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THINK THINKSAFETY
SAFETYSEMINARH a n d b o o k
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TABLE OF CONTENTS
From Enerpac to YOU............................................................................. 4 High Pressure Hydraulic Tools............................................................... 5 Lifting Forces........................................................................................... 6 Components............................................................................................ 7
Bottle Jacks.......................................................................................... 7Cylinders...........................................................................................8-9Hand Pumps......................................................................................... 9Hoses................................................................................................. 10Couplers............................................................................................. 11Oil...................................................................................................... 12Gauges............................................................................................... 13Hydraulic Tools...................................................................................... 14STB-SeriesPipeBenders................................................................14-15HeavyDutyCaterrollerLoadSkates.................................................16-17MachineLifts.................................................................................18-19Pullers...........................................................................................20-21HydraulicPunches.............................................................................. 22NutSplitters....................................................................................... 23HydraulicTorqueWrenches.............................................................24-25Hydraulic Systems................................................................................. 26BasicHydraulicSystem..................................................................26-27Presses.............................................................................................. 28MaintenanceSet............................................................................29-30
Setup Considerations............................................................................ 31
Extensions.......................................................................................... 31WorkArea.......................................................................................... 31
Equipment Storage................................................................................ 31
Brief Summary....................................................................................... 32Questions........................................................................................... 33Answers............................................................................................. 34
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From Enerpac to YOU ThankyouforusingEnerpachydraulictoolsandwelcometotheHydraulicToolSafety Seminar Handbook.ThishandbookisacompaniontotheHydraulicToolSafety Seminar Video,whichispartoftheEnerpac Think Safety Kit.Thehandbookcontainsanoverviewoftheinformationthatwaspresentedinthevideoandquestionstohelpyoustudywhatyoulearnedinthevideo.
PromotingpersonalsafetyistheprimarygoaloftheThink Safety Kit.Whetheryouworkinmaintenanceorproduction;powerplant,shipyard,mine,shopfloor,orconstructionsite;wehopeyouwilllearntouseyourhydraulictoolssafely.Whenyoupracticesafety,youalsobenefitbybeingmoreefficientandbyincreasingtheusefullifeofyourtools.
Thisseminarpresentsrealconcernsthatrealpeopledealwithonaday-to-daybasis.It’snotjustanexercisetofulfillasafetytrainingrequirement.Youmustbediligentwhenitcomestosafety.Wecanprovidehighqualitytoolsandaccessories,butitisuptoyoutobeawareofthesituationsthatyouputyourselfandothersinto.
Ifyouhaveasituationthatisnotcoveredinthisseminar,pleasecallourTechnicalServicesDepartmentat1-800-558-0530.Weareheretomakeevenyourtoughestjobeasier.
WesincerelyhopethisseminarhelpsyougetthemostoutofyourEnerpachydraulictools.
Keep this handbook in your work area for ready reference.
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80%
High Pressure Hydraulic Tools Highpressurehydraulictoolsaredesignedtobeoperatedupto10,000psi[700bar]hydraulicpressure.Mostfluidpowersystemsoperateat3,000psi[210bar];withsomegoingupto5,000psi[350bar].Thehydraulicpressureisthepressurethatbuildsupinsidetheequipment(jacks,pumps,cylinders,hoses).Anycomponentsconnectedtoahighpressurepumpmustalsoberatedtowithstand10,000psi[700bar]becausetheentiresystembecomespressurizedto10,000psi[700bar].
Equipment RatingsEquipmentratingsincludemanydifferentspecifications.Theratingsthatyouneedtobethemostconcernedwitharehydraulicpressureormaximumratedpressure,capacityortonnage,stroke,andoilcapacity.Theseratingsareusedtochoosethecorrectequipmentforyourapplication.Theratingsareexplainedinthetablebelow.
Safety FactorsHighpressurehydraulictoolsaredesignedtobesafelyoperateduptothemanufacturer’sratings.Theyarenotdesignedwithanunspecifiedsafetyfactorthatallowsyoutoexceedtheequipmentrating.Infact,itissafertousehighpressuretoolsat80%oftheirmaximuminsteadof100%.The80%ruleisexplainedingreaterdetailunderSetup Considerationsonpage8.
REMEMBER:The80%Rule–Itissafertousehighpressuretoolsat80%oftheirmaximumratinginsteadof100%.
RATING DESCRIPTION
High pressure or Maximum Rated
Pressure
Thisisthemaximumoperatingpressure.Allcomponentsinahydraulicsystemhaveamaximumpressurerating.Theoperatinghydraulicpressureshouldneverbehigherthanthatofthelowestratedcomponentinthesystem.
Capacity or TonnageThisisthemaximumamountofweightatoolcanlift,push,pull,orsqueeze.Jacks,cylinders,presses,spreaders,andotheraccessorieshavecapacityortonnageratings.
Stroke
Thisisthedistancethattheplungerwillextendoutofajack,cylinder,orpress.Thestrokeratingmustbelongerthanthedistancethatyouaremovingtheload(exceptinstagedliftingapplications.
Oil CapacityThisistheamountofoilacomponentholds.Thepumpmustholdenoughoiltofillthehydrauliccircuit.
NOTE:Ifyouaresizingequipmentforanapplication,choosethecylinderfirstandthenthepump.Thepumpshouldhaveabigenoughreservoirtofillthecylinderandhose(s).Newhosesarenotfilledwithoil.
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Lifting Forces Thissectionbrieflyexplainssomeoftheforcesatworkwhileyouareliftingaloadwithajackorcylinder.Themainlineofforceisthroughthecenteroftheplunger.Theweightshouldbedistributedasclosetothiscenterlineaspossible.Theentirebaseofthejackorcylinderneedstobeonasolidandlevelsurfaceforastablelift.Goodandbadliftsarepicturedbelow.
Iftheloadisnotcenteredortheentirefaceoftheplungersaddledoesnotcontacttheload,sideloadingwilloccur.Sideloadingcreatesanunstablesetupwhichmayshiftorfall.Italsodamagesthejackorcylinderbydistortingthewipersealandbendingtheplunger.Sideloadingincreaseswithdistance.Thefurtheryouextendtheplunger,themoreunstableitbecomes.
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Thebottlejackisoneoftheoldestandmostfamiliarpiecesofhydraulicequipment.Thisfamiliaritycontributestomisusewhichcanleadtopersonalinjury.
Thebottlejackisaloadliftingdeviceandshouldneverbeusedasaloadholdingdevice,especiallywhenapersonwillbegoingunderneaththesupportedload.
KEEP THE FOLLOWING IN MIND WHEN USING A BOTTLE JACK:
◀���Thebaseofthejackshouldbefullysupportedandaslevelaspossible.Whenworkingonsoftsurfaces,putasturdymetalplateunderthebaseofthejackforstability.
◀�����Thesaddleontheendoftheplungershouldmakefullcontactwiththeload.Trytomovetheloadonthecenterlineofforcetopreventsideloading.
◀�����Donottrytoliftaloadmorethantheratedstroke.Ifyouneedtolifttheloadfurther,blocktheload,raisethelevelofthejackwithasturdysupport,andcontinuethelift.
REMEMBER:Donotgounderaloadsupportedbyajack.Aftertheloadhasbeenraised,itshouldbeblocked.
Provide a level and solid support for the entire jack base area.
The entire jack saddle must be in contact with the load. Movement of the load must be in the same direction as jack plunger.
Never place any part of your body under the load. Ensure the load is on a solid support before venturing under.
BOTTLE JACKS
Components Inthissectionyouwillfindinformationaboutthebasiccomponentsthatmakeupahydraulicsystem.
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CYLINDERS Thecylinder(orram)operatesmuchthesameasthejack,exceptthatitismoreversatile.Sincethepumpisseparate,thecylindercanbeusedinseveralpositions.Byaddingextensionsandattachmentstothecylinder,youcancreateawidevarietyofhydraulictools.TheextensionsandattachmentsarecoveredintheMaintenance Setsectionofthishandbookonpages29-30.
Thesaddleintheplungerservestwoimportantpurposes.Itprotectstheplungerthreadsfromdamageanditkeepstheendoftheplungerfrombecomingdeformed.Keepthesaddleinplaceatalltimes.Donotthreadattachmentsintotheplungerandrelyontheplungerthreadsforsupport.Theloadmustbetransferredtothefaceoftheplunger.Thethreadsintheplungermaybestrippedifloaded.
Aswiththebottlejack,thecylinderisaloadliftingdeviceandshouldneverbeusedasaloadholdingdevice,especiallywhenapersonwillbegoingunderneaththesupportedload.
KEEP THE FOLLOWING IN MIND WHEN USING A CYLINDER:
•Thebaseofthecylindershouldbefullysupported.Whereapplicable,useacylinderbaseplateforaddedstability.Donotweldorotherwisemodifythecylindertoattachabaseorothersupport.
•Thesaddleontheendoftheplungershouldmakefullcontactwiththeload.Trytomovetheloadonthecenterlineofforcetopreventsideloading.Beespeciallycarefulaboutsideloadinglong-strokecylinders.
•Donottrytoliftaloadmorethantheratedstroke.Ifyouneedtolifttheloadfurther,blocktheload,raisethelevelofthecylinderwithasturdysupport,andcontinuethelift.
REMEMBER:Donotgounderaloadsupportedbyacylinder.Aftertheloadhasbeenraised,itshouldbeblocked.
SETUP CONSIDERATIONS: THE 80% RULE
Whenyoumakehydraulicsetups,youshouldalwaysexaminethesetupbeforeusingit.Youwanttolookforwaystoprotectyourselfandothers,andwaystoprotectyourequipmentandotherproperty.
Trytocreatetheidealsetup.Sincefewthingsinlifeareideal,followingthe80%rulewillresultinmorestablesetupsandprolong
Provide a solid support for the entire cylinder base area. Use cylinder base attachment for more stability.
Do not use cylinder without saddle. This will cause plunger to “mushroom.” Saddles distribute load evenly on the plunger.
Always protect cylinder threads for use with attachments.
As with jacks, never place any part of the body under the load. Load must me on cribbing before venturing under.
Keep hydraulic equipment away from open fire and temperatures above 150 ⁰F (65 ⁰C).
The entire cylinder saddle must be in contact with the load. Movement of the cylinder must be parallel with the movement of the load.
load bearing face
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HAND PUMPS Handpumpsareaconvenient,portablesourceofhydraulicpower.Theyaredesignedtobestableduringoperation.Forbestperformance,operatethepumphandleatmoderatespeed.Whenthehandlegetshardtopushathighpressure,takeshortstrokes.Themaximumleverageisobtainedinthelast5degreesofstroke.Addinganextensiontothepumphandleisdangerousandisnotrecommended.
THINGS TO REMEMBER WHEN USING A HAND PUMP:
•�Closethereleasevalvefingertightonly.Usingtoolsonthereleasevalvecandamageitandcausethepumptomalfunction.
•�Incertainsituationsthepumphandlecan“kickback.”Alwayskeepyourbodytothesideofthepump,awayfromthelineofforceofthehandle.
•�Manyhandpumpscanbeoperatedinthehorizontalorverticalposition.However,when using it in the vertical position, the hose end must be down or you will pump air instead of oil.Checkthepumpinstructionsheettodeterminethecorrectoperatingpositionforyourpump.
Don’t use handle extenders. Hand pumps should be easy to operate when used correctly.
Close release valve finger tight. Using force will ruin the valve.
thelifeofyourequipment.The80%ruleappliestocylinderstrokeandcylindercapacity.
Cylinder Stroke Theillustrationatrightshowstwobenefitsofapplyingthe80%ruletocylinderstroke.Thefirstisthatleavingdistancebetweenthestopringandthebearingreducessideloadingforceresultinginamorestablecylinder.Thesecondisthatyouavoiddamagingthestopringbyrunningtheplungerallthewayupandhittingthestopringwiththebearing.
Cylinder CapacityThereasonforapplyingthe80%ruletocylindercapacity(tonnage)isthatmostloadsarenotliftedontheirtruecenter.Thisresultsinsideloadingofthecylinder.Allowingforasafetyfactoristhesimplestwaytocompensatefortheoff-centercharacteristicsofaone-pointlift.
80% side load
full side load
more stable
less stable
bearing
stop ring
plunger
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HOSES Rubberhosesaremadein4layers:arubbertubeontheinside,2layersofwirebraid,andaprotectiverubberlayerontheoutside.Ifthewirebraidcanbeseenfromtheoutside,itistimetoreplacethehose.Rubberhoseshavea2:1safetyfactor.Thermoplastichosesarefrequentlyusedwithpower-drivenhydraulicpumps.Only700seriesthermoplastichoseshavea4:1safetyfactor.
USE THE FOLLOWING INFORMATION TO AVOID PROBLEMS WITH HOSES:
•Donotkinkortightlybendhoses.Thiswilldamagethewirebraid.Theminimumbendradiusisapproximately4.5inches[12cm].Thismeansthereshouldbenolessthan9inches[24cm]betweenthestraightsectionsofthehoseaspictured.
•Themostsensitivepartofthehoseisatthefitting.Toreducedamage,donotbendthehoseatthefitting.Keepthestrainrelief(springorboot)guardoverthefittingasshown.Itwillhelptosupportthehose.
•Makethelayoutofthehosessuchthatthereisnoriskofdamageduetovehicles,trucksetc.Donotdropobjectsontohose.
•Hosesarenotdesignedtobeusedasatowropeforyourpump.Donotpullonthehosetomovethepump.
•Neverpressurizeahosewhichhasakinkorsharpbend.
•Hydraulicpressureinahose,cylinderorothercomponentcanincreaseduetoheat.Nevertrytopushcheckballsorpinsincouplerstoreducethepressure.Toavoidsuchproblems,neverstorecomponentsinwarmareas.
REMEMBER:Alwaysdiscarddamagedhosestoeliminatetheriskofsomeoneelseusingthehose.Thenextusermightnotnoticethedamageuntilthehoseispressurized.Aleakinahosecancausehighpressureoiltopenetrateyourskin.IFYOUAREEVERINJUREDBYASPRAYOFOIL,SEEADOCTORIMMEDIATELY.
Don’t kink hoses. Bending radius should be at least 4½ inch. Don’t drive over or drop heavy objects on hose.
Clean both coupler parts before connecting. Use dust caps when coupler parts are not connected.
Keep hoses away from the area beneath loads.
Don’t lift hydraulic equipment by the hoses.
4.5” [12 cm]minimum
bend radius
9” [24 cm]minimumdistance
boot guard
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COUPLERS Theadvantageofusingcouplersratherthanthreadedconnectionsisthatyoucanquicklymakeandbreakhydraulicconnections.Thedisadvantageofusingcouplersisthattheyarefrequentlythepointatwhichdirtentersahydraulicsystem.
OBSERVE THE FOLLOWING WHEN USING COUPLERS:
•�Makesurecouplersarecleanbeforemakinganyconnections.Usedustcapstokeepcouplersclean.Ifadustcapwasnotused,cleanthecouplerbycarefullyblowingthedirtoutwithcompressedair.
•Tightencouplershand tight only;donotusewrenches.Thethreadsmustbefullyengagedtoallowforproperoilflow.Apartiallyconnected,checked-off,couplerisshownbelowalongwithaproperlyconnectedcoupler.
•Couplersaredesignedtobepressurizedonlywhentheyareconnectedtogether.Never pressurize half couplers.
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ION coupler threads
partially engaged
coupler threadsfully engaged
blocked flowblocked flow
free flowfree flow
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CT-604 Safety ToolUsetheEnerpacCT-604torelievehydraulicbackpressurebysafelybleedingthehydrauliccoupler.Minimizeinjuriesfromprojectilepartsandunder-skinhydraulicfluidinjectionsbyeliminatingunsafecouplerbleedingpractices.TheCT-604isEnerpac-engineeringsafeforuseat10,000psi(700bar).NOTE:C-Seriesonly.
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CHARACTERISTIC ENERPAC SPECIFICATIONS EFFECTS
Viscosity 42-45SUS@210⁰F[5.3-5.4cSt@100⁰C]
150-165SUS@100⁰F[30-32cSt@40⁰C]
Viscositydescribestheabilityofanoiltoflow.Iftheoilistoothin,thereisnotenoughlubrication.Iftheoilistoothick,itwillnotflowfastenoughtoperformasrequired.
Operating Temperature
150⁰F[65⁰C]maximum Hightemperaturesalsocausesealdamage.Ingeneral,ifthesystemistoohottotouch,itistoohottouse.
OIL Alloilsarenotalike.Thecorrectoilwillprotectmovingpartsandwillnotdamageseals.Usingthewrongoilwilldamageyourequipmentandleadtomalfunctions.UseEnerpacpremiumhydraulicoil.
Themostimportantoilcharacteristicisviscosity.Heatisalsoanimportantfactor.Seethechartbelowfordetails.
REMEMBER:Alwaysdisposeofusedoilproperly.Observelocalordinances.Donotmixusedhydraulicoilwithotherfluids.
Wi l ly ™
Brake Fluid HYDRAULIC OIL
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Use only genuine Enerpac hydraulic oil. The wrong fluid can destroy your seals and pump and will render your warranty null and void.
▼�Oil Specifications Chart
LX Oil HF OilISO Grade 15 32
Viscosity Index 101 min 100 min
Viscosity at 210 °F 3.2/3.7 S.U.S. 42/45 S.U.S.
Viscosity at 100 °F 13.5/16.5 S.U.S 150/165 S.U.S.
Viscosity at 0 °F <2100 S.U.S. <12000 S.U.S.
API Gravity 31.0/35.0 31.0/33.0
Flash, C.O.C. °F 370 375
Pour Point, °F -30 -25
Paraffinic Base Color Yellow Blue
NOTE:SAEgradesdonotapplytohydraulicoil.
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GAUGES Allhydraulicsystemsshouldhaveagauge.Thegaugeisthewindowtothehydraulicsystem.Inadditiontoindicatingtheoperatingpressure,thegaugecanalsowarnyouthatsomethingisgoingwrong.
IN A LIFTING SITUATION THE GAUGE WILL READ AS FOLLOWS:
•�Thegaugewillnotshowmuchofapressureriseuntilthecylindercontactstheload.
•Thepressurewillstarttoriseafterthecylinderhascontactedtheload.
•Thepressurecontinuestorisewitheachpumpstroke.
•Whentheloadstartstomove,thepressurewillremainconstant.Ifyoucontinuepumpingandtheloaddoesnotmove,youmayhavereachedtheendofthecylinderstroke,orpartofyoursetupmaybeyielding.
REMEMBER:Thegaugeshowsmorethanmaximumpressure.Itcanalsoalertyoutowhatishappeningthroughoutanoperation.
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Hydraulic Tools Inthissectionyouwillfindinformationaboutthebasictoolsthatareusedwithahydraulicsystem.
STB-SERIES PIPE BENDER SETS STB-Serieshydraulicpipebendersetsaredesignedtoprovidequick,safe,andwrinkle-freebendingofschedule40,80,160,andDEHpipein1⁄2”through4”sizes.STB-SeriespipebendersetsincludetheEnerpachydrauliccylinder,hose,andmanual,air,orelectricpoweredpump.Setsarealsoavailablewithouthydraulics.Thebendingframeandshoesarelightweight,heat-treatedaluminum.Eject-O-Matic™seriesbendershavedouble-actingcylinderstoejectpipefromthebendingshoe.
IMPORTANT:Nobendersetisall-purpose,pleaserefertoselectionchartlocatedintheEnerpaccatalogortheinstructionsincludedwiththebenderwhenselectingtheproperbendertosuitthesizeandscheduleofthematerialtobebent.Ifindoubt,callEnerpac.
ASSEMBLY:
1.Fullythreadthehydrauliccylinderintothecylindersupportblockonthebendingframe.
2.Makesurethatthesaddleisfullythreadedintotheplungerfullyhandtight.
3.Makeallhoseconnectionsbetweenthecylinderandhydraulicpump.Makesurethatthecoupler(s)arefullyhandtightened.
4.Selecttheappropriatebendingshoeforthepipesize.Eachshoeismarkedforsize.Anarrowindicatesthecenterofthebendtobemade.
5.Insertandlockthebendingshoeontothecylinderplunger.Makesuretoinstallthe“U”shapedlockpin.
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BENDING:
1.Placethepipeintothebenderframe.
2.Attachtheopticanglegaugetothetopofthepivotshoe.Thepinlocatoronthetopofthepivotshoelocatesthecorrectsettingofzerobeforethebendingcycle.
3.Mountthesecondpivotshoe.Bothpivotshoesaremarkedforvariouspipesizes.The markings on the pivot shoes must match the pipe size being bent and face the pipe.
4.Theanglegaugeshouldnowreadzerowhenreadalongthelinethatisscribedonthebenderframe.
5.Lockbothofthepivotshoesintopositionwiththepush-buttonpivotpins.Thepivotpinsareoperatedbypushingdownonthepush-buttonwhileinsertingthepinintothepivothole.Thepivotpinsmustbecompletelyinsertedthroughtheholethatismarkedwiththecorrespondingpipesize.
6.Actuatethehydraulicpumpandproceedwiththebend.
REMOVING THE PIPE:
1.Onbendersthatareequippedwithasingle-actingcylinder,retracttheplungerandremovethepipefromtheshoe.
2.Onbenderswithdouble-actingcylinders,partiallyretractthecylinder.Thiswilltakeanyremainingforceoffofthepivotshoesandpins.Removeeitheroneorbothpivotshoesandrepositiononepivotpininthepropersize“ejecthole”wherethepinwillrestrainthepipe,nottheshoe,astheyretract.Four-inchcapacityframeshavetwo“ejectholes”.Usebothsides.
3.Nowfullyretractthecylinderplunger.Thebendingshoeandpipewillretracttogetheruntilthepipemeetsthepivotpin.Oncontact,thepipewillstripfromthebendingshoe.
4.Removetheotherpivotpinandpivotshoetoremovethepipefromthebender.
•Ifthemeasuredpipediameterisgreaterthanthemaximumallowablediameter,donotattempttobendthatpipe.Attempting to bend oversized pipe could damage the bender and cause personal injuryandwillresultinanunacceptablebend.
CAUTION:Whenactivatingthehydraulicpump,theoperatormustbelocatedonthecylindersideofthebender.Itisimportanttostayoutofthelineofforceoftheequipmentwhileoperating.
•Duringthebendingprocess,watchtheopticgaugeuntilthegaugeindicatinglineforthedesignatedangleisalignedwiththemarkontheframe.Becauseofpipespringback,itisusuallynecessarytobendslightlymorethanthedesiredangle.
•Forcompletebendinginstructions,refertotheinstructionbookletincludedwitheverybenderorcallEnerpac.
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Lubricaterollers,whenneeded,withmolybdenumdisulfidepasteonly(suchasDowCorning’sMolykote#G-npaste,orequivalent.)
For heavy use, lubricate rollers weekly.
Note:Graphiteformulationsarenotanequivalentlubrication.
HEAVY DUTY CATERROLLERTM LOAD SKATES Loadskatesconsistofarigidsteelframewithsaw-toothededges,acenterguideplateandasetofrollers.Therollersareconnectedbylinkchainoneithersidewithamasterlinkforseparatingthem.Eachrollerturnsindependentlyandtheentiresetrotatesaroundtheguideplate.Loadsmaybeattachedpermanentlybyweldingtotheskate.Loadswithwoodbaseswillsinkintotheframeedgesforbetterstability.Typically,amobileforceof35to50lbspertonisrequiredtomoveloadsmountedontheskates.RefertothespecificationchartintheEnerpacCatalogortheinstructionsincludedwiththeskatesforcapacitiesanddimensions.
CAUTION:Basedonloadsizeandweight,besurethecorrectnumberofskatesareusedtosupporttheload.
CAUTION:Checkallloadroutestoensureramps,floorsandstructureswillsupporttheweightandsizeoftheload.
WARNING:Topreventtheloadfromslipping,placewoodskidsortimbersbetweentheloadandtheskates.Nailchocksintothewoodforaddedsecurity.
CAUTION:Swiveltypeskatesmustbecheckedduringmovestoensureparallelalignmentundertheload.
WARNING:Topreventpossibleinjuryandequipmentdamage,donotexceedtheratedcapacitiesoftheskates.
LOAD REQUIREMENTS:
1.Determinethenumberofskatesneededbycalculatingthetotalweightincludingsupporttimbers,beamsorskids.As a general rule, double the size requirements.
2.Planskatepositionstoequallydistributeweightandtofacilitatemaneuvering.Do not exceed skate capacity.
3.Skateselectionandaccessoriesaredeterminedbytheweightoftheload,thepathwaysurface,andthenumberandnatureofturnsrequiredduringmovement.Forstraight-linemoves,thestandardrigidskateisadequate.Formoveswithturnsandforpositioningtheload,swivelplatesshouldbeaddedtotheskates.
4.Mostmoveswillrequiresomeamountoflifting.Carefullyselecttheliftingequipment.Considertheloadweight,heightofliftandlocationofliftdevicestoallowpositioningoftheskates.
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FLOOR CONDITION AND PATHWAY CLEARANCES:
1.Floorsorotherpathsurfacesmustbecleanandfreeofcracksorholes,whichcanhinderskatetravel.
2.Checkandverifyallload-bearingcapacitiesofallfloorsorpathwaysurfaces.Rampsorotherstructuresshouldbereinforcedtohandletheload.
3.Iframpsorotherinclinesareinthepathway,besurethatmotiveforcesarepowerfulenoughandifneeded,providerestrainingdevicestoholdtheload.
4.Forroughsurfacesorunpavedareas,theuseofsteelchannelswillprovidegoodskatepaths.
LIFTING LOADS:
1.Useload-liftingdeviceswithacapacityexceedingtheloadweightandwithenoughliftheighttosafelyinstallskatesundertheload.
2.RefertotheselectionchartintheEnerpaccatalogortheinstructionsheetsincludedwiththeskatesfordimensionsandskateloadcapacities.
3.Loadsshouldbesupportedwithtimbers,beamsorskidsplacedbetweentheloadbaseandtheskates.
STRAIGHT MOVES:
1.Positionskatesevenlyaroundtheloadbase.Rigidskatesmustbeparalleltoeachotherinordertoprovidestraighttravelinonedirection.
2.Skateswithswiveltopplateswillnotmaintainpositiononroughfloors.Ifswivelskatesareused,thefloormustbecleanandtheskatepositionmustbeconstantlywatchedtoensuresmoothstraighttravel.Ifswivelplatesareused,alwaysusetheminpairs,eitherfrontorrear.
STEERING OR MANEUVERING A LOAD:
1.Steeringisaccomplishedusingskateswithswivelplatesinalllocationsorinpairsatthefrontorrear.
2.Thenumberandplacementoftheswivelplateswilldependonthesize,shapeandtotalloadweight.Alsoconsiderthepathsurfaceconditions.
3.Gradualturnsarefairlyeasytomakewhiletheloadismoving.Sharp90°degreeturnsmayrequireliftingoneendandpivotingaroundtheouter.
STRAIGHT-LINE MOVES:Skatesmustremainparalleltoeachothertoassureeasiestmotioninanyonedirection.Rigid-topskateswillstayinpositionasplaced,butswivelskatesmaybeknockedoutofalignmentifthemoveisoveraroughordirtysurface.Careshouldbetaken,floorscleaned,andalignmentprogressivelymonitoredduringmovesusingswivelskates,especiallyoverlessthanidealsurfaces.
STEERING AND SPOTTING LOADS: Maneuveringtheloadismadeeasierbyusingswivelskatesorcombinationsofswivelskateswithrigid-topskates.Size,configuration,andweightofloadsdeterminemodels,quantity,andplacementofrequiredskates.
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MACHINE LIFTS Enerpacmachineliftsarebuiltfromasteelhousingandasingle-acting,springreturnhydrauliccylinder.Poweredbyanexternalhandorelectricpump,thecylinderplungermovesandactuatesthemachinelift.Thesupportfeetonthe
machineliftmustbeextendedtoprovidemaximumstability.
Theliftingtoeofthemachineliftisadjustabletothreepositionsusingtheslottedholesintheliftingplate.Touse,liftthetoeandpullitoutoftheslotsintheliftingplate,thenmountitintheslotsattherequiredheight.
WARNING:Seriousequipmentdamageandpersonalinjurycanresult,ifthesupportfeetarenotfullyextendedandpinnedintoposition.
WARNING:Toavoidpersonalinjury,keephandsandfeetawayfromtheliftingequipmentandloadduringoperation.
WARNING:Stayclearofloadssupportedbyhydraulics.Aftertheloadhasbeenraised,itmustbeblockedorcribbedmechanically.
WARNING:Neverpressurizeuncoupledcouplers.Makesurethatallcouplersareconnectedandfullytightenedbeforeoperatingthesystem.
WARNING:Avoidsharpbendsandkinksinthehosewhichwillleadtohosefailure.
WARNING:Toavoidpersonalinjuryandpossibleequipmentdamagemakesurethatallhydrauliccomponentswithstandthemaximumpressureof10,000psior700bar.
WARNING:Donotexceedequipmentratings.Neverattempttoliftaloadweighingmorethanthecapacityoftheequipment.Overloadingcausesequipmentfailureandpossiblepersonalinjury.
WARNING:Offcenterloadswillproduceunnecessarystressontheequipment.Avoidpointloading.Distributetheloadevenlyacrosstheentiresurfaceoftheliftingarea.
WARNING:Alwaysprovideaflat,solidandfirmfoundationbeforeattemptingtoliftanyload.
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Machine Lifts
Toplacetheloadskates,theloadmustfirstbelifted.ThiscanbeaccomplishedeasilyandsafelyusingenerpacSOHseriesMachineLifts.
OPERATION:
Beforeliftingaload,thecylindermustbesecurelyattachedtothetoeliftbase.Keepthecontactsurfacebetweenthetoeliftandtheloadclean.Thecontactsurfacemustbefreeofoil,grease,ordirttoavoidslippage.Beforeliftingaloadmakesurethatthecontactsurfaceofthetoeliftcompletelysupportstheload(See Fig. 1).The lock pins must always be properly positioned in the support feet while lifting.
Advancingandretractingthemachinelift.ForcompleteoperatinginstructionsrefertoHAND PUMPSandBASIC HYDRAULIC SYSTEMS inthismanual.
IMPORTANT:Alwayskeeptheguidepathsoftheliftingplategreased.
10 US TONS
101,7 kN
25 US TONS
233,3 kN
8.9 US TONS
81 kN
21.6 US TONS
196 kN
Figure 1
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PULLERS Toavoidpersonalinjuryduringsystemoperation,readandfollowallCAUTIONS,WARNINGS,andINSTRUCTIONSincludedwithorattachedtoeachproduct.Enerpac cannot be responsible for damage resulting from unsafe use of product, lack of maintenance, or incorrect product and system application.
WARNING:Alwayswearproperpersonalprotectivegear(i.e.gloves,safetyglasses).
WARNING:Makesurethattheitemstobepulledaresupportedbyameansotherthanthepuller.
WARNING:Beforeeachuse,lubricatethecenterboltthreadswithagraphite-basedlubricant.
WARNING:Useapullercapableofpullingtheload.Overloadingthepullermaycauseittobreak.
WARNING:Neveruseatooltostrikethepuller.Hittingthepullermaycauseittobreak.
WARNING:Applyingheattothepullermaydamageit,causingthepullertofailatlowerthanratedload.
WARNING:Usepulleronlywithrecommendedattachmentsordamagetothepullermayoccur.
WARNING:NEVERusestandardgradeboltsorpartstorepairpullers.Standardgradepartsmaybreakwhenthepullerisused,causingpersonalinjuryand/orpropertydamage.
MECHANICAL PULLER OPERATION:
1.Makesurethatthespindleiscleanandgreasedbeforeuse.
2.Theshaft(A)musthaveacenterhole(B) asshown.Ifitdoesnot,useashaftprotector (C).(See Fig. 1)
3.Tightenstrapboltstoholdjawslightlyinplace.
4.PositionthepullerasshowninFig 2.
5.Tightenthespindleslightlybyturningthespindlenut.
6.Checkthatthejawsarefullycontactingtheparttobepulled.
7.Tightenthestrapbolts.
8.Applypullingforcebyturningthespindle.
Figure 1
Figure 2
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(C)
(B)
(A)
IMPORTANT:Alwayskeeptheguidepathsoftheliftingplategreased.
POSI LOCK PULLER OPERATION FOR MANUAL PULLERS:
1.Makesurethatallitemsbeingpulledaresupportedbyameansotherthanthepuller.NO LOOSE PIECES!!!
2.Beforeeachuse,lubricatethecenterboltofthepullerwithagraphite-basedlubricant.
3.Tooperatethepuller,graspthepullerwithonehandandturntheT-handlecounter-clockwisewiththeotherhanduntilthejawopeningisbigenoughtofitoverthecomponenttobepulled.
4.TurntheT-Handleclockwisetotightenthejawfirmlyontothecomponent.(Fig. 3A)
5.Makesurethatthecenterofthepullerisalignedwiththecenterofthecomponenttobepulled.Usinghandtoolsonly,tightenthecenterbolttopullthecomponentoffofitsshaft.Never exceed the maximum torque ratings of the puller’s drive bolt. (Fig. 3B)
6.TurntheT-handlecounter-clockwisetoremovethepullerfromthecomponent. (Fig. 3C)
HYDRAULIC PULLER OPERATION:
1.Makesurethatallitemsbeingpulledaresupportedbyameansotherthanthepuller.NO LOOSE PIECES!!!
2.Installthecylinderintothepullerbythreadingcollarthreadsclock-wiseintothejawheadassembly.Makesurethatthepullercollarthreadsarefullyengagedinthepuller.Attachliftplatetothecouplerendofthecylinder.Removethesaddlefromthecylinderandinserttherampointintotheplunger.Select the ram point that will provide the maximum contact with the shaft.
3.Tooperatethepuller,graspthepullerwithonehandandturntheT-handlecounter-clockwisewiththeotherhanduntilthejawopeningisbigenoughtofitoverthecomponenttobepulled.
4.TurntheT-Handleclockwisetotightenthejawfirmlyontothecomponent.
5.Makesurethatthepullerissquarewiththecomponenttobepulled.Advancetheplungeruntiltherampointcontactstheshafttoinsurecorrectalignment.Thecenterpointofthepullermustbealignedwiththecenterpointoftheshaft.Continuetoadvancetheplungerslowlytopullthecomponentoffoftheshaft.Never try to retighten the T-handle during the pulling operation. For 100-ton hydraulic pullers refer to the puller instruction sheet.
Figure 3
For more information on pullers, see the tool section of your Enerpac Industrial Tool catalog.
Enerpac’sBearingpullerattachmentcanbeusedwithgrip,bearing,andbearingcuppullerstosolvemanydifficult
pullingapplicationswherepullingsurfacesarelimited.
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Dry stripping is a principal cause of punch failure.
Lubricationwillfacilitateeasypunchingandwillsignificantlyprolongthelifeofthepunch.
HYDRAULIC PUNCHES Hydraulicpunchesaredesignedtoperforatemetalwithround,squareoroblongholes.Theyaredesignedtoworkonmildsteel,non-ferrousmetalsandsomeplastics(non-shattering).Hydraulicpunchesmaybepoweredbyhandpumps,air/hydraulic,gas,orelectricdrivenpumpswhichdevelopupto10,000psi(700bar).
WARNING:Donotexceedthemaximumpunchlimitsasshownonthetooldecal,instructionsheetsorcatalog.
WARNING:Keeppunchanddiesclean.Lubricationisnotrequired,butwillextendpunchanddielife.
WARNING:Alwaysmatchpunchanddiecorrectly.Installdieswithlargeropeningfacingdown.
WARNING:Protectpunchanddiesets.Returntostoragecaseafteruse.
WARNING:UseonlyEnerpacoilinpunchandpump.
WARNING:Cracked,chipped,orwornpunchesanddiesshouldbereplacedimmediately.
PUNCH AND DIE REPLACEMENT:
1.Removethepunchbyusingthepintoolorspannerwrenchtoloosenthepunchretainer.
2.Useanallenwrenchtoremovethesetscrewinthelowerjawofthepunchframe.Removethediefromtheframe.
3.Installdieswithlargeropeningsfacingdownorawayfromthepunch.
4.Tightenthesetscrew.
5. CAuTION:Indexingslotsareusedwithsquareandoblongdiestokeepthemalignedwiththematchingpunch.
6.I mPOrTANT:Squareoroblongpunchesmustbeinstalledusingthesquarekeyprovidedwiththepunch.Thesquarekeymustengagetheslotofthepunchplunger.Do not use the square key with round punches.
7.Installthepunchwiththelongstemfacingdownward.
8.Beforeusingthepunchmakesurethatthesetscrewandcapnutaretightenedsecurely.
9.Advancethepunchthroughthedieandcheckforproperalignment.Thepunchmustpassfreelythroughthedie.Minoradjustmentstothediearepossiblebylooseningthesetscrewandrepositioningthedie,thenre-tighteningthesetscrew.
For more information on pullers, see the tool section of your Enerpac Industrial Tool catalog.
IMPORTANT:Duringpunchingoperation,periodicallycheckthecapnuttoensurethatthepunchremainstight.Removetheslugsfromthepunchtopreventdamage.
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NUT SPLITTERS Toavoidpersonalinjuryduringsystemoperation,readandfollowallCAUTIONS,WARNINGS,andINSTRUCTIONSincludedwithorattachedtoeachproduct.Enerpac cannot be responsible for damage resulting from unsafe use of product, lack of maintenance, or incorrect product and system application.
WARNING:Alwayswearproperpersonalprotectivegear(i.e.gloves,safetyglasses).
WARNING:Thesystemoperatingpressuremustnotexceedthepressureratingofthelowestratedcomponentinthesystem.
WARNING:Makesurethatallsystemcomponentsareprotectedfromexternalsourcesofdamage,suchasexcessiveheat,flame,movingmachineparts,sharpedges,andcorrosivechemicals.
WARNING:Topreventinjury,donotplacefingersonornearthecuttingbladewhilethenutsplitterisoperating.
WARNING:Topreventinjuryandtoavoiddamage,donotusethenutsplitteronglass,plastic,wood,oranymaterialwhichcouldshatter.
WARNING:Toavoiddamagetothenutsplitterblade,housing,plungerandseals:A.Donotcutchainsorbolts.B. Donotusethenutsplittertorotatenuts.C.Donotmovethenutsplitterduringthe
cuttingoperation.D.Donotheatupnutswhilethenutsplitter
isinposition.
WARNING:EnerpacNutSplittersaredesignedspecificallyformetalnutsthatmatchthesizesaslistedintheselectionchartsintheEnerpaccatalogandnutsplitterinstructionsheets.
WARNING:MaximumallowablehardnessofthenutstobesplitisHRc-44.
NUT SPLITTER OPERATION:
1.Makeallappropriatehydraulicconnections.2.Placethenutsplitterheadoverthenut.
ImPOrTANT:theflatsurfaceofthecuttermustrestflatononeofthenutflats,andtheheadmustrestonaflatsurface.
3.Holdthenutsplitterintheproperposition.4.Operatethepumpuntilthecutterbladecutsthroughthenut.5.Toavoiddamagetotheboltthread,de-energizethepump
assoonasthenutissplit.6.Retracttheblade.7.Repeatthecuttingprocessontheothersideofthenut.
(Mustbe180degreesopposed).8.Retractthecutterbladeandremovebothnuthalves.
INCORRECT
CORRECT
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HYDRAULIC TORQUE WRENCHES Toavoidpersonalinjuryduringsystemoperation,readandfollowallCAUTIONS,WARNINGS,andINSTRUCTIONSincludedwithorattachedtoeachproduct.Enerpac cannot be responsible for damage resulting from unsafe use of product, lack of maintenance, or incorrect product and system application.
PrODuCT DESCrIPTION:
Enerpachydraulictorquewrenchesaredoubleactinghand-controlledtoolsdesignedtotightenandloosenboltedconnections.Anyunauthorizedchangeindesign,constructionorusageofthetorquewrenchisforbiddenforsafetyreasonsandwillvoidthewarranty.Hydraulicflowandpressurethatissuppliedtothewrenchisconvertedtoarotarymotionbymeansofahydrauliccylinderanddrivelever.Advancingandretractingoilflowfromthepumpiscontrolledbyaremoteoperatedvalvewithpendantcontrol.Theadvancepressuresuppliedfromthepumpmustbelimitedto10,000psi(700bar)forS&WSerieswrenchesand11,600psi(800bar)forSQD&HXDwrenches.
WARNING:Useonlyheavy-dutyimpactsocketsforpowerdrivenmachinewrenches,accordingtoISO-2725andISO-1174;DIN 3129andDIN 3121,orASmE-B107.2/1995.Donotusewornordamagedsocketsdrives.Theymustfitpreciselyonthenutorboltbeingtightened.DonotusemetricsizesocketsorAllen-Keydrivesonimperialnutsorboltsorthereverse.Alwayssecurethesockettothesquaredrivetopreventthesocketfromslippingoff.
Alwayssecurethesockettothesquaredrivetopreventthesocketfromslippingoff.
Usethepropersizedsocket(S-wrench)orcassette(W-wrench)onthenut.
1. Drive Unit
2. Square Drive
3. Quick-Release
4. Socket
5. Retainer Pin
6. 0-Ring Pin Retainer
S-Series W-Series
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� �
®
®
P(A)
T(B)®
®
®
Thetorquewrenchmustbeproperlypositionedmanuallytomakesurethatthereactionforceissafelytransmittedviatherereactionarmandnotviaothertorquewrenchparts.Neverusethetorquewrenchwithoutthereactionarm.
Avoidtiltingthewrench.Donotuseextensions.Ifthisisunavoidableduetothereactionpoint,thetorquemustbereduced.Anextrasupportmustbeusedtominimizetiltingandfriction.Whenindoubt,contactEnerpac.
Makesureallcouplersandhosesarefullyconnectedandthatoilcanflowfreelyfrom(AtoA)and(BtoB).Incorrectlymountedcouplerscanstillbeclosed,withtheresultthatoilonthewrenches’retractside(B)canbepressurizedbythepumps’advanceside(A).Thesafetyreliefvalveonthewrenchesretractsidewillopenandpreventoverpressurization.
BLEEDING AIR FROM THE SYSTEM
Duringfirst-timeoperation,thehydraulichosesandwrenchcanbefullofair.Airmustberemovedfromthesystemforsafeandproperoperation.Removetheairbyconnectingthehosesettothevalveonthehydraulicpump.Connectthecouplersontheotherendofthehosetogethercompletingthehydrauliccircuit.Cyclethepumpandvalveseveraltimesbyusingtheremotecontrolpendant.Thiswillforceanyairintothereservoirandouttotheatmosphere.Next,connectthetorquewrenchtothehoseset.Asbefore,cyclethepumpandvalveseveraltimesbyusingtheremotecontrolpendant.Thiswillforceanyairintothereservoirandouttotheatmosphere.
OPERATIONRefertotheinstructionbookletsuppliedwithtorquewrenchsystemforproperoperatinginstructionsandprocedures.
Enerpacrecommendstheuseofspeciallooseningliquidsorsprays.Enerpacoffershydraulicnutsplitterstoremoverustedorfrozennuts.
Becarefultoavoidpinchpointsbetweenthereactionarmandthenutsandboltsyouaretightening.
0
Becarefulnottoworkin-linewiththenutsandboltsyouaretightening.
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Hydraulic Systems Thecomponentsdescribedinthefirstsectionofthishandbookareconnectedtogethertoformabasichydraulicsystemasshownbelow.
BEFORE USING THE HYDRAULIC SYSTEM
•Checkthatallconnectionsaretightandleakfree.Itisespeciallyimportanttocheckallcouplerconnectionsbecause,afterthesystemhasbeenpressurized,youwillnotbeabletotightenthecouplersbyhandandusingtoolswilldamagethecouplers.
•Removeairfromsystem.
•Checkoillevelinpumpreservoir.Fillonlytolevelindicatedonthepump.Over-fillingthereservoirmaycausethepumptomalfunction.Fillthereservoironlywhenallcylindershavebeenretracted.Ifyouaddoilwhenthecylinderisextended,thereservoirwilloverfloworbepressurizedwhenyouretractthecylinder.
•Whenusinganelectric,air,orgaspoweredhydraulicpump,energizethepumponlywhenthedirectionalcontrolvalveisintheneutralposition.
•Inliftingsystems,useliftingbasesthatspreadouttheload.Thisreducesthecontactpressurebetweenthecylinderandthefloorandavoidssinkingorpunchingofthefloor.Mostworkingfloorscannotwithstandhighloads.
•Useshut-offvalvesfortemporaryloadholding.Neverholdaloadonacouplerordirectionalcontrolvalve.
•Nevergetunderaload.
•Usecribbingforloadholdingforlongperiods.
•Donotusehosetoliftorpullequipment.
NPTconnectionsrequirethreadsealant.Leavefirstthreadbaretopreventsealantfromenteringhydraulicsystem.
Foreasymake/breakconnections,installacouplerinthegaugeadaptorport.Thenuseahosewithacouplerendinsteadofathreadedend.
BASIC HYDRAULIC SYSTEM
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Removing Air from the Hydraulic System
How to tell if there is air in the system
Hydraulicsystemoperationshouldbeinstantandsmooth.Foreverypumpstroke,thecylindershouldriseevenly.Ifthecylindermovementiserraticorjerky,theremaybeairinthesystem.
How to remove air from the system
Airwillalwaysgotothehighestpointinthesystem.Thisincludestheinsideofthecylinderplunger.Thatiswhythecylindermustbeturnedupsidedown(single-acting)orlaidonitsside(double-acting)togettheairout.Toremoveairfromthesystem,positionsetupasillustratedbelow.
NOTE:double-actingcylindersmusthavethecouplersfacingup.
Fullyadvanceandretractthecylinder2or3times.Youcanusuallyheartheairescapingthroughthereservoir.
ReservoirVented
AIRHighestpointinthesystem
AIR
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PRESSESWhenusingapress,havenoloosepiecesinthesetup.Ifyouneedtousespacerstogettoyourworkpiece,thespacersshouldbeconstructedinonesolidpiece.Spacerscanbetackweldedtogetherforincreasedstability.
Whenusinghorizontalpresses,tieallpieces.Donotrelyonfrictiontoholdthepiecesup;ifonepiecefallsorbreaks,thewholesetupwillfall.
ELEMENTS OF A SAFE HORIZONTAL PRESS SETUP
1 –Theramandallpartsofthesetuparecenteredonthelineofforce.
2–Blockshavebeentackweldedtogethersothattherearenoloosepiecesinthesetup.
3–Blockassemblyissuspendedbyachainandgearissupportedfrombelow.
Dependinguponyourindividualapplication,guardsand/oradditionalcontrolsmayberequired.Itistheresponsibilityoftheusertoprovidethesedevicesifrequired.
REMEMBER:Keepyourhandsoutoftheworkingareaandstandclearofthepresswhenpressureisapplied.
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MAINTENANCE SETTheEnerpacmaintenancesetincludesapump,hose,cylinder,gauge,andseveralextensionsandattachments.Themaintenancesetisdesignedsothatyoucancreatesetupsforuseinavarietyofsituations.
REMEMBER: Neverexceed5,000psi[350bar]whenusingcylinderattachments.Alwaysuseagauge
toverifytheoperatingpressure.GaugeresponseinaliftingsituationisdescribedunderGAUGESonpage13.
Thefirststepinaddingattachmentstothecylinderistomountthebaseattachmentor
adaptorsaddleasshownbelow.Snugtheboltsonthebaseattachmentwithawrench.Whenusingthreadedattachments,besureallthreadsarefullyengaged.Tightenbyhand;notoolsarerequired.Whenusinglock-onattachments,alwayssecureconnectionwithalockpin.
Themaintenancesetextensionsandattachmentsarenotmadeofstandardpipematerials.Theyaredesignedtobemuchstronger.Standardgradepartswillbendorbreakwithmuchlessloadthanthemaintenancesetcomponents.SeeSETUPCONSIDERATIONSonpage8andEXTENSIONSonpage30forguidelinesonusingyourowncylinderextensions.
Twoexamplesofmaintenancesetsetupsareshownbelow.Notethatallpiecesaresecurelyfastenedtogether.
Adaptor SaddleBase Attachment
Lock-onClamp Toe
Lock-onConnector
Extension Tube
Collar Clamp Head
Saddle Threaded Adapter
ThreadedAdapter
Spreader Toe
BaseAttachment
Lock-on Connector
Male Lock-onAdaptor
Extension TubeRubber Flex Head
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� CollarToe
� LockPins
� LockPin
ChainwithHook
CollarToe
CollarClampHead
18"ExtensionTube
Lock-onClampToe
DoubleChainPlateattachedtotheplungerusinga
ThreadedAdaptor
�RubberFlexHead
� 5"ExtensionTube
5"ExtensionTube 10"ExtensionTubeLock-onConnector
� PipeCoupling
SingleChainPlate
� SerratedSaddle, attachedtothePlunger usingaThreadedAdaptor
BaseAttachment
ThreadedAdaptor
� FlatBase
FlatBase,attachedtotheBaseAttachmentusingaThreadedConnector
SmoothSaddleattachedtotheplunger
usingaThreadedAdaptor
ChainwithHook
DoubleChainPlate��attachedtotheBaseAttachmentusingaThreadedConnector
� LockPin
APPLICATION EXAMPLES OF THE MAINTENANCE SET
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EXTENSIONSInmanysituations,youwillneedtouseextensionsinyoursetup.Theextensionshouldbeonerigidpiece.Whenselectingextensionmaterial,keepinmindthathollowshapesarestrongerthatsolidpieces.
SUITABLE CROSS SECTIONS
WORK AREAExamineyourworkareabeforepressurizingthehydraulicsystem.Again,youwillbelookingforwaystoprotectyourselfandothers,andwaystoprotectyourequipmentandotherproperty.
OBSERVE THE FOLLOWING
•Checkhosesandcouplers.Hosesshouldhavestraightrunsandbefreeoftanglesorkinks.Couplerconnectionsmustbefullytightened.
•Protectyourequipmentfromtheworkyouaredoing.Forexample,trytolocatetheequipmentawayfromweldspatterandpaintover-spray.Useprotectivecoverswhennecessary.
•Haveadequateoperatorspaceandclearaisleways.Forinstance,donotboxyourselfinbetweenthesetupandawall.
Hydraulicequipmentshouldbestoredinadryenvironmentattemperaturesabovefreezing.Storepumpsandcylindersonasturdyshelfandhosesinarack.Thehoserackshownkeepshosesfrombecomingtangledandkinked.Therackcanbemadebycuttingnotchesinasectionofangleiron.
Setup Considerations
Equipment Storage Increaseefficiencyandprotectyourequipmentbyusinggoodstoragetechniques.
REMEMBER:Neverhaveanyloosepiecesinyoursetup.Loosepiecesmayshiftandflyoutwhenpressureisapplied.Useone-pieceextensionsortackweldthepiecestogether.
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1
2
3
BRIEF SUMMARY
You should be familiar with all of the information presented in the Hydraulic Safety Seminar. However, the three practices shown below are essential to promoting personal safety and will help you to protect yourself and others.
You must be diligent when it comes to safety. We can provide high quality tools and accessories, but it is up to you to be aware of the situation that you put yourself and others into.
When you practice safety, you also benefit by being more efficient and by increasing the useful life of your tools.
KEEP OuT FrOm uNDEr LOADS SuPPOrTED BY HYDrAuLICS.
ALLOW FOr A SAFETY FACTOr. uSE EQuIPmENT AT 80% OF mANuFACTurEr’S rATING.
80% OF CYLINDEr CAPACITY Or TONNAGE
NO LOOSE PIECES.uSE SOLID PIECES Or TACK WELD SECTIONS.
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QUESTIONS
1. Which hydraulic components are rated in terms of capacity or tonnage?
2. True or False? Side loading can damage a jack or cylinder by distorting the wiper seal and bending the plunger.
3. What should you do if you have to lift a load further than the rated stroke of the jack or cylinder?
4. True or False? It is OK to work under a load that is held up by a jack or cylinder as long as the load doesn’t exceed the capacity or tonnage rating.
5. True or False? You should never weld or otherwise modify a cylinder to attach a base or other support.
6. True or False? Adding an extension to a pump handle will give you more leverage when pumping.
7. True or False? You should tighten coupler connections with a wrench to be sure they are tight.
8. If cylinder movement is jerky, what may be wrong?
9. When you add extensions to a cylinder, how does it affect the maximum operating pressure?
10. True or False? The 80% rule applies to cylinder stroke and cylinder capacity.
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ANSWERS
1. Jacks, cylinders, presses, spreaders, and other accessories have capacity or tonnage ratings. (See page 5) NOTE: Pumps are rated for maximum operating pressure in psi [bar].
2. True. Side loading can damage a jack or cylinder by distorting the wiper seal and bending the plunger. Side loading also creates an unstable setup which may shift or fall. (See page 6)
3. If you need to lift a load further than the rated stroke, block the load, raise the level of the cylinder with a sturdy support, and continue the lift. You could also switch to a jack or cylinder with a longer stroke. (See page 7)
4. False. Never work under a load that is held up by a jack or cylinder. The load must be securely blocked before anyone goes under it. (See pages 7-9)
5. True. You should never weld or otherwise modify a cylinder to attach a base or other support. (See pages 8-9)
6. False. Adding an extension to a pump handle will not give you more leverage, but it will make the pump unstable. (See page 9)
7. False. You should tighten coupler connections hand tight only, but do be sure that all threads are fully engaged. (See page 11)
8. If cylinder movement is jerky, air may be trapped in the hydraulic system. (See page 15)
9. When you add extensions to a cylinder, the maximum operating pressure must be cut in half, to 5,000 psi [350 bar]. Always use a gauge to verify the operating pressure. (See pages 16-17)
10. True. The 80% rule applies to cylinder stroke and cylinder capacity. Following the 80% rule will result in more stable setups and prolong the life of your equipment. (See pages 8-9)
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Australia and New ZealandActuantAustraliaLtd.BlockVUnit3RegentsParkEstate391ParkRoadRegentsParkNSW2143(P.O.Box261)AustraliaT +61297438988F [email protected]
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