Porto-Power B65041 Instructions for use

Read this manual and follow all the Safety Rules and Operating Instructions before using this product.
Porto-Power Blackhawk Automotive is a licensed trademark
Operating Instructions & Parts Manual
Model Number Capacity
B65041 20 Ton
Porto-Power Kit
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
!

Figure 1 - Pump and Ram Components
Dust Cover
Oil Filler Screw
Handle Release Valve
Ram Plunger
Hydraulic Hose
Hose Coupler
Ram Coupler
Ram
SAFETY and GENERAL INFORMATION
Save these instructions. For your safety, read and understand the information contained within. The owner and
operator shall have an understanding of this product and safe operating procedures before attempting to use this
product. Instructions and Safety information shall be conveyed in the operators native language before use of this
product is authorized. Make certain that the operator thoroughly understands the inherent dangers associated with
the use and misuse of the product. If any doubt exists as to the safe and proper use of this product as outlined in
this factory authorized manual, remove from service.
Inspect before each use. Do not use if broken, bent, cracked or otherwise damaged parts are noted. If any component
of this product has been or suspected to have been subjected to a shock load (a load dropped suddenly, unexpectedly
upon it), discontinue use until checked out by an Porto-Power Blackhawk Automotive authorized service center.
Owners and operators of this equipment shall be aware that the use and subsequent repair of this equipment may
require special training and knowledge. It is recommended that an annual inspection be done by qualified personnel
and that any missing or damaged parts, decals, warning/safety labels or signs be replaced with factory authorized
replacement parts only. Any component of this Porto-Power Kit that appears to be damaged in any way, is worn
or operates abnormally shall be removed from service immediately until such time as it can be repaired/replaced.
Labels and Operator's Manuals are available from manufacturer.
PRODUCT DESCRIPTION
Porto-Power Kits are designed to be used for pushing, spreading, and pressing of vehicle body panels as well as
various component parts and assemblies. A variety of attachments are included. B65114 is rated at 8,000 PSI,
where B65115 is rated at 10,000 PSI. Rams are rated from 4 to 10 tons respectively.
WARNING: To reduce the risk of personal injury and/or property damage, ensure that the rated working
pressure of each pressurized attachment be equal to or greater than the rated working pressure developed
by the hydraulic pump.
Always check connections before using. Alteration of these products is strictly prohibited. Use only those
adapters and attachments provided and approved by the manufacturer.
Note: when extension tubes and/or offset attachments are used, the rated capacity is always reduced by 50% for
each tube or offset attachment connected. See Parts Section for identification of “offset” attachments.
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3
SPECIFICATIONS
Model Pump
Capacity
(psi)
Ram
Capacity
(ton)
Ram Number of
Attachments
Weight
(lb)
Closed
Height
(in)
Extended
Height
(in)
Effective
area
(in2)
B65041 10,000 20 11.77 16.93 5.14 16 206
! WARNING
Failure to comply with the following warnings
may
result in personal injury as well as
property damage.
• Study, understand, and follow all instructions
provided with and on this device before use.
•The user must be a qualified operator familiar
with the correct operation, maintenance, and use of rams.
Wear protective gear when
operating hydraulic equipment.
This device is NOT suitable for use as support
device! As the load is lifted, use blocking and
cribbing to guard against a falling load. Stay
clear of a lifted load before it is properly supported .
Never rely on hydraulic pressure to support a load.
Crush Hazard. Keep hands and feet
away from ram and workpiece
during operation.
•
Do not exceed rated capacity of the ram or
any equipment in the system. The ram is
designed for a max. pressure of 10,000 psi.
• Do not connect a ram to a pump with higher
pressure rating.
• Do not subject ram to a shock loads, a load
dropped suddenly, causing the system pressure to
exceed rated pressure.
The system operating pressure must not exceed
the pressure rating of the lowest rated component
the system. Install a pressure gauge or other load
measuring instrument to monitor the operating pressure. Burst
hazard exists if hose, connection or any other component in
the system exceed its rated pressure.
Avoid damaging hydraulic hose. Do not allow
hose to kink, twist, curl, crush, cut or bend so
tightly that fluid flow within the hose is blocked or
reduced. Periodically inspect the hose for wear.
Do not pull, position or move ram setup by
the hose. Use carrying handle or other means
of safe transport.
Do not handle pressurized hoses. Never attempt
to grasp a leaking pressurized hose. Ensure to
release the system pressure before disconnecting
hydraulic hose or connections.
Hydraulic fluid can ignite and burn. Keep
hydraulic equipment away from flames and
heat. Excessive heat will soften seals, resulting in
fluid leaks. Heat also weakens hose materials.
Ram must be on a stable base which is able
to support the load while pushing or lifting. Use
shims, friction material or constrains to prevent
slippage of the base or load. Ensure ram is fully engaged
into/onto adapters, extension accessories.
Center load on ram. Distribute load evenly
across the entire saddle surface. Do not
off-center loads on a ram. The load can tip
or the ram can “kick out”.
Never try to disassemble a hydraulic ram,
refer repairs to qualified, authorized personal.
Contact BVA Hydraulics tech service for authorized
service center.
Do not subject hose to sharp objects or
heavy impact.
Hose material or seals must not come in
contact with corrosive materials such as
battery acid, creosote-impregnated objects
and wet paint. Never paint a coupler or hose.
• No alteration shall be made to the ram.
• Use only factory authorized fasteners,
accessories and hydraulic fluid.
Heavy

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BEFORE USE
1. Before using this product, read the owner's manual
completely and familiarize yourself thoroughly with
the product, its components and recognize the
hazards associated with its use.
2. Inspect before each use. Do not use if bent, broken,
leaking or damaged components are noted.
3. Check to ensure that all parts of your kit are included
(see illustration and parts list).
4. Carefully remove the dust caps and plugs from hose
coupler and ram coupler.
5. Connect hose coupler to ram coupler, ensure that
there are no fluid leaks.
6. Locate and open release valve. Close release
valve clockwise and pump handle until ram is fully
extended, then open release valve counter-clockwise
until ram has fully retracted.
7. With ram fully retracted and release valve open, place
pump in horizontal position. Open oil filler screw (on
reservoir body, near the back). This will release air
trapped within the reservoir. Re-tighten the oil filler
screw.
8. If using with air actuated units, an air source of at
least 7.8 CFM @ 110 psi is required.
GENERAL SAFETY INFORMATION
1. Ensure that attachments are fully engaged before
applying load.
2. Ensure that load is centrally applied to attachment or
ram saddle. Do not load off center.
3. Always monitor the force applied to workpiece by
using a load cell and indicator or you may monitor
pressure developed in the ram by using an inline
pressure gauge, then calculate the applied force
using the formula:
F = P x A, where F = lb force, P = pressure in psi,
and A = effective ram area in in2 = 5.14 in2
Refer to Load-Pressure correlation chart on page 9.
If bowing or bending of ram or any attachment occurs
during use, "STOP", release pressure immediately
and reconsider application. Application may not
be compatible with product, a ram kit with a higher
capacity may be needed.
Figure 2 - Horizontal and Vertical position
OPERATION
ALWAYS monitor pressure, load or position
using suitable equipment. Pressure may be
monitored by means of an optional manifold and
gauge. Load may be monitored by means of a load
cell and digital indicator.
Note: Any attachment that is not loaded centrally,
as through the centerline of the ram, is considered
to be “offset”. When extension tubes and/or offset
attachments are used, the rated capacity is always
reduced by 50% for each tube or offset attachment
connected.
1. Pump may be used in horizontal and vertical position
as illustrated on figure 2 below.
2. Locate and close release valve by turning it clockwise
until firmly closed. (Do not over tighten)
3. Operate by pumping handle. This will send fluid
from the pump reservoir into the high pressure hose
assembly and into the ram assembly.
4. Continue pumping until ram reaches desired
position.
NEVER operate pump with release valve
closed and disconnected from application. If
operated in this condition, the hose and connections
become pressurized. This increases burst hazard.
Damage may occur to pump and its components.
5. To Release Pressure on work piece: Slowly, carefully
turn the release valve counter-clockwise until ram
retracts to desired position. Never turn release
valve more than 1/2 full turn. The ram return system
is spring loaded and the release valve system is
metered, allowing controlled retraction of the ram.
!
!

B. Clamp & Pull
C. Spread
(i) Vertical Spread (ii) Horizontal Spread (iii) Hydraulic Spreader
Ram Toe
Ram
Extension Tube
Ram Base
Ram Toe
Ram Plunger Base Hydraulic
Spreader
Chain
(i) Clamp with Pull Ram (ii) Pull with Chain
Chain Pull Plate
Saddle
Ram
Ram Toe
Pull Ram Plunger Base
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Basic Setup
The capacity of the body repair kit can be significantly affected by the number of attachments used and the type of
load applied. The approximate load capacity of each function setup is illustrated below. When two or more extension
tubes are used together, be sure to position the shortest tube further away from the ram.
Note: Not all accessories in the illustrations provided in the Porto-Power Kits.
A. Push & Stretch
25%
Extension Tube ClampRam Extension Tube
Threaded Coupling
Flat Base Threaded Coupling Ram Combination
Head (900)
Extension Tube
(iii) Horizontal Push with Extension
(iv) Horizontal Stretch with Extension
Serrated Saddle
Ram
Ram Base
(i) Vertical Push (ii) Horizontal Push
Flat Base
Ram V-Head
100%
100%
12.5%
25%
25%
100%
25%
0.5 Ton

MAINTENANCE
1. Inspect hoses and connections daily. Replace
damaged components immediately with Porto-Power
Automotive Replacement Parts only.
2. Tighten connections as needed. Use pipe thread
sealing compound when servicing connections.
3. Use only a good grade hydraulic oil. Avoid mixing
different types of fluid and Never use brake fluid,
turbine oil, transmission fluid, motor oil or glycerin.
Improper fluid can cause premature failure of the
ram and the potential for sudden and immediate loss
of load. We recommend Hein-Werner HW93291 or
equivalent.
Adding oil
1. With ram fully lowered, set pump unit in its normal,
level position. Locate and remove oil filler screw.
2. Fill until oil is within 3/8" of the oil filler screw hole
opening, re-install oil filler screw.
Changing oil
For best performance and increased system life, replace
the complete fluid supply at least once per year.
1. With ram fully lowered, remove the oil filler screw
from the pump reservoir as above.
2. Lay the pump on its side and drain the fluid into a
suitable container.
Note: Dispose of hydraulic fluid in accordance with
local regulations.
3. Set pump in its level upright position.
4. Fill with good quality jack oil to within 3/8" of the oil
filler screw hole opening. Reinstall oil filler screw.
Lubrication
A coating of light lubricating oil to pivot points and
hinges will help to prevent rust and assure that pump
assemblies move freely.
Cleaning
Periodically check the pump piston and ram for signs
of rust or corrosion. Clean as needed and wipe with
an oily cloth.
Note: Never use sandpaper or abrasive material on
these surfaces!
Storage
When not in use, store with the pump piston and ram
fully retracted.
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How to remove faulty coupler:
If ram does not retract,:
1. Secure load by other means.
2. Depressurize pump and hose
3. Remove the ram from application.
4. Disconnect and replace with new coupler.
Important: Do not attempt to grasp ram with pliers or
wrench without first wrapping the jaws of such tool with
rags or similar padding.
How to bleed air from system:
1. Place pump at a higher elevation than the hose and
ram as shown in figure 3 below.
2. Operate pump to fully extend and retract the ram 2
or 3 times. The objective is to force the air bubbles
up hill and back to the pump reservoir.
3. To bleed the air from pump reservoir, simply open
the oil filler screw. Re-install after bleeding.
Figure 3 - Illustration to bleed air from system
REPLACEMENT PARTS
(refer to page 8)
Not all components of the porto-power kit are
replacement items, but are illustrated as a convenient
reference of location and position in the assembly
sequence. When ordering parts, give Model
number, serial number and description below.

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TROUBLESHOOTING GUIDE
The following information is intended as an aid in determining if problem exists. Pump and ram should be repaired
only by authorized Porto-Power Service Center. For repair service, contact service center in your area.
Symptom Possible Causes Corrective Action
Erratic action •
Air in system or pump cavitation.
• External leakage in ram.
• Ram sticking or binding.
• Vent the system (refer to figure 3).
• Contact service center.
• Contact service center.
Ramr will not extend, or
respond to pressurized fluid
•
Overload condition.
• Loose/Faulty couplers.
• Oil level in pump is low.
• Remedy overload condition.
• Tighten/Replace couplers.
• Fill and bleed the system.
Ram extend only partially • Oil level in pump is low.
•
Overload condition.
• Ram is sticking or binding.
• Pump malfunction.
• Fill and bleed the system.
• Remedy overload condition.
• Contact service center.
• Contact service center.
Ram move slower than normal • Loose connection or coupler.
•
Restricted hydraulic line or fitting.
• Pump not working correctly.
• Ram seals leaking.
• Tighten connection or coupler.
• Clean and replace if damaged.
• Check pump’s operating
instructions.
• Contact service center.
Ram responds to pressurized
fluid, but system does not maintain
pressure
• Overload condition.
• Pump malfunctioning.
• Ram seals leaking.
• Remedy overload condition.
• Contact service center.
• Contact service center.
Oil leaking from ram • Worn or damaged seals. • Contact service center.
Ram will not retract or retracts
slower than normal
• Malfunctioning coupler, damaged
application.
• Pump reservoir overfilled.
• Ram damage internally.
•Secure load by other means.
Depressurize pump and hoses,
remove application and replace
coupler.
•Secure load by other means.
Depressurize pump and hoses,
remove application, then drain
fluid to proper level.
• Contact service center.
Poor performance • Oil level in pump is low.
• Air trapped in system.
• Ensure proper oil level.
• Vent the system (refer to figure 3).

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Model No. B65041
Figure 4 - Replacement Parts Illustration for Model B65041
Item Part# Description Qty.
1 B65073 Wood Chest 1
2 B65775 Chain Pull Plate 1
3 B65778 Ram Base 1
4 B65779 Plunger Base 1
5 B65774 Ram Toe (offset) 1
6 B97518 8’ chain w/hook 1
7 B65772 V Head 1
8 B65773 Wedge Head 1
9 B65776 Threaded Coupling 3
10 B65771 Serrated Saddle 2
11 B65770 Connector 1
12 B65760 3” Extension Tube 1
13 B65762 5” Extension Tube 1
14 B65764 10” Extension Tube 1
15 B65766 18” extension tube 1
16 B65768 30” Extension Tube 1
17 B65740 Ram 1
18 B65582 Female Coupler (3/8” NPTF) 1
19 H18-4-1700-307 Handle 1
20 H18-4-4000-102 Air Vent Plug 1
21 B65593 6’ Hydraulic Hose w/ half coupler 1
22 B65421 2-Speed Hand Pump 1
- H18-3-9902-101 Repair Kit for Ram (not shown) -
- H25-3-9903-100 Repair Kit for Hand Pump (not shown) -

Load - Pressure Correlation For Model B65041
Always monitor the force applied to workpiece by using a load cell and indicator or you may monitor pressure
developed in the ram by using an inline pressure gauge, then calculate the applied force using the formula:
F = P x A
For model B65041, A = 5.14 in² ;
Example1
Pressure required to lift 14,000 lb. load:
Pressure = 14,000 lb / 5.15 in² = 2,720 psi
where F = Force/ Load (lb);
P = Hydraulic working pressure (psi) and;
A = Ram effective area (in²)
Load
(lb)
Pressure of 20 Ton Ram,
where A = 5.14 in2
(psi)
1,000 200
2,000 400
4,000 800
6,000 1200
8,000 1600
10,000 1950
12,000 2350
14,000 2750
16,000 3150
18,000 3500
20,000 3900
22,000 4300
24,000 4700
26,000 5050
28,000 5450
30,000 5850
32,000 6250
34,000 6600
36,000 7000
38,000 7400
40,000 7800
When it comes to quality automotive tools, Blackhawk Automotive is the brand you can depend on.