Hi-Force HP110 User manual

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
NOTE: Spare parts sheets for these products are
available from the Hi-Force website at:
www.hi-force.com
or from your local regional Hi-Force Sales office
or authorized local Hi-Force distributor.
1.0 Inspection of the product upon receipt:
On receipt of the product, visually inspect the
item for any evidence of shipping damage.
Please note shipping damage is not covered
by warranty. If shipping damage is found notify
the carrier immediately and refrain from putting
the product into service. The carrier is
responsible for repair and replacement costs
resulting from damage in transit shipment.
2.0 Safety Precautions:
Read and follow all the instructions and safety
warnings carefully prior to use of the equipment.
Failure to do so could result in equipment
damage or failure of the equipment or personal
injury. Hi-Force will not be held responsible for
any damage to the equipment or personal
injury resulting from unsafe use of the product,
lack of maintenance or incorrect operation. If in
doubt on the correct usage of any Hi-Force
equipment, contact your nearest Hi-Force office
or distributor. If the operator has not been
trained on high pressure hydraulic equipment
and its safe use consult your local Hi-Force sales
office who can offer you training courses for
operators.
All operators should ensure that all necessary
personal protective equipment as specified by
their employer is worn when operating any
hydraulic equipment. Safety shoes, safety
glasses/ visor and protective gloves should be
worn at all times. All relevant risk assessments
should be completed prior to use of the
equipment
Warning: All ancillary equipment to be
used with these ranges of hydraulic
manual pumps MUST be rated for use at the
same operating pressure as the pump model to
be used:-
HP110 –700bar (10,000psi)
HP227 –HP257 –700 bar (10,000psi)
HP211, HP212, HP232, HP252–700 bar (10,000psi)
HP232D, HP252D –700 bar (10,000 psi)
HP245 –HP245D –700 bar (10,000 psi)
HPX1500 –1500 bar (21,755 psi)
HPX2800 –2800 bar (40,610 psi)
Sufficient time should be allocated to
planning your hydraulic system. Make
sure that all the components are fit for the
intended use.
Ensure there is sufficient oil capacity in
the pump reservoir to fully operate the
system to be used.
DO NOT exceed the rated pressure of the
pump or the rated capacity of the
system to be used. Under no circumstances
ever tamper with the internal safety relief valve
of the pump.
Keep hydraulic pumps away from flames
and direct heat.
Hydraulic pumps must only be serviced by a
qualified technician.
To protect your warranty, only use Hi-Force’s
hydraulic oil.
Immediately replace any worn or damaged
parts using genuine Hi-Force parts only.
The system operating pressure must not exceed
the pressure rating of the lowest component in
the system. Where possible, use a pressure
gauge to monitor the system.
Avoid damaging hydraulic hose. Always route
hoses to ensure that they are free from sharp
bends and kinks. Using a bent or kinked hose will
cause severe back-pressure and can also lead
to the failure of the hose.
Never lift or carry any hydraulic
components by the hose or hoses
connected to them.
Do not handle a pressurized hydraulic
hose. Oil escaping under pressure from a
ruptured hose can penetrate the skin and lead
to a serious medical emergency and in certain
cases death. Should this incident happen
medical attention must be sought immediately.

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Always operate the system under no load
condition prior to the actual lift to ensure that no
air is trapped in the hydraulic circuit.
Do not drop or place heavy objects on a
hydraulic hose as this will cause internal
damage to the hose which could result in
rupture when the hose is pressurized and could
result in serious damage to components, and
possible serious personal injury to operating
personnel.
3.0 General Information:
HP110 –Single Speed Manual Operation Steel
Construction Pump –Displacement: 2.9 cm3per
stroke- 700 bar maximum working pressure.
HP227, HP257 –Two Speed Manual Operation
Steel Construction Pump –Displacement: 1st
Stage 12.9 cm3 : 2nd Stage 2.3 cm3- 700 bar
maximum working pressure.
HP245, HP245D –Two Speed Manual Operation
Steel Construction Pump –Displacement: 1st
Stage 113 cm3 : 2nd Stage 4 cm3- 700 bar
maximum working pressure.
HP211 –Two Speed Manual Operation
Aluminium Construction Pump –Displacement:
1st Stage 12.9 cm3 : 2nd Stage 1 cm3- 700 bar
maximum working pressure.
HP212, HP232/D, HP252/D –Two Speed Manual
Operation Aluminium Construction Pump –
Displacement: 1st Stage 12.9 cm3 : 2nd Stage 2.3
cm3- 700 bar maximum working pressure
HPX1500 –Two Speed Manual Operation Steel
Construction Pump –Displacement: 1st Stage
20 cm3 : 2nd Stage 1 cm3- 1500 bar maximum
working pressure
HPX2800 –Two Speed Manual Operation Steel
Construction Pump –Displacement: 1st Stage
20 cm3 : 2nd Stage 0.8 cm3- 2800 bar maximum
working pressure
4.0 Description:
HP110:
1. The pump may be used either horizontally
or vertically with the hose end downwards.
The pump is equipped with a pressure relief
valve factory set at the maximum
operating pressure. Before use unscrew
transit plug and replace with breather on
the top of the tank. This will maximise the oil
volume available. See Figure 1.
2. To advance the cylinder, turn the release
knob clockwise. Operate pump handle.
See Figure 2
3. Note: The cylinder will automatically be
held in the advance position and will not
retract of its own accord.
4. To retract the cylinder turn release knob
anti-clockwise slowly, ensuring that the
cylinder does not retract too fast as to
make the operation unsafe. See Figure 3.

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
5. If pump is to be transported after use,
replace the transit plug in tank.
WARNING: DO NOT RELY ON THE PUMP VALVE
FOR POSITIVE LOAD HOLDING. IF IT IS REQUIRED
TO LOCK THE LOAD IN POSITION USE A MANUAL
SHUT OFF VALVE IN THE CIRCUIT. NEVER WORK
UNDER A LOAD SUPPORTED ONLY BY HYDRAULIC
MEANS.
FILLING WITH OIL.
Ensure cylinder is full retracted.
HP110: Position pump vertically with pump
head downwards. Remove central plug on rear
of pump and check oil level using dipstick fitted
to plug.
Use only Hi-Force HF032 oil.
HP227/HP257
1) The pump may be used either
horizontally or vertically with the hose
end downwards. The pump is
equipped with a pressure relief valve
factory set at the maximum operating
pressure. Before use unscrew transit
plug and replace with breather on the
top of the tank. This will maximise the oil
volume available.
2) To advance the cylinder, turn the
release knob clockwise. Operate
pump handle. The pump will
automatically switch from low pressure
(high flow) operation to high pressure
(low flow) as the pressure increases.
See Figure 1. (HP257 used in diagrams).
Note: The cylinder will automatically be held in
the advance position and will not retract of its
own accord.
3) To retract the cylinder turn release
knob anti-clockwise slowly, ensuring
that the cylinder does not retract too
fast as to make the operation unsafe.
See Figure 2
4) If pump is to be transported after use,
replace the transit plug in tank.
WARNING: DO NOT RELY ON THE PUMP VALVE
FOR POSITIVE LOAD HOLDING. IF IT IS REQUIRED
TO LOCK THE LOAD IN POSITION USE A MANUAL
SHUT OFF VALVE IN THE CIRCUIT. NEVER WORK
UNDER A LOAD SUPPORTED ONLY BY HYDRAULIC
MEANS.
HP211, HP212, HP232, HP252.
The HP211, HP212, HP227, HP232 and HP252 two
speed hand pumps are manually operated
hand pumps suitable for a wide range of
applications. All models are supplied complete,
with a pre-filled oil reservoir ready for
immediate use. All models feature low handle
effort characteristics for easy operation and
lightweight design and are of strong durable
construction. All 4 pumps have a max working
pressure of 700 bar and are of Aluminium
construction.
1) The pump may be used either
horizontally or vertically with the hose
end downwards. The pump is
equipped with a pressure relief valve
factory set at the maximum operating
pressure. Before use unscrew transit
plug and replace with breather on the
top of the tank. This will maximise the oil
volume available

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
2) To advance the cylinder, turn the
release knob clockwise. Operate
pump handle. The pump will
automatically switch from low pressure
(high flow) operation to high pressure
(low flow) as the pressure increases.
See Figure 1. (HP232 used in diagrams).
Note: The cylinder will automatically be held in
the advance position and will not retract of its
own accord.
3) To retract the cylinder turn the release
knob anti-clockwise slowly, ensuring
that the cylinder does not retract too
fast as to make the operation unsafe.
See Figure 2. below
4) If the pump is to be transported after
use, always re-fit the transit plug in the
tank.
WARNING: DO NOT RELY ON THE PUMP VALVE
FOR POSITIVE LOAD HOLDING. IF IT IS REQUIRED
TO LOCK THE LOAD IN POSITION USE A MANUAL
SHUT OFF VALVE IN THE CIRCUIT. NEVER WORK
UNDER A LOAD SUPPORTED ONLY BY HYDRAULIC
MEANS.
FILLING WITH OIL
Ensure cylinder is full retracted.
HP211/HP212/ HP232/ HP252: Position pump
horizontal on a flat surface remove plug on the
top of the tank and check oil level with dipstick
on plug.
Use only Hi-Force HF032 or HFO46 oil only.
BLEEDING THE HYDRAULIC SYSTEM
Connect a cylinder to the pump. Position the
cylinder below the level of the pump with its
pressure ports uppermost. Ensure the bleed
screw on the pump is open. Operate the
cylinder 3-4 times over its full stroke and all air
should be forced back to the pump reservoir.
Warning: when using a small cylinder with long
hoses it is possible that air can remain trapped
in the hose if the volume of the hose is greater
than the volume of the cylinder. In this case the
bleeding must be carried out using a shorter
hose before use.
See Figure 3. Below;
Figure 3:

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
HPX1500 –HPX2800 Ultra High Pressure Manual
Pump.
INTRODUCTION
The operating and maintenance procedures
listed within this manual should be adhered to
and will enable the operator to obtain
maximum efficiency and reliability from the
equipment.
PRECAUTIONS
Prior to connecting the hydraulic pump to any
equipment, the user is to ensure that:-
The working pressure of the hydraulic pump
and the equipment to be operated are
compatible.
The reservoir pump capacity is adequate to
operate the equipment throughout its range.
The hydraulic oil specifications used within
the pump and the equipment are compatible.
TECHNICAL SPECIFICATION- HPX1500
Working Pressure: 1500 Bar
Total Oil Capacity: 1800 cm3
Effective Oil Capacity: 1200 cm3
Displacement/Pump stroke, Low-press: 20 cm3
Displacement/Pump stroke, High-press: 1.0cm3
Pumping Effort: 370N
Weight: 6.5kg
TECHNICAL SPECIFICATION- HPX1500
Working Pressure: 2800 Bar
Total Oil Capacity: 1800 cm3
Effective Oil Capacity: 1200 cm3
Displacement/Pump stroke, Low-press: 20 cm3
Displacement/Pump stroke, High-press: 0.8cm3
Pumping Effort: 370N
Weight: 6.5kg
RECOMMENDED OIL
Hydraulic oil, viscosity class ISO 32
Prior to use:
Operate the handle with the Release valve
open as shown in figure 1. This will assist in
bleeding the pump of air trapped in the
system.
Figure 1:
During test and operation of the pump it is
recommended that a length of hose is either
connected to a tool or terminated with a
coupling and blanking plug is connected to
the pump.
This assists in moving a reasonable quantity of
oil from the pump prior to pressurising and
prevents air from gathering and being trapped
in the system.
Description of Pump Operation:
A dual piston system which delivers low
pressure or high pressure throughout the pump
stroke. The system switches automatically
between low and high pressure to ensure
maximum efficiency whatever the load.
Safety Feature:
The pump is equipped with an internal tamper
proof safety valve that regulates the maximum
working pressure. The safety valve is set to the
maximum pump working pressure and is
factory pre-set.
Installation
General
Always check that hoses, couplings, cylinders
and tools, etc; that are connected to the
pump are designed for use at a working
pressure that equals or exceeds the maximum
working pressure of the pump.
Connecting the hydraulic hose
Connect the hydraulic hose using a G 1/4"
coupling, or use a Hi-Force quick coupling,
tightening to a maximum torque of 40–50
Nm. Air can become trapped in the hydraulic
system when you connect hoses and tools, and
this can lead to problems with operation. Refer
to the heading Bleeding the hydraulic system.

INSTRUCTION MANUAL –HYDRAULIC HAND PUMPS:
Model Series: HP110, HP227-257, HP211-252D, HPX1500-2800
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Other accessories
All accessories that are connected to the
pump must be designed for a working pressure
that is at least equal to the maximum working
pressure of the pump.
Connecting cylinders/tools
Cylinders or tools can only be connected to
the pump when the system is depressurised.
Always make sure that the release knob is in
the open position (Figure. 1) before connecting
any accessory equipment.
OPERATION OF THE PUMP
Rotate the release valve clockwise (figure; 2)
until it seats, then raise the pump handle.
The low pressure piston is withdrawn. The
stationary high pressure piston mounted in the
valve body is simultaneously withdrawn from
the hollow low pressure piston. The vacuum
that is then created both in the low pressure
piston’s pump bore and inside the piston
causes oil to be sucked from the oil container
via a passage, past the two intake balls and
into each other, the intake balls close and the
oil from both the high and low pressure piston is
forced past the discharge ball and out into the
discharge connection.
When the load on the pump increases to
around 20-30 bar, a valve opens a passage
between the low pressure pump piston’s pump
bore and the oil container. The low pressure
function is now disengaged. Only the high
pressure piston is working.
The safety valve opens a passage between the
high pressure piston and the oil container when
the load reaches maximum working pressure.
When the release valve is turned anti-clockwise
(Figure 1), a passage is opened between the
discharge connection and the oil container
allowing the pressure to be released.
Figure: 2
Maintenance
To ensure reliable operation and long life it is
important to carry out maintenance at set
intervals. You should always follow these simple
rules:
Always make sure that:
• The pump is cleaned before returning to
storage.
• Lubricate moving parts.
• Check that there are no external hydraulic oil
leaks.
• Make sure the pump has not suffered any
external damage, as a result of impacts, etc.
Servicing
Checking the oil level
The oil level should always be measured when
the cylinder/tool is in its lowest or retracted
position.
The filler hole on the hydraulic oil reservoir is also
used to check the level. Position the pump with
the pump head facing downwards, and
remove the filler plug. The level is correct
when the oil reaches the bottom edge of the
filler hole. Refit the filler plug, tightening it to a
maximum torque of 20 Nm.
OIL LEVEL
Place the pump on a horizontal surface,
remove filler cap from the oil tank. Fill-up with
the recommended grade of oil until the level is
approx. 20mm from the bottom of the filler
hole.
BLEEDING
Place the pump on a bench or similar, with the
pump head slightly inclined downwards and
the ram on the floor standing on its pressure
head. Pump up to approx. half its stroke and
leave to stand for a few minutes. Allow the ram
to retract very slowly. Repeat this operation a
few times until all the oil has been bled from the
system. In order to bleed the pump system
separately, pump with the release valve fully
open (Figure 1).