Reliable Equipment REL-HPU-2000 Manual

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DISTRIBUTED BY
OPERATORS’ GUIDE
REL-4000SA Manual 03-11
TheREL-HPU-2000providesallthepower
needed to operate any standard Type I or
Type II hydraulic equipment.
The Briggs & Stratton 18 hp gasoline engine
delivers 2,000 psi of hydraulic pressure at
either selected flow setting of 5 or 8 GPM.
REL-HPU-2000
2,000 PSI-POWER UNIT
18HPGasoline/Hydraulic
WARNING
All information found in this guide
must be read and understood
before use or testing of tool.
Failure to read and understand warnings
and safe handling instructions could result in
severe personal injury and or death.
NOTICE
Sizes, weights and tool specifications
listed in this manual are subject to
change without notice.
Please consult factory for information
and updates.

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THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.
Safety of user and others may be in jeopardy if these instructions
are not read and understood.
WARNING
The information in this manual is intended to guide the user
in the use and application of this tool. It is not intended as
a substitute for proper training and experience in safe work
practices for this type of equipment.
Consult your supervisor or safety personnel if you have any
questions regarding the safe operation of this tool.
DISTRIBUTED BY
Failure to observe these warnings could result in serious injury or death.

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TABLE OF CONTENTS
REGISTRATION
UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.
COMPANY _____________________________________________________________
ADDRESS _____________________________________________________________
________________________________________________________________________
PHONE _______________________ FAX____________________________________
SERIAL NUMBER _______________________________________________________
DATE OF PURCHASE ___________________________________________________
DEALER NAME _________________________________________________________
DISTRIBUTOR INFORMATION ................................................................ 2
TABLE OF CONTENTS ............................................................................. 3
REGISTRATION ........................................................................................ 3
DESCRIPTION .......................................................................................... 4
TOOL SPECIFICATIONS .......................................................................... 4
SAFETY INFORMATION AND WARNINGS ...........................................5-8
MAJOR COMPONENTS ILLUSTRATION ................................................. 9
OPERATING INSTRUCTIONS ...........................................................10-11
DAILY MAINTENANCE ............................................................................ 12
HYDRAULIC FLUIDS .............................................................................. 12
LABELS & BATTERY .............................................................................. 13
GENERAL MAINTENANCE .................................................................... 14
TROUBLESHOOTING & REPAIR INTRO ................................................ 15
ENGINE ASSEMBLY - DRAWING & PARTS LIST ..............................16-19
FRAME ASSEMBLY - DRAWING & PARTS LIST ...............................20-21
HOSES FITTINGS & CLAMPS - DRAWING & PARTS LIST.................... 22
WIRING - DIAGRAM & PARTS LIST........................................................ 23
VISUAL WARNINGS, CONTACT INFORMATION & USER NOTES ........ 24

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RELIABLE EQUIPMENT & SERVICE CO., INC.
92 STEAMWHISTLE DRIVE • IVYLAND, PA 18974
TOLL FREE:
800-966-3530 • FAX: [phone]
Visit us on the web at www.Reliable-Equip.com
REL-HPU-2000
2,000 PSI - PUMP
18 HP Gasoline/Hydraulic
SPECIFICATIONS
Engine: Briggs & Stratton 18 HP
Vanguard - V-Twin
Flow Range: 5-8 GPM 20or30lpm
Operating Pressure: 2,000 PSI 140 bar
Circuit Type: Open Center
Hydraulic Reservoir: 3 Gallons 11 liters
Fuel Tank: 7 Gallons 26.5 liters
Height: 29 inches 73.7 cm
Length (Handle Down): 35 inches 89 cm
Width: 21.5 inches 54.6 cm
Weight 330 lbs. 150 kg
The REL-HPU-2000 provides all the
power needed to operate any standard
Type I or Type II hydraulic equipment.
The Briggs & Stratton 18 hp gasoline
enginedelivers 2,000psi ofhydraulic
pressure at either user selected flow
setting of 5 or 8 gallons per minute.
Automatic throttling feature ensures
consistent performance throughout
tool operation.
The oil cooler with high speed blower
reduces operating temperatures and
related system wear.
The electric start, flow selector, and
control valve are located on the front
panel for operator convenience, while
the choke, fuel fill, and hour meter
remain within easy reach.
Theeasyaccessbatterycompartment
located at the front of the unit holds
a 35-Ah maintenance-free battery.
The convertible handle and 12 inch
pneumatic tires provide ease of
movement into hard to access areas.
Meets HTMA
performance standards.

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WARNING
BEFORE USING THIS TOOL, READ THE WARNINGS
and the recommended practices described in this manual.
Failure by the operator to read and fully understand these
warnings will leave this person unqualified to use and
operate this tool. Property damage, severe personal injury,
and/or death could result by not following these warnings.
Eye
Protection
These warnings will appear in appropriate locations when they are pertinent to the
particular subject being shown. Read each one carefully and follow them strictly.
WARNING
Always wear eye protection to avoid
injury from flying debris or hydraulic
oil leaks. Failure to do so can result in
serious personal injury.
Hard Hat
WARNING
Always wear a hard hat to avoid injury
from falling debris. Failure to do so can
result in serious personal injury.
Hearing
Protection
WARNING
Always wear hearing protection,
to avoid hearing loss due to long
term exposure to high noise levels.
Foot
Protection
Always wear foot protection.
Failure to do so can result in serious
personal injury.
WARNING
WARNING
Protective
Gloves
Always wear protective gloves & cloths.
Failure to do so can result in serious
personal injury.
WARNING
Skin
Irritation
Hydraulic oil may cause irritation.
Use care to prevent contact with skin.
In case of accidental contact, wash
affected area immediately

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WARNING
HYDRAULIC POWER SUPPLY
DO NOT attempt to make any changes to any of the component
parts or accessories when connected to the power source.
DO NOT adjust, inspect, or clean any tool whilethetoolisconnected
to the power source. The tool could accidentally start up and cause
serious injury.
DO NOT lock the tool in the On Position. In an emergency, serious
damage or injury could occur during the time required to stop the tool.
SAFE OPERATION & CARE
USE THIS TOOL FOR ITS INTENDED PURPOSE ONLY
Any other use can result in injury or property damage.
INSPECT TOOL BEFORE USE. Replace any worn, damaged
or missing parts. A damaged or improperly assembled tool may
malfunction, injuring operator and/or nearby personnel.
INSPECT HYDRAULIC HOSES AND COUPLINGS before each
use. Repair or replace if any cracking, leakage, wear or damage is
found. Worn or damaged hoses may fail resulting in personal injury
or property damage.
CLEAR WORK AREA of all bystanders and unnecessary personnel
before operating this tool.
KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.
Failure to observe this warning could result in serious injury.
DANGER
OIL INJECTION INJURY
Hydraulic oil or fluid under the skin is a serious injury. Oil under
pressure can penetrate the skin and may cause dismemberment
or loss of life. Seek medical assistance immediately if such an
injury should occur.
Always wear safety gloves, eye protection and all required safety
equipment when operating or handling this tool.
DO NOT use fingers or hands to attempt to locate a leak.
DO NOT handle hoses or couplers while system is pressurized.
NEVER open or service the system before depressurizing.
WARNING

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HOSES AND FITTINGS
There exists the potential for shock in using anything other than
certified non-conductive hoses and hydraulic oil with dielectric
properties,when using system components nearenergizedelectrical
lines.Failuretorecognizetheseconditionscouldcause electrocution.
Hoses and fittings used with this tool must comply with S.A.E. J1273 which
covers recommended practice for selection, installation, and maintenance of hose and
hose assemblies. The correct hoses and fittings are available from your supplier.
WARNING: Failure tocomplywiththesewarningscouldresultinseverebodilyinjuryordeath.
WARNING
UNIT/HOSE CONNECTIONS
ALWAYS DISCONNECT pump/power source and turn the key to the
OFF position before connecting or disconnecting any components.
ALWAYS DEPRESSURIZE hydraulic system, before slowly
disconnecting this unit or any of the systems components.
ALWAYSTIGHTENCOUPLINGSCOMPLETELY.Looseorimproperly
tightenedcouplingswillnotallowfluidtopassthroughthehosecreating
a blockage in the supply or return line.
ALWAYS INSPECT HOSESAND CONNECTORS beforeconnection
to tool. Replace or repair if any leakage is evident. Leakage is a sign
of deterioration in component parts.
Connect hoses and confirm proper flow direction to & from tool.
WARNING
SERIOUS BURN HAZARD
HOTSURFACES&EXHAUSTMAYCAUSESERIOUSBURNINJURY
The hydraulic cylinder may be hot during and after operation.
CAUTION: HYDRAULIC FLUID MAY CAUSE SERIOUS BURNS
Never disconnect tool, hoses, or fittings while the hydraulic power
source is running or if the hydraulic fluid is hot.
NEVER add fuel to the power unit while the unit is running or hot.
WARNING
IF YOU HAVE ANY QUESTIONS REGARDING THE SAFE USE
AND/OR OPERATION OF THIS TOOL, CONSULT YOUR AREA SUPERVISOR,
OR CONTACT RELIABLE EQUIPMENT AT 800-966-3530

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GENERAL SAFETY
USEALLAPPROPRIATEANDAPPLICABLEPERSONALSAFETYEQUIPMENT
as required by the operating company.
NEVER OPERATE THE REL-HPU-2000 POWER UNIT IN A CLOSED SPACE
ALWAYS INSPECT TOOL for wear or deterioration or damage every day.
Worn or damaged parts may cause malfunction of tool or unsafe circumstance.
KEEPALL BODY PARTS AWAY FROM WORKING PARTS OF THE POWER UNIT.
HANDS MUST BE OUTSIDE DANGER ZONES BEFOREACTIVATING TOOLS
MAKESURETHEREISNOPERSONINCLOSEPROXIMITYtoyouorthetoolwho
couldbeinjuredbyanyoperationbeingperformed,toolmalfunctionorflyingdebris.
DONOTOVEREXTEND yourposition byoverreachingorunbalancingthefooting
necessary to maintain physical control of your body.
ALWAYS MAINTAIN a firm grip on the tool to avoid loss of control during an
operation, causing property damage, serious injury or death.
USE THIS TOOL FOR THE MANUFACTURERS’INTENDED PURPOSE ONLY.
OBSERVE CLOSELYALL SAFETYRULES FORAPARTICULAR JOB CLASS
ELECTRICAL SHOCK HAZARD
Always wear and use the necessary clothing, equipment and
safety practices to protect against electrical shock. Failure to
follow these rules can result in serious personal injury or death.
WARNING
WARNING
COMBUSTION HAZARD
NEVERaddfueltothepowerunitwhiletheunitisrunningorhot.
DO NOT operate the power unit if gasoline odor is present.
DO NOT use the power unit around flammable solvents.
DO NOT operate power unit within 3.3 ft. (1 M) of buildings,
obstructions or other flammable objects.
ALLOW POWER UNIT TO COOL completely before storing.

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HANDLE, FOLDING
HANDLE RELEASE
FILL CAP, GASOLINE
BOLT, BATTERY COVER
PNEUMATIC
TIRES
FRAME
OIL CHECK
HANDLE,
LOWER LIFT
COOLER GUARD
FILL CAP, HYDRAULIC FLUID
TANK, HYDRAULIC FLUID
GRILL, BLOWER
TANK, GASOLINE
BATTERY COVER
FOOT
FILTER,
ENGINE OIL
FILTER,
HYDRAULIC
FLUID
REL-HPU-2000
MAJOR COMPONENTS - CONTROL SIDE
18 HP -BRIGGS ENGINE
MOTOR SIDE
CONTROL
PANEL
RELIEF
VALVE

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REL-HPU-2000 OPERATION
NEVER OPERATE THE REL-HPU-2000 POWER UNIT IN A CLOSED SPACE
Inhalation of exhaust fumes may be fatal.
Do not use this tool under unsafe working conditions or locations.
Read entire manual prior to operation of this tool.
(Refer to all safety recommendations and warnings)
The manufacturers manual for the operation and care of the gasoline engine has
beenincludedforyourreference.(Refertoallsafetyrecommendationsandwarnings)
Observeallsafetyprecautions&proceduresrequiredbytheoperatingcompany.
Familiarize yourself with the requirements of the application
and the safe operation of any connected tool.
Alwayscheck EngineOil level beforestartingPowerUnit.(seepage11-OilCheck)
Check Fuel level. (see page 12 - Fill Cap) Fill with unleaded gasoline ONLY.
CAUTION!DONOTCONFUSETHEGASOLINEANDTHEHYDRAULICFLUIDTANKS.
CheckHydraulicFluidLevelbeforebeginningoperation(refertoDailyMaintenance)
Connect alowpressurehydraulictooltoahose assembly suitedtotheapplication.
A hose, rated to 2,500 psi/72 bar, with a 4 to 1 Safety Factor is recommended.
Hose length may vary. Use a length of hose that will not restrict free movement,
or pose any hazard to the operator or other personnel on the work site.
Hoseassemblyshouldincludeflushfacequickdisconnectcouplersasrecommended
by the HTMA. (Hydraulic Tool ManufacturersAssociation)
Connect the hose assembly to the pressure port and return port connections
on the front control panel of the power unit.
DO NOT attempt to reverse tool rotation or operation by changing direction of flow.
WARNING
Operation/Safetymethodsmayvaryinaccordancewiththe
workingguidelinesestablishedbyeachutilityorcontractor.
For your own safety, ensure that you fully comply with
all safe operation guidelines required by your employer.
Consultyourtrainingorsafetypersonnelorsupervisorasneeded.