User Manual - Zinko Jacks
Contents
1. MODELS ZHP 18 amp ZHP 28 Automotive Hydraulic Hand Pumps ZINKO Hydraulic Jack Toll Free 7 800 579 8088 Web www zinko com Operation amp Maintenance Manual Important Receiving Instructions Visually inspect all components for shipping damage Shipping damage is NOT covered by warranty If shipping damage is found notify carrier at once The carrier is responsible for all repairs and replacement costs during product shipping Safety Information Read and follow all instructions warnings cautions and carefully Follow all safety precautions to avoid personal injury or property damage during system operation ZIAKO is not responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact ZIAKO when in doubt as to the safety precautions and operations Failure to comply with the following cautions and warnings could cause equipment damage and personal injury Caution Remarks Used In This Manual AWARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury ACAUTION is used to indicate correct operating maintenance procedures and practices to prevent damage to or destruction of equipment or other property Operator Responsibility It is the operator s responsibility to read and understand all of the following safety statements AWARNING Make sure that all system components are protected fro2. d in dirty environments change oil more often Be sure to dispose of used oil properly 2 Remove vent fill cap or plug from reservoir 3 Tilt pump to drain out old oil 4 Replace the vent fill cap or plug 5 Regularly use roller bearing grease Zinko Hydraulic Jack REV 070207 Models ZHP 18 amp ZHP 28 Parts Breakdown No Description ZHP 18_ ZHP 28_ 11 O Ring RP 21 O Ring OO ORP 22 923 018 23 O Ring TR Back Up ring f RRP 923 018 27 923 018 28 923 018 29 No Description _ZHP 18 ZHP 28 30 923 018 30 923 018 01 923 018 31 923 028 31 2 923 018 02 923 018 32 3 O Rings R 923 018 33 4 923 018 34 923 018 05 923 028 05 O Ring O O P 923 018 06 O Rings RP 923 018 08 8 923 018 093 9 923 018 10 9219401 RP 6 Troubleshooting POSSIBLE CAUSE SOLUTION Oil level in pump reservoir is low Add oil according to Maintenance section page 2 Cylinder does not advance advances slowly or advances in spurts Cylinder plunger binding Check for damage to the cylinder Have cylinder ec a Check that all connection are tight and leak free i z Locate leak dh i iced Cylinder advances but does not Leaking seals oca eak s an ave equipment serviced by a qualified hydraulic technician hold pressure 3 z Internal leakage in pump Locate leak s and have equipment serviced by a qualified hydraulic technician Release valve close Open release valve Pump reservoir is overfilled Drain oi
3. e of oil Single Acting Applications with Release Valve 1 Close the release valve by turning clockwise AXCAUTION Close release valve finger tight ONLY Using tools on release valve can damage it and cause the pump to malfunction 2 Operate pump handle to deliver hydraulic power to the system Pressure will be maintained until release valve is opened 3 Open release valve turn counterclockwise to release pressure allowing oil to flow back to the reservoir Single Acting Applications with 3 Way Position Manual Valve 1 Shift valve handle to position 1 2 Operate pump handle to deliver hydraulic power to the system Pressure will be maintained until the valve is shifted 3 To allow oil to return to the reservoir shift valve handle to position 2 Relief Valve Adjustment All pumps contain a factory set relief valve to prevent over pressurization of the system Lower pressure settings can be obtained contact your Authorized Service Center for more information Bleeding Air From the System Removing air from the hydraulic system will help the cylinder to advance and retract smoothly Air can accumulate in the hydraulic system during the initial setup or after prolonged use which causes the cylinder to respond slowly or in an unstable manner To Remove Air 1 Position the cylinder at a lower level than the pump and turn the cylinder rod down 2 With no load on the system and the pump vented extend and retract the cylinder several ti
4. ent prior to transporting pump to prevent oil leakage NOTE When operating the pump in the vertical position the hose end must be pointed down or the pump will pick up air and will not build pressure properly Operation Before Using the Pump 1 Check all system fittings and connections to make sure they are tight and leak free 2 Check oil level in reservoir before operating pump See Maintenance on page 2 AWARNING a Never add extensions to the pump handle Extensions cause unstable pump operation b In certain situations the pump handle can kick back Always keep your body to the side of the pump and away from the line of force NOTE To reduce handle effort at high pressure take short strokes Maximum leverage is obtained in the last 5 degrees of the stroke Zinko Hydraulic Jack Models ZHP 18 amp ZHP 28 Operation continued Using Two Speed Pumps These pumps provide two stage flow Under no load the pump operates in the high flow stage for rapid advance When the load is contracted the pump automatically shifts to the second stage for building pressure When pump pressure reaches approximately 200 psi you must momentarily stop pumping and raise the handle to shift to the high pressure stage After the pump shifts pumping takes less effort NOTE For best performance operate handle at moderate speed during the high flow first stage Rapid handle speed in the first stage will prevent the pump from delivering a full volum
5. l level to full mark See page instructions for adding oil Loose hydraulic coupler Check that all couplers are fully tightened part way or retracts more slowly z s thamAomal Air trapped in system Remove air according to instructions on page 2 i Hose I D too narrow Use larger diameter hydraulic hose Cylinder retraction spring broken or an r pan y J pang Have cylinder serviced by a qualified service technician other cylinder damage If the above procedures do not correct the problem contact your nearest ZINKO service facility When submitting any jack or equipment to be repaired be sure to state the nature of the problem and indicate whether an estimate of the repair cost is needed Cylinder does not retract retracts ZINKO PO Box 4903 http www zinko com Phone 909 989 9526 Hydraulic Jack Ontario CA 91761 Toll Free 1 800 579 8088 Fax 909 989 1724
6. m external sources of damage such as excessive heat flame moving machine parts sharp edges and corrosive chemicals WEAR PROPER PERSONAL PROTECTIVE GEAR WHEN OPERATING HYDRAULIC EQUIPMENT Always check product limitations regarding pressure ratings load capacities and setup requirements The system operating pressure MUST NOT exceed the pressure rating of the lowest rated component in the system NEVER set the relief valve to a higher pressure than the maximum rated pressure of the pump Higher settings may result in equipment damage and or personal injury Installation Connecting the Pump 1 Thread hose into pump outlet Use 1 1 2 wraps of Teflon tape or suitable thread sealant on hose fitting leaving the first complete thread free of tape to ensure that tape does not shed into the hydraulic system causing damage Trim loose ends 2 Install a pressure gauge in line from the pump for added safety and better control 3 Connect the hose s to your cylinder or tool NOTE For single acting cylinders Connect one hose from the pump to the cylinder For double acting cylinders Connect two hoses Connect one from the pressure port of the pump to the pressure port of the cylinder Connect another hose from the retract port of the pump to the retract port of the cylinder Pump Venting Vented pumps provide slightly better performance For pumps with a nylon reservoir turn vent fill cap 1 4 turn counter clockwise to vent Close v
7. mes Air will be released into the pump reservoir Follow the fluid level instructions for your reservoir type to release the air from the reservoir and top off the fluid supply Maintenance Use only ZIAKO hydraulic oil with these pumps to promote long pump life and protect your warranty ZIAKO seal kits are available for some hand pumps Contact your ZINKO representative for more information on these products and or other products Adding Oil to the Pump AWARNING Check oil level regularly Always add oil with cylinders fully retracted extended if pull cylinders or the system will contain more oil than the reservoir can hold 1 Remove vent fill cap from reservoir 2 Fill reservoir only to level mark shown on pump 3 Remove air from system if necessary Recheck oil level after removing air 4 Return vent fill cap to proper position NOTE Non vented hand pumps are required to be completely filled with air or else a vacuum will form preventing oil from flowing out of the pump Keeping Oil Lines Clean When coupler halves are disconnected always screw on dust caps Use every precaution to guard unit from dirt entering the system because foreign matter may cause pump cylinder or valve failure Lubricating the Pump To extend pump life and improve performance lubricate the beam pin cross pin and piston head and close release valve Changing the Oil 1 Drain all oil and refill with clean ZIAKO oil every 12 months If pump is use
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