Hi-Force AHP1120 Series User manual

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
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:-
Models AHP1120 up to and including AHP1142 –
Max working Pressure - 700bar (10,000psi)
Models HAP21011 up to and including
HAP21046 –Max working Pressure - 700bar
(10,000psi)
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 –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
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 Description AHP series Air Driven Pumps.
The device supplied is an air-powered
hydraulic pump that converts a compressed air
supply into a pressurized hydraulic flow (see
“Technical specifications” – table below Fig 2).
The pump can be utilized to power single and
double acting hydraulic cylinders; in the latter
case a directional control valve between
pump and cylinder is required. The filler/
breather plug can be removed and used as a
return line. (or select model AHP 1141/ 1142).
Any other uses of the pump shall be considered
improper and can cause serious accidents. The
manufacturer declines all liability for damages
resulting from improper use of the pump.
The main components of the pump
Note: Models ending with “R” (AHP1120R/
1121R/ 1122R) are operated with a hand
pendant instead of a treadle (Fig 16).
4.0 Safety:
Observe all the following safety rules. They are
of the maximum importance for your own
safety and the safety of others. In addition to
the safety warnings in this section, please also
take note of all safety related issues in other
sections of this manual.
DO NOT TAMPER WITH THE PROTECTIONS
AND SAFETY DEVICES AND DO NOT
MODIFY THE PUMP IN ANY WAY TO
AVOID CREATING POTENTIALLY
HAZARDOUS SITUATIONS FOR WHICH
THE OPERATOR OR THE SERVICE
TECHNICIAN IS UNPREPARED.
REMOVING OR TAMPERING WITH ANY
OF THE SAFETY DEVICES ON THE PUMP
AUTOMATICALLY INVALIDATES THE
WARRANTY AND ABSOLVES THE
MANUFACTURER FROM ALL LIABILITY
5.0 Installation and start up:
If these instructions are disregarded, the person
who is responsible for the modifications
automatically assumes full liability for any
accidents that may occur during use of the
pump.
Pump model AHP1120 / AHP1120R / AHP1121 /
AHP1121R / AHP1122 / AHP1122R / AHP1141 /
AHP1142 can be installed in a horizontal or
vertical position.
5.1. Filling the reservoir (if the pump is supplied
without oil)
The table above (Fig 2.) shows the oil quantities
required to fill the pump reservoir. The table
also shows the actual usable oil capacities.
Use only HI-FORCE HFO46 oil for your AHP
Pump.
The manufacturer shall not be held responsible
for injury to people or damage to property
caused by the use of incorrect hydraulic oil.
Damage to the pump resulting from the above
mentioned causes is not covered by warranty.
Use a slotted tip screwdriver to remove
the filler plug (Fig:1)
Pour the correct quantity of oil into the
reservoir (see table at Fig:2)
Clean the edges of the filler opening
with a clean cloth and refit the plug,
pressing it down fully.
5.2.1 - Pump hydraulic connections Models
AHP1120/ AHP1121/ AHP1122
Connect the hydraulic pressure hose to
(Port A Fig:14). The hose must be fitted

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
with a 3/8” NPTF fitting after binding the
thread with Teflon tape.
Unscrew the breather screw (Fig: 6) by
three or four turns using an appropriate
screwdriver.
5.2.2 - Pump hydraulic connections Models
AHP1141/ AHP1142
Connect the hydraulic pressure hose to
the outlet port (Port A Fig 5) and the
reservoir port (Port B Fig 5), the hose
must be fitted with a 3/8” NPTF fitting
after binding the thread with Teflon
tape.
Use a slotted tip screwdriver to extract
the breather plug to the first click
(position D in Fig 8)
5.2.3 Pump hydraulic connections:
AHP1120R/AHP1121R/AHP1122R
Connect the hydraulic pressure hose to
(Port A Fig:14). The hose must be fitted
with a 3/8” NPTF fitting after binding the
thread with Teflon tape.
Unscrew the breather screw (Fig: 6) by
three or four turns using an appropriate
screwdriver.
5.3 Connecting the compressed air line.
Select a quick coupler that is
compatible with the air-line supply and
connect it to the air inlet connection
(Fig. 1)
6: Operation
6.1 AHP1120/AHP1121/AHP1122.
To start the pump press down on the
treadle with your foot (Marked: PUMP
Fig. 14). This will make the pump deliver
pressurized oil to the connected
cylinder/tool.
When the treadle pedal is released the
pump will stop delivering oil but the
pressure/load in the system is
maintained.
To return the system pressure/load to
zero, press the treadle in the area
marked “RELEASE” (Fig: 15)
6.2 AHP1141 and AHP1142.
These units are fitted with 4/3 way directional
control valves for use with double acting
cylinders.
Position 1 (Fig11/a) - oil is sent to Port 'B' and
returns to the reservoir via Port 'A' (Fig 5)
Position 2 (Fig11/b) - locked position. Ports 'A'
and 'B' are closed and the Oil flow returns to
the reservoir.

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Position 3 (Fig11/c) - oil is sent to Port 'A' and
returns to the reservoir via Port 'B'.
WARNING:
Immediately after the pump installation,
the circuit may contain air locks that prevent
pressurization. If the pump is unable to
pressurize the oil circuit, proceed as described
below.
The following operations are the only actions
which can be to the pump using the hands.
Under normal circumstances the must be used
by foot operation.
If the pump is mounted vertically,
disassemble it and place it in a
horizontal position on the floor.
Place the treadle at the “PUMP” side.
There is a flat pushbutton beneath the
treadle.
Use one hand to press the “RELEASE”
side of the treadle while pressing the
pushbutton under the “PUMP” side with
your other hand (fig.10, page 13).
Maintain the pressure on the “RELEASE”
side and the “PUMP” pushbutton for
about 15 seconds.
The pump should now work correctly. If you still
have problems, repeat the above mentioned
procedure.
6.3 AHP1120R/AHP1121R/AHP1122R (Hand
Pendant Operation).
The AHP pump is extremely simple to use:
To activate the pump press the button
marked “PUMP” on the hand pendant
(Fig. 16).The pump will start to deliver
pressurized oil and thereby cause the
connected cylinder to advance.
When the button is released, the pump
stops but the pressure is maintained on
the oil side so that the connected
cylinder holds the load in the position it
has reached.
To return the pressure to zero and
hence retract the cylinder to its starting
position, press the button marked
“RELEASE” (Fig 16).
Fig: 16
7 - MAINTENANCE
The routine maintenance work described
below must be performed exclusively by a
skilled technician who has a thorough
knowledge of the pump and its operation and
who has read this manual completely.
Maintenance must be carried out with
maximum caution to avoid possible accidents.
This chapter describes the only maintenance
procedures permitted. Execution of any
unauthorised maintenance work will
automatically invalidate the warranty and free
the manufacturer from all liability.
7.1 - Checking connections
Check the hydraulic and pneumatic
connections once a week. Ensure that the
connections on the pump are screwed down
tightly and show no signs of breakage, cracks
or other damage. Ensure that the hoses are not
damaged in any way (cuts, abrasion, cracks,
etc.).

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
7.2 - Cleaning the air filter
There is an air filter inside the air inlet
connection (Fig 12).
Use a slotted tip screwdriver of the
appropriate size to unscrew the filter
from the air inlet connection until it is
extracted.
Clean the filter with compressed air
and then refit and screw it into position.
Do not over-tighten the filter or
damage may ensue.
Reconnect the air-line quick coupler
after binding the thread with Teflon
tape.
If the air filter is excessively
contaminated or damaged, it must be
renewed.
Order a new filter from the
manufacturer, referring to the list of
spare parts at the end of this manual.
7.3.1 - Checking the hydraulic oil on the 2,5
Litre pump (AHP1120/AHP1120R)
Periodically check that the pump contains the
correct quantity of hydraulic oil by checking
the level on the sight glass (Fig 13). If the oil
level, with cylinder retracted, is below minimum
(E, Fig 13a), refill using the recommended types
of oil.
7.3.2 - Checking the hydraulic oil on the 5/10
Litre pump (AHP1121(R)/ 1122(R)/ 1141/ 1142)
Periodically check the oil level, which must be
between the two notches on the oil cap
dipstick (F in Fig 13b).
7.4 - Hydraulic oil change
Change the oil at intervals of 250 duty hours.
This operation must be performed when the
cylinder is fully retracted: USE ONLY HI-FORCE
HFO46 OIL for your AHP Pump.
If the pump is mounted vertically,
disassemble it and position it
horizontally.
Use a slotted tip screwdriver to remove
the filler plug (Fig 1).
Empty the pump of oil by turning it
upside down over a suitable container.
Allow all the oil to flow into the
container and then fill the pump with
the quantity and type of new oil
specified above.
Clean the filler opening with a clean
cloth and refit the plug, pressing it fully
down or, if necessary, to the partially
inserted breather position.
7.5 - Troubleshooting
The chart below describes the possible issues
that could occur during operation of the
pump, together with an indication of the
appropriate corrective action. If the prescribed
action fails to solve the problem, contact the
manufacturer.
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Pump cannot be
started
Compressed air line closed or
clogged
Check compressed air supply to
pump
Insufficient air pressure
Check compressed air supply to
pump is betw een 2.8 and 10Bar
Air filter dirty or clogged Clean or Renew
Oil leak in the main hydraulic
circuit.
Check the circuit for leaks and
repair as necessary.
Pump internal leak
Check for leaks and return
pump to manufacturer for
repair
Low oil lev el
Check lev el and top up as
necessary
Insufficient air pressure
Check compressed air supply to
pump is betw een 2.8 and 10Bar
Internal relief v alve incorrectly
set.
Contact the manufacturer
Oil leak in the main hydraulic
circuit
Check for oil leaks and ask the
manufacturer
Excess load Reduce
Oil circulation fault
Check if pipelines are
obstructed or if cylinder is
working correctly
Oil leak in the main hydraulic
circuit
Check the circuit for leaks and
repair as necessary.
Pump internal fault
Check for leaks and ask the
manufacturer
Oil pressure line obstructed or
coupling incorrectly connected
Check oil pressure line.
If piston is designed to return
under gravity, ensure load is
sufficient
Increase load on cylinder
Cylinder spring broken Repair
Cylinder release valve not
working
Repair cylinder
Oil pressure line obstructed or
coupling incorrectly connected
Check oil pressure line.
Cylinder release valve not
working
Repair cylinder
Insufficient air pressure.
Check compressed air supply to
pump is betw een 2.8 and 10Bar.
Air filter dirty or clogged. Clean or Renew.
Reserv oir breather plug or
screw not opened
Open breather Plug or screw as
described in section 5
Pump operates but
no pressurizes oil is
delivered
Pump fails to reach
maximum pressure
Pump deliv ers
pressurized oil but
load is not lifting
Piston retracts
although treadle is
not pressed on
RELEASE side
Piston fails to perform
retract stroke (single
acting cylinder)
Piston fails to perform
retract stroke (single
acting cylinder)
Pump flow rate
insufficient
Pump stops working
under load

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
8.0 Description HAP series of Air Driven Pumps
Hi-Force HAP series pumps are designed to
operate high pressure hydraulic cylinders and
tools with a maximum working pressure of 700
bar. These instructions cover all HAP2-3 series
models. Refer to nameplate on pump for
model identification.
Common models and uses are given below:
MODEL
HYDRAULIC CONNECTIONS
HAP21011
HAP21012
HAP21014
HAP21016
No control valve fitted.
Pump (P) and tank (T)
connections for single and
double acting cylinders
controlled by remote mounted
valves.
HAP21021
HAP21022
HAP21024
HAP21026
2 way valve for operating single
acting cylinders and tools
requiring advance and retract
but no “hold” function. For
example crimpers and cutters.
HAP21031
HAP21032
HAP21034
HAP21036
3 way valve for operating single
acting cylinders requiring
advance, retract and central
load hold position. For example
simple lifting operations
HAP21041
HAP21042
HAP31044
HAP21046
4 way valve for operating double
acting cylinders requiring
advance, retract and central
load hold position. For example
lifting and positioning requiring
more control.
9.0 Safety:
FAILURE TO OBSERVE THE FOLLOWING
WARNINGS COULD RESULT IN SERIOUS BODILY
INJURY.
●Ensure that all equipment connected
to the pump is in good condition and is
all rated for 700 bar operating pressure.
●Always stand the pump on a stable
level surface during operation.
●Never invert the pump or lay it on its
side either in use, transport or in
storage.
●Inspect hoses regularly for damage
and wear. Do not use hoses that are
frayed, abraded or leaking.
●Never move the pump by pulling the
hoses.
●Do not work with hoses sharply bent or
kinked.
●Do not handle hoses that are
pressurised. Oil escaping under
pressure can penetrate the skin
causing serious injury. If oil is injected
unde the skin see a doctor
immediately.
●Never pressurise uncoupled couplers.
●Always use eye, ear and hand
protective equipment when using this
pump and associated equipment
10.0 Identification of Components.
Refer to diagrams on following pages.
1. Oil reservoir
2. Hydraulic Oil level gauge
3. Oil filler breather cap
4. Motor
5. Silencer
6. Adjustable pressure relief valve
7. Hydraulic directional control valve –if
fitted (type will vary)
8. Hydraulic service connections
9. Hydraulic oil drain plug
10. Roll frame (optional)
11. Motor air inlet.

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
11.0 Preparing the Pump for first use:
1. Immediately after unpacking, examine
the pump for signs of transit damage
and if found contact the shipping
company.
2. Establish the oil level in the oil reservoir
using the level gauge on the end of
the tank. Depending on the shipping
method used, the reservoir may either
be supplied full or empty. If the
reservoir is empty it must be correctly
filled before use. Remove the
temporary transit plate which is fitted in
the position of the filler breather cap
(3) by undoing the 3 screws. Fit the filler
breather cap (packed separately)
using the 3 screws which held the
transit plate.
3. To fill the reservoir: Remove the filler
cap (3) and fill the tank with clean
HFO46 oil to the upper level indicator
(2).
4. Connect the air supply to the Motor air
inlet (11). Max inlet pressure 7 bar. It is
recommended that a filter and
lubricator are incorporated in the air
supply.
5. Ensure your air supply circuit includes a
ball or sliding valve close at hand,
which can be used to control the air
supply.
6. Remove hexagon headed plugs and
make hydraulic connections to service
ports (8).These ports have a 3/8” NPT
female thread and the corresponding
male connections should be wrapped
with PTFE tape or other suitable
sealant.
7. Ensure the lever of the hydraulic
directional control valve (7) is in the
neutral position. This is fully
anticlockwise for models with 2 way
valve (HAP21021, HAP21022, HAP21024,
HAP21026) and the central position for
models with 3 or 4 way valves
(HAP21031, HAP21032, HAP20134,
HAP20136, HAP21041, HAP21042,
HAP21044, HAP21046) Where valves
are remotely mounted, ensure these
are adjusted such that pressure will not
build up during the starting operation.
11.1 Operation of the Pump:
Hi-Force does not necessarily know what
equipment this pump will power. Read and
understand the appropriate operating
instructions relating to the equipment in use.
1. With all hydraulic connections
made and air motor running,
operate the directional control
valve (7) if fitted to control the
cylinders or tools in use.
2. For pumps with 2 way valves:
Turning the lever full clockwise will
supply oil to the service port and
advance the cylinder. Turning the
lever anticlockwise will retract the
cylinder.
3. For pumps with 3 way valves: Mid
position is the load hold position.
Moving the lever so that it is above
the service port (anti-clockwise)
will supply oil to the port and
advance the cylinder. Moving the
lever away from the service port
will connect the service port to
tank and retract the cylinder.
4. For pumps with 4 way valves: Mid
position is the load hold position.
Moving the lever so that it is above
either service port will supply oil to
that port and connect the
opposite port to tank.
5. The pump is fitted with an
adjustable pressure relief valve (6)
to restrict the out-put pressure to
any desired value up to the
maximum working pressure of the
pump. To increase the relief valve
setting turn the control knob
clockwise. To decrease the relief
valve setting turn the control knob
anticlockwise. Leaving the pump
running for extended periods with
the relief valve operating will
cause the oil to overheat.
6. Ensure that the oil level does not
fall below the minimum level as
shown by the lower indicator (2)
12.0 Maintenance:
In order to ensure the longest service life and
best performance from your pump, regularly
carry out the following routine maintenance.
Inspect the pump for damage after
each use
If a gauge is fitted to the pump ensure
it is regularly checked to ensure it is
within its calibration limits.
Regularly check the oil level in the
pump reservoir by means of the oil
level gauge ( item 2 in the diagrams)
Never run the pump with the oil level in
the reservoir below its bottom limit.

INSTRUCTION MANUAL –AIR DRIVEN HYDRAULIC PUMPS:
Model Series: AHP1120, AHP1120R, AHP1121, AHP1121R, AHP1122, AHP1122R, AHP1141, AHP1142,
HAP21011, HAP21012, HAP21014, HAP21016, HAP21021, HAP21022, HAP21024, HAP21026, HAP21031,
HAP21032, HAP21034, HAP21036, HAP21041, HAP21042, HAP21044, HAP21046,
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Change the oil every 500 working hours
always only use Hi-Force HFO46 oil
Have the pump serviced regularly by a
Hi-Force authorised repair centre.