Page 1
Model:
Product Type:
107EX
PRODUCT INFORMATION:
• "Quick-lock" design for fast and easy assembly and disassembly
• Long handle provides ease of pumping
• Thick wall extension tubes provide added strength and longer life
• Flexible hydraulic hose with spring guards at both ends
• MEETS ANSI STANDARD FOR PERFORMANCE AND SAFETY
• Kit Includes:
- Storage Case
- Hydraulic Hand Pump
- Hose with Male 1/4" NPT Fittings
and Male Coupler
- 4 Ton Hydraulic Ram
with Female Coupler
- Flex Head
- Flat Base
- Serrated Saddle
- Wedge Head
- 90° V-base
- Spreader Toe (1-1/2"-16")
- Plunger Toe
- Spreader Ram with
Female Coupler
- Extension Tube Coupling
- 4" Extension
- 8" Extension
- 12" Extension
- 16" Extension
4 TON CAPACITY PORTABLE POWER KIT
www.astrotools.com
1 YEAR LIMITED WARRANTY
• Astro Pneumatic Tool Co. warrants our products to the original user against
defective material or workmanship for a period of 1 year from the date of 1st use.
Astro reserves the right to determine whether the product failed because of defective
material, workmanship or other causes and to charge back for missing parts. Astro
Pneumatic Tool Co., at its discretion, will repair products covered under this warranty
free of charge. The original user is to return the product (with the exceptions listed
below) with the distributor’s name, address, adequate proof of date of purchase or a
copy of warranty card, and a short note explaining the problem.
Failures caused by accident, alteration, or misuse are not covered by this
warranty.
• Astro will replace free of charge the power unit on select hydraulic
equipment. Please call 800-221-9705 to arrange for replacement.
• Astro Pneumatic Tool Co. or its authorized service representatives must perform all
warranty repairs. Any repair to the product by unauthorized service representatives
voids this warranty. The rights under this warranty are limited to the original user and
may not be transferred to subsequent owners.
• This warranty is in lieu of all other warranties, expressed or implied, including
warranties of merchantability and fitness for a particular purpose. Some states do
not allow the exclusion of limitations of incidental or consequential damages so the
above limitations may not apply to you.
PLEASE DO NOT RETURN ANY PRODUCT WITHOUT CALLING
1-800-221-9705 FOR INSTRUCTIONS
Unpacking
When unpacking, check the parts diagram and part number
listing on page 5 to make sure all parts are included. If any
parts are missing or damage, please call your distributor.
IMPORTANT
4 TON CAPACITY PORTABLE POWER KIT
SPECIFICATIONS:
Weight Capacity:
Min. Saddle Height:
Max. Saddle Height:
Ram Stroke:
Handle Length:
Net Weight:
8,000lbs. (4 Ton)
10-1/2" (269mm)
14-1/2" (369mm)
4" (100mm)
10-1/2" (265mm)
38-1/2lbs. (17.5kg)
MADE IN CHINA
Page 2
Model:
Product Type:
107EX
WARNING
• Study, understand and follow all instructions.
• Do not overload ram beyond its rated capacity.
• When attachments are used, bowing of extension tubes or
slipping attachment often indicates overloading.
• Always reduce the overall capacity of your set by 50% for
each extension tube used.
• Never operate this equipment without using some type of
force measuring equipment to verify the applied load.
• Make certain that attachments are positively engaged before use.
• Do not use this product for any purpose other than that
for which it is intended.
• Failure to heed these warnings may result in loss of load,
damage to the kit, and/or failure resulting in personal injury
and/or property damage.
• Do not remove or obscure this label.
• Make sure the lift point is stable and properly centered on the ram.
• Please keep this equipment away from excessive heat or fire.
• Please refill with hydraulic fluid only and be sure that no dirt gets
into the hydraulic system
• For safety sake, please read owner’s manual carefully.
SAFETY PRECAUTIONS
HOSE
• Before operating the pump, tighten all hose connections using
the correct tools. Do not over tighten; connections need only be
secure and leak-free. Over tightening can cause premature
thread failure or high pressure fittings to split at pressures lower
than their rated capacities.
• Should a hydraulic hose ever rupture, burst, or need to be
disconnected, immediately shut the pump OFF, and open the
control valve to release all pressure. NEVER grasp a leaking,
pressurized hose with your hands; the force of escaping
hydraulic fluid could cause serious injury.
• Do not subject the hose to any potential hazard such as fire,
extreme cold or heat, sharp surfaces, or heavy impact. Do not
allow the hose to kink, twist, curl, or bend so tightly that the fluid
flow within the hose is blocked or reduced. Do not use the hose to
move attached equipment. Periodically inspect the hose for wear
because any of these conditions can damage the hose and
result in personal injury.
• Hose material and coupler seals must be compatible with the
hydraulic fluid used. Hoses also must not come in contact with
corrosive materials such as creosote impregnated objects and
some paints. Consult the manufacturer before painting a hose.
Never paint couplers. Hose deterioration due to corrosive
material can result in personal injury.
PUMP
• Do not exceed the maximum capacity of the pump or tamper with
the internal high pressure relief valve. Creating pressure beyond
the rated capacity can result in personal injury.
• Completely retract the ram before opening the filler screw on the
pump to add hydraulic fluid. An overfill can cause personal injury
due to excess reservoir pressure created
when rams are retracted.
4 TON CAPACITY PORTABLE POWER KIT
Ram
• Do not exceed the maximum capacity of the ram. Creating
pressure beyond the rated capacity can result in person injury.
• Do not set poorly-balanced or off-center loads on a ram.
The load may tip and cause personal injury.
OPERATION INSTRUCTIONS
Setup
The pump may be operated in a horizontal
position or in a vertical position with the
head pointing down as shown.
1. Assemble the hose between the pump and ram.
2. Determine the appropriate attachment for your
application; assemble the attachment to the ram piston.
IMPORTANT
• The use of extension tubes or off-center attachments greatly
reduces the capacity of the hydraulic system. When using
extension tubes, put the shortest tubes on the ends of the
setup; never put the shortest tubes in the middle of the setup.
• Some components in this set do not match the maximum
pressure rating of the pump and ram. USE A PRESSURE
GAUGE IN THE SYSTEM TO MONITOR HYDRAULIC PRE
SURE. Refer to the instructions in this document for Typical
Applications and Load Capacities.
Operation
1. Turn the pump’s release valve clockwise to a closed position.
IMPORTANT: Hand tighten the valve only; applying too much
force to the valve may damage the valve system.
2. Work the pump handle up and down to send oil through the hose
to the ram, causing the piston to extend to the work piece.
3. 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 (when the system meets maximum pressure). In
this case, continued pumping will have no effect on the
system. If an overload situation commonly occurs, a higher
capacity set is needed.
4. To release pressure, slowly turn the release valve
counterclockwise. (The release speed is controlled by how fast
the valve is opened.)
BLEEDING AIR FROM THE SYSTEM
Air can accumulate in the hydraulic system during the initial
setup or after prolonged use, causing the ram to respond slowly
or in an unstable manner. To remove the air:
1. Place the ram at lower level than the pump, with the piston
end pointing down.
2. Extend and retract the ram several times without putting a load
on the system. Air will be released into the pump reservoir.
3. With the ram fully retracted, the pump at sitting level, and no
pressure in the hydraulic system, remove the pump’s filler screw.
Fill the reservoir with approved hydraulic fluid until the fluid level
is within 1/2” (12.7mm) from the top of the reservoir.
Page 2Page 1
Page 3
Model:
Product Type:
107EX
4 TON CAPACITY PORTABLE POWER KIT 4 TON CAPACITY PORTABLE POWER KIT
TYPICAL APPLICATIONS & LOAD CAPACITIES
When offset attachments are used, the rated capacity of the hydraulic system is reduced 50%. For each extension tube used
in the setup, the rated capacity is reduced another 50%. When using two or more extension tubes together, always position the
shortest tube farthest away from the ram.
spreader capacity = 1/2 ton
100% of ram capacity 100% of ram capacity
50% of ram capacity
50% of ram capacity
25% of ram capacity
25% of ram capacity
50% of ram capacity
6% of ram capacity
Page 4
Model:
Product Type:
107EX
TROUBLESHOOTING
To prevent personal injury, release pump pressure and disconnect the hose from the pump before making repair. Repairs must
be performed in a dirt-free environment by qualified personnel who are familiar with this equipment. If the following solutions do
not remedy the problem, take the product to an authorized service center for repair.
Trouble Probable Cause Remedy
Pump loses pressure
Pump not delivering fluid
Pump does not reach rated capacity
Pump handles has a “spongy” feel
Ram piston will not extend
Ram piston extends only partially
Ram piston extends slower than normal
Ram does not hold pressure
Ram leaks hydraulic fluid
Ram will not retract or retracts
slower than normal
1. System components leaking
1. Low fluid level in reservoir
2. Seats are worn
1. Low fluid level in reservoir
2. System components leaking
3. Fluid leaking past inlet
or outlet checks
1. Air trapped in system
2. Too much fluid in reservoir
1. Loose couplers
2. Low fluid level in pump reservoir
3. Ram seals leaking
1. Low fluid level in pump reservoir
2. Load is above capacity of system
1. Loose couplers
2. Restricted hydraulic line or fitting
3. Pump not working correctly
4. Ram seals leaking
1. Leaky connection
2. Ram seals leaking
3. Pump or valve not
working correctly
1. Worn or damaged seals
2. Loose connection
1. Pump release valve closed
2. Loose couplers
3. Blocked hydraulic lines
4. Weak or broken retraction springs
5. Ram damaged internally
6. Pump reservoir too full
1. Repair or replace as necessary
1. Check fluid level
2. Repair seats or replace pump body
1. Check fluid level
2. Repair or replace as necessary
3. Repair inlet or outlet checks, or replace
high pressure piston seal
1. Refer to Bleeding Air from the System
2. Check fluid level
1. Tighten couplers
2. Fill and bleed the system
3. Replace worn seals. Look for
excessive contamination or wear
1. Fill and bleed the system
2. Use correct equipment
1. Tighten couplers
2. Clean and replace if damaged
3. Repair or replace as necessary
4. Replace worn seals. Look for
excessive contamination or wear
1. Clean, reseal with thread sealant,
and tighten connection
2. Replace worn seals. Look for excessive
contamination or wear. Replace contaminated fluid
3. Repair or replace as necessary
1. Replace worn seals. Look for excessive
contamination or wear. Replace contaminated fluid
2. Clean, reseal with thread sealant,
and tighten connection
1. Open pump release valve
2. Tighten couplers
3. Clean and flush lines
4. Send to service center for repair
5. Send to service center for repair
6. Drain fluid to correct level
Page 4Page 3
Page 5
372 Old US Highway 52 South
Mount Airy, NC 27030
Model:
Product Type:
4 TON CAPACITY
107EX
Call 1.800.221.9705 for questions concerning performance of the product
or other inquiries.
1
5
PORTABLE POWER KIT
17
Index
No.
1
2
3
4
5
6
7
8
9
16
107EX-01
107EX-02
107EX-03
107EX-04
107EX-05
107EX-06
107EX-07
107EX-08
107EX-09
15
14
13
2
7 8 9 10 11 12
Storage Case
Hydraulic Hand Pump
Hose with Male 1/4" NPT Fittings
and Male Coupler
Hydraulic Ram with Female Coupler
Flex Head
Flat Base
Serrated Saddle
Wedge Head
90° V-Base
4
6
3
Index
No.
1
1
1
1
1
1
1
1
1
10
11
12
13
14
15
16
17
107EX-10
107EX-11
107EX-12
107EX-13
107EX-14
107EX-15
107EX-16
107EX-17
Spreader Toe (1-1/2"-16")
Plunger Toe
Spreader Ram with Female Coupler
Extension Tube Coupling
4" Extension
8" Extension
12" Extension
16" Extension
1
1
1
1
1
1
1
1
Page 5
Page 6
OTHER ASTRO PRODUCTS AVAILABLE
372 Old US Hi ghway 52 South
Mount Airy, N C 27030
1000EX
10 TONS CAPACITY
HYDRAULIC FLOOR JACK
WD1500EX
3/4 TON DUAL WHEEL DOLLY
AJ22FE
22 TON CAPACITY
AIR OVER JACK
WITH QUICK SPRINGS
500HMJ
1/2 TON CAPACITY TELESCOPING
TRANSMISSION JACK
107EX
4 TON CAPACITY PORTABLE POWER KIT
108EX
10 TON PORTABLE POWER KIT
WITH BLOW MOLDED CASE AND WHEELS
1175E
3/4 TON
UNDERHOIST STAND
1102E
2 TON UNDERHOIST
TRIPOD STAND
AME08
8 TON WELDED
BOTTLE JACK
AME05
5 TON WELDED
BOTTLE JACK
AME12
12 TON WELDED BOTTLE JACK
AME20
20 TON WELDED BOTTLE JACK
Page 6
AME12S
12 TON WELDED
SHORT BOTTLE JACK
AME20S
20 TON WELDED
SHORT BOTTLE JACK
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