Hi-Force HPF Series Instruction Manual

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
1
OPERATING INSTRUCTION MANUAL
HPF PUMP | ELECTRIC DRIVEN
GENERAL DUTY, MEDIUM FLOW
Hi-Force HPF Pump series ElectricDriven Hydraulic Pumps are designedto operate the Hi-Force Hydraulic
press frame range with a maximum working pressure of 700Bar. This manual applies to the Hi-Force HPF
Pump series, Electric Driven Hydraulic Pumps. It contains the latest product information available at the
time of publication and approval. 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-HPF PUMP-01
From Serial Number:
BS8412
2
Table of Contents
1.0 Inspection upon Receipt......................................................................................... 3
2.0 Safety Precautions.................................................................................................. 3
2.1 Introduction ........................................................................................................3
2.2 Work Area Safety................................................................................................3
2.3 General Hydraulic System Safety Precautions.................................................3
2.4 Hydraulic Pump Specific Safety Precautions...................................................5
3.0 Declaration of Incorporation / Conformity............................................................ 5
4.0 Component Identification....................................................................................... 6
5.0 Installation/Setup .................................................................................................... 8
5.1 Before First Use.................................................................................................. 8
5.2 Filling the Pump with Oil....................................................................................9
5.3 Electrical Connection.........................................................................................9
5.4 Bleeding Trapped Air from the System.............................................................9
6.0 Operation............................................................................................................... 10
6.1 Setting the Press Operating Capacity.............................................................10
6.2 Pumps with Manual Valves.............................................................................. 11
6.3 Pumps with Solenoid Valves...........................................................................12
7.0 Maintenance .......................................................................................................... 12
8.0 Specifications........................................................................................................ 13
8.1 HPF Pump Specifications ................................................................................13
8.2 HPF Pump Electrical Characteristics.............................................................. 14
9.0 Troubleshooting.................................................................................................... 14
NOTE: Images contained within this document are for illustrative purposes ONLY.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
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 doubton the 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.
2.2 Work Area Safety
•Keep work areas clean and well lit. Cluttered spaces and inadequate lighting can result in
unnecessary accidents.
•Keep unauthorised persons at a safe distance from the task site.
•NEVER use the tools in the presence of inflammable liquids, gases or material.
•DO NOT usethe tools inpotentially explosive atmospheres (ATEX) this tool is NOT ATEX approved.
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,
safety glasses/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 handle a pressurised hydraulic hose. Hydraulic oil 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.
•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.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
4
•Only use hydraulic cylinders in a complete and tested, coupled system. NEVER attempt to use a
cylinder that is not correctly coupled to its operational pump. NEVER pressurise an uncoupled
coupler/s.
•NEVER attempt to disconnect a hose from a hydraulic system until the systems 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 to remove
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, as the coupler could
become a projectile and hit operatives in the working area.
•Loosening a coupler under pressure can result in the escape of hydraulic oil 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 oil at high pressure, which could cause
significant injury or death.
•Immediately replace any worn or damaged parts using genuine Hi-Force parts only.
•DO NOT remove any labels from the product. Replace any damaged or unreadable label
immediately.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•NEVER lift or carry any hydraulic components by the hose or hoses connected to them.
•Avoid damaging hydraulic hose. ALWAYS route hoses to ensure that theyarefreefrom sharpbends
and kinks. Using a bent or kinked hose will result in severe back-pressure, which can lead to hose
failure.
•ALWAYS operate the system under no-load conditions before the actual operation, to ensure there
is no air trapped in the hydraulic circuit.
•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.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
5
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 cylinder. Hi-Force manufactures its
hydraulic pumps to operate at a maximum working pressure of 700 BAR (10,000 PSI). DO NOT
connect a cylinder/tool with a lower pressure capacity rating to any Hi-Force pump of this model
series.
•This pump is not suitable for work which takes place in explosive environments.
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.
•BEWARE of hot surfaces on the motor. Do not obstruct the flow of cooling air around the motor.
•To protect your warranty, only use the hydraulic oil grade as specified in Section 5.2.
3.0 Declaration of Incorporation / Conformity
Hi-Force declares that this product has been tested and complies with the standards set out in the relevant
EU directives. The EU Declaration of Incorporation / Conformity is included as Annex A to this instruction
document and is supplied with all shipments of this product.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
6
4.0 Component Identification
1
On/Off Switches
8
Hydraulic Oil Level Gauge
2
Hydraulic Service Connections*
9
Hydraulic Oil Drain Plug
3
Directional Control Valve **
-
4
Motor ***
-
5
Adjustable Pressure Relief Valve
-
6
Oil Reservoir
-
7
Oil Filler Breather Cap with Dipstick
-
* One or two ports, depending on valve type.
** If fitted (Type will vary)
*** Motors will vary depending on supply requirements
Figure 4.1: Component Identification

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
7
Figure 4.2: Component Identification

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
8
5.0 Installation/Setup
5.1 Before First Use
1. Immediately after unpacking, examine the pump for signs of transit damage and if found contact the
shipping company.
2. Remove the temporary transit fitting / plate which is fitted in the position of the oil filler breather cap
(7) and fit the oil filler breather cap which is packed separately.
3. Establish the oil level in the oil reservoir using the level gauges (8). 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 (See section 5.2). If the pump was supplied full of oil, no further action is
required.
IMPORTANT: Running the pump without oil will result in damage.
CAUTION: Ensure the oil level does not fall below the minimum level as shown by the level gauge
(8) or the oil level on the dipstick (7) measures more than 180mm from the underside
of the filler breather cap (7).
4. Ensure the lever of the hydraulic directional control valve (3) is set to the neutral position: This is
fully anti-clockwise for models with a 2-way valve, or the central position for models with a 3-way or
4-way valve.
5. Make sure that the voltage indicated on the motorrating plate corresponds with the available supply.
6. Connect the motor to required power source. (See section 5.3)
7. Check the direction of rotation of the motor by pressing the green ‘ON’ button (1), then immediately
pressing the red ‘OFF’ button. While doing this observe the motor fan. The motor should run in a
clockwise direction when viewed from above. If the motor turns anti-clockwise, check the wiring of
the electrical connector.
CAUTION: Running the pump with the motor turning in the incorrect direction may damage the low-
pressure pump unit.
8. The pump is fitted with an adjustable pressure relief valve (5) to restrict the output capacity to any
desired value, up to the maximum working capacity of the press. (See section 6.1)

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
9
5.2 Filling the Pump with Oil
IMPORTANT: The HPF series of hydraulic pumps use ISO46 Grade Hydraulic Oil.
•Remove the oil filler breather cap dipstick assembly (7).
•Fill the reservoir with clean, high quality ISO46 hydraulic oil via the filler breather until the oil level
reaches the upper-level indicator (8) or until the oil level on the dipstick (7) measures approximately
90mm from the underside of the filler breather cap (7).
•Replace the oil filler breather cap dipstick assembly (7).
NOTE: More hydraulic oil can be added to the reservoir to assist with cooling if required, but NEVER more
than 25mm below the tank lid.
IMPORTANT: Only add oil to the reservoir when the connected cylinder is fully retracted. Failure to do so
will result in the system containing more oil than the reservoir can hold.
5.3 Electrical Connection
Before making an electrical connection, refer to the data plate located on the motor (4) for voltage and
current requirements (also refer to section 8.2). Once satisfied the supply is suitable, an electrical
connection can be made.
NOTE: Supply voltages vary from country to country. Hi-Force pumps will operate within the normal voltage
tolerance ranges, but in extreme cases where they are operated for long periods at high pressures
and in low voltage conditions, the motor may overheat and shut down.
NOTE: A common cause of pump failure is the use of long extension cables to connect the pump to the
mains supply. The pump should be situated as close as possible to the wall outlet.
5.4 Bleeding Trapped Air from the System
The bleeding of trapped air from a hydraulic system must only be performed by
qualified personnel who have been trained and are competent to do so.
Cylinders, 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
connected to the pump, but not operating under load.
To remove air from the system, proceed as detailed below:
•Make sure the oil filler breather cap dipstick assembly (7) is fitted.
•Single-Acting: Using the pump, fully advance the cylinder piston and allow to return under spring
force. Repeat several times untiltheoperation is smooth. (Seesection 6 for details of pump operation).
•Double-Acting: Using the pump, fully advance and retract the cylinder piston several times until the
operation is smooth. (See section 6 for details of pump operation).

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
10
6.0 Operation
Prior to operation 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 being used.
6.1 Setting the Press Operating Capacity
NOTE: When setting the press operating capacity, never exceed the maximum operating capacity of the
press frame. The tonnage will be clearly marked on the press frame name plate.
The procedure for setting the operating capacity is as follows:
•Turn the pump on by pressing the green ‘ON’ button (1)
•Place the pump in advance mode.
For 2-Way manual valves, turn the level fully clockwise (See figure 6.1).
For 3 & 4-Way manual valves, turn the lever fully anti-clockwise (See figure 6.2).
For solenoid valves, press and hold the ‘advance’ button on the pendant.
Increasing the capacity
•Release the locking feature and turn the pressure release valve slowly (5) clockwise until the
required operating capacity is read on the press gauge.
•Engage the locking feature to lock the pressure relief valve at the desired operating capacity.
Decreasing the capacity
•Release the locking feature and turn the pressure release valve (5) anti-clockwise until a tonnage
value lower than the required tonnage is read on the press gauge.
•Turn the pressure release valve (5) slowly clockwise until the required operating capacity is read on
the press gauge.
•Engage the locking feature to lock the pressure relief valve at the required operating capacity.
NOTE: ALWAYS adjust up to the desired capacity and NEVER down. When setting the press to a lower
capacity, reduce below the desired value (anti-clockwise) and then increase back up to the desired
value (clockwise) as read on the press gauge.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
11
6.2 Pumps with Manual Valves
1. Set the adjustable pressure relief valve (5) if required. See section 6.1 for details.
2. Turn the motor on by pressing the green ‘ON’ button (1).
3. Operate the directional control valve (3) to control the cylinder.
For pumps with a 2-way valve: Turning the lever fully clockwise will supply oil to the service port and
advance the cylinder. Turning the lever anti-clockwise will retract the cylinder. (See figure 6.1)
For pumps with a 3-way or 4-way valve: Mid position is the load hold position. Turning the lever so
that it is above the service port (anti-clockwise) will supply oil to the service port and advance the
cylinder. Moving the lever away from the service port (clockwise) will connect the service port to the
tank and retract the cylinder. (See figure 6.2)
Figure 6.1: 2-Way Manual Valve
Figure 6.2: 3 & 4-Way Manual Valves
NOTE: 2nd Port only on 4-Way Valves

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
12
6.3 Pumps with Solenoid Valves
1. Set the adjustable pressure relief valve (5) if required. See section 6.1 for details.
2. Turn the motor on by pressing the green ‘ON’ button (1).
3. Press and hold the ‘advance’ button on the pendant to advance the cylinder. Release the button
once the cylinder has been advanced the desired amount. The cylinder will remain in the load
holding position when the button is released.
4. Press and hold the ‘retract’ button to retract the cylinder. Release the button once the cylinder has
been retracted.
NOTE: After operation of the press, it is good practice to return the cylinder piston
7.0 Maintenance
•Inspect the pump for damage after each use.
•Change the oil every 500 working hours using high quality ISO46 hydraulic oil.
•Before storing ensure the cylinder piston has been fully retracted.
•Have the pump serviced regularly by a Hi-Force authorised repair centre.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
13
8.0 Specifications
An average A-Weighted sound pressure level of 75dB was measured for undefined workspaces, as per EU
Directive 2006/42/EC Section 1.7.4.2 (u).
8.1 HPF Pump Specifications
Refer to the nameplate on the pump for model identification.
Refer to section 8.2 for motor electrical characteristics.
HPF │ELECTRIC DRIVEN PUMPS –GENERAL DUTY, MEDIUM FLOW
Model
Number
Valve
Type
Oil
Capacity
Maximum Flow Rate
(litres/minute)
Motor
Voltage
Weight
(litres)
1st Stage
2nd Stage
(kg)
HPF207311
3-Way
10
7
0.65
110V 50 Hz-1Ph
50.0
HPF207311H
3-Way
10
7
0.65
120V 60 Hz-1Ph
50.0
HPF207311HS
3-Way
10
7
0.65
120V 60 Hz-1Ph
50.0
HPF207311S
3-Way
10
7
0.65
110V 50 Hz-1Ph
50.0
HPF207312
3-Way
10
7
0.65
230V 50 Hz-1Ph
50.0
HPF207312H
3-Way
10
7
0.65
220V 60 Hz-1Ph
50.0
HPF207312HS
3-Way
10
7
0.65
220V 60 Hz-1Ph
50.0
HPF207312S
3-Way
10
7
0.65
230V 50 Hz-1Ph
50.0
HPF207314
3-Way
10
7
0.65
400V 50 Hz/460V
60 Hz-3Ph
50.0
HPF207314S
3-Way
10
7
0.65
400V 50 Hz/460V
60 Hz-3Ph
50.0
HPF207411
4-Way
10
7
0.65
110V 50 Hz-1Ph
50.0
HPF207411H
4-Way
10
7
0.65
120V 60 Hz-1Ph
50.0
HPF207411HS
4-Way
10
7
0.65
120V 60 Hz-1Ph
50.0
HPF207411S
4-Way
10
7
0.65
110V 50 Hz-1Ph
50.0
HPF207412
4-Way
10
7
0.65
230V 50 Hz-1Ph
50.0
HPF207412H
4-Way
10
7
0.65
220V 60 Hz-1Ph
50.0
HPF207412HS
4-Way
10
7
0.65
220V 60 Hz-1Ph
50.0
HPF207412S
4-Way
10
7
0.65
230V 50 Hz-1Ph
50.0
HPF207414
4-Way
10
7
0.65
400V 50 Hz/460V
60 Hz-3Ph
50.0
HPF207414S
4-Way
10
7
0.65
400 50 Hz/460V
60 Hz-3Ph
50.0

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
14
8.2 HPF Pump Electrical Characteristics
Refer to the nameplate on the pump for model identification.
9.0 Troubleshooting
Hi-Force HPF electric driven 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.
TROUBLE SHOOTING GUIDE
Problem
Possible Cause
Solution
1. Pump will not start
a. Power not connected.
Connect power.
b. Damaged power cord.
Repair or replace power cord.
c. Circuit breaker tripped.
i. Reset Circuit breaker.
ii. Ensure breaker is adequately rated.
d. Damaged pendant.
Contact your local Hi-Force office/distributor.
e. Blown fuse.
Replace blown fuse.
f. Burnt out motor.
Contact your local Hi-Force office/distributor.
2. Motor stalls before full
operating pressure is
reached.
a. Low supply voltage.
i. Use heavier gauge extension cord.
ii. Turn off excess electrical loads.
3. Pump runs but will not
build up to full operating
pressure.
a. Reservoir breather has not been
installed.
Remove transit plate and install reservoir
breather as per section 5.1
b. Low oil level.
Add oil as per section 5.2.
c. Adjustable relief valve incorrectly set.
Adjust relief valve pressure as per
section 6.1.
d. External oil leak in system.
Contact your local Hi-Force office/distributor.
4. Noisy Operation
a. Air trapped in the system.
Bleed air from the system as per section 5.4
b. Low oil level
Add oil as per section 5.2
c. Reservoir breather has not been
installed.
Remove transit plate and install reservoir
breather as per section 5.1
Motor
Voltage
Motor
Frequency
Motor
Current
Motor
Output
110V-1Ph
50 Hz
16 A
1.1 kW
120V-1Ph
60 Hz
23 A
1.8 kW
230V-1Ph
50 Hz
9.3 - 9.6 A
1.5 kW
220V-1Ph
60 Hz
12.7 A
1.8 kW
400V-3Ph
50 Hz
3.6 A
1.5 kW
460V-3Ph
60 Hz
3.2 A
1.5 kW

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
15
5. Pump builds to full
pressure, but cylinder
does not operate.
a. Advance or return flow line to
cylinder restricted or blocked.
Check couplers for full engagement.
6. Pump running hot.
a. Low oil level.
Add oil as per section 5.2.
b. Advance or retract flow restricted.
Check couplers for full engagement.
c. High pressure leakage at pump.
Contact your local Hi-Force office/distributor.
7. Cylinder not
functioning correctly.
a. Cylinder incorrectly connected to
pump.
Check for correct system setup. Check
couplers for full engagement
b. Pump solenoid faulty.
Contact your local Hi-Force office/distributor.
c. Cylinder fault.
See cylinder troubleshooting guide or contact
your local Hi-Force office/distributor.
d. Low oil level
Add oil as per section 5.2.
e. Air trapped in the system
Bleed air from the system as per section 5.4
8. Cylinder will not
retract.
a. Valve malfunction.
Contact your local Hi-Force office/distributor.
b. Return flow line restricted or
blocked.
i. Check couplers for full engagement.
ii. Run motor while retracting cylinder.
9. Gauge displays no
capacity reading.
a. Faulty gauge.
Contact your local Hi-Force office/distributor
b. Pump will not build pressure.
See problem 3 above.

Operating Instruction Manual:
OM-HPF PUMP-01
From Serial Number:
BS8412
16
Head Office:
Hi-Force Limited
Prospect Way, Daventry
Northamptonshire NN11 8PL
United Kingdom
Tel: + 44 1327 301000 | Fax: + 44 1327 706555
www.hi-force.com
Regional Offices:
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