HYDRA-JACK 100 Ton Climbing Jacks

Transcription

1 HYDRA-JACK 100 Ton Climbing Jacks OPERATING MANUAL TECHNICAL DATA & REPAIR PARTS Revision: Aug 18, 2015 For Customer Support and Troubleshooting: (Don) (Janine) (Robert) Hydra-Slide Ltd th Line, Rockwood, ON N0B 2K info@hydra-slide.com

2 Table of Contents 1. General Safety Precautions Ton Climbing Jack General Arrangement Drawing 3. Climbing Jack Procedure 4. Enerpac Hydraulic Cylinder Instruction Sheet 5. Enerpac Repair Parts Sheet Model RR Hose Break Valves 7. Couplers Hydra-Slide Ltd th Line, Rockwood, ON N0B 2K info@hydra-slide.com

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4 Hydra-Slide Ltd th Line, Rockwood, ON N0B 2K info@hydra-slide.com

5 Hydra-Slide Ltd th Line, Rockwood, ON N0B 2K info@hydra-slide.com

6 Climbing Jack Procedure Figures courtesy of Rigging Engineering Basics By J. Keith Anderson REPEAT AS NECESSARY TO LOWER - REVERSE ABOVE PROCEDURE

7 Instruction Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. Hydraulic Cylinders L1608 Rev. E 07/11 Index: English Français Deutsch Italiano Español Nederlands Português Suomalainen Norsk Svensk Repair Parts Sheets for this product are available from the Enerpac web site at or from your nearest Authorized Enerpac Service Center or Enerpac Sales offi ce. 1.0 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 repair and replacement costs resulting from damage in shipment. SAFETY FIRST 2.0 SAFETY PRECAUTIONS Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic safety, consult your distribution or service center for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. 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. WARNING: Wear proper personal protective gear when operating hydraulic equipment. WARNING: Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting device, should never be used as a load holding device. After the load has been raised or lowered, it must always be blocked mechanically. WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. Carefully select steel or wood blocks that are capable of supporting the load. Never use a hydraulic cylinder as a shim or spacer in any lifting or pressing application. DANGER: To avoid personal injury keep hands and feet away from cylinder and workpiece during operation. WARNING: Do not exceed equipment ratings. Never attempt to lift a load weighing more than the capacity of the cylinder. Overloading causes equipment failure and possible personal injury. The cylinders are designed for a max. pressure of 700 bar [10,000 psi]. Do not connect a jack or cylinder to a pump with a higher pressure rating. 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. WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is happening in the system. CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a bent or kinked hose will cause severe backpressure. Sharp bends and kinks will internally damage the hose leading to premature hose failure.

8 Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture. IMPORTANT: Do not lift hydraulic equipment by the hoses or swivel couplers. Use the carrying handle or other means of safe transport. CAUTION: Keep hydraulic equipment away from flames and heat. Excessive heat will soften packings and seals, resulting in fl uid leaks. Heat also weakens hose materials and packings. For optimum performance do not expose equipment to temperatures of 65 C [150 F] or higher. Protect hoses and cylinders from weld spatter. DANGER: DO NOT HANDLE PRESSURIZED HOSES. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. WARNING: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the cylinder becomes extremely overloaded, components can fail catastrophically causing severe personal injury. WARNING: BE SURE SETUP IS STABLE BEFORE LIFTING LOAD. Cylinders should be placed on a fl at surface that can support the load. Where applicable, use a cylinder base for added stability. Do not weld or otherwise modify the cylinder to attach a base or other support. Avoid situations where loads are not directly centered on the cylinder plunger. Off-center loads produce considerable strain on cylinders and plungers. In addition, the load may slip or fall, causing potentially dangerous results. Distribute the load evenly across the entire saddle surface. Always use a saddle to protect the plunger. IMPORTANT: Hydraulic equipment must only be serviced by a qualifi ed hydraulic technician. For repair service, contact the Authorized ENERPAC Service Center in your area. To protect your warranty, use only ENERPAC oil. WARNING: Immediately replace worn or damaged parts by genuine ENERPAC parts. Standard grade parts will break causing personal injury and property damage. ENERPAC parts are designed to fi t properly and withstand high loads. 3.0 INSTALLATION 1. Make hydraulic connections. For single-acting cylinders (1) use a pump with a release valve (or a 3-way valve) and one hose. For double-acting cylinders (2) use a pump with a 4-way valve and two hoses. WARNING: On double-acting cylinders be certain that hoses are connected at BOTH couplers. Never attempt to pressurize a double-acting cylinder if only one hose is connected. 2. Fully hand-tighten all couplers. Loose coupler connections will block the fl ow of oil between the pump and the cylinder. 3. Remove air from the cylinder: Single-acting cylinders: Position the cylinder so that the plunger is pointed down and the cylinder is lower than the pump. Fully extend and retract the cylinder several times, until operation is smooth. Double-acting cylinders: Lay the cylinder on its side so that the couplers are facing up. Fully extend and retract the cylinder several times, until operation is smooth. 4. Install adaptors and attachments as required. NOTES: During adaptor installation, extend the plunger and apply approximately 1500 to 2000 psi [103 to 138 bar] of hydraulic pressure. This will help keep the plunger from turning inside the cylinder base. Air Air 2

9 Do not allow the plunger to rotate during adaptor installation. Plunger rotation may damage the internal seals and/or the plunger return spring (if equipped). Use care when installing adaptors and attachments. Be careful not to nick or mar the plunger rod surface. Collar threads are rated for the full capacity of the cylinder when fully engaged in attachments. 4.0 OPERATION WARNING: Some cylinder attachments require that the cylinder be used at no more than 50% of its rated capacity. Refer to the accessory instruction sheet for additional information. Operate the hydraulic pump to advance and retract the cylinder. Some single-acting cylinders are springreturn, others are load-return. The speed of retraction is affected by the length of the hose and other restrictions in the line. Double-acting cylinders are powered in both directions by the pump. The cylinder stop ring is designed to take the full load. However, to reduce cylinder wear, use less than full stroke and pressure when possible. 6.0 MAINTENANCE 1. Use only Enerpac oil with the cylinder. The use of any other oil may invalidate your warranty. 2. Use dust cap(s) when cylinder is disconnected from the hose(s). Keep the entire cylinder clean to prolong its life. 3. Single-acting cylinders only: Before long term storage, fully extend and retract the plunger once. Then, store the cylinder upside-down. This will help protect the cylinder from corrosion. 7.0 TROUBLESHOOTING Refer to the troubleshooting chart for a list of typical cylinder problems and possible causes. The troubleshooting chart is not all-inclusive, and should be considered only as an aid to help diagnose the most common problems. The cylinder should be repaired only by trained and experienced hydraulic technicians. WARNING: Single-acting cylinders are spring-loaded and require special disassembly techniques to prevent personal injury. 5.0 RELIEVING TRAPPED PRESSURE Pressure can sometimes become trapped in a hydraulic cylinder if a hose is disconnected before pressure is completely relieved. If a trapped pressure condition occurs, always use the Enerpac model CT-604 coupler bleed tool (available from your Authorized Enerpac Distributor) to safely relieve the remaining pressure. DANGER: Never attempt to relieve hydraulic pressure by loosening a coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly with great force. Serious personal injury or death will result if the coupler becomes a projectile and strikes persons working in the area. WARNING: Loosening a coupler may result in an escape of high pressure oil that can penetrate the skin. Serious personal injury or death could result. WARNING: Never use a hammer and punch (or other similar method) to unseat a coupler check ball that is under pressure. Serious personal injury or death could result due to the sudden and uncontrolled escape of high pressure oil. 3

10 TROUBLESHOOTING CHART PROBLEM Cylinder will not advance. POSSIBLE CAUSE Pump release valve open. Coupler not fully tightened. Oil level in pump is low. Pump malfunctioning. Load is too heavy for cylinder. Cylinder seals leaking. Cylinder advances part way. Oil level in pump is low. Coupler not fully tightened. Cylinder plunger binding. Cylinder advances in spurts. Air in hydraulic system. Cylinder plunger binding. Cylinder advances slower than normal. Leaking connection. Coupler not fully tightened. Pump malfunctioning. Cylinder advances but will not hold. Pump malfunctioning. Leaking connection. Incorrect system set-up. Cylinder seals leaking. Cylinder leaks oil. Worn or damaged seals. Internal cylinder damage. Loose connection. Cylinder will not retract or retracts slower than normal. Pump release valve is closed. Coupler not fully tightened. Pump reservoir over-fi lled. Narrow hose restricting fl ow. Broken or weak retraction spring (if equipped). Cylinder damaged internally. Oil leaking from external relief valve. Coupler not fully tightened. Restriction in return line. 4

11 Hydraulic Technology Worldwide Repair Parts Sheet RR-1006, RR-10013, RR L990 Rev. E 10/08 RR For Date Codes Beginning with the Letter D RR-10013, RR For Date Codes Beginning with the Letter C To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil. Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product. NOTE: Cylinder base, item 12, is not available as a service item. Order complete cylinder. CAUTION: Indicates staked threads. Stake marks must be removed prior to disassembly. Failure to do so may result in damage to parts. Some cylinder stop rings are assembled with Loctite material on threads. Stake threads when reassembling. NOTE: Safety valve (item 14) preset to 11,000-11,500 psi [ Bar] Figure 1, 100-ton, Double Acting, Solid Plunger Hdraulic Cylinders

12 Repair Parts List for Figure 1 Item Part Number Qty. Description RR-1006 RR RR L748900SR L748900SR L748900SR 1 Saddle Assembly 2 1 Wiper Ring 3 CL CL CK Stop Ring 4 1 Back-Up Washer 5 1 O-Ring 6 1 Back-Up Washer 7 1 O-Ring 8 G L CK Plunger 9 1 G-T Ring 10 1 U-Cup 11 1 Retaining Ring 12 Not available as a service item. Order complete cylinder. Cylinder 13 CR400 CR400 CR400 2 Coupler 14 CJ160900W CJ160900W CJ160900W 1 Relief Valve 15 BSS6350D BSS6350D BSS6350D 2 Eyebolt 16 CL Thread Protector (not shown) Indicates items included in and available only as part of Repair Kit RR1006K. Enerpac Worldwide Locations info@enerpac.com internet: Africa Actuant China Ltd. (Beijing) Italy ENERPAC Middle East FZE 709B Diyang Building ENERPAC S.p.A. Office 423, JAFZA 15 Xin No. 2 Via Canova 4 P.O. Box Dong San Huan North Rd Corsico (Milano) Jebel Ali, Dubai Beijing City Tel: United Arab Emirates China Fax: Tel: +971 (0) Tel: Fax: +971 (0) Fax: Australia, New Zealand Actuant Australia Ltd. Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 2143 (P.O. Box 261) Australia Tel: Fax: Brazil Power Packer do Brasil Ltda. Rua dos Inocentes, Sao Paulo (SP) Tel: Fax: Toll Free in Brazil: Tel: vendasbrasil@enerpac.com Canada Actuant Canada Corporation 6615 Ordan Drive, Unit Mississauga, Ontario L5T 1X2 Tel: Fax: Toll Free: Tel: Fax: Technical Inquiries: techservices@enerpac.com China Actuant China Ltd. 1F, 269 Fute N. Road Waigaoqiao Free Trade Zone Pudong New District Shanghai, China Tel: Fax: Central and Eastern Europe, Greece ENERPAC GmbH P.O. Box D Düsseldorf Willstätterstrasse13 D Düsseldorf Germany Tel: Fax: France, Switzerland francophone ACTUANT - ENERPAC France S.A., ZA de Courtaboeuf 32, avenue de la Baltique Villebon / Yvettte France Tel: Fax: Germany, Austria and Switzerland ENERPAC GmbH P.O. Box D Düsseldorf Willstätterstrasse13 D Düsseldorf Germany Tel: Fax: India ENERPAC Hydraulics (India) Pvt. Ltd. Office No. 9,10 & 11, Plot No. 56, Monarch Plaza, Sector 11, C.B.D. Belapur Navi Mumbai , India Tel: Tel: Fax: Japan Applied Power Japan Ltd. Besshochou 85-7 Saitama-shi, Kita-ku, Saitama Japan Tel: Fax: Middle East, Turkey and Caspian Sea ENERPAC Middle East FZE Office 423, JAFZA 15 P.O. Box Jebel Ali, Dubai United Arab Emirates Tel: +971 (0) Fax: +971 (0) Russia and CIS (excl. Caspian Sea Countries) Actuant LLC Admiral Makarov Street Moscow, Russia Tel: Fax: Singapore Actuant Asia Pte. Ltd. 37C, Benoi Road Pioneer Lot, Singapore Tel: Fax: Toll Free: Technical Inquiries: techsupport@enerpac.com.sg All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them. For your nearest authorized Enerpac Service Center, visit us at South Korea Actuant Korea Ltd. 3Ba 717, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea Tel: Fax: Spain and Portugal ENERPAC Avda. Los Frailes, 40 Nave C & D Pol. Ind. Los Frailesanzo De Arriba (Madrid) Spain Tel: Fax: The Netherlands, Belgium, Luxembourg, Sweden, Denmark, Norway, Finland and Baltic States ENERPAC B.V. Galvanistraat 115, 6716 AE Ede P.O. Box 8097, 6710 AB Ede The Netherlands Tel: Fax: Technical Inquiries Europe: techsupport.europe@enerpac.com United Kingdom, Ireland Enerpac Ltd Bentley Road South Darlaston, West Midlands WS10 8LQ, United Kingdom Tel: +44 (0) Fax: +44 (0) USA, Latin America and Caribbean ENERPAC P.O. Box N. Baker Road Milwaukee, WI USA Tel: Fax: User inquiries: Inquiries/orders: Technical Inquiries: techservices@enerpac.com 02_08_08

13 Check valves Line rupture protection valve type LB Line rupture protection valves, also called pipe rupture protection valves are a type of check valve. The valves are normally mounted directly on the cylinder. They prevent uncontrolled cylinder movement in the event of a pipe rupture or hose break. The line rupture protection valve type LB offers a high level of safety in the event of pressure peaks. It features reproducibly accurate, secure closing at the pre-set trigger volumetric flow. Higher volumetric flows causes a plate raised from the valve seat by a spring to be pressed onto the housing seat. The valve closes. A variant with restrictor bore in the valve plate permits a low volumetric flow in the check direction. Type LB is available as a screw-in valve and in a housing design for line installation. The pipe rupture protection valve type LB is used in industrial trucks, lifting platforms and lifting equipment. Features and benefits: Pressures up to 700 bar Intended applications: Industrial trucks Lifting devices Nomenclature: Design: Adjustment: Line rupture safety valve Valve insert with housing for in-line installation Tool adjustable p max: 700 bar Q max: lpm Design and order coding example LB 2 G 1,0-25 Response flow [lpm] With/without orifice Design Screw-in valve (C) Design with housing (F, G) Fitting Trigger volumetric flow Q A in l/min Basic type, size: Line rupture safety valve type LB, size 2 to 4 Version with imperial thread Version with metric thread Design with UNF thread Orifice diameter 0.5 / 0.8 / 1.0 / 1.2 / 1.5 / 2 (dep. on type and size) Function LB Simplified Series With orifice Detailed

14 General parameters and dimensions LB..C Screw-in valve LB 11(21)C LB..G LB..F LB 3 E LB 4 E Valve with housing Thread seal ring Q max [lpm] p max [bar] Ports (BSPP) Dimensions [mm] G G1 L L1 L2 SW = a/f SW = a/f 1 LB 1 (C, G, F) G 1/4 (A) a/f 19-6 / 70 LB 11 C 1) G 1/4 (A) / 70 LB 2 (C, G, F) G 3/8 (A) a/f / 100 LB 21 C 1) G 3/8 (A) / 100 LB 3 (C, G, F) G 1/2 (A) a/f / 170 LB 4 (C, G, F) G 3/4 (A) a/f / 375 LB 3 E LB 4 E G 1/4 A - G 3/4 A M18x1.5 - M36x SW 27 - SW 41 SW 7 150/210 LB G ) Mounting thread, additionally sealed 2) Dimensions for insert valve and/or housing version m [g] 2) Associated technical data sheets: Line rapture protection valves, type LB: D 6990 Line rupture safety valves type LB.E as a screw joint: Sk 6990 E K_LB-en

15 Hydraulic Couplers Shown: FH-604, FR-400, A-630 disassembled, C-604, AH-604, AR-400 Quick Connection of Hydraulic Lines Thread Sealer To seal NPTF threads use one of the new anaerobic thread sealers or Teflon paste. When using Teflon tape, apply the tape one thread back from the end of a fitting to prevent it from entering the hydraulic system. ⅜" High Flow Couplers Standard equipment on most Enerpac cylinders Recommended for use on all Enerpac pumps and cylinders where space and porting permits Include 2-in-1 dust cap for use on male and female coupler halves ⅜" High Flow Flush-face Couplers Featuring Push-to-connect operation, to guarantee good connection every time Flush-face, zero-leak operation for minimal spillage HTMA* recognized for safety and performance ⅜" Regular Spee-D-Coupler For medium duty applications; for use with hand pumps Includes female steel dust cap ¼" Regular Coupler For use with small cylinders and hand pumps Includes female steel dust cap WARNING! Couplers should be pressurized only when completely connected, and should not be coupled or uncoupled when pressurized. More safety instructions in our Yellow Pages. Page: S- and W-Series Torque Wrench Couplers 242 S- and W-Series Torque Wrenches require 1/4" spin-on couplers and THQ hoses. Page: 183 With the use of Enerpac High Flow Couplers, hoses are easily installed for multiple hydraulic line connections in this 34 points PLC-controlled lifting system. * Hydraulic Tool Manufacturers Association 116

16 F-Series Flush-faced couplers provide reduced pressure drop verses other types and are preferred in dirty, grimy construction and mining environments due to easy clean, non-dirt trapping faces. Metal Dust Caps Steel dust caps are available for the C-604 series couplers. Order model number: CD-411M for female half CD-415M for male half Hydraulic Couplers A C F Series Maximum Flow Capacity: 2,500 in 3 /min. A B Thread: ¼" and ⅜" NPTF E C D C Maximum Operating Pressure: 10,000 psi C-604 F G E C F-604 E C F A D A D B G B C C CT-604 Safety Tool Use the Enerpac CT-604 to relieve hydraulic back pressure by safely bleeding the hydraulic coupler. Minimize injuries from projectile parts and under-skin hydraulic fluid injections by eliminating unsafe coupler bleeding practices. The CT-604 is Enerpac-engineering safe for use at 10,000 psi (700 bar). NOTE: C-Series only. F A-604, A-630 Maximum Flow Capacity (in 3 /min) Coupler Type Complete Set Model Numbers Female Half Male Half Dimensions (in) A* B C D E F G Dust Cap(s) 2,500 2,500 High Flow Coupler Flush-face coupler C-604 F-604 CR-400 FR-400 CH-604 FH ⅜" NPTF ⅜" NPTF (2x) CD-411 Included 462 Regular Spee-D-Coupler A-604 AR-400 AH ⅜" NPTF Z-410 female only Included 462 Regular Coupler A-630 AR-630 AH ¼" NPTF Z-640 female only * Value A is total length when male and female halves are connected. Included 117

17 English Metric CT-604 Safety Tool Enerpac coupler bleed tool eliminates unsafe pressure relieving and bleeding activities such as: using a hammer and punch to unseat check balls, cones & poppets using a wrench to loosen a coupler. Coupler Bleed Tool Model Number Fits on High Flow Couplers Maximum Operating Pressure Female Half Male Half psi bar CT-604 CR-400 CH

18 Instruction Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. CT-604 Hydraulic Coupler Bleed Tool L2755 Rev. C 02/11 Index: English Français Deutsch Italiano Español Nederlands Portuguese Finnish Norwegian Swedish 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 repair and replacement costs resulting from damage in shipment. 2.0 INTENDED USE The Enerpac CT-604 coupler bleed tool is designed to safely relieve pressure from hydraulically locked highfl ow hydraulic couplers, Enerpac coupler models CH- 604 (male half), CR-400 (female half) and C-604 (male and female set). 3.0 SAFETY ISSUES Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic safety, consult your distribution or service center for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. 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. WARNING: Wear proper personal protective gear when operating hydraulic equipment. 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. WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is happening in the system. CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose leading to premature hose failure. Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture. DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. IMPORTANT: Hydraulic equipment must only be serviced by a qualifi ed hydraulic technician. For repair service, contact the Authorized ENERPAC Service Center in your area. To protect your warranty, use only ENERPAC oil. WARNING: Immediately replace worn or damaged parts with genuine ENERPAC parts. Standard grade parts will break causing personal injury and property damage. ENERPAC parts are designed to fi t properly and withstand high loads. 1

19 4.0 INSTRUCTIONS DANGER: Never attempt to relieve hydraulic pressure by loosening a coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly with great force. Serious personal injury or death will result if the coupler becomes a projectile and strikes persons working in the area. WARNING! Loosening a coupler may result in an escape of high pressure oil that can penetrate the skin. Serious personal injury or death can result. Always use coupler bleed tool to safely depressurize and remove couplers. WARNING! Be sure that loads are supported with blocking and cribbing before using bleed tool. Actuator movement may occur when hydraulic pressure is relieved. Serious personal injury or death could occur if load shifts or drops. WARNING! The CT-604 coupler bleed tool is designed for a maximum hydraulic pressure of 10,000 psi [700 bar]. Do not use the tool on systems and components operating at higher pressures. Depressurize a hydraulically-locked coupler as described in the following steps: 1. I f the hydraulic device is supporting a load, block and crib the load as required, so that the load will not shift or drop when hydraulic pressure is relieved. 2. Check that the threads on the coupler half to be depressurized are clean and in good condition. Do not attempt to bleed a coupler if threads are damaged. 3. Check that all threads on the bleed tool main body and cap/bolt assemblies are clean and in good condition. Do not use bleed tool if threads are damaged. Note: Hand-tighten the bleed tool main body onto the coupler half as described in steps 4 and 5. See Figure 1, below. Note: The bleed tool main body is marked male coupler on one end and female coupler on the other. Be sure to use the proper end. 4. If bleeding a male coupler half: Thread the bleed tool main body onto the male coupler half and tighten it hand-tight. 5. If bleeding a female coupler half: Thread the bleed tool main body into the retaining collar of the female coupler half. Tighten the retaining collar hand-tight. 6. The bleed tool includes two cap/bolt assemblies as shown in Figure 1, below. Be sure to use the correct one: For MALE coupler halves, use the cap/bolt assembly with the SHORT bolt. For FEMALE coupler halves, use the cap/bolt assembly with the LONG bolt. Note: Before proceeding, ensure that the cap is tight on the bolt. 7. Thread the cap/bolt assembly into the bleed tool main body. Slowly turn the cap/bolt assembly clockwise until the coupler check ball opens and hydraulic pressure is relieved. If necessary, use an adjustable wrench on the bolt. Note: When the cap/bolt assembly is tightened, pressurized hydraulic oil will fl ow through the bleed tool main body and into the cap. Allow any excess oil to drain into a suitable container. 8. Remove coupler half, main body and cap/bolt assembly from the hydraulic device (manifold, cylinder, etc.) as a complete unit. Important: Keep bleed tool parts installed on coupler while it is being loosened and removed. 9. Disassemble bleed tool components from the coupler half. Clean bleed tool components and store in provided container. CAUTION: Discard the coupler half removed in the previous steps. Never attempt to repair or reuse a worn or damaged coupler! Figure 1 Male Coupler Half Short Cap/Bolt Assy (use with male coupler halves) Long Cap/Bolt Assy (use with female coupler halves) Main Body Female Coupler Half 2