Model No.: PPK4, PPK10

OPERATING INSTRUCTIONSPorta Power Kits- 700 Bar (10,000 psi)

WARNINGRead and follow all Safety Instructions, Warnings, Cautions and Important information provided in this manual before using the

equipment. They are provided for the safety of those operating the equipment and to prevent personal injury and/or damage to property

when using this equipment.

THIS EQUIPMENT SHOULD ONLY BE USED BY OPERATORS WHO HAVE BEEN TRAINED IN THE SAFE USE OF HIGH

PRESSURE HYDRAULIC EQUIPMENT

www.bosshydraulics.com.au

Form: BM010

BM0102

WARNING:

• Always wear the correct personal protective equipment when operating high pressure hydraulic tools and equipment

• Always stay clear of loads supported by hydraulic systems, the load must be secured mechanically before work can commence

• Always keep your hands and feet clear of the work activity during operation to avoid personal injury

• Never handle pressurised hydraulic hoses. Escaping oil under pressure can penetrate the skin causing serious injury. Contact a doctor immediately if oil is injected under the skin

• Never operate the system above the maximum rated output pressure

• Never connect to the system components, fittings, couplers, hoses, valves etc. that are NOT rated to the full system operating pressure

• Never exceed equipment ratings. Never attempt to lift a load greater than the capacity of the cylinder. Overloading causes equipment to fail and possible personal injury or damage to equipment

• Boss cylinders and pumps are designed to operate at a maximum of 700 bar (10,000 psi) unless specified. Never connect a cylinder to a pump with a higher output pressure

• Never use pumps and cylinders with disconnected couplers. Always ensure where couplers are used that they are all fully engaged. Failure to do so can result in the system becoming overloaded and can result in a catastrophic component failure potentially causing severe personal injury

• Always ensure the system has a stable set up before operating the equipment. Cylinders should be located on a flat surface that has the capacity to support the load, cylinder bases and other supports should be used where applicable. Avoid situations where the load is not directly centred on the cylinders. Loads that are off centre place considerable strain on the cylinder and piston. This can result in the load slipping or the cylinder failing with potentially dangerous results. Always distribute the load evenly across the entire surface of the cylinder saddle. Always use a saddle to protect the cylinder rod

BM010 3

IMPORTANT:• Never lift or carry hydraulic

equipment by the hose or couplers. Use carry handles or another safe method to transport or lift components

• High pressure hydraulic equipment should only be serviced, adjusted, repaired and tested by qualified hydraulic technicians

• After unpacking the equipment it should be inspected by a qualified person to ensure there is no shipping damage or missing part

• A gauge is highly recommended to be used, so the pressure in the hydraulic system can be monitored

Hydraulic Pumps:

• Do not use a gauge or other load measuring instrument to verify load

• Do not exceed the rated capacity of the pump or any equipment in the system

• Do not operate the system witrh bent or damaged couplers or damaged threads

• Do not subject the pump and its components to shock loads

• Do not connect to an application which can return more oil to the reservoir than the pump reservoir can hold

CAUTION:

• Avoid damage to hydraulic hoses from sharp objects, vehicles and heavy objects falling on them, never kink or fit hoses with a sharp bend in them. All of these things can cause internal damage to the hose leading to premature hose failure

• Keep hydraulic equipment away from sources of heat and flames. Heat will soften seals and hoses which results in hydraulic fluid leaks. For optimum performance, equipment should not be exposed to temperatures of 65° C (150° F) or higher. Always protect hoses from weld splatter or sparks from cutting or grinding tools

• Never weld to or modify cylinders, pumps or other system components as they have been engineered and tested to meet specific standards

• Always immediately replace worn or damaged parts with genuine Boss Hydraulics parts. The use of non- genuine parts can result in failure potentially causing personal injury and/or property damage

WARNING:

BM0104

WARNING:

• Do not connect the pump to a hydraulic system that is powered by another pump

Hydraulic Cylinders/ Spreaders:

• If bowing or bending of the spreader jaws occurs, STOP immediately and release the pressure. Evaulate the set up and consider a higher rated capacity system.

• Use only rigid pieces to hold load. Never use hydarulic cylinders as a spacer in any lifting or pressing application

• Be sure setup is stable before lifting load

• Avoid situations where loads are not directly centred on the cylinder piston

• Distribute the load evenly across the entire saddle surface. Always use a saddle to protect the piston

• Ensure that both spreader jaws fully engage the load and that the load is centred on the serrated portion of each spreader jaw before pressurising the spreader

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

• Cylinders and spreaders should be stored away from the elements, dust and damage

Hydraulic Hoses & Fluid Transmission Lines:

• Avoid short runs of straight line tubing

• Reduce stress in tube lines. Long tubing runs should be supported by brackets or clips. Before operating the pump connections should be tightened securely and leak free

• Should a hydraulic hose rupture, burst or need to be disconnected, immediately shut off the pump and release all pressure. Never attempt to grasp a leaking pressurised hose with your hands or this may result in injury

• Do not subject the hose to potential hazards such a fire, sharp objects, extreme heat or heavy impact

• Do not allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid flow within the hose is blocked or reduced

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

Attachments:

• Attachments and extension tubes must be aligned and fully engaged so cylinder force is straight, avoiding an off-centre load collection

BM010 5

2. OPERATION

IMPORTANT:• Do not add extensions to the

pump handle. Extensions may cause unstable pump operation

• In certain situations the pump handle can “kick back”. Always keep your body to the side of the pump, away from the force of the handle

• Do not operate a pump that is disconnected from the application. This may cause damage to the pump, its components and operators

The pump may be operated in a horizontal or in a vertical position.

Before using the pump:• Check all system fittings and

connections to be sure they are tight and leak free

• Check oil levels in reservoir before operating the pump

Using a Two-Speed Pump:• Under no-load the pump operates

in the high flow first stage for rapid advance. When the load is contacted the pump automatically shifts to the second stage for building pressure. After the pump shifts pumping takes less effort

• To reduce handle effort at high pressure take short strokes. Maximum leverage is obtained in the last 5 degrees of stroke

1. INSTALLATION

IMPORTANT:• Always secure the threaded port

connections with high grade, non hardening pipe thread sealant. Teflon tape can be used if only one layer of tape is used and it is applied carefully, two threads back to prevent the tape from being introduced into the hydraulic system which could cause jamming of precision-fit parts

• Do not allow the piston rod to rotate when installing adaptors. Damage to the spring may prevent piston rod retraction

Make hydraulic connections:• Remove the manifold plug then

connect oil output port to suitable fittings and cylinder/ application

• Fully hand tihten all couplers. Loose coupler connections will block the flow of oil between the pump and the cylinder/ spreader

Remove air from the system:• Air can accumulate in the

hydraulic system during the initial setup or after prolonged use causing the cylinder and/ or spreader to respond slowly or in an unstable manner. Should the removal of air be required please follow instructions in section 3: “Bleeding Air From the System”

BM0106

3. MAINTENANCE

IMPORTANT:• Check oil regularly• Use only high quality hydraulic

fluid. DO NOT use brake fluid, transmission fluid, turbine oil, motor oil, alcohol, glycerine etc. use of anything other than high quality hydraulic oil will void warranty and damage the pump, hose and application

• Equipment must be serviced by a qualified hydraulic technician. For repair service contact your local authorised Boss Hydrualics service centre.

• Inspect and replace hydraulic hoses on a regular basis

• Tighten connections as needed. Use non-hardening pipe thread compound when servicing connection

Bleeding Dirt and sand etc will quickly ruin a hydraulic system. Ensure that couplings are clean and free of foreign matter. After each use clean couplings and attach dust caps.

Maintenance is required when wear or leakage is noticed. Periodically inspect all components to detect any problem that may require service and maintenance.

2. OPERATION (CONT)

• For best performance, operate pump handle at moderate speed during the high flow first stage. Rapid handle speed in the first stage will prevent the pump from delivering full volume of oil

Advance and Retraction of Single Acting Applications:• Turn the pump’s release valve

clockwise to a closed position• Only hand tighten the valve.

Applying too much force to the valve may damage the valve stem

• Work the pump handle up and down to send oil through the hose to the cylinder, causing the piston to extend to the work piece

• Monitor the pressure gauge while completing the application

NOTE: The pump is equipped with an overload valve that will bypass oil back into the pump reservoir in an overload situation. In this case con-tinued pumping will have no effect on the system. If an overload sutuation commonly occurs a higher capacity set is required.To release pressure, slowly turn the release valve counter clockwise. The release speed is controlled by how fast the valve is opened

Before Relief Valve Adjustment:• All pumps contain a factory set

relief valve to prevent over-pressurisation of the system

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Adding Hydraulic Fluid:• Depressurise and disconnect the

hydraulic hose from the cylinder• Put the pump in a vertical

position (pump head face down) and remove the oil filter plug located on the rear of the pump reservoir

• Use a small funnel to fill the reservoir to approximately 75mm from the top of the oil filler hole

• Bleed air from system if necessary

• Wipe up any spilled fluid and reinstall the air vent plug/ reservoir cap

Bleeding Air From the System:• Depressurise and disconnect the

hydraulic hose from the cylinder• Put the pump in a vertical

position (pump head face down) and remove the oil filter plug located on the rear of the pump reservoir

• Use a small funnel to fill the reservoir to approximately 75mm from the top of the oil filler hole

• Extend and retract the cylinder several times without putting a load on the system. Air will be released into the pump reservoir

• Recheck oil level after removing air

Changing Hydraulic Fluid:• Depressurise and disconnect the

hydraulic hose from the cylinder• Put the pump in a vertical position

(pump head face down) and remove the oil filter plug located on the rear of the pump reservoir

• Pour fluid into a sealable container

• Use a small funnel to fill the reservoir to approximately 75mm from the top of the oil filler hole

• Bleed air from system if necessary

• Wipe up any spilled fluid and reinstall the air vent plug/ reservoir cap

• Dispose of fluid in accordance with local regulations

Lubrication:• To extend pump life and improve

performance, lubricate the beam pin, cross pin and piston head regularly, using roller bearing grease

Storage:• When not in use, depressurise

and disconnect the hydraulic pump from the application

• Wipe clean thoroughly and store in a clean, dry environment. Avoid temperature extremes

• Sheild pump with a protective cover

3. MAINTENANCE (CONT)

BM0108

When using accessories the working limit is reduced depending on the type and amount of accessories used. The below should be used as a reference when using the PPK kits.

100% of cylinder capacity

75% of cylinder capacity

25% of cylinder capacity

50% of cylinder capacity

50% of cylinder capacity

6% of cylinder capacity

BM010 9

4. TROUBLESHOOTING

PROBLEM CAUSE SOLUTIONPump/cylinder loses pressure

Coupling or hose not connected fuly Tighten fittings

Pump doesn’t deliver fluid

Low fluid level in reservoir Check fluid levels

Check balls failingReplace or clean check balls

Replace body

Pump doesn’t reach rated capacity

Low fluid level in reservoir Check fluid levels

Relief valve failing Repair or replace as required

Inlet check balls failing Replace or clean check balls

Pump handle feels “spongy”

Air trapped in the system Bleed system as per instructions

Too much fluid in the reservoir Check fluid levels

Cylinder piston won’t extend

Loose couplers Tighten couplers

Low fluid level in pump reservoir Fill and bleed the system

Leaking cylinder seals Replace worn seals.

Cylinder piston extends only partially

Low fluid level in pump reservoir Fill and bleed the system

Load above capacity of system Use larger capacity cylinder

Cylinder piston extends slower than normal

Loose couplers Tighten couplers

Pump not operating correctly

Refer to pump operating instructionsRepair or replace as necessary

Low fluid level in pump reservoir Fill and bleed the system

Cylinder will not retract or retracts slower than normal

Closed pump release valve Open pump release valveLoose couplers Tighten couplersWeak or broken retraction springs

Send to an authorised Boss Hydraulics service centre

Internally damaged cylinder Drain fluid to correct level

BM01010

5. PARTS BREAKDOWN - PPK4

Item No. Part No. Description

1 PH1035 Heavy Duty Hand Pump

2 1B12057 Hose - 6 Feet

3 1B12059 4 Ton Cylinder - 4” Stroke

4 1B12060 ½ Ton Spreader

5 1B12033 16” Extension Tube

6 1B12034 12” Extension Tube

7 1B12035 8” Extension Tube

8 1B12036 4” Extension Tube

9 1B12028 Male Connector

9 10

12

16

12

3

4

5

6

7

8

11

13

14

15

17

Item No. Part No. Description

10 1B12049 Flat Base

11 1B12050 90° “V” Base

12 1B12051 Wedge Head

13 1B12052 Plunger Toe

14 1B12053 Cylinder Toe

15 1B12025 Rubber Flex Head

16 1B12048 Serrated Saddle

17 1B12055 Blow Moulded Case

BM010 11

6. PARTS BREAKDOWN - PPK10

Item No. Part No. Description

1 PH1060 Heavy Duty Hand Pump

2 1B12057 Hose - 6 Feet

3 B1B2058 10 Ton Cylinder - 6” Stroke

4 1B12060 ½ Ton Spreader

5 1B12029 19” Extension Tube

6 1B12030 14” Extension Tube

7 1B12031 10” Extension Tube

8 1B12032 5” Extension Tube

9 1B12027 Male Connector

1

2

3

4

5

6

7

8

9

10 11 12

1314 15

16

17

Item No. Part No. Description

10 1B12043 Flat Base

11 1B12044 90° “V” Base

12 1B12045 Wedge Head

13 1B12046 Plunger Toe

14 1B12047 Cylinder Toe

15 1B12026 Rubber Flex Head

16 1B12042 Serrated Saddle

17 1B12054 Blow Moulded Case

BOSS HYDRAULICS: Head Office: 19 Ricketts Road, Mt Waverley VIC 3149 I P: 1300 BOSS HYD (1300 267 749)E: sales@bosshydraulics.com.au I W: www.bosshydraulics.com.au