Hi-Force ATDP63 Instruction Manual

Operating Instruction Manual:
OM-ATDP-01
From Serial Number:
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OPERATING INSTRUCTION MANUAL
ATDP –Air driven, twin, double acting hydrotest pumps
This manual applies to the Hi-Force ATDP series of air driven hydrotest pumps only. It contains the latest
product information available at the time of publication and approval. For information relating to the servicing
of an ATDP pump, see the servicing instructions, which are available on the Hi-Force website. Hi-Force
reserves the right to make changes to this document at any time without notice.
This ‘Original instructions’ document assumes that the operator carrying out any operation with this
product is trained and competent to do so. This manual does not attempt to cover all details or variations
in the equipment. Nor does thismanual claim to provide for every possible contingency met in connection
with the installation, operation, or maintenance thereof. Should further information be desired, or should
a particular problem arise which is not covered in sufficient detail, the matter should be referred to
Hi-Force.

Operating Instruction Manual:
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Table of contents
1.0 Specifications………………………………………………………………………………….Page 3
2.0 System Components/Accessories…….……………………………………………….....Page 4
3.0 Inspection upon receipt……………………………………………………………………...Page 4
4.0 Safety Precautions……………………………………………………………………………Page 4
4.1 Introduction……..……………………………………………………………………….Page 4
4.2 Work area safety…………………………………………………………………….….Page 5
4.3 Electrical Safety ATEX………………………………………………………….……..Page 5
4.4 General precautions……………………………………………………………………Page 5
4.5 ATDP Specific safety precautions…………………………………………………….Page 7
5.0 Declaration of conformity…………………………………………………………………...Page 7
6.0 General description…………………………………………………………………………..Page 8
7.0 Component identification……………………………………………………………..…….Page 9
8.0 Installation / Setup…………………………………………………………………………..Page 10
8.1 Before first use………………………………………………………………………...Page 10
8.2 Operation……………………………………………………………………………....Page 11
9.0 Maintenance / Storage…………………………………………………………………..….Page 12
10.0 Trouble shooting………………………………………………………………………..…Page 13
11.0 Contact details……………………………...................................................................Page 14
NOTE: Images contained within this document are for illustrative purposes ONLY.

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1.0 Specifications
Max air consumption:
6 m³ (212scfm) at 7 bar.
A minimum supply pipe bore of ½” diameter is required to allow the pump to operate correctly.
Fluid inlet port:
1” BSP (All models)
Outlet Port:
ATDP63 = ½” NPT
ATDP125 = ½” NPT
ATDP216 = 1.1/8” -12 UNF
Pump operating temperatures:
-20c to +50c
Noise level:
An average A-Weighted sound pressure level of 75dB was measured for undefined workspaces, as per
Directive 2006/42/EC Section 1.7.4.2 (u).
Recommended Fluids:
•De-ironised / De-minerelised water.
•Water Glycol
•Hydraulic oil (see chart below)
Hi-Force tools use 2 grades of hydraulic oil, dependant on the tool.
ISO Hydraulic oil grade
Temperature range Degrees Celcius
From:
To:
ISO15
-23
44
ISO46
-2
73
IMPORTANT: If in doubt about the suitability of the operating fluid you intend to use, please consult
your nearest Hi-Force office or distributor. Use of unsuitable operating fluids WILL void your
warranty.

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ATDP Models
Refer to name plate on the pump for identification.
2.0 System Components/Accessories
(Refer to the Hi-Force website or latest Hi-Force catalogue, for further details)
•Stroke counter system.
•Chart recorder (including spare pens and charts).
•Isolation section for chemical duty.
3.0 Inspection upon Receipt
Upon receipt of the product, visually inspect the item for any evidence of shipping damage. Please note:
the warranty does not cover shipping damage. Notify the courier immediately if shipping damage is found
and refrain from putting the product into service. The carrier is responsible for repair and replacement costs
resulting from damage that occurred in transit.
4.0 Safety Precautions
4.1 Introduction
Read and follow all the instructions and safety warnings carefully before handling, installation or
use of any hydraulic equipment. Failure to do so could lead to equipment damage, equipment
failure, personal injury or even death. Hi-Force will not be held responsible for any damage to the
equipment, injury or death resulting from the unsafe use of, lack of maintenance to, or incorrect operation
of the product. If in doubt onthe correct use of any Hi-Force equipment, contact your nearest Hi-Forceoffice
or distributor. Only qualified personnel should be allowed to operate hydraulic equipment. If an operator has
not been trained on high-pressure hydraulic equipment and its safe usage, consult your local Hi-Force sales
office or distributor who can offer training courses for operators.

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4.2 Work Area Safety
•Keep work areas clean and well lit. Cluttered spaces and inadequate lighting can result in
unnecessary accidents.
•Keep bystanders clear of any hydraulic tool activity. Personnel working in close-range should be
made aware of all high-pressure work before commencing.
4.3 Electrical Safety ATEX
•If the unit is to be used in an ATEX environment it should be adequately earthed to prevent static.
The mounting plate of the pump unit to the frame has been left clean for this purpose.
•When cleaning the unit, a damp cloth should be used to prevent static build up.
4.4 General Precautions
Failure to observe and obey the following safety precautions could result
in property damage, significant personal injury or death;
•When operating any hydraulic equipment, all operators should ensure that all necessary personal
protective equipment (PPE) is worn, as specified by their employer. Steel toe-cap safety shoes,
safetyglasses/visor, and protective gloves shouldbe worn at alltimes. All relevant risk assessments
should be completed before the use of the equipment.
•Keep hydraulic equipment away from open flames and direct heat.
•NEVER handle a pressurised hydraulic hose. Hydraulic fluid escaping under pressure from a
ruptured hose can penetrate the skin and lead to a significant medical emergency, and in some
cases, death. Should this incident occur, seek out medical attention immediately.
•Seek medical attention immediately if a hydraulic injection injury (no matter how minor) occurs.
•The system operating pressure MUST NOT exceed the pressure rating of the lowest-rated
component in the system.
•Only use hydraulic tools/cylinders in a complete and tested, coupled system. NEVER attempt to
use a tool/cylinder that is not correctly coupled to its operational pump. NEVER pressurise
uncoupled male couplers.
•NEVER attempt to disconnect a hose from a hydraulic system until the system’s pressure has been
completely released. Doing so can result in that pressure becoming trapped within the system and
relieving trapped pressure can be dangerous.
•Loosening a hydraulic fitting under pressure can result in the escape of hydraulic fluid at high
pressure, which can penetrate the skin and cause significant injury or death.

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•NEVER attempt to solve, or clean-up leaks in the system while the system is pressurised.
•Immediately replace any worn or damaged parts using genuine Hi-Force parts only.
•DO NOT use any hydraulic equipment if you are under the influence of alcohol, drugs or medication.
Lack of attentionwhilst operating high-pressure hydraulic tools canresult in personal injury or death.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•NEVER lift, carry or move any hydraulic components by the hose or hoses connected to them.
•Avoid damaging hydraulic hoses. ALWAYS route hoses to ensure that they are free from sharp
bends and kinks. Using a sharply bent or kinked hose will result in severe back-pressure, which can
lead to hose failure.
•NEVER use a coupler/s to lift, carry or position a tool.
•Servicing of hydraulic equipment must only be undertaken by a qualified technician.
•DO NOT drop or place heavy objects on a hydraulic hose, as this may cause
internal damage, which could result in rupture of the pressurised hose. A
ruptured hose could cause significant damage to components and possible
severe injury to personal operating nearby.
•DO NOT let familiarity gained with any hydraulic tools allow you to become complacent.
Complacency with any tooling can result in a lack of discipline toward working guidelines and safety
principles.
•DO NOT remove any labels from the product. Replace any damaged or unreadable labels
immediately.
•Avoid loose clothing and jewellery that could get caught in moving parts, tie back long hair.

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4.5 ATDP Specific Safety Precautions
Failure to observe and obey the following safety precautions could result
in property damage, serious personal injury or death;
•NEVER exceed the maximum rated pressure or load capacity of any hydraulic pump. Hi-Force
manufactures its ATPD range of hydrotest pumps to operate at a maximum working pressure of
1489bar (21,596 psi). See Specifications
•DO NOT adjust or remove the external pressure/air relief valve (ARV) on any Hi-Force product.
•NEVER invert the unit or lay it on its side, either in use, in transport or in storage.
•DO NOT weld any items to the unit or modify it in any way from itsdelivered condition. Your warranty
may be invalidated, and it could lead to serious personal injury.
•NEVER exceed the maximum rated capacity of any hydraulic system component.
•Keep hands and feet away from the hydraulic system during operation.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•To protect your warranty, only use the fluids specified in Section 1.0.
•When moving the unit, make sure all power cables and hoses are kept clear of the pump to avoid
damage.
5.0 Declaration of Incorporation/Conformity
Hi-Force declares that this product has been tested and complies with the standards and
declarations as set out in the Declaration of Incorporation/Conformity (DoI/DoC). The DoI/DoC is
included as Annex A to this instruction document and is supplied with all shipments of this
product.

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6.0 General Description
Hi Force ATDP Hydrotest pumps are designed to have an infinately variable output pressure and
displacement speed. They are fitted with an integral filtration and lubrication unit and air pressure
gauge. An airline regultor allows for easy setting of air inlet pressure and output hydraulic
pressure. The air start/stop valve allows for easy and fast pressure shut off. An air relief valve
(ARV) is fitted to the air inlet. The ARV is factory set to allow maximum pressure to be achieved
and vent any overpressurisation to the atmosphere.
The Hi-Force ADTP range of Hydrotest pumps are supplied in a range of 3 models with output
pressures ranging from 87 bar(1260psi) to 1489bar (21596psi) and are suitable for use with
various fluids. See 1.0 Specifications.
The ADTP air driven liquid pump range work on an automatic reciprocating differential area
piston principle that uses large area air drive pistons connected to smaller area hydraulic pistons
to convert compressed air power into hydraulic power.
The ADTP pump range has a double acting motion incorporating two hydraulic cylinder and
piston assemblies, as liquid is introduced into one hydraulic cylinder on the pump suction stroke,
liquid is automatically delivered from the second high pressure cylinder at the same time on the
pump delivery stroke and vice versa. When the pump reaches the end of its stroke the spool
valve in the air change over valve motor automatically shifts, reversing the pump direction; hence
delivery flow is relatively smooth with only a small interruption in flow (dwell) as the pump air
pistons change direction.
The units consist of a robust framework, fitted with an air driven hydraulic pump and complete
with all necessary hydraulic accessories i.e. a 150mm diameter hydraulic pressure gauge, a
hydraulic pressure release valve and all interconnecting pipe-work fittings and adaptors,
terminating at a single high pressure outlet connection port. Pneumatic accessories include an
air filter, air pressure regulating valve, oil lubricator, air gauge, ARV and air on/off valve.
A fluid inlet connection is provided and a Y type fluid strainer and fluid relief valve set at
approximately 10 bar is fitted between this connection and the pump inlet check valves.
Provision is provided for fluid drainage via a nylon hose connected to the hydraulic pressure
release valve.
The ATDP63 has a maximum working pressure of 434Bar (6,295psi) on the hydraulic pressure
circuit. The hydraulic pressure to be generated by the air driven pump is dependent upon the air
pressure applied i.e. Pump ratio 63/1: 1psig air drive pressure applied can generate 63psig
hydraulic pressure.
The ATDP125 has a maximum working pressure of 862Bar (12502psi) on the hydraulic pressure
circuit. The hydraulic pressure to be generated by the air driven pump is dependent upon the air
pressure applied i.e. Pump ratio 125/1: 1psig air drive pressure applied can generate 125psig
hydraulic pressure.
The ATDP216 has a maximum working pressure of 1489Bar (21596psi) on the hydraulic
pressure circuit. The hydraulic pressure to be generated by the air driven pump is dependent

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upon the air pressure applied i.e. Pump ratio 216/1: 1psig air drive pressure applied can
generate 216psig hydraulic pressure.
7.0 Component Identification

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8.0 Installation/Setup
8.1 Before First Use / Preparation
It is recommended to use good quality clean & dry air (without moisture content) to drive the air driven pump
unit. As the air pressure drops at the pump exhaust ports, the air will cool and any water droplets in the air
can freeze prematurely due to temperature variation. For this reason we include and recommend the use
of ‘Killfrost’ at all times to be placed in the installed pump oil lubrication bottle. The lubricator bottle drop
feed rate is advised at 1 drop per 20 pump strokes. A COSHH sheet for ‘Killfrost’ is available on request.
If for any reason the lubricator is not used, the air motor should be disassembled, inspected and repacked
with suitable compound grease every 1 million strokes. Silicone type grease is prone to stiffening when not
in use, at a minimum the grease should be changed after a 6month idle period and every 12 months in a
scheduled routine service interval at a minimum.
Connect the hydraulic pressure outlet port to the equipment to be pressurised via a flexible hose assembly
or via a rigid pipe-work system. Ensure that all attached hose, pipe-work and fittings are rated suitably to
match, at a minimum, or exceed the maximum working pressure rating of the pump unit.
Direct the provided drain hose into a suitable container or drain.
Connect an air supply hose of at least ½” bore, to the power pack air inlet port. Use appropriately pressure
rated air hose and fittings for this purpose, these components must be rated at a higher working pressure
than the maximum supply air pressure that can be applied to the power pack. (1/2” bore air supply tubing
is the smallest size that will allow the pump to operate).
Ensure that the air on/off valve on the pump is in the closed before switching on the air supply. (Note: To
achieve the potential maximum working pressure and output flow capability, ensure an air supply of 7 bar
(100psi) is available with a flow rate of 212 SCFM (6m³/min). The use of a smaller bore air hose or a smaller
SCFM volume supply is acceptable but will diminish the maximum potential flow-rate from the pump.
Make connections to the fluid inlet port using suitably rated hose, pipe-work and fittings and a fluid isolation
valve. The fluid inlet hose and fittings bore is recommended to be not less than 1” bore.
Once the pump has raised hydraulic pressure DO NOT close the fluid inlet isolation valve.
Ensure the water supply is sufficient and only at 7 bar maximum pressure. It is advisable to ensure clean
water (fluid) is used as this prevents any possible chance of debris contaminating the pump check valves
(Y type strainer filter built in pump unit water line).
If fluid is being supplied from a tank ensure the tank is sited close to the fluid inlet port on the power pack
or sited above the level of the fluid inlet port (positive head/displacement pump).
Reducing the fluid supply inlet hose/pipe bore or supplying water from a tank at a lower level than the pump
inlet port may cause pump cavitation’s and potential damage, so should always be avoided.
IMPORTANT: Running the pump dry will result in damage.

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8.2 Operation
1) Check that the pump on/off air valve is closed, and that the hydraulic pressure release valve is in the
open position.
2) Adjust the pump air pressure-regulating valve anticlockwise until it is fully wound out. Switch on the air
supply to the pump by external means.
3) Plug the hydraulic outlet connection.
4) Turn on the water supply to the pump. As long as the water supply is above approximately 0.7bar (10
psi) the water will flow through the pump andthrough the drain hose attached to the pressurerelease valve,
bleeding the system. If not (flowing water) turn the pump air pressure regulating valve slowly clockwise until
15-20 psi is shown on the air pressure regulators own air pressure gauge, the pump will operate pumping
the inlet water supply to drain.
5) Turn the pump air on/off valve to the off position and close the hydraulic pressure release valve once any
air bubbles, seen in the nylon drain hose, have disappeared and the system is bled properly.
6) To use the pump:
•Open the pump air on/off valve.
•Slowly adjust the pump air pressure-regulating valve clockwise, the pump will reciprocate and start
to displace fluid into the system and build up pressure, the pressure generated can be viewed on
the hydraulic pressure gauge.
•The maximum pressure achievable at various air pressures can be seen in the Hi-Force catalogue
ATDP page under the heading “Max output pressure at airline input pressure” e.g. ATDP63 if 80 psi
air pressure is applied then the maximum pressure the pump can generate is approximately 80psi
x the pump ratio 63/1 = 5,040psi (347bar). ATDP125 if 80 psi air pressure is applied then the
maximum pressure the pump can generate is approximately 80psi x the pump ratio 125/1 =
10,000psi (700bar). ATDP216 if 80 psi air pressure is applied then the maximum pressure the pump
can generate is approximately 80psi x the pump ratio 216/1 = 17280psi (1191bar).
•If a slower pump cycle rate is required the drive air pressure can be reduced by turning the air
pressure regulating valve anticlockwise and/or by partially closing the pump air on /off valve
•The pump can operate as a transfer pump filling the vessel under test with liquid.
•The pump will gradually and naturally start to cycle at a slower rate as the pressure in the vessel
under test increases until it stops (stalls) when a balance of forces is reached i.e. when the air drive
pressure x air drive piston area = stall pressure x driven hydraulic piston area.
•The pump will hold pressure indefinitely unless a leak occurs, at which time the pump will
automatically cut in once the leak rate reaches a certain level to try to maintain the pressure in the
system.

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•If the air supply is turnedto the OFF positionthe hydraulic pressure generated will hold on the pumps
integral check valves (in small volume systems the hydraulic pressuremay fall slightly and then stop
whilst the check valve balls reseat, this is normal).
The pump will continuously stroke if the circuit is open (flushing mode). Close the air start/stop valve to stop
the pump at any point, if required.
7) Once the test is completed to release hydraulic system pressure:
•Turn the air on/off valve to the off position
•Turn the air pressure- regulating valve anticlockwise until it fully is wound out.
•Slowly open the pressure release valve and fluid will return via the drain hose to drain until zero
pressure is indicated on the pump hydraulic pressure gauge.
It is possible to pre-set the pump so it stalls automatically at the desired pressure. This can be done by
plugging the pressure outlet port and operating the pump. Adjust the air pressure regulator gradually
upwards such that the pump stalls at the correct pressure. Release the pressure by opening the pressure
release valve. Close the pressure release valve once more to check the set pressure. Provided that no
adjustments are made the pump will repeat this set pressure when connected to a pressure vessel.
9.0 Maintenance and Storage
Carry out basic maintenance on a regular basis to keep the system operating in a trouble-free manner.
Maintenance intervals are determined by the frequency of use of the system and the operating conditions
on site.
•Keep the unit clean. Use a damp cloth to avoid any static build up.
•Silicone type grease is prone to stiffening when not in use, at a minimum the grease should be
changed after a 6 month idle period and every 12 months in a scheduled routine service interval at
a minimum.
•ALWAYS keep the unit upright in storage.
IMPORTANT: ALWAYS dispose of used fluids in a responsible manner, in accordance with local
regulations.

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10.0 Troubleshooting
Hi-Force ATDP pumps should be serviced and repaired only by authorised Hi-Force repair centres. The
following table gives possible causes and solutions for common problems.
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Solution
1. Pump will not start. Or
runs erratically.
a. Mufflers blocked or iced up.
I. Check mufflers.
II. Check Killfrost level.
b. Fluid supply starvation.
Check supply.
c. Insufficient air supply,
Check supply lines and pressure.
d. Insufficient lubrication.
I. Check lubrication level.
II. Service pump.
e. Pump is damaged, seized or worn.
Contact your local Hi-Force office/distributor.
2. Motor stalls before full
operating pressure is
reached.
a. Insufficient air supply.
Check supply lines and pressure.
3. Pump struggles to
build pressure or
maintain pressure
under load.
a. Release valve incorrectly closed.
Check release valve.
b. Valve is damaged, seized or worn
Contact your local Hi-Force office/distributor.
4. Overload protection
valve leaking.
a. Air/hydraulics overloaded
b. Faulty Valve.
I. Check pressures.
II. Contact your local Hi-Force
office/distributor.
5. Noisy Operation
a. Air trapped in the hydraulic system.
Bleed air from the system. (See section 5.3)
b. Air leaking into the hydraulic
system.
Visually inspect all areas where air might leak
into the hydraulic system.
c. Oil level too low.
Check unit for visible leaks. Add oil as per
section 5.2.

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UK Head Office:
Hi-Force Limited
Prospect Way, Daventry, Northamptonshire
NN11 8PL
United Kingdom
Tel: + 44 1327 301000
Fax: + 44 1327 706555
Email: [email protected]

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Hi-Force Regional Offices:
Hi-Force Caspian
Baku
Azerbaijan
Tel: [phone]
Email: [e-mail]
Hi-Force Hydraulics (Asia) S.B.
Selangor
Malaysia
Tel: [phone]
Email: [e-mail]
Hi-Force Nederland B.V.
Numansdorp
Netherlands
Tel: [phone]
Email: hollan[email protected]m
Hi-Force Saudi
Dammam
Saudi Arabia
Tel: [phone]
Email: [e-mail]
Hi-Force Hydraulics
Abu Dhabi
United Arab Emirates
Tel: [phone]
Email: [e-mail]
Hi-Force FZE
Dubai
United Arab Emirates
Tel: [phone]
Email: [e-mail]
Hi-Force Jebel Ali
Dubai
United Arab Emirates
Tel: [phone]
Email: [e-mail]
GLOBAL BRAND. LOCAL SERVICE.
www.hi-force.com