PORTO POWER B65115 Operators Manual

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Porto-Power Blackhawk Automotive is a licensed trademark

Porto-Power Kit

Operating Instructions & Parts Manual

Model Number Capacity B65114 4 Ton B65115 10 Ton

Model B65114

Model B65115

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

! ADVERTENCIA

• Leer, comprender, y seguir las instrucciónes antes de utilizar el aparato.

• El manual de instrucciónes y la información de seguridad deben estar comunicado en lengua del operador

antes del uso.

• No seguir estas indicaciónes puede causar daños personales o materiales.

SFA Companies

10939 N. Pomona Ave. Kansas City, MO 64153

sales@blackhawk-automotive.com

Read this manual and follow all the Safety Rules and Operating Instructions before using this product.

Printed in China

B65114-M0 rev 12/07

SAFETY and GENERAL INFORMATION

Save these instructions. For your safety, read and understand the information contained within. The owner and

operator shall have an understanding of this product and safe operating procedures before attempting to use this product. Instructions and Safety information shall be conveyed in the operators native language before use of this product is authorized. Make certain that the operator thoroughly understands the inherent dangers associated with the use and misuse of the product. If any doubt exists as to the safe and proper use of this product as outlined in this factory authorized manual, remove from service.

Inspect before each use. Do not use if broken, bent, cracked or otherwise damaged parts are noted. If any component of this product has been or suspected to have been subjected to a shock load (a load dropped suddenly, unexpectedly upon it), discontinue use until checked out by an Porto-Power Blackhawk Automotive authorized

service center. Owners and operators of this equipment shall be aware that the use and subsequent repair of this

equipment may require special training and knowledge. It is recommended that an annual inspection be done by

qualied personnel and that any missing or damaged parts, decals, warning/safety labels or signs be replaced with

factory authorized replacement parts only. Any component of this Porto-Power Kit that appears to be damaged in any way, is worn or operates abnormally shall be removed from service immediately until such time as it can be

repaired/replaced. Labels and Operator's Manuals are available from manufacturer.

PRODUCT DESCRIPTION

Porto-Power Kits are designed to be used for pushing, spreading, and pressing of vehicle body panels as well as various component parts and assemblies. A variety of attachments are included. B65114 is rated at 8,000 PSI; B65115 is rated at 10,000 PSI. Rams are rated from 4 to 10 tons respectively.

WARNING: To reduce the risk of personal injury and/or property damage, ensure that the rated working

pressure of each pressurized attachment be equal to or greater than the rated working pressure developed by the hydraulic pump.

Always check connections before using. Alteration of these products is strictly prohibited. Use only those

adapters and attachments provided and approved by the manufacturer.

Note: when extension tubes and/or offset attachments are used, the rated capacity is always reduced by 50% for

each tube or offset attachment connected. See Parts Section for identication of “offset” attachments.

Release Valve

Handle

Hose

Oil Filler

Screw

Dust Cover

Hose

Coupler

Plunger

Ram

Ram Coupler

Figure 1 - Pump and Ram Components

SPECIFICATIONS

Model Pump

Capacity

(psi)

Ram

Capacity

(ton)

Closed

Height

(in)

Ram Number of

Extended

Height

(in)

Effective

area

(in

)

Attachments

B65114 8,000 4 11 15 3/4 0.998 14 46

B65115 10,000 10 13 5/8 19 3/4 2.411 13 84

! WARNING

may

property damage.

• Study, understand, and follow all instructions provided with and on this device before use.

with the correct operation, maintenance, and use of rams.

Wear protective gear when

operating hydraulic equipment.

This device is NOT suitable for use as support device! As the load is lifted, use blocking and cribbing to guard against a falling load. clear of a lifted load before it is properly Never rely on hydraulic pressure to support a load.

during operation.

•

Do not connect a ram to a pump with higher

pressure rating.

• Do not subject ram to a shock loads, a load

dropped suddenly, causing the system pressure to exceed rated pressure.

The system operating pressure must not exceed

measuring instrument to monitor the operating pressure. Burst hazard exists if hose, connection or any other component in the system exceed its rated pressure.

Avoid damaging hydraulic hose. Do not allow hose to kink, twist, curl, crush, cut or bend so

tightly that uid ow within the hose is blocked or

reduced. Periodically inspect the hose for wear.

Failure to comply with the following warnings

result in personal injury as well as

• The user must be a qualied operator familiar

Stay

supported.

Crush Hazard. Keep hands and feet away from ram and workpiece

•

Do not exceed rated capacity of the ram or any equipment in the system. The ram is designed for a max. pressure of 10,000 psi.

the pressure rating of the lowest rated component

the system. Install a pressure gauge or other load

Do not pull, position or move ram setup by the hose. Use carrying handle or other means of safe transport.

Do not handle pressurized hoses. Never attempt

to grasp a leaking pressurized hose. Ensure to

release the system pressure before disconnecting hydraulic hose or connections.

Hydraulic uid can ignite and burn. Keep

heat.

uid leaks. Heat also weakens hose materials.

Ram must be on a stable base which is able to support the load while pushing or lifting. Use shims, friction material or constrains to prevent

slippage of the base or load. Ensure ram is fully engaged

into/onto adapters, extension accessories.

Center load on ram. Distribute load evenly across the entire saddle surface. Do not off-center loads on a ram. The load can tip

or the ram can “kick out”.

Never try to disassemble a hydraulic ram,

refer repairs to qualied, authorized personal.

Contact Porto-power tech service for authorized service center.

Do not subject hose to sharp objects or heavy impact.

Hose material or seals must not come in contact with corrosive materials such as battery acid, creosote-impregnated objects and wet paint. Never paint a coupler or hose.

• Use only factory authorized fasteners,

accessories and hydraulic uid.

hydraulic equipment away from ames and

Excessive heat will soften seals, resulting in

Heavy

•

No alteration shall be made to the ram.

Weight

(lb)

BEFORE USE

1. Before using this product, read the owner's manual

completely and familiarize yourself thoroughly with the product, its components and recognize the hazards associated with its use.

2. Inspect before each use. Do not use if bent, broken, leaking or damaged components are noted.

3. Check to ensure that all parts of your kit are included (see illustration and parts list).

4. Carefully remove the dust caps and plugs from hose coupler and ram coupler.

5. Connect hose coupler to ram coupler, ensure that

there are no uid leaks.

6. Locate and open release valve. Close release

valve clockwise and pump handle until ram is fully extended, then open release valve counter-clockwise until ram has fully retracted.

7. With ram fully retracted and release valve open, place

pump in horizontal position. Open oil ller screw (on

reservoir body, near the back). This will release air

trapped within the reservoir. Re-tighten the oil ller

screw.

8. If using with air actuated units, an air source of at least 7.8 CFM @ 110 psi is required.

GENERAL SAFETY INFORMATION

1. Ensure that attachments are fully engaged before

applying load.

2. Ensure that load is centrally applied to attachment or

ram saddle. Do not load off center.

Always monitor the force applied to workpiece by using a load cell and indicator or you may monitor pressure developed in the ram by using an inline pressure gauge, then calculate the applied force using the formula:

F = P x A, where F = lb force, P = pressure in psi,

and A = effective ram area in in2.

Ram Area of Model B65114 is: 0.998 in Ram Area of Model B65115 is: 2.411 in

Refer to Load-Pressure correlation chart on page 11.

If bowing or bending of ram or any attachment occurs during use, "STOP", release pressure immediately and reconsider application. Application may not be compatible with product, a ram kit with a higher capacity may be needed.

OPERATION

ALWAYS monitor pressure, load or position

using suitable equipment. Pressure may be monitored by means of an optional manifold and

gauge. Load may be monitored by means of a load

cell and digital indicator.

Note: Any attachment that is not loaded centrally, as through the centerline of the ram, is considered

to be “offset”.

attachments are used, the rated capacity is always reduced by 50% for each tube or offset attachment connected.

1. Pump may be used in horizontal and vertical position

as illustrated on gure 2 below.

Figure 2 - Horizontal and Vertical position

2. Locate and close release valve by turning it clockwise until rmly closed. (Do not over tighten)

3. Operate by pumping handle. This will send uid

from the pump reservoir into the high pressure hose assembly and into the ram assembly.

4. Continue pumping until ram reaches desired position.

NEVER operate pump with release valve

closed and disconnected from application. If operated in this condition, the hose and connections become pressurized. This increases burst hazard. Damage may occur to pump and its components.

5. To Release Pressure on work piece: Slowly, carefully turn the release valve counter-clockwise until ram retracts to desired position. Never turn release valve more than 1/2 full turn. The ram return system is spring loaded and the release valve system is metered, allowing controlled retraction of the ram.

When extension tubes and/or offset

Basic Setup

The capacity of the body repair kit can be signicantly affected by the number of attachments used and the type of

load applied. The approximate load capacity of each function setup is illustrated below. When two or more extension tubes are used together, be sure to position the shortest tube further away from the ram. Note: Not all accessories in the illustrations provided in the Porto-Power Kits.

A. Push & Stretch

Serrated Saddle

Ram

Male Connector

Flat Base

100%

(i) Vertical Push

Extension Tube

Flat Base

Male Connector

(ii) Horizontal Push

Male Connector

(iii) Horizontal Push with Extension

Male Connector

Ram

(iv) Horizontal Stretch with Extension

Ram

Extension Tube

Ram

Rubber Head

100%

Combination

Head (90

)

25%

Clamp

12.5%

B. Clamp & Pull

Pull Ram

C. Spread

Ram

Ram Toe

Extension Tube

Flat Base

Lifting Toe

(i) Clamp with Pull Ram

25%

(i) Vertical Spread

Plunger Base

25%

Chain Pull Plate

Ram

(ii) Horizontal Spread

Ram Toe

Ram

(ii) Pull with Chain

Plunger Toe

25%

Chain

100%

Saddle

0.5 Ton

(iii) Hydraulic Spreader

Hydraulic Spreader

MAINTENANCE

1. Inspect hoses and connections daily. Replace damaged components immediately with Porto-Power Automotive Replacement Parts only.

2. Tighten connections as needed. Use pipe thread sealing compound when servicing connections.

3. Use only a good grade hydraulic oil. Avoid mixing

different types of uid and Never use brake uid, turbine oil, transmission uid, motor oil or glycerin. Improper uid can cause premature failure of the

ram and the potential for sudden and immediate loss of load. We recommend Hein-Werner HW93291 or equivalent.

Adding oil

1. With ram fully lowered, set pump unit in its normal,

level position. Locate and remove oil ller screw.

2. Fill until oil is within 3/8" of the oil ller screw hole opening, re-install oil ller screw.

Changing oil

For best performance and increased system life, replace

the complete uid supply at least once per year.

1. With ram fully lowered, remove the oil ller screw

from the pump reservoir as above.

2. Lay the pump on its side and drain the uid into a

suitable container.

Note: Dispose of hydraulic uid in accordance with

local regulations.

3. Set pump in its level upright position.

4. Fill with good quality jack oil to within 3/8" of the oil

ller screw hole opening. Reinstall oil ller screw.

Cleaning

Periodically check the pump piston and ram for signs of rust or corrosion. Clean as needed and wipe with an oily cloth.

Note: Never use sandpaper or abrasive material on these surfaces!

Storage

When not in use, store with the pump piston and ram fully retracted.

How to remove faulty coupler:

If ram does not retract,:

1. Secure load by other means.

2. Depressurize pump and hose

3. Remove the ram from application.

4. Disconnect and replace with new coupler.

Important: Do not attempt to grasp ram with pliers or

wrench without rst wrapping the jaws of such tool with

rags or similar padding.

How to bleed air from system:

1. Place pump at a higher elevation than the hose and

ram as shown in gure 3 below.

2. Operate pump to fully extend and retract the ram 2 or 3 times. The objective is to force the air bubbles up hill and back to the pump reservoir.

3. To bleed the air from pump reservoir, simply open

the oil ller screw. Re-install after bleeding.

Lubrication

A coating of light lubricating oil to pivot points and hinges will help to prevent rust and assure that pump assemblies move freely.

Figure 3 - Illustration to bleed air from system

TROUBLESHOOTING GUIDE

The following information is intended as an aid in determining if problem exists. Pump and ram should be repaired only by authorized Porto-Power Service Center. For repair service, contact service center in your area.

Symptom Possible Causes Corrective Action

Erratic action •

Ramr will not extend, or

respond to pressurized uid

Ram extend only partially • Oil level in pump is low.

Ram move slower than normal • Loose connection or coupler.

Ram responds to pressurized

uid, but system does not maintain

pressure

Oil leaking from ram • Worn or damaged seals. • Contact service center.

Air in system or pump cavitation.

• External leakage in ram.

• Ram sticking or binding.

•

Overload condition.

• Loose/Faulty couplers.

• Oil level in pump is low.

•

Overload condition.

• Ram is sticking or binding.

• Pump malfunction.

•

Restricted hydraulic line or tting.

• Pump not working correctly.

• Ram seals leaking.

• Overload condition.

• Pump malfunctioning.

• Ram seals leaking.

• Vent the system (refer to gure 3).

• Contact service center.

• Remedy overload condition.

• Tighten/Replace couplers.

• Fill and bleed the system.

• Remedy overload condition.

• Contact service center.

• Tighten connection or coupler.

• Clean and replace if damaged.

• Check pump’s operating

instructions.

• Contact service center.

• Remedy overload condition.

• Contact service center.

Ram will not retract or retracts slower than normal

Poor performance • Oil level in pump is low.

• Malfunctioning coupler, damaged

application.

• Pump reservoir overlled.

• Ram damage internally.

• Air trapped in system.

• Secure load by other means.

Depressurize pump and hoses, remove application and replace coupler.

• Secure load by other means. Depressurize pump and hoses,

remove application, then drain

uid to proper level.

• Contact service center.

• Ensure proper oil level.

• Vent the system (refer to gure 3).

REPLACEMENT PARTS

Not all components of the porto-power kit are replacement items, but are illustrated as a convenient reference of location and position in the assembly sequence. When ordering parts, give Model number, serial number and description below. Call or write for current pricing: SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153, U.S.A.

Tel:(816)891-6390 Fax:(816)891-6599 E-Mail: sales@blackhawk-automotive.com

Model No. B65114

Ref No. Part# Description Qty

1 B65161 Extension Tube (19-1/2") 1 2 B65160 Extension Tube (16-1/2") 1 3 B65159 Extension Tube (8-1/2") 1 4 B65158 Extension Tube (6-1/8") 1 5 B65157 Extension Tube (3") 1 6 B65177 Male connector 1 7 B65153 Wedge Head (offset) 1 8 B65151 Serrated Saddle 1 9 B65156 Flat Base 1 10 B65154 Plunger Toe (offset) 1

11 B65155 Ram Toe (offset) 1 12 B65178 Rubber Head 1 13 B65152 Combination Head, 90 14 B65123 Hydraulic Spreader (1000 lb. capacity) 1 15 F040-20012-000 Dust Cover - Hose 1 16 F040-30007-000 Dust Cover - Ram 1 17 B69478 Hose Coupler, Male 1 18 B69477 Ram Coupler Assy, Female 1 19 B65187 Ram Assembly 1 20 F040-21000-000 Release Valve Knob 1 21 F040-90009-K03 Pump Handle 1 22 B65291 Hose Assembly (with coupler) 1 23 F040-90107-K02 Oil Filler Screw 1 24 B65186 Pump Assembly 1 25 B65067 Blow Molded Case 1

- F0400S-85 Repair Kit -

Figure 4 - Replacement Parts Illustration for Model B65114

Model B65115

Ref No Part# Description Qty

1 B65162 Extension Tube (27") 1 2 B65163 Extension Tube (18") 1 3 B65164 Extension Tube (10") 1 4 B65165 Extension Tube (4") 1 5 B65179 Male Connector 1 6 B65166 Wedge Head (offset) 1 7 B65167 Serrated Saddle 1 8 B65168 Flat Base 1 9 B65172 Plunger Toe (offset) 1

10 B65169 Ram Toe (offset) 1

11 B65180 Rubber Head 1 12 B65173 Combination Head (90o) 1 13 B65123 Hydraulic Spreader (1000 lb. capacity) 1 14 F040-20012-000 Dust Cover - Hose 1 15 F040-30007-000 Dust Cover - Ram 1 16 B69478 Hose Coupler, Male 1 17 B69477 Ram Coupler Assy., Female 1 18 B65189 Ram Assembly 1 19 F040-21000-000 Release Valve Knob 1 20 F100-90009-K01 Pump Handle 1 21 B65291 Hose Assembly 1 22 F040-90107-K02 Oil Filler Screw 1 23 B65188 Pump Assembly 1 24 B65068 Blow Molded Case 1

- F1000S-85 Repair Kit -

Figure 5 - Replacement Parts Illustration for Model B65115

ONE YEAR LIMITED WARRANTY

For a period of one (1) year from date of purchase, SFA Companies will repair or replace, at its option, without charge, any of its products which fails due to a defect in material or workmanship under normal usage. This limited warranty

is a consumer's exclusive remedy.

Performance of any obligation under this warranty may be obtained by returning the warranted product, freight prepaid, to SFA Companies Warranty Service Department, 10939 N. Pomona Ave., Kansas City, MO 64153.

Except where such limitations and exclusions are specically prohibited by applicable law. (1) THE CONSUMER'S SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF

DEFECTIVE PRODUCTS AS DESCRIBED ABOVE.

(2) SFA COMPANIES SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGE OR LOSS

WHATSOEVER.

(3) ANY IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL BE LIMITED TO ONE YEAR, OTHERWISE THE REPAIR, REPLACEMENT OR REFUND AS PROVIDED UNDER THIS EXPRESS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER, AND IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.

(4) ANY MODIFICATION, ALTERATION, ABUSE, UNAUTHORIZED SERVICE OR ORNAMENTAL DESIGN VOIDS

THIS WARRANTY AND IS NOT COVERED BY THIS WARRANTY.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty gives you specic legal rights, and you may also have

other rights which vary from state to state.

Porto-Power Blackhawk Automotive is a licensed trademark

SFA Companies

10939 N. Pomona Ave. Kansas City, MO 64153

816-891-6390

sales@blackhawk-automotive.com

Load - Pressure Correlation For Model B65114 & B65115

F = P x A

For model B65114, A = 0.998 in² ; For model B55115, A = 2.411 in²

Example1

Model B65114 lifting 5,000 lb will require what presure? Pressure = 5,000 lb / 0.998 in² = 5,010 psi

where P = Hydraulic working pressure (psi) and; A = Ram effective area (in²)

F = Force/ Load (lb);

Load

(lb) 1,000 1,002 415 2,000 2,004 830 3,000 3,006 1,244 4,000 4,008 1,659 5,000 5,010 2,074 6,000 6,012 2,489 7,000 7,014 2,903 8,000 8,016 3,318 9,000 3,733

10,000 4,148 11,000 4,562 12,000 4,977 13,000 5,392 14,000 5,807 15,000 6,221 16,000 6,636 17,000 7,051 18,000 7,466 19,000 7,881 20,000 8,295

Pressure of 4 Ton Ram,

where A = 0.998 in

(psi)

Example2

Model B65115 operating at 6,000 psi will generate what force? Force = 6,000 psi x 2.411 in2 = 14,466 lb

Pressure of 10 Ton Ram,

where A = 2.411 in

(psi)

SFA Companies

10939 N. Pomona Ave. Kansas City, MO 64153

Tel: 888-332-6419

E-mail: sales@blackhawk-automotive.com

PORTO POWER B65115 Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual