Hi-Force HP110 Instruction Manual

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
1
OPERATING INSTRUCTION MANUAL
HP-MANUALLY OPERATED HYDRAULIC PUMP - STEEL
Hi-Force HP-Manually Operated Hydraulic Pumps (Steel) are designed to operate single-acting hydraulic
cylinders and tools with a maximum working pressure of 700 bar (10,000 psi) This manual applies to the
Hi-Force HP-Manually Operated Hydraulic Pumps (Steel) ONLY. It contains the latest product information
available at the time of publication and approval. For information relating to the servicing of HP-Manually
operated hydraulic 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:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
2
Table of Contents
1.0 Inspection upon Receipt .................................................................3
2.0 Safety Precautions...........................................................................3
3.0 Declaration of Incorporation/Conformity......................................6
5.0 Component Identification................................................................7
6.0 Installation/Setup ............................................................................8
7.0 Operation........................................................................................10
8.0 Maintenance and Storage..............................................................11
9.0 Troubleshooting.............................................................................12
11.0 Contact Details ............................................................................13
NOTE: Images contained within this document are for illustrative purposes ONLY.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
3
1.0 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.
2.0 Safety Precautions
2.1 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 on the correct use of any Hi-Force equipment, contact your nearest Hi-Forceoffice
or distributor. Onlyqualified 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 localHi-Force sales
office or distributor who can offer training courses for operators.
2.2 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. People working in close-range should be made
aware of high-pressure work before commencing.
2.3 General Hydraulic System Safety 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 all times. All relevant risk assessments
should be completed before the use of the equipment.
Keep hydraulic equipment away from open flames and direct heat.
NEVER use a coupler as a tool handle, especially if the system is pressurised.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
4
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. It is good practice to use a pressure gauge to monitor the entire system.
NEVER attempt to pressurise a system that is not correctly coupled to its operational pump.
NEVER pressurise an unconnected male coupler/s.
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.
NEVER try to relieve trapped hydraulic pressure in the system by loosening or attempting toremove
the coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly
with great force. This action could result in serious personal injury or death.
Loosening a coupler under pressure can result in the escape of hydraulic fluid at high pressure,
which can penetrate the skin and cause significant injury or death.
NEVER use a hammer and punch to unseat a coupler check valve that is under pressure. Doing so
could result in the sudden, uncontrolled release of hydraulic fluid at high pressure, which could cause
significant injury or death.
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 attention whilst operating high-pressure hydraulic tools can result 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.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
5
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.
2.4 Hydraulic Pump Specific Safety Precautions
Failure to observe and obey the following safety precautions could result
in property damage, serious personal injury or death;
NEVER invert the pump or lay it on its side, either in use, in transport or in storage.
DO NOT weld any items to the pump or modify it in any way from its delivered condition. Your
warranty may be invalidated, and it could lead to serious personal injury.
NEVER exceed the maximum rated capacity of any hydraulic pump/circuit. See Section 4.1 for
model-specific pressure capacity ratings.
DO NOT overload hydraulic systems. The pump relief valve only protects against overloading of the
pump. It does not protect against overloading of the system.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
ALWAYS stand the pump on a stable, level surface during operation.
To protect your warranty, only use the hydraulic oil grade specified in Section 6.2.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
6
3.0 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.
4.0 Oil Specification
Hi-Force tools will use 1 of 2 grades of oil, dependant on the tool. The tools are designed to operate at
temperatures between -20°C and 80°C. Details of the oil used in this product can be found in, Section 6.2
ISO Hydraulic Oil Grade
Temperature Range: Degrees Celcius (°C)
From:
To:
ISO15
-23
44
ISO46
-2
73
4.1 HP-Steel Specifications
Refer to the nameplate on the pump for identification.
Model
Number
Valve
Type
Displacement per
stroke (cm3)
Usable
Oil
Capacity
(litres)
Handle
Effort
(kg)
Weight
(kg)
1st stage
2nd
stage
Single stage pumps for single acting cylinders and tools.
HP110
2-way
2.9
-
1.0
45
5.6
Two stage pumps for single acting cylinders and tools.
HP227
2-way
12.9
2.3
2.3
38
10.5
HP257
2-way
12.9
2.3
4.1
38
15.2
HP227FP*
2-way
12.9
2.3
2.3
38
10.5
HP227FPC**
2-way
12.9
2.3
4.1
38
15.2
*HP227FP comes with a foot operated handle.
**HP227FPC Comes with a foot operated handle, pressure gauge, gauge mounting block and 3 meter
hoses with male coupler.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
7
5.0 Component Identification
1
Oil Reservoir
5
Filler Cap (dipstick attached)
2
Handle
6
Outlet Port 3/8 NPT
3
Transit plug
7
Release Valve
4
Breather
8
Identification plate
5
Figure 5.1: Component Identification (HP110 Model shown)
2
7
4
5
3
1
6
8

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
8
6.0 Installation/Setup
6.1 Before First Use / Preparation
Check for any signs of wear in the pump or connected components.
Unscrew the transit plug (3) and fit the breather (4) this will maximise the oil volume available and
prevent oil reservoir pressure build up.
6.2 Filling the Pump with Fluid - ISO15 grade.
IMPORTANT: Only add fluid to the reservoir when the connected system is fully de-pressurised and
returned to its closed position. Failure to do so will result in the system containing more fluid
than the reservoir can hold.
Fill/top-up the pump as follows: HP110
Stand the pump Head down on a firm, level surface.
Remove the filler cap (5) from the reservoir.
Fill the reservoir with clean, high quality ISO15 hydraulic oil, leaving a small air space of
approximately 1-2cm between the top of the fluid and the filler plug.
Replace the filler cap (5).
Fill/top-up the pump as follows: HP227/HP257
Stand the pump on a firm, level surface.
Remove the transit plug/breather (3/4) from the reservoir.
Fill the reservoir with clean, high quality ISO15 hydraulic oil, leaving a small air space of
approximately 1-2cm between the top of the fluid and the filler plug.
Replace the transit plug/breather (3/4).
6.3 Hydraulic Connections
Remove the hexagon headed plug and make a hydraulic connection to the outlet port (6). This port has a
3/8” NPT femalethread,and the connection should besealed, as appropriate,with a suitable threadsealant.
DO NOT overtighten this fitting. It can cause damage to the pump head or lead to failure
of the fitting at below rated pressure.
When making a connection between two couplers, ensure that these connections are fully connected, with
no thread gap and hand tight only.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
9
To do so: Ensure that all threads are clean with no damage [1] Press the male coupler into the female
coupler, [2] then turn the threaded-collar clockwise (by hand) until the threads are fully engaged.
IMPORTANT: Make sure that all coupler threads are fully engaged.
Only use hoses with a 4:1 safety rating on burst pressure.
6.4 Bleeding Trapped Air from the Hydraulic System
The bleeding of trapped airfrom ahydraulic system must only be performed by qualified
personnel who have been trained and are competent to do so.
The method of air removal will depend on the hydraulic system under test. Safe, effective methods of air
removal, must be established before starting any operation. Pressuretesting with air trappedinthe hydraulic
system can lead to an increased risk to the equipment and the operator.
NOTE: To reduce the likelihood of introducing air into the hydraulic system, make sure that all hoses are
pre-filled with fluid before connecting them to the hydraulic system.
Cylinder and hoses are not always completely filled with oil when new. For safe and efficient operation,
trapped air must be removed from the system. The following procedure must be carried out with the
cylinder/s connected to the pump, but not operating under load.
To remove air from the system, proceed as detailed below:
Make sure the pumps oil filler breather cap is fitted. (if applicable)
With all hydraulic connections made, position thecylinder/s below the level of the
hydraulic pump, as illustrated in figure 5.2.
Using the pump, fully advance and retract the cylinder/tool piston several times
until the operation is smooth. (Refer to the pumps operating
manual for details of pump operation).
Figure 5.2

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
10
7.0 Operation
Hi-Force will not always be aware of what equipment this pump will be used with. It is the responsibility of
the owner and all operators to read, understand and comply with all appropriate safety warnings and
operating instructions relating to the equipment used.
NOTE: Every pump is factory-fitted with an adjustable pressure relief valve. The valve is factory set to the
maximum working pressure of the pump model specified.
This valve can be adjusted by the customer, to any desired pressure within the rating of the pump.
Details for the method of adjustment for this valve are available on request.
NEVER set the pressure relief valve above the rated maximum working
pressure of the pump (as displayed on the specification plate) or above the
maximum pressure for the system.
IMPORTANT: Before use, make sure the reservoir has sufficient capacity for the required operation.
Make sure the fluid level does not drop below the minimum operating level, as this may
cause air to be pumped into the system. Fluid levels can be checked using the dipstick
attached to the reservoir filler cap (4).
Turn the pressure release valve (7) clockwise to close it. (See figure 5.1)
Pressurise the system by operating the pump handle (2) (See figure 5.1)
Only use the pump handle supplied. DO NOT use handle extensions.
NEVER jerk the handle during operation. This makes the pump inefficient and
can cause unexpected over pressurisation. A smooth, steady action produces
the best results and will reduce operator fatigue.
Release the system pressure by slowly opening the pressure release valve (7) anti-clockwise.
(See figure 5.1)
IMPORTANT: After operation, fully return all hydraulic fluid to the pump. Monitor the hydraulic fluid level in
the reservoir to prevent over-filling of the tank.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
11
8.0 Maintenance and Storage
Inspect the pump for damage before and after each use.
Keep hydraulic fluid clean. Change as necessary.
Keep contaminants from entering the system, by fitting dust caps to couplers and blanking off open
ports.
Zero the pump pressure before storing.
Have the pump serviced regularly, by a Hi-Force authorised repair centre.
Replace the transit plug to prevent the entry of moisture and/or dirt into the oil. This will also prevent
any accidental environmental spillage.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
12
9.0 Troubleshooting
Hi-Force HP manually operated hydraulic 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. No delivery of
operating fluid.
a. No oil in the reservoir.
Fill reservoir as per section 5.2
b. Suction valve not seating.
Remove contaminants or have steel balls
replaced.
c. Relief valve sticking or not sealing.
Contact your local Hi-force distributor.
d. Delivery valve failure.
Have steel balls replaced.
2. Handle drops rapidly
on its own.
a. Suction ball not sealing correctly.
With the release valve open, pump fluid
around the pump. This may dislodge the dirt.
If this does not work, contact your local
Hi-Force office/distributor.
3. Handle rises as
pressure drops.
a. Delivery valve not sealing correctly.
With the release valve open, pump fluid
around the pump. This may dislodge the dirt.
If this does not work, contact your local
Hi-Force office/distributor.
4. Handle is hard to
pump in low pressure.
HP227/HP257 only
a. The low pressure relief valve is set
been adjusted to high.
Contact your local
Hi-Force office/distributor.
5. Loss of effective
pumping stroke, and/or
high-pressure building.
a. Air trapped in the pump.
Follow bleeding procedure as per section 5.4
6. erratic pressure
reading on gauge
and/or slight over-
pressurisation
a. Uncontrolled use of the pump
handle.
Follow operation guidance notes in section 6.
If this does not work, contact your local
Hi-Force office/distributor.

Operating Instruction Manual:
OM-HP-STEEL-01
Serial Numbers:
From: DF6685
13
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]
GLOBAL BRAND. LOCAL SERVICE. www.hi-force.com
Hi-Force Global offices: www.hi-force.com/en-uk/hi-force-offices