Durapac DHS-5 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia

sales@absoluteequipment.com.au –Phone: +61 7 3865 4006 –Fax: +61 7 3102 6288

Maximum Operating Pressure –700 bar

Instruction Manual

Hydraulic Remote Spreaders

Model –DHS-5

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 2 of 9

This is a safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid injury or death

1.0 Product Information

DURAPAC –Hydraulic Remote Spreaders are engineered to meet Industrial Standards for

Performance and Safety. The DHS-5 model is a small, light and powerful precision tool that

generates 5 tons of spreading force at the feet and has a spring return cylinder. The spreader

features parallel opening jaws that will not drift away or creep down. It is a high strength steel

construction that is designed for applications such as flange spreading.

5 ton spreading force

2.3-76 mm spreading capacity

Jaws open parallel

Will not drift away or creep down

All metal construction

Special skill, knowledge and training may be required for a specific task and the product may not be

suitable for all jobs. The user must ultimately make the decision regarding suitability of the product

for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac

representative if you are unsure of your spreader’s suitability for a particular application.

2.0 Receiving Instructions

It is recommended prior to use that an inspection be done by qualified personnel and that any

missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac

authorised replacement parts only. Any spreader that appears to be damaged in any way, is worn,

leaking or operates abnormally should be removed from service immediately until such time as

repairs can be made. Any spreader that has been or suspected to have been subject to a shock load

should be removed from service immediately until inspected by a Durapac authorised service centre.

Owners and operators of this equipment should be aware that the use and subsequent repair of this

equipment may require specialised training and knowledge.

3.0 Safety

Save these instructions. For your safety, read and understand the information contained within. The

owner and operator should have an understanding of this product and safe operating procedures

before attempting to use this product. Instructions and safety information should be conveyed in the

operator's native language before use of this product is authorised. 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 authorised

manual, remove from service immediately.

DANGER:

To avoid personal injury keep hands and feet away from work area during operation

Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin

causing serious injury. If oil is injected under the skin, see a doctor immediately

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 3 of 9

Stay clear of loads supported by hydraulics. A spreader, when used as a load lifting

device, should never be used as a load holding device. After the load has been raised

or lowered, it must always be blocked mechanically

WARNING:

The system operating pressure must not exceed the pressure rating of the lowest

rated component in the system. Install pressure gauges in the system to monitor

operating pressure. It is your window to what is happening in the system

Always wear protective gear when operating hydraulic equipment. The operator must

take precaution against injury due to failure of the tool or work piece(s)

Do NOT hold or stand directly in line with any hydraulic connections while pressurising

Do NOT attempt to disconnect hydraulic connections under pressure. Release all line

pressure before disconnecting hoses

All personnel must be clear before lowering load or depressurising the system

Do NOT attempt to lift a load weighing more than the capacity of the cylinder

IMPORTANT:

If at any stage, the safety related decals become hard to read, these must be replaced

Minimum age of the operator must be 18 years. The operator must have read and

understood all instructions, safety issues, cautions and warnings before starting to

operate the equipment. The operator is responsible for this activity towards other

persons

Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or

other means of safe transport

Hydraulic equipment must only be serviced by a qualified hydraulic technician. For

repair service, contact the Durapac authorised service centre in your area. To protect

your warranty, use only high quality hydraulic oil

CAUTION:

KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can

ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.

Heat also weakens hose materials and packings. For optimum performance do not

expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment

from weld spatter

No alteration should be made to this device

3.1 Hydraulic Spreaders

If bowing or bending of the spreader jaws occurs, STOP. Immediately release

pressure. Evaluate the set-up and consider a higher capacity system. Bowing or

bending of components indicates that the spreader is overloaded

Spreaders should be stored where protected from the elements, abrasive dust, and

damage. These devices may be stored in virtually any position

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 4 of 9

Use only those adapters and attachments provided and approved by Durapac

Never pressurise uncoupled couplers. Only use hydraulic equipment in a coupled

system

3.2 Hydraulic Hoses & Fluid Transmission Lines

Avoid short runs of straight line tubing. Straight line runs do not provide for

expansion and contraction due to pressure and/or temperature changes

Reduce stress in tube lines. Long tubing runs should be supported by brackets or

clips. Before operating the pump, connections should be tightened securely and

leak-free. Over tightening can cause premature thread failure or high pressure

fittings to burst

Should a hydraulic hose ever rupture, burst or need to be disconnected,

immediately shut off the pump and release all pressure. Never attempt to grasp a

leaking pressurised hose with your hands. The force of escaping hydraulic fluid can

inflict injury

Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme

heat or cold or heavy impact

Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid

flow within the hose is blocked or reduced. Periodically inspect the hose for wear

Hose material and coupler seals must be compatible with the hydraulic fluid used.

Hoses also must not come in contact with corrosive materials such as battery acid,

creosote-impregnated objects and wet paint. Never paint a coupler or hose

FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.

4.0 Installation

IMPORTANT: Always secure threaded port connections with high grade, non-hardening pipe

thread sealant. Teflon tape can be used if only one layer of tape is used and it is applied

carefully, two threads back, to prevent the tape from being introduced into hydraulic system,

which could cause jamming of precision-fit parts

4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.

Know your spreader, its limitations and how it operates before attempting to use. Refer

to the specification chart below or if in doubt, contact a Durapac representative.

4.2 Make hydraulic connections; use a pump release valve or a 3-way valve and one hose

for a single-acting cylinder.

IMPORTANT: Fully hand-tighten all couplers. Loose coupler connections will block

the flow of oil between the pump and the spreader

DHS-5 5 82 2.3 76 6.2

Weight

(kg)

Model

Number

Capacity

(ton)

Oil Capacity

(cc)

Tip Clearance

Min (mm)

Spread Max

(mm)

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 5 of 9

4.3 Check all system fittings and connections to be sure they are tight and leak free.

4.4 Check oil level in reservoir before operating pump.

4.5 Remove air from the system –Position the spreader so that the piston rod is pointed

down and the cylinder is lower than the pump. Advance and retract the cylinder

several times, avoiding pressure build-up. Air removal is complete when the cylinder

motion is smooth.

5.0 Operation

Inspect before each use. Do not use if bent, broken, leaking or damaged components are noted

Maintain a constant grip on the spreader during operation as the tool does not attach to other

equipment

The DHS-5 spreaders have a spring return cylinder and the speed of retraction is affected by

the length of the hose and other restrictions in the line. Most 700 bar hand or power pumps

for use with single acting tools are compatible with the DHS-5 spreader.

For complete operating instructions refer to the instruction sheet included with each pump.

5.1 Spreader Loads

5.1.1 Ensure that both spreader jaws fully engage the load and that the load is

centred on the serrated portion of each spreader jaw before pressurising

spreader. Do not load off centre.

Figure 1 –Typical Spreader Nomenclature

5.1.2 Ensure load is mechanically blocked before personnel commence operations

near the work area.

5.2 Advancing and retracting the Spreader

5.2.1 To spread the feet, connect the hydraulic cylinder to a pump and pressurise.

5.2.2 To close the feet, release the pressure of the pump.

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 6 of 9

6.0 Maintenance

IMPORTANT:

Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,

turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality

hydraulic oil will void warranty and damage the pump, hose, and application. We

recommend Durapac Hydraulic Oil or equivalent

Equipment must only be serviced by a qualified hydraulic technician. For repair service,

contact your local Durapac authorised service centre

Damage to hydraulic hoses may not be detected during visual inspections. For this

reason, Durapac recommends that hydraulic hoses be replaced on a regular basis

Tighten connections as needed. Use non-hardening pipe thread compound when

servicing connections

Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and

free of foreign matter. After each use, clean couplings and attach dust caps.

Maintenance is required when wear or leakage is noticed. Periodically inspect all

components to detect any problem that may require service and maintenance.

6.1 Check for loose connections and leaks

6.2 Replace damaged parts immediately

6.3 Do not exceed oil temperature above 60oC

6.4 Keep all hydraulic components clean

6.5 Use dust caps when spreader is disconnected from the hose. Keep clean to prolong the

product’s life.

6.6 Wipe thoroughly clean and store spreader upright, with feet closed, in clean, dry

environment. Avoid temperature extremes.

6.7 Change hydraulic oil in your system as recommended in the pump instruction sheet

6.8 Periodically lubricate lifting wedge with a small amount of high quality grease.

6.9 Periodically apply a coating of light lubricating oil to pivot points and hinges.

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 7 of 9

7.0 Troubleshooting

Problem

Cause

Solution

Spreader moves but

does not maintain

pressure

Leaking connection

Clean, reseal with thread sealant

and tighten connection

Leaking cylinder seals

Replace worn seals

Check for excessive contamination

or wear

Replace contaminated fluid as

necessary

Malfunctioning pump/valve

Check pump or valve operating

instructions

Repair or replace as necessary

Spreader leaks hydraulic

fluid

Worn or damaged seals

Replace worn seals

Check for excessive contamination

or wear

Replace contaminated fluid as

necessary

Loose connections

Clean, reseal with thread sealant

and tighten connection

Spreader will not retract

or retracts slower than

normal

Closed pump release valve

Open pump release valve

Loose couplers

Tighten couplers

Blocked hydraulic lines

Clean and flush lines

Weak or broken retraction

springs

Send to a Durapac authorised

service centre for repair

Internally damaged cylinder

Send to a Durapac authorised

service centre for repair

Pump reservoir too full

Drain hydraulic fluid to correct

level

Erratic Action

Air in system or pump

cavitation

Add fluid, bleed air and check for

leaks

External leakage

Replace worn packings

Check for excessive contamination

fluid as necessary

Replace contaminated fluid as

necessary

Sticking or binding cylinder

Check for dirt or leaks

Check for bent, misaligned, worn

parts or defective packings

Spreader does not move

Loose couplers

Tighten couplers

Faulty coupler

Verify that female coupler is not

locked up (ball wedged into seat)

Replace both male and female

couplers

Improper valve position

Close release valve or shift to new

position

Low or no hydraulic fluid in

pump reservoir

Fill and bleed the system

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 8 of 9

Problem

Cause

Solution

Air-locked pump

Prime pump according to pump

operating instructions

Pump not operating

Check pump’s operating

instructions

Load is above the capacity of

the system

Use the correct equipment

Spreader extends only

partially

Low or no hydraulic fluid in

pump reservoir

Fill and bleed the system

Load is above the capacity of

the system

Use the correct equipment

Sticking or binding cylinder

Check for dirt or leaks

Check for bent, misaligned, worn

parts or defective packings

Spreader moves slower

than normal

Loose couplers

Tighten couplers

Restricted hydraulic line or

fitting

Clean

Replace if damaged

Pump not operating correctly

Check pump’s operating

instructions

Repair or replace as necessary

Low fluid level in pump

reservoir

Fill and bleed the system

Leaking cylinder seals

Replace worn seals

Check for excessive contamination

or wear

Replace contaminated fluid as

necessary

Instruction Manual

DHS-5 Remote Spreader - V1.0 www.durapac.com Page 9 of 9

8.0 Parts Breakdown and List

Note –Not all components of the Hydraulic Spreader are

replacement items, but are illustrated as a convenient reference of

location and position in the assembly sequence.

Item Description Qty

1 Body 1

2 Inner tube 1

3 M-toe 1

4 Bolt 6

5 L-toe 1

6 R-toe 1

7 Bolt 1

8 Bolt 1

9 Bolt 1

10 Cylinder 1

11 Fast couplers 1

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