Hi-Force HEP2 Instruction Manual

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

OPERATING INSTRUCTION MANUAL

HEP2 & HEP3 SERIES | ELECTRIC DRIVEN PUMPS

HEP2 - GENERAL DUTY, MEDIUM FLOW

HEP3 - GENERAL DUTY, HIGH FLOW

Hi-Force HEP2 and HEP3 series Electric Driven Hydraulic Pumps are designed to operate high pressure

hydraulic cylinders and tools with a maximum working pressure of 700Bar. This manual applies to the Hi-

Force HEP2 and HEP3 series, Electric Driven Hydraulic Pumps. It contains the latest product information

available at the time of publication and approval. For information relating to the servicing of an electric driven

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-HEP2/3-01

From Serial Number:

BQ3323

Table of Contents

1.0 Inspection upon Receipt .................................................................3

2.0 Safety Precautions...........................................................................3

3.0 Declaration of Incorporation / Conformity.....................................5

4.0 Component Identification................................................................6

5.0 Installation/Setup.............................................................................8

6.0 Operation........................................................................................11

7.0 Maintenance and Storage..............................................................13

8.0 Specifications.................................................................................14

9.0 System Components / Accessories .............................................16

10.0 Troubleshooting...........................................................................17

11.0 Contact Details ............................................................................19

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

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 anyHi-Force equipment, contact your nearest Hi-Force office

or distributor. Onlyqualified personnel should beallowed to operatehydraulic 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 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 should be 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 pressurefrom 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.

Only use hydraulic tools/cylinders in a complete and tested, coupled system. NEVER attempt to use

a tool/cylinder that is not correctly coupled to its operational pump. NEVER pressurise an uncoupled

coupler/s.

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

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 theyare free from sharp bends

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-HEP2/3-01

From Serial Number:

BQ3323

2.3 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/tool. 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-HEP2/3-01

From Serial Number:

BQ3323

4.0 Component Identification

Hydraulic Oil Drain Plug

Adjustable Pressure Relief Valve

Hydraulic Oil Level Gauge

Oil Reservoir

Hydraulic Service Connections *

Electrical Enclosure

Directional Control Valve **

Oil Filler Breather Cap

700 bar Pressure Gauge

Motor ***

Protective Roll Frame

On/Off Switches

Cable Winding/Stowage Hooks

* 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-HEP2/3-01

From Serial Number:

BQ3323

Figure 4.2: Component Identification

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

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

(11) and fit the oil filler breather cap which is packed separately.

3. Establish the oil level in the oil reservoir using the level gauges (2). 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 lower

indicator (2).

4. Remove the steel or plastic hexagon headed plugs and make hydraulic connections to the service

ports (3). These ports have a 3/8” NPT female thread and the corresponding male connections

should be wrapped with PTFE tape or other suitable sealant.

NOTE: On a pump equipped with a 3-way valve the service port is the one on the right-hand side,

when viewed from the front. (See figure 4.1).

5. Ensure the lever of the hydraulic directional control valve (4) 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.

NOTE: Where valves are remotely mounted, make sure they are adjusted such that pressure will

not build up during the starting operation. See section 8 for applicable models.

6. Make sure that the voltage indicated on the motor rating plate corresponds with the available supply.

7. Connect the motor to required power source. (See section 5.3)

8. Check the direction of rotation of the motor by pressing the green ‘ON’ button (14), 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.

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

9. The pump is fitted with an adjustable pressure relief valve (8) to restrict the output pressure to any

desired value, up to the maximum working pressure of the pump.

Check the adjustable pressure relief valve is working:

NOTE: Checking / setting the relief valve pressure is to be done with the hydraulic female couplers

fitted to the service ports only.

Press the green ‘ON’ button (13) and turn the directional control valve to the advance position (for 2

way valves turnthe lever fullyclockwise, for the 3 and 4-way valves turn the lever fullyanti-clockwise

and for the solenoid valves press and hold the ‘advance’ button on the pendant).

Then release the locking feature and turn the control knob clockwise to increase the relief valve

setting (the pressure reading on the gauge should increase) and anti-clockwise to decrease the

relief valve setting (the pressure reading on the gauge should decrease).

5.2 Filling the Pump with Oil

IMPORTANT: The HEP2 & HEP3 series of hydraulic pumps use ISO46 Grade Hydraulic Oil.

Stand the pump on a firm, level surface.

Remove the filler cap (11) from the filler breather.

Fill the reservoir with clean, high quality ISO46 hydraulic oil via the filler breather until the oil level

reaches the upper level indicator (2).

Replace the filler cap (11) on the filler breather.

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/tool 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. 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.

Operating Instruction Manual:

OM-HEP2/3-01

From Serial Number:

BQ3323

5.4 Hydraulic Connections

Connect the hydraulic hose/s between the cylinder/tool and the pump, ensuring that the coupling/s (if fitted)

are fully hand-tightened only. NEVER use wrenches in an attempt to connect the coupling/s. Incorrectly

connected coupling/s are one of the most common causes of faulty operation.

IMPORTANT: Make sure that all coupler threads are fully engaged.

5.5 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, tools 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 follow procedure must be carried out with the

cylinder/tool 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 (11) is fitted.

With all hydraulic connections made, position the cylinder/tool below the level of

the hydraulic pump, as illustrated in figure 5.1.

Single-Acting: With smaller single-acting cylinders, positioned them with the

piston facing downward, as illustrated in figure 5.1

Double-Acting: If possible, position double-acting cylinders on their side with the

couplers facing upward, as illustrated in figure 5.2

Using the pump, fully advance and retract the cylinder/tool piston several times

until the operation is smooth. (See section 6 for details of pump operation).

NOTE: When longer hoses are used (especially in the case of smaller capacity

cylinders), the above procedure may not remove all the air from the system. In these

cases, contact your Hi-Force representative for advice on pre-filling hoses with

hydraulic oil.

Figure 5.1

Figure 5.2

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