Fervi 0664 User manual

OPERATION AND
MAINTENANCE MANUAL
Hydraulic pump with pneumatic pedal control
Art. 0664
ORIGINAL INSTRUCTIONS
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PREFACE
Please ensure you have read this manual before operation
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
It is compulsory to r
ead this instruction manual before starting operation. The guarantee of
smooth operation and full performance of the machine is highly dependent on the application
of all the instructions contained in this manual.
Operator qualifications
The workers
responsible for the use of this machine must have all the necessary
information and instruction and should be given adequate training in relation to safety
regarding:
a)
Conditions of use for the equipment;
b)
Foreseeable, abnormal situations;
c)
pursuant to art.
73 of Legislative Decree no. 81/08.
We guarantee the
machine complies with
the specifications and technical instructions
described in the Manual on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important
technical changes in the future, without
the manual being updated.
Therefore, contact FERVI for information about modifications that may have been
implemented.
REV. 1
May 2013
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INDEX
1
GENERAL INFORMATION
................................
................................
...........
4
2
GENERAL SAFETY WARNI
NGS
................................
................................
...
5
2.1
Technical support
................................
................................
................................
.......
5
2.2
Other provisions
................................
................................
................................
........
5
3
INTENDED USE AND DES
CRIPTION OF THE PUMP
................................
.....
6
3.1
Identification Plate and Pict
ograms
................................
................................
...........
7
3.2
Safety devices
................................
................................
................................
............
7
4
TECHNICAL SPECIFICAT
IONS
................................
................................
...
8
5
IMP
ROPER USE AND HAZARD
S
................................
................................
.
8
6
TRANSPORTING, LIFTIN
G AND MOVING
................................
...................
9
7
USING THE PUMP
................................
................................
....................
10
7.1
Commissioning
................................
................................
................................
.........
10
7.2
Pressure Release
................................
................................
................................
.....
11
8
MAINTENANCE
................................
................................
........................
12
9
TROUBLESHOOTING
................................
................................
................
14
10
WAREHOUSE STORAGE
................................
................................
.........
14
11
DECOMMISSIONING
................................
................................
.............
15
12
SPARE PARTS
................................
................................
.......................
16
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1
GENERAL INFORMATION
This manual is considered an integral part of the machine it was attached to at the time of
purchase.
The manufacturer holds all ownership to material and intellectu
al property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
forbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the
Air powered Hydraulic P
ump Art. 0664
and create a sense of
responsibility and an understanding of the capabilities and limitations of the means entrusted
to the operator.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the
staff responsible for commissioning, operation and maintenance of the
pump. This is to make all operations as safe and effective as possible for those who carry out
these tasks. Therefore, it is imperative to strictly comply with the requirements in this
m
anual, a necessary condition for safe and satisfactory operation of the pump.
Before using the machine, authorized personnel must:

read this technical document carefully;

know which protections and safety devices are available, their location and how they
work.
The users must be properly trained, that they are aware of all the information and
instructions in this manual and are aware of the potential risks of operating the pump.
The manufacturer will not be held responsible for any damage to people and/or
p
roperty caused by non
-
compliance with any instructions in this manual.
Users will be held fully responsible for any changes made to the machine and the
manufacturer will not, therefore, be held responsible for any damage caused to
persons and/or property r
esulting from maintenance performed by unqualified
personnel and in a manner that differs from the operating procedures shown below.
The pump is equipped with safety devices and labels placed to protect and inform the user, so
as to avoid possible physical
damage.
It is strictly forbidden to modify or remove safety devices and caution labels. If this must be
done (for example, for cleaning or repair), make sure that no one can use the pump.
G
RAPHIC REPRESENTATIO
N OF SAFETY
,
OPERATIONAL AND RISK
WARNINGS
The
following boxes are designed to attract the attention of the reader/user for the purposes
of proper and safe use of the machine:
Attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
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2
GENERAL SAFETY WARNI
NGS
Even if you are already familiar with the
Hydraulic Pum
p,
you must read this manual
carefully to acquire full knowledge of the machine and general precautions to be observed
during operation.
Risks associated with using the machine

For safe use of the pump, it is necessary to take note of all the requirem
ents for the
prevention of accidents detailed in the various sections of this manual.

The pump must only be used by personnel who have been specially trained by
authorized personnel.

Only use the pump with single
-
acting cylinders.

Before starting work, m
ake sure that the pump is in good condition.
Do not adjust the safety valve!

Place the pump on a flat, solid and durable work surface.

Do not try to operate the machine at higher performance levels than those for which it was
designed,
in particular rega
rding the magnitude of the load to be lifted.
In other
words, do not load the pump beyond its capacity.

If you use the pump to lift a vehicle, lock the wheels of the vehicle with the parking brake.

Always use a safety support, such as a tripod, to support
the load in case you
need to work under the load.

It is recommended that users of this publication, for maintenance and repair, have a basic
knowledge of the mechanical principles and procedures inherent in repair technique.

Replace worn or damaged parts,
check that the repairs and protection work correctly
before operating.

Make sure that the work environment is forbidden to children, non
-
employees and animals.
2.1
Technical support
For any problems or concerns, please do not hesitate to contact the dealer who
sold the item.
2.2
Other provisions
The first thing to do when starting work is to check the presence and integrity of the
protections and the operation of the safety devices.
Do not use the Pump if it is defective!
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3
INTENDED USE AND DES
CRIPTION OF THE PUMP
The
Hydraulic Pump Art. 0664
is designed to provide pressure to cylinders or single
-
acting
hydraulic tools.
The pump must be used on surfaces that are supportive, flat, smooth, and adequately strong
and hard.
The operating temperature is within
–
20/+50°C
.
The working environment must also be sufficiently well lit to ensure maximum operational
safety (at least 200 lux are recommended).
Other types of use, or the extension of use beyond that envisaged, does not
correspond to the designation attributed by
the manufacturer, and therefore the
latter cannot accept any responsibility for any damage resulting therefrom.
Figure
1
-
General view.
The hydraulic pump is formed by (see
Figure
1
):

a support base (1) made of steel;

a pumping unit made up of the hydraulic cylinder and oil tank (2);

a pedal (3) for operating the pump and the release of air;

a flexible tube (4) for the hydraulic oil, equipped with screw connection (5);

a
hinge for adjusting the release speed (6);

screw with drain valve (7);

a compressed air nozzle with oiler (8).
The control system of the pump, consists of:

the pedal which, by opening a valve, allows the compressed air to drive the piston and
send oil to
the tool;

the vent valve which, once opened, allows the retraction of the piston rod of the hydraulic
cylinder, that is, the reverse flow of oil to the pump.
1
2
7
5
6
4
8
3
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3.1
Identification Plate and Pictograms
The identification plate is attached to the hydraulic cylinde
r. (
Figure
2
).
Figure
2
-
Identification Plates
3.2
Safety devices
The flexible tube that carries the high
-
pressure hydraulic oil, is connected by an external hose
and protected by a metal c
onnector, which is adapted to prevent excessive bending at the
connection points.
Figure
3
–
Hose protector.
Pump Overload

It is strictly forbidden to alter or modify the hose.

The tube should only be replaced with one of e
qual characteristics.
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4
TECHNICAL SPECIFICAT
IONS
Description
Unit of
measurement
Art. 0664
Nominal pressure
MPa / bar
70/700.
Operating pressure
MPa
0.7
–
0.8
Oil flow
cm
3
/min a 0 MPa
500
Oil flow
cm
3
/min a 700 MPa
130
Oil tank
cm
3
690
Tube l
ength
mm
1500
Air consumption
m
3
/ h
17
Weight
kg
9
Size
mm
370 x 170 x 180
Package dimensions
mm
450 x 190 x 190
5
IMPROPER USE AND HAZ
ARDS
The following actions described, which obviously can not cover the entire range of potential
possibilities o
f "misuse" of the machine, are to be considered
strictly prohibited.
THE FOLLOWING IS STRICTLY PROHIBITED

Using the pump to lift persons and/or animals that could fall.

Using the pump to lift loads while people are passing near the machine.

Working un
der lifted loads without using additional safety supports, such as a tripod.

Exceeding the maximum capacity of the pump, as indicated on the identification plate.

Lifting "dangerous" loads (molten metals, acids, radio
-
active materials, fragile and/or
crumb
ly).

Leaving the pressure pump unattended.

Allowing untrained personnel to use the pump.

Using the pump if you are not mentally and physically capable of doing so.

Using the pump without due care.

Using the pump for purposes other than those for which it w
as designed.

Using the pump in environmental conditions for which it was not intended (poor
weather conditions, refrigerators, high magnetic fields, etc.).

Using the machine in potentially explosive atmospheres.

Use the pump with insufficient lighting.

Usi
ng the pump on offshore boats.

Placing the pump in contact with foodstuffs.
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6
TRANSPORTING, LIFTIN
G AND MOVING
The operator may manually lift the pump for transporting. Make sure the drain valve screw is
fully tightened.
The operator is to grasp the pump
with both hands, using the pedal and the base of the
hydraulic cylinder as lifting points (
Figure
4
).
Figure
4
–
Transporting the pump.
Avoid Dropping to P
rotect Feet from Crushing

Move the pump by holding it with both hands, one on the gripping handle and one
below the hydraulic cylinder.

Do not hold with just one hand. It could fall and crush your feet!
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7
USING THE PUMP
Avoid Crushing Body Parts

Ther
e is a risk of crushing body parts while lifting heavy loads resulting from
mishandling. Workers must be equipped with standard safety equipment, such as
gloves and crush resistant shoes.

Workers involved in load lifting must operate the pump carefully and
pay the utmost
attention.

In particular, the pump, lift and load should be controlled during movement.

It is absolutely forbidden to work under a load that is lifted and supported only by a
hydraulic lift.
Hose Rupture
Before operating the pump, chec
k the integrity and correct mounting of the hose.
7.1
Commissioning
1.
Unscrew the drain valve screw. The screw must then be fully tightened when the pump
is not in use or before each transport.
2.
Press the foot pedal to release the pressure inside the cylinder.
Figure
5
–
pressure release
3.
Screw the connector with oiler, at the rear of the pump. Check that there is sufficient
oil inside for the work that you wish to perform.
Figure
6
–
Compressed air connector
4.
Connect the air hose coming from the compressor to the connector.
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5.
Remove the plastic protective cap from the hydraulic hose and connect it to the
hydraulic cylinder or tool such as Art. 0256/50 or simi
lar.
Figure
7
–
Connection of the hydraulic hose.
6.
Press the pedal to operate the air admittance valve and pressurise the hydraulic oil.
Figure
8
–
A
ctivating the pump.
7.2
Pressure Release
To reduce the pressure to the load and make the hydraulic oil move back inside the tank of
the pump
Figure
9
–
Pressure release.
The speed of the pressure drop, can be adjusted by means of t
he hinge to the right of the
pump (ref. 9 in
Figure
9
).
9
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8
MAINTENANCE
The purpose of this chapter is to provide the timing and maintenance procedures required to
maintain the
Hydraulic Pump.
Maintenance and repai
rs must be performed by qualified personnel.
ACTION
Frequency
Daily
Weekly
Monthly
1.
General visual inspection
X
2.
Check legibility of plates
X
3.
Check for the absence of oil leaks
X
4.
General cleaning
X
5.
Check the lubricating oil level and top up
X
6.
Lubrication and greasing
X
7.
Check the hydraulic oil level and top up
X
8.
Bleed air from the circuit
If necessary
9.
Replace the hose
By the expiration date
1.
General visual inspection:
check the general condition of the pump, if there are any
damag
ed or missing parts.
2.
Check the clear visibility and legibility of labels:
the identification label on the pump
must be perfectly visible and legible. It is necessary to keep it clean and ask for a
replacement if it becomes illegible.
3.
Verify the absence of
hydraulic oil leaks:
there can be no measurable accidental loss in
the hydraulic circuit, except for slight moisture insufficient to form a drop.
4.
General cleaning:
cleaning is necessary to free the structure and moving parts from the
accumulation of dust,
dirt and stains caused by excess lubricants. Cleaning should be done
with the use of means, equipment and detergents or solvents commonly used in the
cleaning of industrial equipment.
5.
Check the lubricating oil level and top up:
inside the compressed air c
onnector there is
lubricating oil for pneumatic circuits. Filling should be done by removing the screw on the
body of the small tank and inserting the oil, using a syringe (without needle) or a suitable
oiler with a thin spout.
Figure
10
–
Pneumatic connector.
6.
Lubrication and greasing:
it is necessary to grease the moving parts of the pump, such
as pins, hinges and levers on the pumping system.
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7.
Check the hydraulic oil level and top up:
Check the oil le
vel and if necessary top up
with hydraulic mineral oil.
-
place the pump in a horizontal position;
-
completely release the pressure, pressing the pedal as shown in
Figure
9
-
unscrew the oil filler cap (see
Figure
11
), with a screwdriver;
-
add hydraulic mineral oil (fill up to the bottom edge of the opening);
-
bleed the air;
-
replace the cap and use a screwdriver to tighten.
Figure
11
–
Hydraulic oil cap.
Precautions when replacing the oil

Only use hydraulic oil top up the oil level.

Do not use brake fluid or engine oil.

Add oil only when the pressure inside the pump has been fully released.
8.
Bleed air from the hydraulic circ
uit:
To remove any air bubbles in the hydraulic system
of the pump, which could reduce its efficiency, follow these instructions:
-
keep the pressure release pedal pressed down, then unscrew the oil filler cap using a
screwdriver;
-
pump repeatedly to release
the air;
-
replace the cap and use a screwdriver to tighten;
-
check that the pump functions properly.
If you still have problems, repeat the procedure or, if necessary, contact the Customer
Service Department.
9.
Replacing the hose
: attached hydraulic hoses are
marked with working pressure levels,
the burst pressure level and the expiration date. Replace the hose with one that has the
same characteristics.
Replace the hose
Never use the hose past the expiration date provided by the manufacturer and indicated
on
the hose itself.
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9
TROUBLESHOOTING
The following table shows the type of defect / problem, possible causes, and possible
remedies for the malfunction. The table is a useful aid for the maintenance technician when
looking for problems with the machine.
Fault
Cause
Solution
The oil is not pressurized.
The vent valve is not
properly closed.
Close the vent valve.
The pressure decreases
under stress.
The vent valve is not
properly closed.
Close the vent valve.
The pump is noisy.
The pneumatic circuit i
s not
properly lubricated.
The spring and/or pump
shaft are worn.
Add lubricating oil inside the
air fitting.
Check the integrity of the
pump with Customer Service.
The pump is weak.
Low oil level.
Add hydraulic oil.
The oil leaks from the tank.
Tank ov
erflow.
Remove the excess oil.
10
WAREHOUSE STORAGE
In the event that the machine should be stored and unused for some time, proceed as
follows:

Release all pressure from inside the pump;

Keep the vent valve slightly unscrewed;

Keep the pump indoors and fr
ee from moisture.
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11
DECOMMISSIONING
If the pump is to be scrapped, its parts must be disposed of separately.
Respect the environment !
Contact a specialist centre for the collection of waste materials.
The structure of the pump is made
from steel while some seals are made
from polymeric
material. The pump and the tank contain hydraulic oil. In this regard, differentiate the
materials according to their nature, with the assistance of specialist compan
ies authorized for
waste disposal, in compliance with the requirements of the law.
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12
SPARE PARTS
Ref.
Description
Quantity
Ref.
Description
Quantity
0664/01
Air connector
1
0664/11
Air valve rod
1
0664/02
Oiler
1
0664/12
O
-
Ring
1
0664/03
Screws
3
0664/13
O
-
Ring
1
0664/04
Washer
3
0664/14
Spring
1
0664/05
Cap
1
0664/15
Pump body
1
0664/06
O
-
Ring
1
0664/16
Screw
4
0664/07
O
-
Ring
1
0664/17
Washer
4
0664/08
Piston
1
0664/18
Sealing cap
1
0664/0
9
Vent bolt
1
0664/19
Seeger
1
0664/10
O
-
Ring
1
0664/20
Ring
1
0664/21
O
-
Ring
1
0664/53
Hydraulic joint shaft
1
0664/22
Piston
1
0664/54
Washer
1
0664/23
Ring
1
0664/55
O
-
Ring
1
0664/24
Piston shaft
1
0664/56
Hydraulic hose joint
1
0664/25
Washer
1
0664/57
Locking nut
1
0664/26
Spring
1
0664/58
Screw
1
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Ref.
Description
Quantity
Ref.
Description
Quantity
0664/27
Nut
1
0664/59
O
-
Ring
1
0664/28
Sealing ring
1
0664/60
Spring
1
0664/29
Valve
1
0664/61
Sphere base
1
0664/30
Screw
1
0664/62
Steel ball
1
0664/31
O
-
Ring
1
0664/63
Hydraulic pump body
1
0664/32
Spring
1
0664/64
Steel ball
1
0664/33
Steel ball
1
0664/65
Screw
1
0664/34
Spring
1
0664/66
O
-
Ring
1
0664/35
Steel ball
1
0664/67
Pin
1
0664/36
Pedal
1
0664/68
Oil tank shaft
1
0664/37
Screw
1
0664/69
Washer
3
0664/38
Slide
1
0664/70
Screw
3
0664/39
Spring
1
0664/71
Base
1
0664/40
Washer
1
0664/72
Rubber foot
4
0664/41
Release lever
1
0664/73
Hydraulic hose
1
0664/42
Elastic pin
1
0664/74
Hydraulic connector
1
0664/43
Spring
1
0664/75
Hydraulic connector
cap
1
0664/44
O
-
Ring
1
0664/76
Hy
draulic tank
chamber
1
0664/45
Release valve
1
0664/77
Vent screw
1
0664/46
O
-
Ring
1
0664/78
O
-
Ring
2
0664/47
Steel ball
1
0664/79
Nut holder
1
0664/48
Sphere base
1
0664/80
Blind nut
1
0664/49
Spring
1
0664/81
O
-
Ring
1
0664/50
Pressure screw
1
0664/
82
Tank lock
1
0664/51
O
-
Ring
1
0664/83
O
-
Ring
1
0664/52
Washer
1
0664/84
Tank shaft nut
1
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