visual inspections. For this
reason, Durapac recommends that hydraulic hoses be replaced on a regular basis
•Tighten connections as needed. Use non-hardening pipe thread compound when
servicing connections
Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and free of
foreign matter. After each use, clean couplings and attach dust caps.
Maintenance is required when wear or leakage is noticed. Periodically inspect all components to
detect any problem that may require service and maintenance.
6.1 Adding Hydraulic Fluid
WARNING: Always add oil with cylinders fully retracted (or extended, if pull cylinders) or
the system will contain more oil than the reservoir can hold
6.1.1 Depressurise and disconnect hydraulic hose from application/cylinder.
6.1.2 With the power unit in its upright, horizontal position, remove the air vent plug
located on the top plate of the reservoir.
6.1.3 Use a small funnel to fill the reservoir to within 19mm (3/4") of the opening.
6.1.4 Bleed air from system if necessary.
6.1.5 Wipe up any spilled fluid and reinstall the air vent plug/reservoir cap.
6.2 Bleeding Air from the System
6.2.1 Repeat Steps 6.1.1 to 6.1.3 (above), if required.
6.2.2 Invert cylinder and place at a lower level than the power unit reservoir.
6.2.3 Extend and retract the cylinder several times without putting a load on the
system. Air will be released into the power unit reservoir.
6.2.4 Recheck oil level after removing air.
6.3 Changing Hydraulic Fluid
For best results, change fluid once a year or every 300 hours of use
6.3.1 Repeat Steps 6.1.1 to 6.1.2 (above).
6.3.2 Pour used fluid into a sealable container.
6.3.3 Repeat Steps 6.1.3 to 6.1.5 (above).
6.3.4 Dispose of fluid in accordance with local regulations.

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 7 of 10
6.4 Lubrication
When power unit is operated daily, it is recommended that an inline oiler and air dryer
is installed and SAE grade oil (5W to 30W) is used.
6.5 Storage
6.5.1 When not in use, depressurise and disconnect the hydraulic power unit from
the application.
6.5.2 Wipe clean thoroughly and store in a clean, dry environment. Avoid
temperature extremes.
6.5.3 Close the air vent for transportation or long storage.
6.5.4 Shield power unit with a protective cover.

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 8 of 10
7.0 Troubleshooting
Problem
Cause
Solution
Application does not extend,
move or respond to
pressurised fluid
Overload condition
•Remedy overload condition
Loose couplers
•Tighten couplers
Faulty couplers
•Replace couplers
Malfunctioning power unit
•Contact a Durapac authorised
service centre
•Repair or replace as
necessary
Inadequate air supply
•Ensure air source can
dedicate 7.8 cfm @ 4-12
bar/60-175 psi
Application responds to
pressurised fluid, but system
does not maintain pressure
Overload condition
•Remedy overload condition
Malfunctioning power unit or
valve
•Contact a Durapac authorised
service centre
•Repair or replace as
necessary
Leaking
application/connection
•Replace
application/connection
Application responds slower
than normal
Loose connection or coupler
•Tighten connection or
coupler
Restricted hydraulic line or
fitting
•Clean and replace if damaged
Leaking
application/connection
•Replace
application/connection
Application does not return
fluid to power unit (i.e.
cylinder will not retract)
Malfunctioning coupler/
damaged application
•Secure load by other means
•Depressurise power unit and
hose
•Remove coupler and/or
application
•Repair or replace as
necessary
Application does not fully
extend (cylinder or spreader)
Overfilled reservoir
•Secure load by other means
•Depressurise power unit and
hose
•Remove application
•Drain fluid to proper level
Low fluid level in power unit
•Secure load by other means
•Depressurise power unit and
hose
•Remove application
•Fill fluid to proper level
Poor performance
Low fluid level in power unit
•Ensure proper fluid level

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 9 of 10
8.0 Parts Breakdown
Note: Not all components of the power unit are replacement items but are illustrated as a
convenient reference of location and position in the assembly sequence.

Instruction Manual
DPA-16 Air Hyd. Power Unit - V1.0 www.durapac.com Page 10 of 10
Items marked with a * are contained within a standard Repair Kit.
Serial, model and part numbers need to be quoted when ordering parts.
9.0 Parts List
Item Description Part No. Qty Item Description Part No. Qty
1 Piston pump body ZCZ1001 1 46 Reservoir cover ZCZ1046 1
2 Relief valve ZCZ1002 1 47 Oil outlet o-ring* ZCZ1047 1
3 Relief valve body ZCZ1003 1 48 Air vent o-ring* ZCZ1048 1
4 Relief valve one-way valve* ZCZ1004 1 49 Air inlet o-ring* ZCZ1049 1
5 Relief valve ball holder ZCZ1005 1 50 Oil outlet valve block ZCZ1050 1
6 Relief valve spring* ZCZ1006 1 51 Anti-dust ring ZCZ1051 1
7 Adjustment plug ZCZ1007 1 52 Muffler ZCZ1052 1
8 Copper washer ZCZ1008 1 53 Oil drain spring* ZCZ1053 1
9 Suction filter ZCZ1009 1 54 Oil drain switch ZCZ1054 1
10 Suction filter one-way valve* ZCZ1010 1 55 Oil drain pressure bar o-ring* ZCZ1055 1
11 Copper washer ZCZ1011 1 56 Oil port end cap ZCZ1056 1
12 Piston body ZCZ1012 1 57 Oil port end cap o-ring ZCZ1057 1
13 Piston seal washer* ZCZ1013 1 58 Air inlet valve body ZCZ1058 1
14 Piston seal washer* ZCZ1014 1 59 Air inlet switch ZCZ1059 1
15 Front cover ZCZ1015 1 60 Air inlet switch o-ring* ZCZ1060 1
16 Oil outlet one-way valve* ZCZ1016 1 61 Washer* ZCZ1061 1
17 Spring* ZCZ1017 1 62 Air inlet seal washer cap ZCZ1062 1
18 Pressure stem ZCZ1018 1 63 Air inlet spring* ZCZ1063 1
19 HP nozzle o-ring* ZCZ1019 2 64 Pin ZCZ1064 1
20 Oil drain valve ZCZ1020 1 65 Foot pedal ZCZ1065 1
21 Oil drain valve spool ZCZ1021 1 66 Return spring ZCZ1066 1
22 Oil drain valve spring* ZCZ1022 1 67 Reservoir seal washer* ZCZ1067 1
23 Oil drain one way valve* ZCZ1023 1 68 Reservoir ZCZ1068 1
24 Oil drain ball holder* ZCZ1024 1 69 Air inlet connector ZCZ1069 1
25 Oil drain thimble* ZCZ1025 1 70 Snap ring ZCZ1070 2
26 Oil drain valve o-ring* ZCZ1026 1 71 Washer ZCZ1071 2
27 Copper washer ZCZ1027 1 72 Bolt ZCZ1072 2
28 Air cylinder seal ring* ZCZ1028 2 73 Breathing valve ZCZ1073 1
29 Cylinder bore ZCZ1029 1 74 O-ring ZCZ1074 1
30 Piston return spring* ZCZ1030 1 75 Breathing cap ZCZ1075 1
31 Piston stop plate ZCZ1031 1 76 Seal ZCZ1076 1
32 Pump piston ZCZ1032 1 77 Bolt ZCZ1077 1
33 Washer* ZCZ1033 1 78 Nylon washer ZCZ1078 1
34 Large piston ZCZ1034 1 79 Oil return filter* ZCZ1079 1
35 Large piston o-ring* ZCZ1035 2 80 Snap ring ZCZ1080 1
36 Large piston seal* ZCZ1036 2 81 Air inlet filter ZCZ1081 1
37 Small piston ZCZ1037 1 82 Snap ring ZCZ1082 1
38 Small piston o-ring* ZCZ1038 1 83 Bolt ZCZ1083 1
39 Small piston return spring* ZCZ1039 1 84 Bolt ZCZ1084 1
40 Large piston seal washer* ZCZ1040 1 85 Filter ZCZ1085 1
41 Large piston cover ZCZ1041 1 86 Snap ring ZCZ1086 1
42 Small piston seal washer* ZCZ1042 1 87 Spring washer ZCZ1087 1
43 Cylinder head spring* ZCZ1043 1 88 Bolt ZCZ1088 1
44 Back cover ZCZ1044 1 * Repair kit ZCZ1089 1
45 Pump cover seal washer* ZCZ1045 1 Oil Drain Assembly Kit ZCZ1000 1