User Manual - Abest Industrial Supply
Contents
1. 6 12 Spring Washer TOO 6 13 Fitting Screw 6 14 Oil Feeding Plug Gageqesconcosaeses Moin UN WOK I bd 72 M IL JH o nmm eee ez 1 1 1 1 1 3 1 3 2 3 3 3 4 3 5 3 6 3 7 i O 4 1 4 2 4 3 1 11 Pump Portion 2 4 2 5 2 6 i 2 7 Steel Ball 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 Blind Cover 6 7 ilter teel Ball pring opper Packing UIVIJIOIVVIVITIVIO ONIN o 2 2 lo g e 2 alojo 9 8 5 9 vl 2 lo alse D D c N n e O Ry O 5 Ro P a ree ER E i1 LI AERE all NS ase dde WAX AA dde x NS T NN pp f j NS ER E EDY BOO O NA Fo Zinko Hydraulic Jack REV 110707 Models ZPE 35RH 1M amp ZPE 35RH 1MB Troubleshooting Troubleshooting PROBLEM CAUSE SOLUTION 1 No supply voltage 1 Check line voltage Motor Does Not Run 2 Broken lead wire or defective power 2 Replace defective part cord plug AWARNING 3 Defective switches 3 Check switches Disconnect Power Supply 4 Worn carbon brushes 4 Replace carbon brushes see page 4 Before Disassembly or Repair 5 Defective motor 5 Repair or replace motor 6 Defective remote switch 6 Repair or replace switch 7 Unit is not plugged in 7 Plug in unit 1 Damage to pump or motor 1 Repair or replace unit Ab IN F Motor donde ies Me SET 2 Damage of ball bearings etc 2 Replace2. 0 7 0 100 110 10 0 11 0 Make sure that tape does not shed into the hydraulic system causing damage Trim loose ends Zinko Hydraulic Jack Models ZPE 35RH 1M amp ZPE 35RH 1MB High Pressure Hoses 1 Hose Installation Install hoses leaving something in the reserve because high pressure hoses expand and contract more or less when full pressure is applied Be careful that the hoses do not rub against other soild materials Never allow the hoses to kink twist curl or bend so tightly that oil flow within hoses are blocked or restricted DO NOT CLAMP THE HOSES Clamping the hoses can cause problems Hose Handling Never drop heavy things against the hoses This can cause bursting of the hoses resulting in serious accident or injury Do not subject the hoses to any potential hazard fire extreme heat or cold heavy impact or sharp surfaces which may rupture or weaken the hoses Never pull hoses to move or lift equipment connect ed with hoses Should a hose ever burst or rupture STOP OPERATING THE PUMP IMMEDIATELY before attempting to remedy the situation Never attempt to grasp a leaking hose under pressure with your hands The force of the escaping hydraulic fluid could cause serious permanent injury Quick Couplers Connections Make sure that all couplers are connected properly Incomplete coupling connections might cause partial or complete blockage of oil flow resulting in trouble of hydraulic system Handling If the
3. Damage from such accidents as fire submersion dropping etc ZINKO PO Box 4903 http www zinko com Phone 909 989 9526 O Hydraulic Jack Ontario CA 91761 Toll Free 1 800 579 8088 Fax 909 989 1724
4. ball bearings 1 Damage of release valve 1 Repair or replace release valve 2 Oil level is too low 2 Fill reservoir to 1 2 of level gauge with all cylinders retracted Motor Runs But Cylinders 3 Air in the system 3 Bleed the system see page 4 Do Not Advance or Retract 4 Filter plugged or dirt in the pump 4 Pump filter should be dismantled and cleaned if necessary 5 Damage of the pump body 5 Repair pump 6 Relief valve out of adjustment 6 Readjust as needed 1 Damage of release valve 1 Repair or replace release valve Cylinders Work But Full 2 Air in the system 2 Bleed the system see page 4 Pressure is Not Reached 3 Damage of the pump body 3 Repair pump 4 Lowering of set pressure 4 Readjust set pressure 1 Damage of release valve 1 Repair or replace release valve Cylinders Work But 2 Air in the system 2 Bleed the system see page 4 Speed is Too Slow or Erratic 3 Unacceptable rise in oil temperature 3 Stop operation or install oil cooler 4 Damage of the pump body 4 Repair pump 1 Damage of release valve 1 Repair or replace release valve Cylinders Do Not Retract 2 Damaged cylinder return springs or 2 Repair or replace springs or couplers damaged quick couplers Leaking Oil 1 Damaged seals seats or steel balls 1 Replace damaged component s 1 Damaged cords 1 Replace damaged component s Short Circuit 2 Bad insulation of electric parts 2 Locate and repla
5. phase Make sure your line voltage is compatible with your pump The wrong voltage connection or voltage drop of your line will cause burning or heating AXCAUTION 1 BE CAREFUL ABOUT VOLTAGE DROP WHEN USED WITH AN ELECTRIC GENERATOR 2 When the power supply is disconnected ALWAYS GRASP THE POWER PLUG AND PULL IT OUT Disconnect by grasping the cord and pulling it out will cause breaking of a wire or a short circuit 3 When a supplement cord is used use only three wire grounded cords of such sufficient gauge as 1 25mm2 or more with a maximum length of 10M This will help to avoid voltage drop or damage of the solenoid valves or the electric motor Zinko Hydraulic Jack Models ZPE 35RH 1M amp ZPE 35RH 1MB Specifications Model Hydraulic Pump Commutator and open type M Work 0 35KW 110V or axmum Work Flow Rate L min 50Hz amp aPacttY ZPE 35RH Pressure Mpa 1 0L 1MIL 220V 50 60Hz TES single phase E Vom st Stage 2nd Stage 1st Stage 2nd Stage m j ose os Remarks 2L usable oil 1 6L reservoir pumps are also available 0 8L Description of Components Oil Plug Reservoir Pump Motor Electric Cord Switch Handle Release Valve Output 3 8 NPT cO C010 01 2050 ND Instructions Before Use 15 2 3 4 Inspection of all components for shipping damage or oil leakage If any shipping damage is found notify carrier at once
6. MODELS ZPE 35RH 1M amp ZPE 35RH 1MB Electric Hydraulic Pumps Hydraulic Jack Toll Free 7 800 579 8088 Web www zinko com Operation amp Maintenance Manual Safety Information Read and follow all WARNINGS CAUTIONS and INSTRUCTIONS included with each product to use the product correctly and to avoid personal injury or property damage during system operation ZIAKO will not be held responsible for damage or injury resulting from unsafe use of products lack of maintenance or incorrect system application Caution Remarks Used In This Manual As a result of incorrect use and or disregard of this remark imminent danger may occur resulting in DANGER a serious injury or death AWARNING As a result of incorrect use and or disregard of this remark could cause serious injury or death As a result of incorrect use and or disregard of this remark there is a possibility that an operator may CAUTION receive an injury or material damage may occur Cautions When Installing Pump Install a pump unit for better balance Since the reservoirs of totally enclosed rubber structures are used in these series of pumps the pumps can be placed for use in any position slanted inverted or perpendicular However the pumps should be installed on stable places When a pump is used aslant make sure it is firmly affixed to prevent sliding which may result in damage or personal injury Prepare a suitable working environment Make sure a
7. Shipping damage is not covered by warranty The carrier is responsible for all repair or replacement costs resulting from damage in shipment ACAUTION Oil feeding plugs Code No 5 are always shut tightly when in shipment and even in use because the tanks are completely enclosed Use them together with quick couplers with check valves Check your power supply Power supply is AC110V or 220V 50 60Hz single phase Make sure AWARNING that a grounded outlet or a plug adapter with a grounding attachment must be used N WARNING Check hydraulic oil Always check oil level before operation with the connected cylinders fully retracted extend if pull cylinders In case oil is added with cylinders fully extended and then cylinders are retracted the returned oil will overflow in the reservoirs causing generation of high pressure in the reservoirs Verify required oil volume in a reservoir as follows a Retract the connected cylinder fully b Pull power plug out c Turn oil feeding plug counterclockwise and remove it d Clean the oil gauge of the removed oil feeding plug with a piece of cloth and put it in the oil feeding port again to check oil level BE CAREFUL WITH THE O RING Zinko Hydraulic Jack Models ZPE 35RH 1M amp ZPE 35RH 1MB e It is OK if the reservoir is filled with oil reaching to the upper bound of the oil gauge Replenish of oil is short See Maintenence section for hydraulic oil details f Replace the oil feeding plu
8. ce damaged component s If the above procedures do not correct the problem contact your nearest ZIAKO 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 WARRANTY Warranty period is for one year from purchase ll ZIAKO products and parts with the exception mentioned below are warranted against defects in materials and workmanship which results in damage to products and parts This warranty shall cover repair and or replacement of the products or components parts free of charge To qualify for warranty consideration return the ZINKO product freight prepaid to a ZIAKO service facility Warranty Exceptions No warranty claim will be accepted for damage or breakdown arising for any of the following reasons Abuse or improper use fair wear and tear faulty or negligent operation improper storage chemical electrical influences or climatic or other effects which can not be related specially to faults in manufacture No liability is accepted for packing seals springs and or the like and the following e Alterations or remodeling on the products undertaken by the purchasers without any prior notice and agreement to ZINKO e Severe and very highly frequent use deviating from product specifications e Damage due to faulty installation or assembly by puchasers or third parties e Damage from natural disaster e
9. coupler becomes damaged stop operating the pump The damaged coupler can cause a serious accident DO NOT DISCONNECT COUPLER SETS they are under pressure Bleeding Air From the System Reservoirs of ZPE 35RH series pumps are made of totally enclosed rubber tanks and tank covers Rubber tanks are filled with oil making no room for air accumulation However in case a new cylinder and or new hose is connected with the pump or oil is exchanged air may accumulate in the hydraulic system This air will prevent the pump from delivering oil or cause the cylinder to respond in an unstable or slow manner Be careful with air accumulation in the system To remove air a Make sure the tank is full with oil Open the oil supply cork on the upper part of the pump check the quantity of oil and carry out until full b When oil does not come out or pressure does not rise when a return valve is opened push the button on the operation switch about 10 times and perform air omission of the pump c Air may accumulate in the pump rubber tank when hydraulic equipment is connected Always check and confirm that the oil tank is full before use Carbon Brushes Always check the wearing condition of the carbon brushes When the carbon brushes have been worn AWARNING down and replacing them is necessary the motor will stop automatically Replace when a brush has been worn down to 6mm in length as shown below or working time of the motor is 500 hours or mo
10. g and screw it in by turning counterclockwise Operation When using a pump with an opened type turn the oil supply cork twice counterclockwise at the time of use NOTE TURN CLOCKWISE AT THE TIME OF CONVEYANCE AND FASTEN THE OIL SUPPLY CORK When using a pump with a sealed type use it with the oil supply cork fastened 1 Close the release valve lever by turning clockwise and depress the ON switch to advance the plunger 2 To retract the plunger turn the valve lever counterclockwise to open the valve Maintenance Hydraulic Oil Use only ZINKO hydraulic oil or an approved high grade oil ISO 32 viscosity 32 cSt 040 C with these pumps Oil Temperature Aptitude temperature for use of hydraulic oil is maximum 55o C If the color of the temperature seal attached to the tank has changed and indicated 55 as shown below an unacceptable rise in oil temperature has occured STOP WORKING IMMEDATELY to decrease the oil s temperature Installation of an oil coller may be appropriate Temperature Seal 0 6 NORMAL CONDITION UNACCEPTABLE RISE IN OIL TEMPERATURE HAS OCCURED Oil Exchange The frequency of oil change depends upon general working conditions severity of use and overall cleanliness 300 hours working time of use or about 3 months is considered as a standard change interval Periodically compare samples of the reservoir oil with new oil Inspect oil color for contaminants or differences Remove oil feeding plug and ti
11. ll system components are protected from external sources of damage such as excessive heat flame moving machine parts sharp edges or corrosive chemicals CAUTION DO NOT USE PUMP IN THE RAIN OR ON IN WET AND DUSTY PLACES DO NOT EXPOSE HYDRAULIC SYSTEM TO THE DIRECT RAYS OF THE SUN Be careful with unacceptable rise in hydraulic oil temperature which can cause trouble in hydraulic equipment In the case pumps are used outdoors in extremely cold regions exchange oil for hydraulic oil with the proper viscosity Increased viscosity due to a drop in oil temperature may cause equipment to function improperly AWARNING 1 BE CAREFUL TO AVOID ELECTRIC SHOCK Do not pull power plug out with a wet hand Use a grounded outlet or a plug adapter with a grounding attachment in order to protect the operator from electric shock 2 DO NOT OPERATE PUMP BY THE SIDE OF AN ELECTRIC WELDER 3 DO NOT PLACE THE PUMP ON EARTHED MATERIALS OR EQUIPMENT N C2 Using the Pump Be Sure to Take Appropriate Safety Measures When hydraulic equipment is operated protect yourself with a personal safeguard working clothes and shoes safety glasses etc Always Check Pressure Limitations of the Hydraulic Circuit Always confirm in advance that maximum permissible working pressure of a hydraulic pump is lower than the pressure rating of the lowest rated component connected in the system Power Supply The power supply is AC110V or 220V 50 60Hz single
12. lt the pump to drain out old oil Be careful that impurities such as dust do not enter into the reservoir and that new oil is filled up to the gauge level mark indicated in the pump Precautions for oil change are a Reatract all cylinders fully to the return position b Do not fill with even a small quantity of replensihment of different kinds of oil c Be careful that impurities or foreign matter do not enter into new oil Oil Safety Notes When oil enters into the eyes wash it away fully with clean water and consult a doctor immediately AWARNING In case oil enters into an open wound wash it away with soapy water and quickly consult a doctor Pressure and Piping 1 AWARNING Composition of hydraulic equipment system When a pump high pressure hose s cylinder valve or couplings are connected together always check product limitations regarding pressure ratings and load capacities The system operating pressure must not exceed the pressure rating of the lowest rated compo nent in the system 2 Pressure gauges Always install or prepare a pressure gauge in line from the pump in order to monitor pressure ce CAUTION Piping Use wrapping of teflon tape on hose fittings valves and couplers Make sure all hose connections are tight use proper tools to tighten connections with reference to the following table DO NOT OVERTIGHTEN CONNECTIONS NPT PT TIGHTENING TORQUE SIZES N m kgf m 18 14 1 3 1 4 30 40 3 0 4 0 60 70 6
13. re NOTE Carbon brush replacement times may depending on the conditions of use Use only ZIAKO approved brushes with these pumps to extend the life of the unit s When they have been worn down the spring exerts insufficient pressure to hold brush against the commutator How To Change 1 Disconnect the power supply 2 Remove rubber caps on two places and loosen Code No 1 21 3 Remove fitting screws inside with a screwdriver so the carbon brush can be taken out 4 Replace brushes with new ones and reattach the screws and rubber caps Relief Valve Adjustment Range of standard pressure adjustment available is from 58 8 to 68 6MPa Loosen lock screw on the high pressure relief valve and turn the adjusting screw a few turns counterclockwise to decrease pressure setting to a lower desired pressure Clockwise rotation of the adjusting screw will increase pressure After setting pressure replace the lock screw NOTE A different kind of spring is needed to adjust and set at a lowe pressure than standard Consult a ZINKO authorized dealer Zinko Hydraulic Jack Models ZPE 35RH 1M amp ZPE35RH 1MB Parts Description Parts Description Circuits CODE DESCRIPTION il Seal ccentric Collar all Bearing pring Pin haft otor Tank Portion Electrical Parts Portion 6 2 Protection Tube 6 3 Pendant Switch 6 4 Cord Clip 6 5 Fitting Screw Muffler Fitting Screw Dashboard 1 Dashboard 2 6 10 Hand Grip 6 11 Fitting Screw
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