Durapac DHS-5 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Hydraulic Remote Spreaders
Model –DHS-5

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 2 of 9
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 –Hydraulic Remote Spreaders are engineered to meet Industrial Standards for
Performance and Safety. The DHS-5 model is a small, light and powerful precision tool that
generates 5 tons of spreading force at the feet and has a spring return cylinder. The spreader
features parallel opening jaws that will not drift away or creep down. It is a high strength steel
construction that is designed for applications such as flange spreading.
5 ton spreading force
2.3-76 mm spreading capacity
Jaws open parallel
Will not drift away or creep down
All metal construction
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 spreader’s suitability for a particular 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 spreader 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 spreader 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 have an understanding of 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
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 3 of 9
Stay clear of loads supported by hydraulics. A spreader, 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 blocked 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 protective gear 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 Spreaders
If bowing or bending of the spreader jaws occurs, STOP. Immediately release
pressure. Evaluate the set-up and consider a higher capacity system. Bowing or
bending of components indicates that the spreader is overloaded
Spreaders should be stored where protected from the elements, abrasive dust, and
damage. These devices may be stored in virtually any position

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 4 of 9
Use only those adapters and attachments provided and approved by Durapac
Never pressurise uncoupled couplers. Only use hydraulic equipment in a coupled
system
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 pump, 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 pump 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
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your spreader, 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 Make hydraulic connections; use a pump release valve or a 3-way valve and one hose
for a single-acting cylinder.
IMPORTANT: Fully hand-tighten all couplers. Loose coupler connections will block
the flow of oil between the pump and the spreader
DHS-5 5 82 2.3 76 6.2
Weight
(kg)
Model
Number
Capacity
(ton)
Oil Capacity
(cc)
Tip Clearance
Min (mm)
Spread Max
(mm)

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 5 of 9
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 pump.
4.5 Remove air from the system –Position the spreader so that the piston rod is pointed
down and the cylinder is lower than the pump. Advance and retract the cylinder
several times, avoiding pressure build-up. Air removal is complete when the cylinder
motion is smooth.
5.0 Operation
Inspect before each use. Do not use if bent, broken, leaking or damaged components are noted
Maintain a constant grip on the spreader during operation as the tool does not attach to other
equipment
The DHS-5 spreaders have a spring return cylinder and the speed of retraction is affected by
the length of the hose and other restrictions in the line. Most 700 bar hand or power pumps
for use with single acting tools are compatible with the DHS-5 spreader.
For complete operating instructions refer to the instruction sheet included with each pump.
5.1 Spreader Loads
5.1.1 Ensure that both spreader jaws fully engage the load and that the load is
centred on the serrated portion of each spreader jaw before pressurising
spreader. Do not load off centre.
Figure 1 –Typical Spreader Nomenclature
5.1.2 Ensure load is mechanically blocked before personnel commence operations
near the work area.
5.2 Advancing and retracting the Spreader
5.2.1 To spread the feet, connect the hydraulic cylinder to a pump and pressurise.
5.2.2 To close the feet, release the pressure of the pump.

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 6 of 9
6.0 Maintenance
IMPORTANT:
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 pump, 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 Check for loose connections and leaks
6.2 Replace damaged parts immediately
6.3 Do not exceed oil temperature above 60oC
6.4 Keep all hydraulic components clean
6.5 Use dust caps when spreader is disconnected from the hose. Keep clean to prolong the
product’s life.
6.6 Wipe thoroughly clean and store spreader upright, with feet closed, in clean, dry
environment. Avoid temperature extremes.
6.7 Change hydraulic oil in your system as recommended in the pump instruction sheet
6.8 Periodically lubricate lifting wedge with a small amount of high quality grease.
6.9 Periodically apply a coating of light lubricating oil to pivot points and hinges.

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 7 of 9
7.0 Troubleshooting
Problem
Cause
Solution
Spreader moves but
does not maintain
pressure
Leaking connection
Clean, reseal with thread sealant
and tighten connection
Leaking cylinder seals
Replace worn seals
Check for excessive contamination
or wear
Replace contaminated fluid as
necessary
Malfunctioning pump/valve
Check pump or valve operating
instructions
Repair or replace as necessary
Spreader leaks hydraulic
fluid
Worn or damaged seals
Replace worn seals
Check for excessive contamination
or wear
Replace contaminated fluid as
necessary
Loose connections
Clean, reseal with thread sealant
and tighten connection
Spreader will not retract
or retracts slower than
normal
Closed pump release valve
Open pump release valve
Loose couplers
Tighten couplers
Blocked hydraulic lines
Clean and flush lines
Weak or broken retraction
springs
Send to a Durapac authorised
service centre for repair
Internally damaged cylinder
Send to a Durapac authorised
service centre for repair
Pump reservoir too full
Drain hydraulic fluid to correct
level
Erratic Action
Air in system or pump
cavitation
Add fluid, bleed air and check for
leaks
External leakage
Replace worn packings
Check for excessive contamination
fluid as necessary
Replace contaminated fluid as
necessary
Sticking or binding cylinder
Check for dirt or leaks
Check for bent, misaligned, worn
parts or defective packings
Spreader does not move
Loose couplers
Tighten couplers
Faulty coupler
Verify that female coupler is not
locked up (ball wedged into seat)
Replace both male and female
couplers
Improper valve position
Close release valve or shift to new
position
Low or no hydraulic fluid in
pump reservoir
Fill and bleed the system

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 8 of 9
Problem
Cause
Solution
Air-locked pump
Prime pump according to pump
operating instructions
Pump not operating
Check pump’s operating
instructions
Load is above the capacity of
the system
Use the correct equipment
Spreader extends only
partially
Low or no hydraulic fluid in
pump reservoir
Fill and bleed the system
Load is above the capacity of
the system
Use the correct equipment
Sticking or binding cylinder
Check for dirt or leaks
Check for bent, misaligned, worn
parts or defective packings
Spreader moves slower
than normal
Loose couplers
Tighten couplers
Restricted hydraulic line or
fitting
Clean
Replace if damaged
Pump not operating correctly
Check pump’s operating
instructions
Repair or replace as necessary
Low fluid level in pump
reservoir
Fill and bleed the system
Leaking cylinder seals
Replace worn seals
Check for excessive contamination
or wear
Replace contaminated fluid as
necessary

Instruction Manual
DHS-5 Remote Spreader - V1.0 www.durapac.com Page 9 of 9
8.0 Parts Breakdown and List
Note –Not all components of the Hydraulic Spreader are
replacement items, but are illustrated as a convenient reference of
location and position in the assembly sequence.
Item Description Qty
1 Body 1
2 Inner tube 1
3 M-toe 1
4 Bolt 6
5 L-toe 1
6 R-toe 1
7 Bolt 1
8 Bolt 1
9 Bolt 1
10 Cylinder 1
11 Fast couplers 1