Equalizer HP350S, HP350D, HP1000S, HP550S, HP1000D Operator's Instruction Manual
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OPERATOR INSTRUCTION MANUAL
HP350S/HP350D
HP550S/HP550D
HP1000S/HP1000D
EQUALIZER INTERNATIONAL LTD
www.equalizerinternational.com
HYDRAULIC
SEALED HAND
PUMPS
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
1
CONTENTS
1. INTRODUCTION
2. TOOL SAFETY
2.1 GENERAL SAFETY
2.2 PERSONNEL COMPETENCY
2.3 DISCLAIMER
2.4 DEFINITION OF TERMS
2.5 HAZARDS
3. GENERAL HAND PUMP OPERATION
3.1 GENERAL GUIDANCE
3.2 HP350S, HP550S & HP1000S INSTALLATION
AND OPERATION
3.3 HP350D, HP550D & HP1000D INSTALLATION
AND OPERATION
3.4 USE OF EQUALIZER INTERNATIONAL TOOLS
WITH A HYDRAULIC MANIFOLD
4. HAND PUMP MAINTENANCE
4.1 INSPECTION
4.2 CLEANING
4.3 MAINTENANCE
4.4 STORAGE & TRANSPORTATION
4.5 SUB-SEA USAGE
4.6 LONG-TERM STORAGE - MAINTENANCE PLAN
5. TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA
5.2 KIT CONTENTS
5.3 HP350S, HP550S & HP1000S WEIGHTS AND
DIMENSIONS
5.4 HP350D, HP550D & HP1000S WEIGHTS AND
DIMENSIONS
6. TROUBLESHOOTING
6.1 HP350S/HP550S/HP1000S HP350D/HP550D/
HP1000D TROUBLESHOOTING
7. REGULATORY INFORMATION
7.1 REGISTERED HEAD OFFICE
8. PARTS LISTS & SERVICE KITS
15/05/2018
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
2
1.
INTRODUCTION
The Equalizer™ HP-S hydraulic single-port sealed hand
pump and HP-D hydraulic twin-port sealed hand pump
replace the Equalizer P142 hydraulic hand pump.
The HP350S, HP550S, HP1000S and HP350D, HP550D and
HP1000D are tailored for use with Equalizer International
Ltd hydraulic equipment. Their output is regulated to
700 bar (10 000psi) and is delivered from an output port
threaded ⅝” NPT.
The HP350S and HP350D can be used with any 700 bar
(10 000 psi) rated hydraulic equipment with an oil capacity
of 350 cc (21.4 in
3
) or less.
The HP550S and HP550D can be used with any 700 bar
(10 000 psi) rated hydraulic equipment with an oil capacity
of 550 cc (33.6 in
3
) or less.
The HP1000S and HP1000D can be used with any 700 bar
(10 000 psi) rated hydraulic equipment with an oil capacity
of 1000 cc (61.0 in
3
) or less.
The diaphragm oil reservoir means that, unlike
conventional hand pump units, the HP-S and HP-D pump
ranges are operable at all angles and are highly resistant
to accidental spillage of hydraulic uid.
PRESSURE RATING:
● 1st stage: 13.8 bar (197 psi)
● 2nd stage: 700 bar (10 000 psi)
2.
TOOL SAFETY
2.1
GENERAL SAFETY
These instructions cover the safe operation and
maintenance of THE EQUALIZER HP350S, HP550S,
HP1000S, HP350D, HP550D and HP1000D
HYDRAULIC SEALED HAND PUMPS. The use of these tools
should be as part of a broader task-based risk assessment,
which should be carried out by the operation supervisor or
other competent person.
Failure to comply with the safety information contained
within this manual could result in personal injury or
equipment damage. Read all instructions, warnings and
cautions carefully, and follow all safety precautions.
The safety of the operator, any assisting personnel and
the general public is of paramount importance. Always
work in accordance with applicable national, local, site &
company-wide safety procedures.
2.2
PERSONNEL COMPETENCY
Only personnel deemed competent in the use of mechanical
and hydraulic equipment should use these tools.
2.3
DISCLAIMER
Equalizer cannot be held responsible for injury or damage
resulting from unsafe product use, lack of maintenance
or incorrect product and/or system operation. If in doubt
as to the safety precautions and applications, contact
Equalizer using the contact details at the back of this
manual.
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
3
2.4
DEFINITION OF TERMS
A CAUTION is used to indicate correct operating or
maintenance procedures and practices to prevent damage
to, or destruction of equipment or other property.
A WARNING indicates a potential danger that requires
correct procedures or practices to avoid personal injury.
A DANGER is only used when your action or lack of action
may cause serious injury or even death.
DO: an illustration showing how the tool should
be used.
DON’T: an illustration showing an incorrect way
to use a tool.
2.5
HAZARDS
IMPORTANT: Operator must be competent in
the use of hydraulic equipment. The operator
must have read and understood all instructions,
safety issues, cautions and warnings before
starting to operate the Equalizer equipment.
WARNING: To avoid personal injury and
possible equipment damage, make sure all
hydraulic components are rated to a safe
working pressure of 700 bar (10,000 psi)
WARNING: Do not overload equipment.
Overloading causes equipment failure and
possible personal injury.
CAUTION: Make sure that all system
components are protected from external
sources of damage, such as excessive heat,
ame, moving machine parts, sharp edges and
corrosive chemicals.
CAUTION: Avoid sharp bends and kinks that
will cause severe back-up pressure in hoses.
Bends and kinks lead to premature hose failure.
Do not drop heavy objects onto hoses. A sharp
impact may cause internal damage to hose
wire strands; applying pressure to a damaged
hose may cause it to rupture. Do not place
heavy weights on the hoses, or allow vehicles
to roll over the hoses; crush damage will lead
to premature hose failure.
WARNING: Immediately replace worn or
damaged parts with genuine Equalizer parts.
Equalizer parts are designed to t properly and
withstand rated loads. For repair or maintenance
service contact your Equalizer distributor or
service centre.
DANGER: To avoid personal injury keep hands
and feet away from the tool and workpiece
during operation.
WARNING: Always wear suitable clothing and
Personal Protective Equipment (PPE).
DANGER: Do not handle pressurised hoses.
Escaping oil under pressure can penetrate the
skin, causing serious injury. If oil is injected
under the skin, seek medical attention
immediately.
WARNING: Never pressurize unconnected
couplers. Only use hydraulic equipment in a
connected system.
IMPORTANT: Do not lift hydraulic equipment
by the hoses or couplers. Use the carrying
handle or other means of safe transport.
CAUTION: Do not operate the equipment
without lubricating all moving parts. Use only
high pressure molybdenum disulphide grease.
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
4
3.
GENERAL HAND PUMP
OPERATION
3.1
GENERAL GUIDANCE
The release valve is closed fully by rotating clockwise
until hand tight
CLOSE RELEASE
VALVE
The pump handle is raised, which creates a vacuum in
the piston chamber which sucks oil from the reservoir
into the chamber
The pump handle is depressed, which pumps the oil from
the chamber through the outlet port and into the system
to which the pump is connected
Steps 2 & 3 are repeated, which will pump oil into
the system until the maximum pressure of 700 bar
(10 000 psi) is achieved, at which point the safety release
valve will open and the oil will cycle back to the reservoir
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
5
3.2
HP350S, HP550S & HP1000S
CONNECTION AND OPERATION
WARNING: Never attempt to pressurise the
pump when the pressure gauge is not connected
or the pump is not connected to a system.
DANGER: Always check the hydraulic system
in which the pump is to be used, is rated for
700 bar (10 000 psi). Over pressurizing a
hydraulic system will result in component failure
and personal injury.
1. Prior to using the pump the hydraulic gauge must be
tted. Push the male connector on the gauge fully
into the female connector on the gauge adaptor and
rotate the locking ring counterclockwise until fully
tight.
LOCKING
RING
2. Ensure the hydraulic system you wish to pressurise
has been bled and is free from air and leaks. Connect
the pump into the system using the screw connector
supplied with the pump, push the male and female
connectors together fully and rotate the locking ring
clockwise until fully tight.
WARNING: Never disconnect the pump or
other components when the system is
pressurised.
LOCKING
RING
MALE AND FEMALE
CONNECTORS
3. Close the release v alve fully by rotating clockwise until
hand tight.
CLOSE RELEASE
VALVE
4. Pressurise the system by raising and depressing the
pump handle until the desired pressure is indicated
on the pressure gauge. N.B. max. pressure 700 bar
(10 000 psi).
5. To depressurise the system, gently open the release
valve by rotating the release knob anti-clockwise
OPEN RELEASE
VALVE
6. Once the system has been fully depressurised,
the pump can be disconnected by unscrewing the
connectors.
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
6
3.3
HP350D, HP550D & HP1000D
CONNECTION AND OPERATION
The HP350D, HP550D and HP1000D pumps have been
designed for use with Equalizer maxi kit systems; however
the HP350D, HP550D and HP1000D can be used in any
situations where two separate hydraulic systems require
to be pressurised and controlled independently by the
same operator.
WARNING: Never attempt to pressurise the
pump when the pressure gauge is not connected
or the pump is not connected to a system.
DANGER: Always check the hydraulic system
in which the pump is to be used, is rated for
700 bar (10 000 psi). Over pressurizing a
hydraulic system will result in component failure
and personal injury.
1. Prior to using the pump, the hydraulic gauges must
be tted. Push the male connector on the gauges
fully into the female connector on the gauge adaptors
and rotate the locking ring counterclockwise until fully
tight.
2. Ensure the hydraulic systems you wish to pressurise
have been bled and are free from air and leaks.
Connect the pump into the systems using the screw
connectors supplied with the pump, push the male
and female connectors together fully and rotate the
locking rings clockwise unti fully tight.
WARNING: Never disconnect the pump or
other componnents when the system is
pressurised.
MALE AND FEMALE
CONNECTORS
LOCKING
RING
LOCKING
RING
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
7
3. The HP-D pumps are tted with two control valves and
a release valve. This enables the operator to adjust
the pressure on both hydraulic systems independently
or simultaneously.
CONTROL VALVE 1
CONTROL VALVE 2
RELEASE VALVE
a. If control valves 1 and 2 are set to the fully open
position and the release valve is screwed fully,
when the pump handle is raised and lowered
both hydraulic systems will be pressurised to an
equal pressure (max. 700 bar (10 000 psi)).
b. If control valve 1 is open and control valve 2
is closed with the release valve screwed fully,
when the pump handle is raised and lowered only
the system connected to control valve 1 will be
pressurised (max. 700 bar (10 000 psi)).
c. If control valve 2 is open and control valve 1 is
closed with the release valve screwed fully, when
the pump handle is raised and lowered only
the system connected to control valve 2 will be
pressurised (max. 700 bar (10 000 psi)).
OPERATOR INSTRUCTION MANUAL
IM_HP_Rev10_A4
HP350S; HP350D; HP550S; HP550D;
HP1000S; HP1000D
HYDRAULIC SEALED HAND PUMPS
8
d. If after pressurising one system the control valve
for the unpressurised system is opened then the
pressure in both systems will adjust until they are
equal.
4.
a.
To depressurise both systems simultaneously,
open both control valves and gently open the
release valve by rotating the release knob anticlockwise.
b. To depressurise only one system, open only the
control valve for that system and gently open
the release valve by rotating the release knob
anti-clockwise.
5. At any time, during pressurisation of the systems,
the appropriate control can be closed to hold one
system at a xed pressure while the pressure in
the other system can be increased by raising and
lowering the pump handle or decreased by opening
the release valve.
6. Once both systems have been fully depressurized
the pump can be disconnected by unscrewing the
couplers
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