Hi-Force HEP3 User manual

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Description:
Hi-Force HEP series pumps are designed to
operate high pressure hydraulic cylinders
and tools with a maximum working
pressure of 700 bar. These instructions
cover all HEP series models. Refer to
nameplate on pump for the full model
identification.
Please read this instruction booklet
carefully before operating the product
and keep in a safe place for future
reference.
It is the responsibility of the purchaser to
ensure that operators are properly trained
in the safe use of this equipment and have
access to HI-Force Operating and Safety
Instructions.
No modification and/or additions may be
made to this equipment without the
written permission of the manufacturer.
It is expected that the product is used by
competent technical personnel who have
been properly trained to use hydraulic
lifting equipment
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:-
HEP12 series –700bar (10,000psi)
HEP103 series –700 bar (10,000psi)
HEP2, HEP3 &HEP5 series–700 bar(10,000psi)
Sufficient time should be allocated to
planning your hydraulic system.

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
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 hoses. Always
route hoses to ensure that they are free
from sharp bends and kinks. Using bent or
kinked hoses will cause severe back-
pressure and can also lead to failure of the
hose.
Always stand the pump on a stable
level surface during operation.
Never invert the pump or lay it on its
side either in use, during transportation or
in storage.
Inspect all hoses on a regular basis
for damage and wear. Do Not use
hoses that are frayed, abraded or leaking.
Never lift, pull or carry any hydraulic
pump or 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.
Never pressurize disconnected
couplings
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.
Always isolate the pump from the
electrical supply when carrying out
any maintenance work or adjustments
to the pump.
Be aware of hot sufaces on the
motor of the electric pump. Do not
obstruct the free flow of cooling air around
the motor fan and casing.
Instructions for HEP1 series two stage
compact pumps:
Two Models: HEP1211S and HEP1212S
Specification:
Model No:
Electric
Motor
Hydraulic Pump
Oil
Capacity
HEP1211S
0.35kW-
110v- 1-
Phase-
50/60Hz
Ist Stage: 2 l/min to 10 Bar
2nd Stage: 0.2 l/min to 700
Bar
1.0 litres
(Useable
0.8 litres)
HEP1212S
0.35kW-
220v- 1-
Phase-
50/60Hz
Ist Stage: 2 l/min to 10 Bar
2nd Stage: 0.2 l/min to 700
Bar
1.0 litres
(Useable
0.8 litres)

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
These pumps are suitable for use with
single acting cylinders or tools only. All
cylinders used with these pumps must be
rated at 700 bar maximum operating
pressure. These pumps should never be
used with double acting cylinders. If in
doubt consult Hi-Force Ltd; or your
approved Hi-Force distributor.
Description of parts:
HEP1 pump unit
1. Oil reservoir
2. Electric motor
3. Loop for carrying strap
4. Hydraulic connection.
5. Oil filler plug.
6. Power lead
7. Lead to control pendant.
8. Carbon brush cover.
Operation.
Connect pump to power supply.
Depress the ON button on the
control pendant to start the motor
and advance the cylinder/ tool.
When the button is released the
motor stops and the pump will
maintain pressure to hold the load
in place.
To retract the cylinder depress the
OFF button on the pendant to
return oil to tank. Note: The
cylinder will retract fully even if the
button is released.
If it is required to stop the cylinder
retracting part way through its
travel then it will be necessary to
press the ON button once more to
build up pressure again.
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:
Use only Hi-Force HFO32 oil to keep
the reservoir topped up. Ensure
that connected cylinders are fully
retracted before checking oil level
otherwise reservoir may become
pressurised and damaged.
The Oil should be changed
completely after approximately
300 hours working time. To drain
the oil, remove the filler plug and
tip the oil out. Dispose of used oil in
accordance with environmental
procedures.
The oil reservoir is sealed but when
connecting new hoses and
cylinders air can become trapped
in the reservoir causing intermittent
operation or the pump not to
deliver oil. To remove the air, fully
retract cylinder. Stand pump
vertically with filler plug (5)
uppermost. Remove the filler plug,
and top up with oil. Replace filler
plug and operate pump several
times in a vertical position.
If the pump will still not deliver oil
stand the pump level on its feet
and insert a smooth round ended
rod through the hole in the rear
end of the reservoir and push the
rubber bladder inwards by about
30mm while operating the motor.
Take care not to damage the
rubber bladder.
Carbon brush replacement. The
brushes will wear down in use and
eventually cause the motor to
stop. Replace with genuine brushes
only. Disconnect from power
supply. Remove the two rubber
covers (8) and remove fitting
screws so that brushes can be

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
removed and replaced. Replace
covers afterwards.
Instructions for HEP103 series two stage
compact pumps:
Models: HEP103241LS,HEP103242LS,
HEP103241S, HEP103242S, HEP103341,
HEP103342, HEP103441, HEP103442,
HEP103441LS, HEP103442LS
Specification:
Instructions before use.
Visually inspect all components for
damage or oil leaks.
Ensure control pendant cable is correctly
fitted before connecting to the mains
supply.
Oil filler plugs are shut tightly when being
shipped and not in use.
Before pump is to be used, turn this plug
by 1 to 2 turn anti- clockwise to open the
vent. See Figure 1.
Figure 1:
DO NOT OPERATE PUMP WITH VENT
CLOSED AS THIS MAY CAUSE NO OIL
DELIVERY OR A BUILD UP OF PRESSURE.
●Ensure the correct power supply is
used for your model of Hi-Force
pump. Either 110V or 220/ 240V
50/60Hz single phase.
●Check the oil level before use.
Retract the cylinder fully
beforehand to do so. Only use Hi-
Force Hydraulic oil.
Operation.
HEP103341 and HEP103342
1. Close release valve lever by turning
clockwise 45°. See Figure 2.
2. Press ‘ON’ button to advance cylinder.
Release the button and the cylinder will
hold its position.
3. To retract cylinder return release valve
lever to its original position.
Figure: 2
Circuit Diagram: HEP103341, HEP103342
HEP103241LS HEP103242LS
1. Press ‘ON’ button to run the motor to
advance the cylinder. If the ‘ON’ switch is
released the motor stops and the
cylinder’s piston remains stopped for load
holding.
2.Press ‘OFF’ button to retract cylinder.
Circuit Diagram: HEP103241LS,HEP103242LS
Model No:
Electric
Motor
Hydraulic Pump
Oil
Capacity
HEP103**
0.45kW-
100/110v-
1- Phase-
50/60Hz -
9.5A
Ist Stage: 2.5 l/min to
150 Bar
2nd Stage: 0.35 l/min to
700 Bar
5.0 litres
(Useable
4 litres)
HEP103**
0.45kW-
220/240v-
1- Phase-
50/60Hz -
9.5A
Ist Stage: 2.5 l/min to
150 Bar
2nd Stage: 0.35 l/min to
700 Bar
5.0 litres
(Useable
4 litres)

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
HEP103241S HEP103242S
1. Press ‘ON’ button to run the motor to
advance the cylinder.
2. Release ‘ON’ button to stop the motor
and the cylinder retracts.
Note: The ‘OFF’ button has no function.
Circuit Diagram: HEP103241S, HEP103242S
HEP103441 HEP103442
1. Turn manual valve handle to left hand
side position (45° max). Press ‘ON’ button
to advance cylinder. (Flow to port A. Port
B returns flow to the reservoir). See Figure 2.
2. Before retracting the cylinder, return
valve handle to neutral (front) position.
(Both ports A and B are blocked).
3. Turn manual valve handle to the right
hand side position (45° max). Press ‘ON’
button to retract the cylinder (Flow to port
B; port A; returns flow to the reservoir). See
Figure 3.
Figure: 3
Circuit Diagram: HEP103441, HEP103442:
HEP103441LS HEP103442LS
1. Press ‘ON’ button to run the motor and
to advance the cylinder. (Flow to port A.
Port B returns flow to reservoir). The motor
stops with button ‘ON’ released.
2. Press ‘OFF’ button to run the motor and
to retract the cylinder. (Flow to port B; port
A; returns to the reservoir.)
3. Pressure holding of both A and B ports
by means of pilot-operated check valves
when no buttons pressed.
Circuit Diagram:HEP103441LS, HEP103442LS
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:
Inspect the pump for damage
after each use.
Change the oil every 300 working
hours using Hi-Force HFO46 oil.
Have the pump serviced regularly by a Hi-
Force authorised repair centre.

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
Instructions for HEP2, HEP3 &HEP3 series two
stage electric Driven Pumps
Motor size and supply options:
HEP2 Series: Motor 1.5kW
Supply: 110/115v single phase 50Hz or 60Hz
220/240v single phase 50Hz or 60 Hz
380/440v three phase 50/60Hz
HEP3 & HEP5 Series: Motor 2.2kW
Supply: 110/115v single phase 50Hz or 60Hz
220/240v single phase 50Hz or 60 Hz
380/440v three phase 50/60Hz
Common models and typical uses are
given below:-
Note: Models with a suffix ‘S’ (e.g.
HEP207414S) have a 3 or 4 way solenoid
operated valve with a remote control
pendant.
Note: Models with a suffix ‘S-AR’ (e.g.
HEP310322S-AR) have a 3 way solenoid
operated valve with an auto retract
function.
IDENTIFICATION OF COMPONENTS
Refer to figure 1 and 2.
1. Hydraulic oil drain plug.
2. Hydraulic directional control valve –if
fitted (type will vary)
3. Roll frame (optional).
4. Motor.
5. Oil filler breather cap.
6. Tank.
7. Hydraulic oil level gauge.
8. On/off switches
9. Electrical control box.
10. Adjustable pressure relief valve.
11. Hydraulic service connections,(one or
two ports, depending on valve type)
12. Remote control pendant (fitted to
models with solenoid valves only).
Model No: Hydraulic Connection
HEP207111
HEP207112
HEP207114
HEP207121
HEP207122
HEP207124
HEP310121
HEP310122
HEP310124
HEP310141
HEP310142
HEP310144
HEP517122
HEP517142
HEP517144
HEP517162
HEP517164
No control valve, Pump (P)
and Tank (T) connections for
single and double acting
cylinders, controlled by
remote mounted valves.
HEP207211
HEP207212
HEP207214
HEP207221
HEP207222
HEP207224
HEP310221
HEP310222
HEP310224
HEP310241
HEP310242
HEP310244
HEP517242
HEP517244
HEP517262
HEP517264
2 way valve for operating
single acting cylinders and
tools requiring advance and
retract, but no "hold"
function. E.g. Crimpers and
cutters
HEP207311
HEP207312
HEP207314
HEP207321
HEP207322
HEP207324
HEP310321
HEP310322
HEP310324
HEP310341
HEP310342
HEP310344
HEP517342
HEP517344
HEP517362
HEP517364
3 way valve for operating
single acting cylinders
requiring advance, retract
and central load hold
position. E.g. Simple lifting
operations
HEP207411
HEP207412
HEP207414
HEP207421
HEP207422
HEP207424
HEP310421
HEP310422
HEP310424
HEP310441
HEP310442
HEP310444
HEP517442
HEP517444
HEP517462
HEP517464
4 way valve for operating double
acting cylinders, requiring
advance, retract and central load
hold position.E.g. lifting and
positioning where more control
is required.

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
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 (5) 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
(5) and fill the tank with clean HFO46 oil to
the upper level indicator (7).
4. Make sure that the voltage indicated on
the motor rating plate corresponds with
the available supply.
5. Remove steel or plastic hexagon
headed plugs and make hydraulic
connections to service ports (11). These
ports have a 3/8” NPT female thread and
the corresponding male connections
should be wrapped with PTFE tape or
other suitable sealant. N.B On 3 way valves
the service port is the right hand one,
when viewed as in figure 1.
6. Ensure the lever of the hydraulic
directional control valve (2) is in the
neutral position: This is fully anticlockwise
for models with 2 way valve or the central
position for models with 3 or 4 way valves.
Where valves are remotely mounted,
ensure these are adjusted such that
pressure will not build up during the
starting operation. See table on page 1.
7. Ensure switch is set to ‘off’ (8). Connect
motor to required power source.
8. Check the direction of the motor
rotation by turning the starter switch (8) to
the ‘ON’ position then to the ‘off’ position,
whilst doing this observe the motor fan.
The motor should run in a clockwise
direction viewed from above. If the
direction is wrong check the wiring of the
electrical connector. Running the pump
with incorrect rotation may damage the
low pressure pump unit.
OPERATION OF PUMPS WITH MANUAL
VALVES
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 motor running, operate the
directional control valve (2) if fitted to
control the cylinders or tools in use.
For pumps with 2 way valves: Turning the
lever fully clockwise will supply oil to the
service port and advance the cylinder.
Turning the lever anticlockwise will retract
the cylinder.
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.
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.
2. The pump is fitted with an adjustable
pressure relief valve (10) to restrict the
output pressure to any desired value up to
the maximum working pressure of the
pump. To increase the relief valve setting

INSTRUCTION MANUAL –Electric Driven Pump Series HEP:
Model Series: HEP1, HEP103, HEP2, HEP3, HEP5
Hi-Force Limited –Prospect Way –Daventry –Northants NN11 8PL –United Kingdom
Tel: [phone]: Fax: [phone]: Website: www.hi-force.com
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.
3. Ensure that the oil level does not fall
below the minimum level as shown by the
lower indicator (7)
OPERATION OF PUMPS WITH SOLENOID
VALVES
1. Turn switch to ‘on’ position (8)
2. Depress ‘advance’ button on pendant
to advance cylinder. (Cylinder remains in
the load holding position when button
released).
3. Depress ‘retract’ button to retract
cylinder.
OPERATION OF PUMPS WITH SOLENOID
VALVE AND AUTO RETRACT FUNCTION
1. Turn switch to ‘on’ position (8)
2. Depress ‘advance’ button on pendant
to advance cylinder. (Cylinder will not
remain in the load- holding position when
button is released).
3. Release ‘advance’ button to retract
cylinder.
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:
•Inspect the pump for damage after each
use.
•Change the oil every 500 working hours
using Hi-Force HFO46 oil.
•Have the pump serviced regularly by a
Hi-Force authorised repair centre.
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.