PPT. LP WARRANTY

WARRANTY

lPT, LP wi l l repai r or rep lace any por t ion of the equipment which proves to be de-fect ive wi th in a pg lod of 3 months f rom the da ie of sh ipment upon the re turnof the same to PPT, LP at Purchaser 's expense when such defe 'c ts are due todefect ive mater ia ls suppl ied by PPT, LP or defect ive workmanship of i ts employees,prov ided that the equipment shal l have been proper ly ins ta l led, mainta ined, andut i l ized dur ing the per iod covered by th is warranty , and prov ided fur ther that th iswarranty shal l extend _o1! ' to the Purchaser and no other par ty by any means, andprov ided, . f ina l ly , that PPT, LP shal l in no event be responsib16 fc i r the cost o f f ie ldlabor , ca l ibrat ions or o ther charges incurred by the Purchaser . At a l l t imes, ppT, Lpsha. l l hav.e-and possess the so le r ight and opi ion to determine whether to repai r orrep lace defect ive equipment . Machinery par ts , accessor ies and components manu-factured by others are warranted on ly to the extent o f the or ig ina l manufacturer 'swarranty.

EXCLUSION OF OTHER WARRANTIES:

EXCEPT FOR THE ABOVE EXPRESS WARRANTY, THERE ARE NO WARRANTIES,INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FORANY PARTICULAR PURPOSE, WHICH EXTEND BEYOND THE DESCRIPTION OF THEEQUIPMENT ON THE FACE HEREOF, NO WARRANTIES OR REPRESENTATIONS ATANY TIME MADE BY ANY SALES REPRESENTATIVE OF PPT, LP SHALL BEEFFECTIVE TO VARY OR EXPAND THE FOREGOING EXPRESS WARRANTY OR ANYOTHER TERMS HEREOF.

Precision Post Tension, LP704-8 West SimondsSeagoville, Texas 75159 USA

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TABLE OF CONTENTS

PPT, LPContents

Equipment Warranty

Warranty Cla imsPar ts Order ingAssembly & Genera l Inst ruct ionContro lsContro l o f Jack ing ForceSet t ing Pressure Regula tors . . . . . . . . .Jogging Di rect ional Contro l ValveTension ing CableGauge Cal ib ra t ion. . . . . . . . . . . . . .Gauge - Pressure Rela t ionsh ipCal ib ra t ion Procedures . . . . . . .Set t ing Gauge SnubbersChanging GaugesMaintenance of St ra iner and Oi l F i l terClean ing the St ra iner . . . . . . . . . . .Hydrau l ic Oi l . . . . . . . . . .Repai r ing Hydrau l ic Leaks in F i t t ing Jo in tsPump Uni t Cutaway l l lus t ra t ionMani fo ld and Cont ro l Va lve Hose l l lus t ra t ion . . . . . . . . . . . . .Par ts L is t #1 through #32. . . . . . . .Par ts L is t #33 through #51 . . . . . . . . .S tant ion and Chuck Box Inspect ion. . . . . . . . . . . . .Rebui ld ing Cy l inder . . . . . . . . . . . . . .Ram Cutaway l l lus t ra t ionPar ts L is t #52 through #79. . . . . . . . .Mani fo ld Va lve l l lus t ra t ions . . . . . . . . . . .Par ts L is t #80 through #92. . . . . . . , .Faul t Test ing

1233457788

101010111112121212131415161717192021222324Notes

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WARRANTY CLAIMS

, Pro.per .presentat ion of warranty c la ims wi l l expedi te the c la im handl ing. Theprocedure is s imple and oui l ined as fo l lows:

(a) Ngl i fy PRESTRESS suPPLY, rNC. of any mar funct ion or fa i ture ofPPT, LP Equipment .

(b) Order Genuine PPT, LP rep lacement or repai r par ts . Use of o thers wi l ll imi t or vo id warranty cons iderat ion

( . . ) A lways g ive model and ser ia l number of equipment .(d) Return damaged or mal funct ion ing par ts to ppT, Lp

for warranty cons iderat ion.(e) warranty c la ims must be completed, s igned by owner , and returned

fre ight prepaid to the factory wi th in a per iod o i SO days.

PARTS ORDERING

_l"!3tt_oI lepJa_cgment parts for your PPT, LP equipment shoutd be orderedf rom PRESTRESS SUPPLY, lNC. Stanc iard hardware i t 'ems are noted byan; i t terthe par t number and may be loca l ly ava i lab le .

When orqqr lng repai r or rep lacement par ts , a lways re fer to model and ser ia lnumber of y .our PPT, LP equipment . The ser ia l number and model p la te is locatedon the rear bot tom area of the machine between motor and reservo ' i r .

Most eve jy par t order is .an.emergency to some degree. When order ingpar ts {or your PSI HERCULES JACK, usd the- manual drawings to locate the re-qu. i . red.par t or par ts . Select proper re ference number f rom dr iwing and mat th i tw i th re ference number on par ts l is t . Th is wi l l g ive you proper par t nu inbers to orderand assures you of rece iv ing the par t wi th the lea6t poss ib le be lay.

. 4 lyayq check par t number and descr ip t ion caref u l ly . A few minutes ver i fy -ing par t ident i f icat ion wi l l save you many houis o f unprof i tdOte "down t ime."

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ASSEMBLY INSTRUCTIONS

Read operat ing inst " ruct ion manual .

Remove s t ress ing jack f rom shipp ing pa l le t ; remove the rear t i re f rom theoperator 's s ide of the machine. Use a fork l i f t to p ick up the machine f romthe same s ide. Replace the t i re and lower the jack do l ' ly wheel . D isposeof pa l le t .

Connec. t the pu l l and return hoses to the ram. Do NoT a l low any d i r t orcontaminat ion to get in to the hoses or the ram.

At tach appropr ia te length of power cord to the motor s tar ter(use on. ly a qual i f ied e lect r ic ian) . conf i rm proper vor tage once theelect r ic i ty is connected. Turn the machine on and check motor fan ro tat ion.l f the ro tat ion is opposi te o f the d i rect ion ar row, change the po lar i ty .

Conf i rm o i l leve l in tank.

Turn machine on and extend and ret ract the ram severa l t imes hold ing theva. lve open for 4 to 5 seconds af ter the ram has s topped moving. Th i ;wi l l remove any a i r in the system.

Prepare an assembly to hang or crad le the ram at the l ive end of the form.Make sure there is enough adjustab i l i ty to ensure the ram can reach a l lo f the s t rands whi le remain ing para l le l w i th each s t rand be ing tens ioned.

The s t resq ing jack is nqt ca l ibrated. To ensure that you are s t ress ing tothe correct load, have the jack ca l ibrated ( fo l lowing ihe inst ruct ions in thecal ibrat ion sect ion of the manual ) .

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GENERAL INSTRUCTIONS

Do not a l low anyone to operate the machine unt i l they have s tud ied andfu l ly understand the inst ruct ions. The operator should pract ice operat ingthe s t ress ing j .ack wi thout any s t rand in the ram. This can be dor ie Oy pul t -ing the ram a l l the way back (unt i l i t bot toms out ) . Fu l l pressure can-bbexer ted wi th no harm to the machine. The operator should pract ice movingthe ram, set t ing the pressure regulators and us ing the easd of f funct ion.

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Before tens ion ing each morn ing, the operator shou ld inspect the hydrau l ichoses and e lect r ic cable for n icks, cuts and abras ions and check thehydrau l ic f lu id leve l . A lso inspect the ram beh ind the chuck box to conf i rmthat noth ing has been dropped in to i t ( jaws, rebar , s t rand, e tc . ) .

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Key453386874651

Par t No.c8045c8033c8084c8085c8046c8051

Descr ip t ionIn i t ia l Gauge, 0 - 10,000 lbs .Main Contro l ValveIn i t ia l Regulator Contro l ValveFina l Regulator Contro l ValveFina l Gauge, 0 - 100,000 lbs .Complete Power Uni t and Ram Decal Set

(Not shown)

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CONTROLS

Direct ion Contro l Valve

The le f t hand va lve on the dash cont ro ls the d i rect ion the ram moves. Pul lon the handle pu l ls the cable, push returns the ram. The ram wi l l not re turnun less the In i t ia l -F ina l -EaseOf f hand le is in the F ina l pos i t ion .

I n i t ia l -F i na l -EaseOff Valve

The r ight hand va lve se lects In i t ia l or F ina l for tens ion ing, or EaseOff tore lease the pressure in the cy l inder s lowly , a l lowing the chuck to seatgradual ly . In terna l ly in the hydraul ics , a car t r idge va lve must be pressur-ized open to per form the EaseOff funct ion. l t is normal for the machine tosound l ike i t i s bu i ld ing pressure even though i t does not show on the gauge.Actual ly the F ina l Gauge reading wi l l drop dur ing EaseOff . The ln i t ia l read-ing wi l l d rop dur ing Return .

In i t ia l Pressure Regulator

Cont ro ls the max imum pressure when the In i t ia l -F ina l -EaseOf f hand le is inthe In i t ia l pos i t ion .

F ina l Pressure Regulator

Cont ro ls the max imum pressure when In i t ia l -F ina l -EaseOf f hand le is inF ina l pos i t ion. Note: F ina l pressure regulator must be set to a h igherpressure than In i t ia l pressure regulator .

0 - 10,000 lbs . Gauge ( ln i t ia l )

Used to measure the tens ion dur ing In i t ia l tens ion ing. Th is gauge has are l ie f va lve which protects the gauge f rom over load.

0 - 100,000 lbs . Gauge (F ina l )

Used to measure tens ion dur ing F ina l tens ion ing. Ind icates the tens ion onthe ram when the Di rect ional Contro l Valve is in the pu l l pos i t ion.

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Al l f low and regulat ion of the o i l is cont ro l led by the:

Main Contro l ValveMain Valve BodyGauge Valve BlockGauge Snubbers

Car t r idge Valves located in these housings manage the f low accord ing to whichlever the operator pushes or pu l ls . Adjustab le Gauge Snubbers protect the gaugesf rom sudden shock and pulsat ions. Gauges should move smooth ly anO rap i -Otyenough to re f lect the des i red tens ion by the t ime the s t rand s tops moving, but shouldnot be je rky or bounce. (See Set t ing Gauge Snubbers , page 11) .

The car t r idge system was des igned so i f a prob lem develops, a Car t r idge Valve canbe eas i ly removed and rep laced by f ie ld personnel . C leanl iness is o f the utmostimpor tance when serv ic ing th is un i t , as most o f the va lves have smal l or i f ices whichcould be b locked. Caut ion should a lso be exerc ised when rep lac ing hoses andl ines to make sure they are f ree of debr is or d i r t .

Press_ure bypass va lves re fer red to as: In i t ia l Pressure Regulator and F ina l Pres-sure.Regulator , a l low the tens ion to be cont ro l led so the ram wi l l s top when a presettens ion is reached. The accuracy of set t ing of automat ic regulators should bb ver i -f ied by running to a des i red target load severa l t imes wi thouiad just ing the regulatorto assure constancy. Th is test should be per formed at the beginn ing of each bpera-t ion. Th is can be accompl ished wi thout the use of s t rand by re t ract ing the ram a l lthe way back. Then your pressure can be adjusted.

SETTING PRESSURE REGULATORS

The le f t -hand regulator cont ro ls the In i t ia l tens ion pressure.

The r ight -handregulator cont ro ls the F ina l tens ion pressure.The F ina l tens ion regu-

CONTROL OF JACKING FORCE

forln i t ia l regulator .

Before p lac ing ram on the s t rand:

(1) Set se lec tor to F ina l .

(2) Pul l D i rect ion Contro l Valve and bot tom ram.

(3) S lowly turn the F ina l regulator c lockwise unt i l gauge reads des i redFina l tens ion.

(4) Ease pressure of f w i th EaseOff handle and return ram an inch or so.

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Release tens ion, then pul l again to see i f the tens ion repeats . l f i t doesnot , reset and recheck.

Se lec t In i t ia l .

S lowly turn the In i t ia l regulator c lockwise unt i l the In i t ia l gauge readsthe des i red pressure.

(8) Release tens ion, then pul l again to see i f the tens ion repeats . l f i t doesnot , reset and recheck.

JOGGING DIRECTIONAL CONTROL VALVE

The system is des igned to temporar i ly 'Hold ' the h ighest pressure reached.Once the ram has s topped moving, jogging the Di rect ional Contro l Valve causespressure surges to the system. Al though i t may not be enough to actua l ly move thest rand more, i t w i l l most l ike ly increase the gauge reading, resu l t ing in inaccuratetens ion ind icat ions. DO NOT JOG DIRECTIONAL CONTROL VALVE!

Cal ibrat ing wi th a shor t p iece of s t rand can cause s imi lar e f fects as jogging,because pressure is reached instant ly when no e longat ion of the s t rand has to oc-cur . Th is is why i t is recommended to ca l ibrate on a bed wi th the same length ofs t rand you would normal ly use. (See Cal ibrat ion Procedures, page 10) .

TENSIONING CABLE

The Prest ressed Concrete Inst i tu te recommends:

Af ter St rands have been pos i t ioned, an in i t ia l tens ion in the range of 5% to25" / " o f the f ina l force should be appl ied.

Reference marks should then be estab l ished f rom which e longat ion can bemeasured. F ina l tens ion ing forces can be measured. E longat ion can be accurate lymeasured f rom these reference marks. E longat ion measurement shal l take in toaccount a l l operat ional losses and compensat ions in the tens ion ing system.

ln i t ia l Tens ion:

(1) Set In i t ia l and F ina l Regula tors to proper tens ions as out l ined in Set t ingPressure Regulators .

(2) Set se lec tor to In i t ia l .

(3) Pul l D i rect ion Contro l Valve unt i l gauge reads the preset in i t ia l tens ionand s tops. DO NOT JOG! Mark Chuck Box to measure e longat ion.

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Final Tension

(1) Set se lec tor to F ina l

(2) Hold Di rect ional Contro l Valve unt i l gauge reaches the preset F ina ltens ion and s tops. Release the t ran"Ote, - DO NOT JOG! Check theelongat ion. Loads ind icated by the gauges should cont ro l the tens ion-ing, wi th e longat ion checked on every s t rand.

CAUTION: THE OPERATOR SHOULD NOTE THE TENSTON ANDELONGATION TO SEE THAT NEITHER ARE EXCEEDED

DURING TENSIONING.

Return ing Ram

(1) Ease-Of f the pressure severa l thousand pounds to a l low the chuck tograb the s t rand.

(2) Push the Di rect ion Contro l Valve unt i l the ram fu l ly re turns. Now youcan remove the s t rand.

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GAUGE PRESSURE RELATIONSHIP

PSI Hercu les Jacks are composed of two separate systems, in ter - re la ted butseparate. They are:

1 . The Gauge System

2. Pressure Contro l System

1. The gauges measure how much o i l p ressure is in t roduced in to the Jack c i rcu i t ,noth ing e lse .

2. The pressure cont ro l system governs o i l pressure to put in to the Jack c i rcu i t .The regulators on the panel te l l the system what pressure to ho ld .

GAUGE CALIBRATION

Why ca l ibrate the gauges? l t 's not to check the gauges, but to measure thef r ic t ion loss in the jack ing cy l inder . Th is is why a new ca l ibrat ion is requi red af terrebu i ld ing the cy l inder .

The seals in the PSI Hercu les Jack are pressure energ ized for a pos i t ivesea l . Because the sea ls are dragg ing on the cy l inder and rod, a cer ta in amount o fpressure is requi red to o f fset th is drag, which, i f not a l lowed for , w i l l g ive an incor-rect gauge reading. Th is f r ic t ion (drag) is constant and wi l l cause no problem i fcorrect ca l ibrat ion and operat ing procedures are fo l lowed.

CALIBRATION PROCEDURES

Gauges, Cy l inders , and Power Uni ts must be ca l ib ra ted as a SYSTEM inthe SAME MANNER they are used in Tens ion ing operat ions. The ca l ib ra t ion shou ldbe per formed through and just beyond the expected range of tens ion ing wi th actua land ind icated gauge pressures estab l ished at var ious load points .

Cal ibrat ions should be per formed by an approved test ing laboratory , ca l i -brat ion serv ice, or under the superv is ion of a reg is tered profess ional engineer , anda cer t i f ied ca l ibrat ion curve should be mainta ined for each tens ion ing system. Pres-sure readings can be used d i rect ly i f the ca l ibrat ion determines a reading is wi th inthe proper to lerance. Serv ice condi t ions wi l l determine the f requency of ca l ibra-t ions. However , ca l ibrat ion shal l be per formed at any t ime a tens ion ing systemindicates er rat ic resu l ts , and in any case at in terva ls not greater than 12 months

When ca l ibrat ing gauges wi th a s t ra in gauge, the fo l lowing proceduremust be fo l lowed:

1. Set regulators for requi red pressure before p lac ing Stant ion on s t rand.Strand should be in the form of average length Jack wi l l be used on.

2 . Inser t s t ra in gauge.

NOTE: The Di rect ional Contro l Valve should be he ld in pu l l unt i l the ram stops, thenre leased. Do not jog the handle as th is causes pressure surges and wi l l a f fectaccuracy. (See Set t ing Gauge Snubbers , page 11) .

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CAUTION: DO NOT ALLOW FINAL TENSION TO BEEXCEEDED FOR SIZE OF STRAND BEING USED.

Fina l Tension Gauge

3. Pul l D i rect ional Contro l Valve handle and hold a l lowing ram to s top.4. Compare s t ra in gauge and f ina l gauge. Adjust as needed.5 . Return ram. Pu l l aga in and compare.6. Repeat s teps 3 thru 5 as necessary for each pressure set t ing des i red.

In i t ia l Tens ion Gauge

7. Pul l D i rect ional Contro l Valve handle and hold a l lowing ram to s top.8. Compare s t ra in gauge and tens ion gauges. Adjust asheeded.9 . Return ram 1 or 2 inches, pu l l aga in and compare.

10. Repeat s teps 7 thru 9 as necessary before cont inu ing.

SETTING GAUGE SNUBBERS

The gauges-are protected f rom rap id pressure changes and pulsat ions byGauge Snubbers . l f the snubbers are improper ly se t , the gauges can be damagedor wear .qu ick ly . l f the gauge pointer moves too s lowly , the s t iand tens ion may bereached, caus ing the ram to s top moving, but the po inter may not be to the pr6perreading yet . Th is can g ive a fa lse ind icat ion the Jack is not per forming cons is tdnt .A lso, i f the snubbers are set too t ight , the gauges may not zbro.

The gauge pointer should move quick ly as pressure is increased, but shouldnot s lam i f pressure is suddenly appl ied. To ad just , loosen lock nut , turn c lockwiseto increase amount o f snubb ing, or counterc lockwise to decrease snubbing. Re-t igh ten lock nut .

CHANGING GAUGES

Remove hydrau l ic l ine f rom gauge snubber .Remove the three gauge mount ing bo l ts and l i f t gauge out o f panel .Remove snubber f rom gauge. Use a wrench on f la ts prov ided on gaugein le t (on both gauge & snubber) .Apply thread sealant to pressure connect ion on gauge tak ing care not toa l low sealant to b lock gauge por t . Insta l l snubber , again us ihg wrench onI la ts prov ided. Do not over- t ighten snubber and sp l i f rubber hbus ing.Place new gauge on panel and re insta l l bo l ts .Bot tom the ram and set pressure to 1 ,500 to 2 ,000 lbs. to remove t rappedai r . P lace a smal l pan or rag under the snubber to catch lost o i l . Thenret ighten.Check gauge snubber set t ings (see above) .New gauges must be ca l ibrated. (See Gauge Cal ibrat ion, page 10) .

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MAINTENANCE OF STRAINER AND OIL FILTER

The pump is protected f rom fore ign par t ic les by a s t ra iner located ins ide thetank. (See pump uni t breakdown, page 13) . The o i l is then f i l tered between thepump and Di rect ion Contro l Valve. The o i l f i l ter MUST be changed quar ter ly . Theo i l shou ld be changed and the s t ra iner serv iced annual ly . Under ex t reme cond i -t ions the un i t w i l l requi re serv ic ing more of ten. l f the pump becomes excess ive lynoisy or per formance fa l ls o f f , the s t ra iner may need c leaning. l f the ar row on top ofthe car t r idge f i l ter is in the red area, t ry to move i t back in to the green. l f i t w i l l notmove then the car t r idge needs to be rep laced.

CLEANING THE STRAINER

1. Dra in o i l by removing 314" p ipe p lug f rom inspect ion p la te .

2. Remove s t ra iner , and wash in minera l sp i r i ts . B low c lean andre insta l l a l l par ts .

3 . F i l l tank wi th c lean o i l .

HYDRAULIC OIL

Use any h igh qua l i ty pet ro leum based hydrau l ic o i l , l igh t tu rb ine dext ron, orA.T.F.NOTE: Under no c i rcumstances shou ld a heavy o i l be used.

REPAIRING HYDRAULIC LEAKS IN FITTING JOINTS

O-r ing jo in ts shou ld be repa i red by rep lac ing the O-r ing and reassembl ing.

Taper jo in ts shou ld be repa i red by the fo l lowing method:

1 . Unscrew jo in t .2 . Clean jo in t wi th safety so lvent . -

3 . Pr ime wi th Loct i te Pr imer Grade T.4. A l low to dry .5 . Coat jo in t wi th Loct i te P ipe Sealant wi th Tef lon #59231.6 . Assemble jo in t .

NOTE: DO NOT use Tef lon Tape Sealant on p ipe jo in ts . Tef lon Tape reducesthe f r ic t ion, a l lowing jo in ts to be t ightened too far and caus ingpermanent damage. Jo in ts wi l l a lso v ibrate loose and leak.

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denotescontinueldrawing

J

hoses to next

+

I

Pump Unit Cutaway(13)

(Denotes HoseContinuing toNext Drawing)

I

Manifold and Hose

Main Control Valve

Key Part No.1 C80012 C80023 C80034 C80045 C80056 C80067 C80078 C8008I C800910 c801011 C801112 C801213 C801314 C801415 C801516 C801617 C801718 C801819 C801920 c802021 C802122 C802223 C802324 C802425 C802526 C802627 C802728 C802829 C802930 c803031 C803132 C8032

Descr ip t ionHose f rom Pump to Reservo i r Case Dra inHose f rom Main Valve Return to Reservo i rHose f rom Gauge Block to Reservo i rHose f rom Valve Body to Reservo i rHose f rom Oi l F i l ter to Main ValveSuct ion HoseHose f rom Pump to F i l te rMotor Wi r ing Dog HouseElect r ic Motor (Baldor cm2334T 256to) .Hydrau l ic Pump (Hydra p fwh10- lsay-nn) .Coupl ing Hous ing and AdapterCoupl ing Par t A (Not Shown) Motor s ideCoupl ing Par t B (Not Shown) Pump s ideCoupl ing Inser t (Not Shown)High Pressure F i l te r *Replacement F i l te r E lement (Not Shown)*Reservo i r F i l le r CapIn-Tank Stra iner (Not Shown)F ina l Gauge SnubberIn i t ia l Gagge SnubberHose f rom Gauge B lock to In i t ia l GaugeIn i t ia l Un lock L ineIn i t ia l to Gauge B lock L inePressure L ine to H.P. S ide of Gauge BlockHose f rom Gauge Block to F ina l GaugeGauge Dra in Unlock L ineHose f rom Valve to Valve Body F ina lHose f rom Return Ram to Mani fo ldMain Valve to Valve Body (1)Main Valve to Valve Body (2)Hose f rom Pul l S ide o f Ram to Mani fo ldEase-Of f L ine

* lnd icates par t may be found loca l ly .

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Key Part No. Descr ipt ion33 C803334 C803435 C803536 C803637 C803738 C803839 C803940 c804041 C804142 C804243 C804344 C804445 C804546 C804647 C804748 C804849 C804950 c805051 C8051

Main Contro l ValveHorn to L ight K i t (Not Shown)Replacement Horn (Not Shown)Replacement L ight (Not Shown)Replacement St robe L ight Bulb (Not Shown)Horn But ton (Not Shown)On Power But ton (Not Shown)Of f Power But ton (Not Shown)Starter Overload Circuit , 220 volt (Not Shown)Star ter Over load Ci rcu i t , 440 vo l t (Not Shown)TransformerReplacement Wheel and T i re (Foam F i l led)In i t ia l Gauge, 0 - 10,000 lbs .F ina l Gauge, 0 - 100,000 lbs .Glass Replacement LensLexan Replacement LensSnap Ring for LensLens GasketComplete Power Uni t and Ram Decal Set

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1.

RAM AND CHUCK BOX INSPECTION

The fo l lowing inspect ion should be per formed month ly .

Turn ram ups ide down and wash out the s tant ion and chuck box. Thenlub. r icate wi th l ight o i l . V isual ly inspect the ram and f i t t ings for cracksor breaks, e i ther is cause for immediate rep lacement .

Check the chuck box and s tant ion wear p la te . l f not f la t and smooth,rep lace them. l f you are us ing the nose reducer , inspect i t for deformat ionand rep lace i f necessary.

Check cy l inder rod for any abnormal marks or scrapes that could be thes igns o f a warped or damaged cy l inder rod.

REBUILDING CYLINDER

Remove hoses f rom cy l inder and p lug.

Wash cy l inder to complete ly remove a l l d i r t .

Cover work bench wi th c lean paper .

Remove jack ing s tant ion.

Remove cap bol ts . P lace 3 bo l ts in tapped holes and evenly pu l l head.

Pu l l rod and p is ton f rom cy l inder tube. Use the head as a s l ide hammer,bumping the chuck box gent ly wh i le pu l l ing on the chuck box.

Inspect cy l inder bore and cy l inder rod. Both MUST be smooth and f reeof deep scratches, gouges, and dents .

Gr ip chuck box in a v ise. Put a wrench on the p is ton nut and unscrewwhichever one loosens f i rs t . (P is ton nut or chuck box f rom rod) . S l idethe head of f the cy l inder rod.NOTE: l f both p is ton nut and chuck box need to be removed, as to changea rod, screw two nuts onto threads, lock together and unscrew other endll f chuck box res is ts , warm the threaded area evenly to 300e F us ing anoxygen acety lene torch.

Remove ln_ap_r ing and seal . change seal and assembre. pry out wiperr ing, but Do NoT gouge seal . Pop in new wiper . Remove ar id rep labeO-r ing and backup.

Rem.ove p is ton seal and rep lace. Be carefu l not to gouge p is ton. l f p is tonnui d id not come of f , do not worry . wi th o- r ing i t do-es not wear .

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11.

12.

13.

S l ide head back on ' rod.NOTE: l f chuck box unscrewed, the fo l lowing MUST be fo l lowed:

A. Complete ly c lean o i l f rom rod threads and chuck box threadswi th lacquer th inner , then Loct i te Grade N Pr imer ,

B. Coat threads wi th Loct i te 601.C. Assemble and t ighten to 600 f t . lbs .

Reassemble wi th one threaded hole in cy l inder head down. T ighten a l l bo l tsto 85 f t . lbs .

Jack must be ca l ibrated af ter cy l inder rebui ld ing.(See Gauge Cal ib ra t ion, page 10) .

(18)

I

Ram Cutaway

(1e)

K€y52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

Part No.c9052**c8053c8054c8055**c8056c8057*.c8058c8059CBO6Oc8061c8062c8063c8064c8065c8066c8067c8068c8069c8070c8071c8072c8073c8074c8075c8076c8077c8078c8079

Descr ip t ionCyl inder BodyCyl inder Rod NutPis tonCyl inder RodCyl inder HeadStant ionChuck BoxReta iner P inChuck Box Wear PlateTapered Nose Piece Extens ionReplacement Nose Piece Wear PlateReplacement Latch AssemblySocket Head Cap Screw*Pis ton SealWear R ing"O" RingPis ton WasherSnap RingRod SealRod Wiper Bear ingRod Wiper"O" Ring #2Back ing RingSocket Head Cap Screw (112 x 1-114) .Cap Screw (112 x 1-3 /4) .Hose Swive l Pressure*Hose Swive l Return*Seal K i t (conta ins #65, 66, 67,70,72,73,74)

(Not shown)

\

\

.!

" lnd icates par t may be found loca l ly .** When order ing, g ive s t roke length of ram; load ce l l or not load ce l l equipped.

(20)

:61{N\SJ

Gauge Manifold

@

Main Manifold

(21)

Key8081

82

83

84

85

86

87

88

89

90

91

92

Part No.c8080c8081c8081c8081c8082c8083c8084c8085c8081c8081c8086c8087c8082

Descr ip t ionGauge Block (No Valves)P. O. Check Valve*P. O. Check Valve*P. O. Check Valve*Check Valve*Main Valve Mani fo ld (No Valves)In i t ia l Regulator Contro l Valve*Fina l Regulator Contro l Valve*P. O. Check Valve*P. O. Check Valve*Rel ie f ValveP. C. Check Valve*Check Valve*

. Ind icates par t may be found loca l ly .

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FAULT TESTING

1' Ram stops moving, but pressure gaug_e cont inues to r ise s lowly , then s tops.a) Gauges react too s low. (see set t ing Gauge snubbers. j

2 . In i t ia l or F ina l gauge reads requi red pressure and repeats , but s t rands arenot a t the correct e longat ion.

a) Gauges need to be ca l ib ra ted. (see ca l ib ra t in ! Gauges. )

3 . In i t ia l tens ion insuf f ic ient .a) F ina l !e .ns i91 regulator set lower than In i t ia l regulator .

(See In i t ia l -F ina l Regula tors . )

4 . Insuf f ic ie_nt pressure on e i ther regulator .a) See In i t ia l -F ina l Regula tors . )

5 . In i t ia l or F ina l regulator wi l l not accurate ly repeat .3) lncorrect snubber set t ing. (see set t i 'ng Gauge snubbers. )b) Wqtn, or damaged regulators . (See ln i t ia t - f i ia l RegulatorS.)c) Debr is or t rash in the system.

6. In i t ia l o rF ina l regu la tor has no cont ror over h igh pressure.a) Clogged seat in regulator . (See In i t ia l lF ina l Regulators . )

7 . l f no re turn pressure.e) ! -mOending cy l inder seal fa i lure caus ing minor leakage.b) There is an in terna l fa i lure in the va lve body,c) Check hose connect ions.

8. Ram returns s lowly .g) _Clean debr is f rom jack ing s tant ion.b) There is an in terna l fa i lu ie in the va lve body.

9. Af ter moving jack, noth ing works.' a) Motor is running the wrong way.

(23)