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EST GROUP DC4042 06/18
PAGE 1 OF 6
ORIGINAL INSTRUCTIONS
POP-A-PLUG® SYSTEM
HYDRAULIC RAM PACKAGE OPERATING INSTRUCTIONS
EST Group Hydraulic Ram Package consist of an Air Activated Hydraulic Pump, a High
Pressure Hydraulic Hose with quick connects, and a Hydraulic Ram. EST Group Ram Kits are
used for installation and removal of Pop-A-Plug Heat Exchanger Tube Plugs manufactured by
Curtiss-Wright EST Group.
Operating Instructions for:
Part Number Description Components Description
PAP-6605 5 Ton Ram Assembly
PAP-6600-SIL Small Ram Package
PAP-1010 Hose Assembly
PAP-1000 Pump Assembly
PAP-123-RA 12 Ton Ram Assembly
PAP-123-RK Medium Ram Package
PAP-1010 Hose Assembly
PAP-1000 Pump Assembly
PAP-1755 17.5 Ton Ram Assembly
PAP-1750 Large Ram Package
PAP-1010 Hose Assembly
PAP-1000 Pump Assembly
Workstation Sound Pressure Level: 84 dB(A) at Rated Capacity
Operation Air Pressure: 90 – 120 PSIG (6.2 – 8.2 BARG)
MAX Pump Pressure: 7500 PSIG (517 BARG)
Authorized European Distributor: EST Group B.V. Hoorn 312a, 2404 HL Alphen aan den Rijn, The Netherlands.
Year of Construction: _____
Updated at date of mfg.
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
Page 2
EST GROUP DC4042 06/18
PAGE 2 OF 6
SAFETY SYMBOLS AND DEFINITIONS
Safety symbols are used to identify any action or lack of actions that can cause personal injury.
DANGER
Danger is used only when actions or lack of actions will cause serious human injury or death
WARNING
Warning is used to describe and action or lack of action where serious injury can occur
READ INSTRUCTIONS - Read all instruction prior to operating equipment
EYE PROTECTION - Wear proper eye protection to protect against ejected parts or projectiles
EAR PROTECTION - Wear proper ear protection to protect against hearing loss or damage
PUMP - Activating the pump with the pedal end marked with this pictogram, the flow of fluid is directed
out of the reservoir.
RELEASE - Activating the pump with the pedal end marked with this pictogram, the flow of fluid is
directed back to the reservoir.
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
Page 3
EST GROUP DC4042 06/18
PAGE 3 OF 6
The user must read and thoroughly understand these installation
instructions before any work begins. The user should read and
thoroughly understand the installation procedures as supplied with
WARNING
every kit of Pop-A-Plug’s. It is advisable to watch the P2 Installation
or CPI/PERMA Training Video to learn how to properly handle the
equipment. It is the responsibility of the user to establish appropriate
safety, health and training measures for their personnel using,
servicing or working in an area where this equipment is being used.
The user must be a qualified operator familiar with correct operation, maintenance, and use of hydraulic tools.
Lack of knowledge in any of these areas can lead to personal injury.
Wear proper eye protection to protect against ejected parts or other
projectiles. A face shield is acceptable.
Wear proper ear protection to protect against hearing loss or damage.
Possible Kickback and Parts Ejection Hazard. Keep body, head, face and
all extremities clear from rear of hydraulic ram during operation.
Tools and components listed in this instruction are designed for the sole
purpose of installing and removing P2 and CPI/PERMA plug heat exchanger tube plugs. The equipment is not
designed or intended to be used for other tasks.
Never leave the equipment unattended when connected to pneumatic pressure supply.
EST Group Ram Kits are not generally suited for coming in contact with electrical power sources.
EST Group Ram Kits shall not be used in an explosive atmosphere.
Unexpected tool movement or breakage of inserted tool could cause injury to personnel.
Unsuitable postures may not allow for proper counteracting of normal or unexpected movement of the tool
during operation.
Inspect equipment before each use to prevent unsafe conditions from developing. Do not use equipment if it is
damaged, altered or in poor condition.
Other than refilling / changing the hydraulic fluid, there are no serviceable parts in these assemblies. If any
equipment is damaged or faulty, contact EST Group for service or replacement.
These instructions are intended for the end-user or operator of this equipment. For additional information or
parts lists contact an EST Group facility listed below.
1. INSPECTION
Prior to use, all equipment must be inspected to ensure safe and reliable operation. Only qualified
operators should assemble, operate, and maintain this equipment.
General: Ensure the area around all port connections is clean and free of dirt or debris.
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
Page 4
EST GROUP DC4042 06/18
PAGE 4 OF 6
Small Ram
PAP-6605
Pump Assembly
PAP-1000
Medium Ram
PAP-123-RA
Large Ram
PAP-1755
Hose Assembly
PAP-1010
Safety Cable Attachment Locations
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
Page 5
EST GROUP DC4042 06/18
PAGE 5 OF 6
1.1. Pump
Ensure the red shipping cap is removed from the pump reservoir and has been replaced with the black vent plug.
RED: SHIPPING PLUG
Ensure there is sufficient hydraulic fluid in the reservoir. Add additional fluid as required. Check oil level prior to first
use of the day and at least after every 10 hours of use.
Follow the safety and handling instructions with regards to the hydraulic oil in accordance with the provided SDS.
1.2. Hose
Ensure the hose is free of cracks, kinks, or any visible damage. Inspect all threads and fittings for signs of wear or
damage.
BLACK: OPERATIONAL VENT
PLUG
1.3. Ram
Visually inspect for cylinder damage, leaking fluid, and excessive wear or damage. Ensure the safety cables are
securely attached to the ram.
2. ASSEMBLY
Remove all thread protective caps. Connect the hose assembly to the
pump and ram. Ensure mating quick-connects are fully engaged and
hand tight. All connections are to be tightened securely and leak-free
but do not overtighten.
WARNING
CONNECT
AIR SUPPLY
ENSURE HYDRAULIC HOSE QUICK CONNECTS
ARE FULLY ENGAGED AND TIGHTENED. FAILURE
TO CORRECTLY SEAT AND TIGHTEN
HYDRAULIC FITTINGS WILL CAUSE RAM PISTON
TO LOCK IN EXTENDED POSITION AFTER
ACTIVATION.
Connect the air supply to the ¼” F-NPT port at the rear of the pump.
The air supply should be at least 20 CFM (.57 m³/min) and 100 PSIG (7 BARG) to obtain the rated hydraulic pressure. Air
pressure must be regulated to no more than 120 PSIG (8.3 BARG) maximum.
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
Page 6
EST GROUP DC4042 06/18
PAGE 6 OF 6
3. TESTING
3.1. Test Ram/Pump set-up
To verify Ram/Pump set-up, step on the end of the
pump pedal marked "PUMP"
the Hydraulic Ram. Within a few seconds, the Ram
should begin to stroke. Note that the piston strokes out
of the back of the hydraulic Ram. If the Ram does not
stroke, check all connections, the oil level and repeat
this step.
Proper operation will be indicated by cylinder of the ram
extending 1” – 3” (25.4 to 76.2 mm) (model dependent)
followed by the pressurization indicated on the gauge
increasing to 7500 PSIG (517 BARG).
3.2. Release Pump pressure
While holding the Ram handle step on end of the Pump
Pedal marked "RELEASE".
the piston of the Ram to retract.
To remove the pneumatic power to the equipment,
disconnect the pneumatic quick connect.
4. OPERATION
while watching
This will allow
FRONT
PISTON
STROKES
STEP
HERE
Assemble the ram head with the pullrod assembly in accordance with DC1220 or DC4000: Pop-A-Plug installation
instructions. Follow Pop-A-Plug installation instructions.
DURING RAM OPERATION, THE SAFETY CABLE MUST ALWAYS
BE ATTACHED TO THE PULLROD.
NEVER LEAVE THE EQUIPMENT UNATTENDED WHILE
WARNING
CONNECTED TO A PNEUMATIC PRESSURE SUPPLY.
NEVER DISCONNECT THE HOSE FROM THE RAM OR PUMP
WHEN THE EQUIPMENT IS PRESSURIZED.
5. CLEANING AND MAINTENANCE
The Ram system should be cleaned of all dirt and oils after ever use. Keeping the Ram Kit components wiped free of
debris before and after use will lessen the chances of foreign materials entering the hydraulic or pneumatic system
and extend the life of the equipment. Change hydraulic oil every 300 hours of use approximately; use Power-Team
AW Hydraulic Oil ISO-46.
There are no serviceable parts on the Ram Kit. Contact EST Group for any repair or replacements of components.
Questions? Contact EST Group Customer Service at any of the following locations.
www.cw-estgroup.com
North, Central & South America
EST Group Corporate Office
2701 Township Line Road
Hatfield, PA 19440-1770 USA
P: +1.215.721.1100
+1.800.355.7044
F: +1.215.721.1101
Europe / Middle East / Africa
EST Group B.V.
Hoorn 312a
2404 HL Alphen aan den Rijn
The Netherlands
P: +31.172.418841
F: +31.172.418849
China
P +86.400.636.5077
Singapore
P +65.3158.5052
©2018 Curtiss-Wright
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