Durapac P-2800 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
sales@absoluteequipment. com.au –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Two Speed High Volume Hand Pump
Models –P-2800 and P-2800D

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 2 of 12
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 –Hand Pumps are engineered to meet Industrial Standards for Performance and Safety.
The P-2800 is a high flow, 2 speed hand pump with a 2 way valve designed to be used with single
acting hydraulic equipment.
The P-2800D is a high flow, 2 speed hand pump with a 4 way valve designed to be used with double
acting hydraulic equipment.
Both models are the ultimate in high performance two speed portable power. They are ideally suited
to operate high tonnage cylinders where conventional power sources are not available. Both models
feature a first stage high flow of 113cc per stroke for fast cylinder advance and retract and a high
pressure power flow of 4cc per stroke. The pumps are a robustly built, industry proven performer.
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 pumps 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 hand pump 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 hand pump 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
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 3 of 12
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 Pumps
Do use a gauge or other load measuring instrument to verify load
Do NOT exceed the rated capacity of the pump 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
Do NOT subject the pump and its components to shock loads

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 4 of 12
Use only Durapac approved accessories and components
Do NOT connect to an application which can return more oil to the reservoir than
the pump reservoir can hold
Do NOT connect pump 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 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 hand pump, 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 Remove the manifold plug and then connect oil output port to suitable fittings and
application/cylinder.
1st Stage
2nd Stage
1st Stage 2nd Stage
P-2800 S/A 2 Way 27.5 700 8,000 113.0 4.0 3/8" NPTF 29 29.0
P-2800D D/A 4 Way 27.5 700 8,000 113.0 4.0 3/8" NPTF 29 30.0
Weight
(kg)
Max
Handle
Effort (kg)
Valve
Type
Model
Number
Used
with
Cylinder
Pressure Rating
(bar)
Usable
Oil
Capacity
Oil Volumes
per Stroke (cc)
Oil Port
Thread

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 5 of 12
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 –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 pump be required, please follow the
steps in 6.2 –Bleeding Air from the System in the Maintenance Section.
5.0 Operation
IMPORTANT:
This pump is operated with a non-vented reservoir. If the reservoir is subjected to high
pressure, the casing may rupture, causing personal injury and/or equipment damage.
NEVER attempt to return more oil to the reservoir than it is capable of holding
Do NOT add extensions to the pump handle. Extensions cause unstable pump
operation
In certain situations the pump handle can "kick back". Always keep your body to the
side of the pump, away from the line of force of the handle
Do NOT operate a pump that is disconnected from application. If operated in this
condition, the hose and connections will become pressurised. This increases burst
hazard. Damage may occur to pump and its components
The pump may only be operated in a horizontal position as shown.
Figure 1 –Hand Pump Operation
5.1 Before Using the Pump
5.1.1 Check all system fittings and connections to be sure they are tight and leak free.
5.1.2 Check oil level in reservoir before operating pump.
5.2 Using Two-Speed Pumps:
These pumps provide 2-stage flow. Under no load, the pump operates in the high flow
first stage for rapid advance. When the load is contacted, the pump automatically shifts
to the second stage for building pressure.
For P-2800 or P-2800D models, when pump pressure reaches approximately 27.5 bar,
you must momentarily stop pumping and raise the handle to shift to the high pressure
stage. After the pump shifts, pumping takes less effort.

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 6 of 12
Note: To reduce handle effort at high pressure, take short strokes. Maximum leverage
is obtained in the last 5° of stroke. For best performance, operate pump handle at
moderate speed during the high flow first stage. Rapid handle speed in the first stage
will prevent the pump from delivering full volume of oil.
5.3 Single-Acting Applications with 2 Way Valve
Figure 2 –2 Way valve positioning
5.3.1 Shift valve handle to the open position (ADV).
5.3.2 Operate pump handle to deliver hydraulic power to the system. Pressure will be
maintained until the valve is shifted.
5.3.3 To allow oil to return to the reservoir, shift valve handle to closed position (180o
- RET).
5.4 Double-Acting Applications with 4 Way Valve
WARNING: Operate double-acting cylinder only when both hoses are connected to the
pump. If one coupler is left unconnected, high pressure will build behind the coupler
which could cause personal injury and/or equipment damage
Pumps with 4-way control valves are designed to operate double-acting cylinders.
Figure 3 –4 Way valve positioning
5.4.1 Position lever on 4-way valve to select function as follows:
(A) Flow to Port "A"; port "B" returns flow to the reservoir
(T) Neutral; ports "A" and "B" are blocked
(B) Flow to port "B"; port "A" returns flow to the reservoir
5.4.2 Operate pump to perform work.
5.4.3 Change valve positions as needed.

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 7 of 12
5.5 Relief Valve Adjustment
All pumps contain a factory set relief valve to prevent over-pressurisation of the
system.
6.0 Maintenance
IMPORTANT:
Check oil level regularly
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 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
Air is required in the reservoir to function properly. If the reservoir is completely filled, a
vacuum will form preventing oil from flowing out of the pump
6.1.1 Depressurise and disconnect hydraulic hose from application/cylinder.
6.1.2 With the pump 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 approximately 25 mm from the top of
the oil filler hole.
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
Air can accumulate in the hydraulic system during the initial setup or after prolonged
use, causing the cylinder / spreader to respond slowly or in an unstable manner. To
remove the air:

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 8 of 12
Figure 4 –Bleeding Air from the System
6.2.1 Pump With Single-Acting Cylinder (A)
6.2.1.1 Repeat Steps 6.1.1 to 6.1.3 (above), if required.
6.2.1.2 Position pump at higher elevation than cylinder.
6.2.1.3 Position cylinder with the plunger end down (up if using pull cylinder).
6.2.1.4 Operate pump to fully extend the cylinder (retract if using pull cylinder).
6.2.1.5 Open release valve to retract cylinder (extend if a pull cylinder). This will
force the trapped air to move up to the pump reservoir.
6.2.1.6 Repeat the above steps as necessary.
6.2.1.7 Recheck oil level after removing air.
6.2.1.8 Return vent/fill cap to operating position.
6.2.2 Pump With Double-Acting Cylinder (B)
6.2.2.1 Repeat Steps 6.1.1 to 6.1.3 (above), if required.
6.2.2.2 Position pump at higher elevation than cylinder.
6.2.2.3 Put cylinder in horizontal position with ports up.
6.2.2.4 Fully advance and retract the cylinder 2 to 3 times.
6.2.2.5 Repeat the above steps as necessary.
6.2.2.6 Recheck oil level after removing air.
6.2.2.7 Return vent/fill cap to operating position.
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.
6.4 Lubrication
To extend pump life and improve performance, lubricate the beam pin (A), cross pin
(B), and piston head (C) regularly, using roller bearing grease.

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 9 of 12
Figure 5 - Lubrication
6.5 Storage
6.5.1 When not in use, depressurise and disconnect the hydraulic pump from the
application.
6.5.2 Wipe clean thoroughly and store in a clean, dry environment. Avoid
temperature extremes.
6.5.3 For transportation or long storage, replace the air vent plug with shipping plug.
6.5.4 Shield pump with a protective cover.

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 10 of 12
7.0 Troubleshooting
Problem
Cause
Solution
Pump loses pressure
Leaking system components
Repair or replace as
necessary
Pump not delivering
fluid
Low fluid level in reservoir
Check fluid level
Worn seats
Repair seats
Replace pump body
Pump does not reach
rated capacity
Low fluid level in reservoir
Check fluid level
Leaking system components
Repair or replace as
necessary
Fluid leaking past inlet or outlet
checks
Repair inlet or outlet checks
Replace high pressure piston
seal
Pump handle has a
“spongy” feel
Air trapped in system
Refer to 6.2 - Bleeding Air
from the System
Too much fluid in reservoir
Check fluid level
Cylinder piston will not
extend (or retract for P-
2800D model)
Loose couplers
Tighten couplers
Low fluid level in pump reservoir
Fill and bleed the system
Leaking cylinder seals
Replace worn seals. Look for
excessive contamination or
wear
Cylinder piston extends
(or retracts for P-2800D
model) only partially
Low fluid level in pump reservoir
Fill and bleed the system
Load above capacity of system
Use correct equipment
Cylinder piston extends
(or retracts for P-2800D
model) slower than
normal
Loose couplers
Tighten couplers
Restricted hydraulic line or fitting
Clean and 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
Cylinder does not hold
pressure
Leaky connection
Clean, reseal with thread
sealant, and tighten
connection
Leaking cylinder seals
Replace worn seals. Look for
excessive contamination or
wear. Replace contaminated
fluid
Pump or valve not operating
correctly
Repair or replace as
necessary
Cylinder 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 fluid to correct level

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 11 of 12
8.0 Parts Breakdown and List ***Supersedes all previous versions***
8.1 P-2800 Model
Item Description Part No. Qty Item Description Part No. Qty Item Description Part No. Qty
1 Reservoir assembly ZAL1195 1 21 Split ring ZAL1270 1 41 Steel ball ZAL1368 1
2 Hand pump base ZAL1547 1 22 Piston ZAL1028 1 42 Spring end cap ZAL1144 1
3 Spring washer ZAL1343 4 23 Cone seat ZAL1153 1 43 Spring ZAL1360 1
4 Screw ZAL1296 12 24 Cone ZAL1152 1 44 Link tube ZAL1172 1
5 Reservoir gasket ZAL1260 1 25 Spring ZAL1361 1 45 Valve gasket ZAL1711 1
6 Cover plate ZAL1057 1 26 O-ring* ZAL1210 1 46 Screw ZAL1322 3
7 Junction block ZAL1171 1 27 Overload cover screw ZAL1287 1 47 Yoke ZAL1198 1
8 Tube connector ZAL1385 2 28 Pump cylinder ZAL1091 1 48 Yoke pin ZAL1156 2
9 Screw ZAL1319 4 29 Bearing ZAL1157 1 49 E-ring ZAL1327 2
10 Pump body ZAL1032 1 30 O-ring ZAL1222 1 50 Rubber ZAL1261 1
11 O-ring ZAL1258 2 31 Wiper ZAL1214 1 51 Gasket seal ZAL1712 12
12 Steel ball ZAL1377 1 32 Pump collar ZAL1159 1 52 Breather assembly ZAL1025 1
13 O-ring* ZAL1251 3 33 Yoke base ZAL1158 1 53 Handle ZAL1081 1
14 Back-up ring* ZAL1250 3 34 Pin ZAL1145 1 54 Handle grip ZAL1263 1
15 Piston ZAL1146 1 35 O-ring ZAL1237 4 55 Cover ZAL1259 2
16 E-ring ZAL1330 1 36 Screw ZAL1316 4 56 Fixing hook ZAL1549 1
17 Retaining ring ZAL1336 1 37 Connector base ZAL1548 1 57 Washer ZAL1550 1
18 Back-up ring ZAL1257 1 38 Screw ZAL1296 1 58 Screw ZAL1551 1
19 O-ring ZAL1256 1 39 Tube assembly ZAL1093 2 59 Screw ZAL1713 4
20 O-ring ZAL1254 1 40 Valve assembly ZAL1027 1 Repair kit ZAL1325 1

Instruction Manual
P-2800 & P-2800D Hand Pumps - V1.1 www.durapac.com Page 12 of 12
8.2 P-2800D Model
Item Description Part No. Qty Item Description Part No. Qty Item Description Part No. Qty
1 Reservoir assembly ZAL1195 1 21 Split ring ZAL1270 1 41 Screw ZAL1322 3
2 Hand pump base ZAL1547 1 22 Piston ZAL1028 1 42 Valve block ZAL1035 1
3 Spring washer ZAL1343 4 23 Cone seat ZAL1153 1 43 Link tube ZAL1172 1
4 Screw ZAL1296 12 24 Cone ZAL1152 1 44 Valve gasket ZAL1711 1
5 Reservoir gasket ZAL1260 1 25 Spring ZAL1361 1 45 Screw ZAL1714 4
6 Cover plate ZAL1057 1 26 O-ring* ZAL1210 1 46 Washer ZAL1357 4
7 Junction block ZAL1171 1 27 Overload cover screw ZAL1287 1 47 Yoke ZAL1198 1
8 Tube connector ZAL1385 2 28 Pump cylinder ZAL1091 1 48 Yoke pin ZAL1156 2
9 Screw ZAL1319 4 29 Bearing ZAL1157 1 49 E-ring ZAL1327 2
10 Pump body ZAL1032 1 30 O-ring ZAL1222 1 50 Rubber ZAL1261 1
11 O-ring ZAL1258 2 31 Wiper ZAL1214 1 51 Gasket seal ZAL1712 12
12 Steel ball ZAL1377 1 32 Pump collar ZAL1159 1 52 Breather assembly ZAL1025 1
13 O-ring* ZAL1251 3 33 Yoke base ZAL1158 1 53 Handle ZAL1081 1
14 Back-up ring* ZAL1250 3 34 Pin ZAL1145 1 54 Handle grip ZAL1263 1
15 Piston ZAL1146 1 35 O-ring ZAL1237 4 55 Cover ZAL1259 2
16 E-ring ZAL1330 1 36 Screw ZAL1316 4 56 Fixing hook ZAL1549 1
17 Retaining ring ZAL1336 1 37 Connector base ZAL1548 1 57 Washer ZAL1550 1
18 Back-up ring ZAL1257 1 38 Screw ZAL1296 1 58 Screw ZAL1551 1
19 O-ring ZAL1256 1 39 Tube assembly ZAL1093 2 59 Screw ZAL1551 4
20 O-ring ZAL1254 1 40 4 way valve ZAL1038 1 Repair kit ZAL1325 1
Items marked with a * are contained within a standard Repair Kit.
Serial number, model and part number need to be quoted when ordering parts.