Hafco PBK-10H User manual

OPERATION MANUAL
Edition No : PBK-10H-3
Date of Issue : 07/2020
Model PBK-10H
Order Code A366
Hydraulic Panel Beater Kit

2
OPERATION MANUAL
HYDRAULIC PANEL-BEATER KIT
MACHINE
PBR-10H
MODEL NO.
SERIAL NO.
DATE OF MANF.
Distributed by
www.machineryhouse.co.nz
PRODUCT DETAILS
NOTE: THIS MANUAL IS ONLY FOR YOUR REFERENCE. OWING TO THE CONTINUOUS IMPROVEMENT OF
THE HAFCO PRODUCT, CHANGES MAY BE MADE AT ANY TIME WITHOUT OBLIGATION OR NOTICE.
C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1. Specications.................................................................. 3
2. Identication................................................................... 3
3. General Machine Shop Safety................................... 4
4. Safe Operating Of Portable Hydraulic Press......... 6
5. Operating Instructions................................................ 7
6. Inspection, Maintenance, And Cleaning............... 7
7. Troubleshooting............................................................ 8
8. Spare Parts....................................................................... 9
Risk Assement...................................................................... 16

3
OPERATION MANUAL
SPECIFICATION & IDENTIFICATION
Order Code A366
MODEL PBK-10H I.D.
Pump Capacity (Tonne) 10 1
10 Tonne Ram Push Stroke (mm) 322 - 452 2
Ram Base Size (mm) 160 x 90 3
Extension Tube x 1 (mm) 520 4
Extension Tube x 1 (mm) 365 5
Extension Tube x 1 (mm) 265 6
Extension Tube x 1 (mm) 110 7
Round Rubber Ball Head (mm) 78 8
Spreader Bar Capacity (Tonne) 0.5 9
Round Head (mm) 10
Square Head (mm) 11
Tapered Wedge Head 12
Cylinder Toe (mm) 13
Extension Toe (mm) 14
Nett Weight (Kg) 32
12
4
5
6
7
9
13
14
11
8
10
12
3

4
OPERATION MANUAL
GENERAL MACHINE SHOP SAFETY
DO NOT use this machine unless you have read this manual or have been instructed in the use
of this machine in its safe use and operation
Safety glasses must be worn at
all times in work areas. Earmus
should be worn if the work area is
noisy.
Sturdy footwear must be worn
at all times in work areas.
Long and loose hair must be
contained with a net or under a
hat
This manual provides safety instructions on the proper setup, operation, maintenance, and
service of this machine. Save this manual, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual may result in re or
serious personal injury—including amputation, electrocution, or death.
The owner of this machine is solely responsible for its safe use. This responsibility includes, but
is not limited to proper installation in a safe environment, personnel training and authorization
to use, proper inspection and maintenance, manual availability and comprehension, of the
application of the safety devices, integrity, and the use of personal protective equipment.
The manufacturer will not be held liable for injury or property damage from negligence,
improper training, machine modications or misuse.
WARNING
DISCONNECT POWER FIRST. If using power,
always disconnect the machine from power sup-
ply before making adjustments, or servicing the
machine. This prevents any risk of injury from
unintended startup or contact with live
electrical equipment
OWNER’S MANUAL. Read and understand this
owner’s manual before using the machine.
TRAINED OPERATORS ONLY. Operators that
have not been trained have a higher risk of
being seriously injured. Only allow trained or
supervised people to use this machine. When
the machine is not being used, disconnect the
power, to the machine to prevent unautho-
rized use—especially around children. Make
the workshop safe.
Gloves should NOT be worn when
operating this machine. Should
only be used when handling the
workpiece

5
OPERATION MANUAL
WEARING PROPER APPAREL Do not wear
clothing, apparel or jewelry that can become
entangled in moving parts. Always tie back
or cover long hair. Wear non-slip footwear to
avoid accidental slips, which could cause loss of
operating control.
HEARING PROTECTION. Always wear hearing
protection when operating or observing loud
machinery. Extended exposure to this noise
without hearing protection can cause perma-
nent hearing loss.
REMOVE ADJUSTING TOOLS. Tools left on
machinery can become dangerous projectiles
upon startup. Never leave hex keys, wrenches,
or any other tools on machine. Always verify
removal before starting!
USE CORRECT TOOL FOR THE JOB. Only use
this tool for its intended purpose. Do not force
the machine or its attachments to do a job for
which they were not designed. Never make
unapproved modications. Modifying the ma-
chine or using it dierently than intended may
result in malfunction or mechanical failure that
can lead to personal injury or death!
AWKWARD POSITIONS. Keep proper footing
and balance at all times when operating ma-
chine. Do not overreach! Avoid awkward hand
positions that make operating control dicult.
This could increase the risk of accidental injury
GUARDS & COVERS. Guards and covers reduce
accidental contact with moving parts or ying
debris. Make sure they are properly installed,
undamaged, and working correctly.
FORCING MACHINERY. Do not force the ma-
chine. It will do the job safer and better at the
rate for which it was designed.
NEVER STAND ON MACHINE. Serious injury
may occur if the machine is tipped or if the
cutting tool is unintentionally contacted
STABLE MACHINE. Unexpected movement
during operation greatly increases risk of injury
or loss of control. Before starting, verify ma-
chine is stable and if using a mobile base it is
locked in position.
UNATTENDED OPERATION. To reduce the
risk of accidental injury, turn the machine OFF
and ensure all moving parts have completely
stopped before walking away. Never leave the
machine running while unattended.
MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to keep
the machine in good working condition. A
machine that is improperly maintained could
malfunction, leading to serious personal injury
or death.
CHECK DAMAGED PARTS. Regularly inspect
the machine for any condition that may af-
fect the safe operation. Immediately repair or
replace damaged or parts that are incorrectly
tted before operating.
CHILDREN & BYSTANDERS. Keep children and
bystanders at a safe distance from the work
area. Stop using machine if they become a
distraction.
GENERAL MACHINE SHOP SAFETY Cont.

6
OPERATION MANUAL
SAFE OPERATING OF PANEL BEATERS KIT
DO NOT use this equipment unless you have been instructed in its safe use
and operation and have read and understood this manual.
Safety glasses must be worn at
all times in work areas.
Close tting protective clothing or
overalls are encouraged
Appropriate protective footwear
with substantial uppers must be
worn.
Rings and jewelery must NOT be
worn in the workshop
PRE-OPERATIONAL SAFETY CHECKS
1. Ensure you are familiar with the operation of the portable hydraulic press.
2. Check for any hydraulic uid leaks.
3. Ensure safety glasses or goggles are available and are worn by all persons in the vicinity.
4. Make sure the area around the portable press is clean.
5. The entire cylinder end plate must be in contact with the load. Movement of the cylinder
must be parallel with the movement of the load.
6. Keep hydraulic equipment away from open re and temperatures above 65 °C.
7. Faulty equipment must not be used. Immediately check suspect equipment.
OPERATIONAL SAFETY CHECKS
1. Ensure the pressure release valve is closed before operation.
2. Provide a solid support for the entire cylinder base area.
3. Use the press handle, in a pumping action, to slowly lower the press hammer.
4. Use your shoulder muscles when operating – NOT your lower back.
5. Keep hands and ngers away from all clamping and moving parts.
6. Carefully and accurate alignment the press hammer face with the work piece for even force
to be applied.
7. Don’t use handle extenders. Hand pumps should be easy to operate when used correctly.
8. If lling the pump, only ll the pump to the recommended level. Fill only when connected
cylinder is fully retracted.
9. DO NOT apply excessive force with the pump.
AFTER OPERATION COMPLETED
1. After use, clean the equipment and place any tools and equipment in the appropriate
storage area.
2. Place equipment back in the blow mold case.
POTENTIAL HAZARDS
Beware of high forces applied  Eye injuries – ying or shattering objects
Pinch and squash Laceration injuries
Potentially uneven forces being applied to the work piece

7
OPERATION MANUAL
OPERATING INSTRUCTIONS
Before starting work, read and thoroughly understand all warnings and precautions in this
manual along with all documentation provided with the hydraulic ram kit, when in use.
INSPECTION, MAINTENANCE, AND CLEANING
1. Inspect the general condition of the Panel Beaters Repair Kit before each use,. Check
for bent, cracked, worn or damaged parts, loose or missing parts, and any other condition
that may aect the Kit’s safe operation. If a problem occurs, have the problem corrected
before further use. Do not use damaged equipment.
2. To clean, use a damp cloth and a mild detergent or mild solvent. Do not use ammable or
corrosive agents.
3. The Panel Beaters Repair Kit when not in use should be stored in its carrying case and
kept in a clean, dry, safe location out of reach of children and other unauthorized people.
4. CAUTION! If any maintenance, service, and repairs not discussed in this manual are required
seek help from a qualied service technician.
BASIC SETUP
The capacity of the Panel Beaters Repair Kit can be signicantly aected by the number of
attachments used and the type of load applied. The load capacity of each function could
change when two or more extension tubes are used together. Be sure to position the shortest
tube further away from the ram
Note: Inspect before each use for evidence of uid leaks, damaged hydraulic ttings, bent or
broken attachments and missing parts.
1. Locate and close the release valve by turning it clockwise until rmly closed. (Do not over
tighten)
2. Operate the pump by pumping the handle. This will send uid from the pump reservoir into
the high pressure hose assembly and into the ram assembly.
3. Continue pumping until ram reaches desired height.
Note: Pump can be used in horizontal and vertical position.
To Release Pressure on the work piece:
Slowly, and carefully turn the release valve counterclockwise until the ram retracts to the
desired position. Never turn the release valve more than 1/2 full turn. The ram return system is
spring loaded, allowing for controlled retraction of the ram.
How to bleed air from system
1. Bleed air from Ram: Place the pump on a bench or table at a higher elevation than the hose
and ram. The objective is to get the air bubbles to rise and travel back to the reservoir.
2. Close the release valve and extend the ram as fast as possible. Open the release valve fully
allowing the oil and air to return to the reservoir. Repeat this procedure two or three times.
3. Bleed air from pump: With the ram fully retracted, remove the oil ller screw to let the
pressurized air escape, then reinstall oil ller screw.
OPERATION

8
OPERATION MANUAL
TROUBLESHOOTING
Symptoms Possible Cause Possible Solution
Hydraulic Ram will
not push or pull the
load.
1. Release Valve on Hydraulic Pump
not tightly closed.
2. Overload condition.
3. Air trapped in Hydraulic Pump
system.
4. Hydraulic Pump oil level low.
5. Loose connection from Hydraulic
Pump to Hydraulic Ram.
1. Close Release Valve tightly.
2. Do not exceed maximum PSI or range of travel
for Hydraulic Ram.
3. Purge air from Hydraulic Pump system.
4. Add oil to proper level.
5. Make sure connection from Hydraulic Pump to
Hydraulic Ram is secure.
Hydraulic Ram will
push or pull, but
will not maintain
pressure.
1. Release Valve on Hydraulic Pump
not tightly closed.
2. Overload condition.
3. Hydraulic Pump or Hydraulic
Ram malfunction.
1. Close Release Valve tightly.
2. Do not exceed maximum PSI or range of travel
for Hydraulic Ram.
3. Have a qualied service technician check out
1he Hydraulic Pump and/or Hydraulic Ram.
Handle
kick-back Dirt in the return check valve Flush the system
Poor
performance
• Fluid level low
• Air trapped in system
• Ensure proper uid level
• Bleed air from system
Ram bleeds o after
lift
• Release valve not tightly closed
• Dirt in pump’s return check valve
• Hydraulic unit malfunction
• Ensure release valve tightly closed
• Flush the system
• Replace ram/pump or, contact service center
Ram will not lower
after unloading
• Reservoir overlled
• Damage coupler
• Bent plunger/ ram damaged
• Drain uid to proper level
• Replace coupler
• Replace ram
If the kit develops a problem, review the trouble shooting section below to nd a x for the
problem. If the problem cannot be solved then contact your dealer for help or to book a
service appointment.

9
OPERATION MANUAL
The following section covers the spare parts diagrams and lists that were current at the time
this manual was originally printed. Due to continuous improvements of the machine, changes
may be made at any time without notication.
HOW TO ORDER SPARE PARTS
1. Have your machines model number, serial number & date of manufacture
on hand, these can be found on the specication plate mounted on the machine
2. A scanned copy of your parts list/diagram with required spare part/s
identied.
NOTE: SOME PARTS MAY ONLY BE AVAILABLE AS AN ASSEMBLY
3. Go to www.machineryhouse.com.au/contactus and ll out the inquiry form attaching a
copy of scanned parts list.
SPARE PARTS SECTION
CONTENTS
PBR-10H Parts List..................................................... 10
10 Tonne Pump Assembly Diagram................... 11
10 Tonne Pump Assembly List............................. 12
10 Tonne Ram Assembly Diagram...................... 13
10 Tonne Ram Assembly List................................ 14
0.5 Spreader Assembly........................................... 15
Edition No : PBK-10H-3
Date of Issue : 07/2020
Model PBK-10H
Order Code A366
Hydraulic Panel Beater Kit

10
OPERATION MANUAL
N0. DESCRIPTION
1 Pump and Hose
2 Ram
3 Spreader
4 Blow Mould Case
5 Ram Extensions
6Cylinder Toe
7Ram Toe
8 Wedge Head
9 Square Head
10 Active Connection Shaft
11 Round Head
12 Spherical Rubber Head
13 Ram Base
PBR-10H PARTS LIST

11
OPERATION MANUAL
10 TONNE PUMP ASSEMBLY DIAGRAM
NOTE: SUPPLIED AS AN ASSEMBLY. INDIVIDUAL PARTS NOT AVAILABLE

12
OPERATION MANUAL
NO. DESCRIPTION Qty. NO. DESCRIPTION Qty.
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
Screw
O-ring
The back cover
O-ring
Tie rod
Oil barrel
Quad plug
Oil lter screen
Pump body
Steel ball
Steel ball
Spring
Washer
Screw
O-ring
Small pump PTFE gasket
U-ring
Small pump
Ring
Large pump
Steel ball
Ball seat
1
1
1
2
1
1
1
1
1
5
3
2
2
2
1
1
1
1
1
1
1
1
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P36
P37
P38
P39
P40
P41
P42
P43
Spring
Screw
O-rings
Screw
Decorative caps
O-rings
Drain valve assembly
Oil hose
Inch hose assemblies
Tubing shield
Pump pin
Ring
Pin
Handle base
Handle
Handle cover
Screw
Low pressure regulator
Screw
Spring
Magnetic steel
1
1
3
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
10 TONNE PUMP ASSEMBLY LIST
NOTE: SUPPLIED AS AN ASSEMBLY. INDIVIDUAL PARTS NOT AVAILABLE

13
OPERATION MANUAL
10 TONNE RAM ASSEMBLY DIAGRAM
NOTE: SUPPLIED AS AN ASSEMBLY. INDIVIDUAL PARTS NOT AVAILABLE

14
OPERATION MANUAL
NO. DESCRIPTION Qty. NO. DESCRIPTION Qty.
RO1
R02
R03
R04
R05
R06
R07
R08
R09
Piston rod protection
Connecting shaft collars
Piston rod
Wire spacing ring
Washer
PTFE gasket
Imports u-ring
Axial spring collar
O-ring
1
1
1
1
1
1
1
1
1
R10
R11
R12
R13
R14
R15
R16
R17
Tension spring
Imperial dust caps
Cylinder Sleeve
Limit circle
Cylinder components
Elastic straight pins
Imperial connector nut
Cylinder connectors
1
1
1
1
1
1
1
1
10 TONNE RAM ASSEMBLY LIST
NOTE: SUPPLIED AS AN ASSEMBLY. INDIVIDUAL PARTS NOT AVAILABLE

15
OPERATION MANUAL
0.5 TONNE SPREADER ASSEMBLY
NO. DESCRIPTION Qty.
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
Pin shaft
Shaft retaining ring
Flexible part
spring
Fix part
Small piston
Piston ring
O-ring
Top Cap
Imperial connector nut
Cylinder connectors
O-ring
Imperial dust cover
1
2
1
1
1
1
1
1
1
1
1
1
1
NOTE: SUPPLIED AS AN ASSEMBLY. INDIVIDUAL PARTS NOT AVAILABLE

General Machinery Safety Instructions
1. Read the entire Manual before starting
machinery. Machinery may cause serious injury if
not correctly used.
2. Always use correct hearing protection when
operating machinery. Machinery noise may cause
permanent hearing damage.
3. Machinery must never be used when tired, or
under the influence of drugs or alcohol. When
running machinery you must be alert at all times.
4. Wear correct Clothing. At all times remove all loose
clothing, necklaces, rings, jewelry, etc. Long hair
must be contained in a hair net. Non-slip protective
footwear must be worn.
5. Always wear correct respirators around fumes
or dust when operating machinery. Machinery
fumes & dust can cause serious respiratory illness.
Dust extractors must be used where applicable.
6. Always wear correct safety glasses. When
machining you must use the correct eye protection
to prevent injuring your eyes.
7. Keep work clean and make sure you have good
lighting. Cluttered and dark shadows may cause
accidents.
8. Personnel must be properly trained or well
supervised when operating machinery. Make
sure you have clear and safe understanding of the
machine you are operating.
9. Keep children and visitors away. Make sure
children and visitors are at a safe distance for you
work area.
10. Keep your workshop childproof. Use padlocks,
Turn off master power switches and remove start
switch keys.
11. Never leave machine unattended. Turn power off
and wait till machine has come to a complete stop
before leaving the machine unattended.
12. Make a safe working environment. Do not use
machine in a damp, wet area, or where flammable
or noxious fumes may exist.
13. Disconnect main power before service
machine. Make sure power switch is in the off
position before re-connecting.
14. Use correct amperage extension cords.
Undersized extension cords overheat and lose
power. Replace extension cords if they become
damaged.
15. Keep machine well maintained. Keep blades
sharp and clean for best and safest performance.
Follow instructions when lubricating and changing
accessories.
16. Keep machine well guarded. Make sure guards
on machine are in place and are all working
correctly.
17. Do not overreach. Keep proper footing and
balance at all times.
18. Secure workpiece. Use clamps or a vice to
hold the workpiece where practical. Keeping the
workpiece secure will free up your hand to operate
the machine and will protect hand from injury.
19. Check machine over before operating. Check
machine for damaged parts, loose bolts, Keys and
wrenches left on machine and any other conditions
that may effect the machines operation. Repair and
replace damaged parts.
20. Use recommended accessories. Refer to
instruction manual or ask correct service officer
when using accessories. The use of improper
accessories may cause the risk of injury.
21. Do not force machinery. Work at the speed and
capacity at which the machine or accessory was
designed.
22. Use correct lifting practice. Always use the
correct lifting methods when using machinery.
Incorrect lifting methods can cause serious injury.
23. Lock mobile bases. Make sure any mobile bases
are locked before using machine.
24. Allergic reactions. Certain metal shavings and
cutting fluids may cause an ellergic reaction in
people and animals, especially when cutting as the
fumes can be inhaled. Make sure you know what
type of metal and cutting fluid you will be exposed
to and how to avoid contamination.
25. Call for help. If at any time you experience
difficulties, stop the machine and call you nearest
branch service department for help.
Machinery House
requires you to read this entire Manual before using this machine.

Manual Hydraulic Porta Power Safety Instructions
1. Maintenance. Check oil levels and fill to correct oil
levels if necessary. Apply oil to surface of ram to
maintain good lubrication.
2. Porta Power Condition. Porta Power must be
maintained for a proper working condition. Never
operate a Porta Power that has low oil levels, damaged
or worn parts. Scheduled routine maintenance should
performed on a scheduled basis. Check all hoses,
heads, rams, tubes and rods for cracks or damage.
Replace if necessary.
3. Hand Hazard. Keep hands away from the pressure
head and away from pinch areas, under any
circumstances, while the machine is in operation.
Serious injury can occur.
4. Gloves & Glasses. Always wear leather gloves and
approved safety glasses when working on or around
a Porta Power.
5. Work area hazards. Keep the area around the Porta
Power clean from oil, tools, objects & chips. Pay
attention to other persons in the area and know what
is going on around the area to ensure unintended
accidents.
6. Trained Personnel. Allow only trained, authorized
personnel to operate a porta-power.
7. Using Porta Power. Stay clear of a Hydraulic Ram
when using the tool. Position your body as far away
from the Ram as is practical when the Ram is under
a load. It is possible for a Ram to slip under a load,
possibly resulting in serious injury and / or property
damage.
8. Overloading Porta Power. Do not exceed the
maximum PSI capacity of each Hydraulic Ram in this
Kit, Also, do not operate a Ram beyond its maximum
range of travel. Exceeding the maximum PSI and
travel capacity of a Ram can cause personal injury
and / or property damage.
9. Warning Labels. Take note of any warning labels on
the Porta Power and do not remove them.
10. Vehicle Hazard. Before working on a vehicle,
always set the parking brake and block the tires.
Never attempt a repair while the engine is running or
the vehicle is moving. Avoid off-center loads. If the
Hydraulic Pump unit seems unusually hard to pump,
immediately stop the operation. Adjust the Hydraulic
Ram unit to eliminate or diminish an off-center load.
11. Storing Porta Power. Store idle jacks and equipment
out of reach of children and other untrained people.
Jacks and equipment are dangerous in the hands of
untrained users.
12. Call for help. If at any time you experience
difficulties, stop the machine and call you nearest
branch service department for help.
Machinery House
requires you to read this entire Manual before using this machine.

Manager:
Hydraulic Porta Power
Developed in Co-operation Between A.W.I.S.A and Australia Chamber of Manufactures
This program is based upon the Safe Work Australia, Code of Practice - Managing Risks of Plant in the Workplace ( WHSA 2011 No10 )
NEW MACHINERY HAZARD IDENTIFICATION, ASSESSMENT & CONTROL
CUTTING, STABBING
MEDIUM
Use equipment in the correct manner as to avoid parts being ejected out under pressure.
Safety officer:
Authorised and signed by:
PLANT SAFETY PROGRAM
No.
Hazard
Identification
Item
Hazard
Assessment
STRIKING
B
C
E
CRUSHING
MEDIUM
OR PUNCTURING
Risk Control Strategies
(Recommended for Purchase / Buyer / User)
Never put any part of your body between hydraulic ram and material.
Do not exceed maximum capacity.
Wear safety boots.
Ensure Job will not move around and is on level solid ground.
Wear safety glasses to protect eyes
HIGH
Always support material properly with Porta Power.
Check equipment for damage prior to use.
Revised Date:
www.machineryhouse.com.au
www.machineryhouse.co.nz
12th March 2012
Plant Safety Program to be read in conjunction with manufactures instructions
Use equipment in the correct manner as to avoid parts being ejected out under pressure.