KHP5000PF KHP5000PH Hydraulic Pump

KHP5000PF KHP5000PH Hydraulic Pump

Table of Contents Introduction...3 Safety...3 Danger...4 Warning...4 Important...5 Description...5 Before Use...6 Operation...6-7 Maintenance...8 Troubleshooting... 9-10 Pump Data Use this to fill out information about your pump for quick reference. Model # Purchase Date: - - Purchase Order: Purchased From: Delivery Date: Serial No.: Note: Make sure to register your warranty online at www.kurtworkholding.com 2 Table of Contents

Introduction Carefully inspect all components for shipping damage. If shipping damage is found, notify carrier at once. The carrier is responsible for any damage resulting from shipment. Safety To avoid personal injury or property damage, please follow all safety precautions. Kurt will not be responsible for injury or damage resulting from unsafe and incorrect products use or system operation, or lack of maintenance. DANGER: Is used when your action or lack of action may cause serious injury or even death. WARNING: Indicates a potential danger that requires correct action to avoid personal injury. IMPORTANT: Indicates correct action to prevent damage or equipment failure. Introduction / Safety 3

DANGER: The hydraulic equipment operator must be a qualified operator with correct training and work experience with hydraulic equipment. Lack of knowledge in any of these areas can lead to equipment damage or personal injury. To avoid personal injury, please do not modify or weld hydraulic equipment without approval of KURT. Keep hands and feet away from cylinder and workplace during operation to avoid personal injury. WARNING: Wear safety glasses, helmet and other necessary personal protective equipment when operating hydraulic equipment. Install Pressure gauges in the system to monitor the operating pressure. The gauge must have the same pressure rating as the pump and cylinder. The wrong gauges may result in personal injury. The system operating pressure must be lower than the lowest rated pressure component in the system. Carefully inspect the cylinder and couplers before using the cylinder. Never connect a cylinder with damaged couplers or damaged port threads. The damaged coupler or damaged port threads may cause equipment failure and possible personal injury. Install coupler in a clean environment; prevent dirt or other debris from entering into cylinder body or tube. Dirt or other debris will damage the cylinder and result in equipment failure and possible personal injury. Before removing or tightening hose or coupler, release hydraulic pressure in system. Never handle pressurized hoses; escaping oil under high pressure can penetrate the skin, causing serious injury. Seek medical aid immediately if injured. Use high quality hydraulic oil. For hydraulic technical help or repair service, please contact KURT. KURT has no obligations under any warranty with respect to products that have been repaired by un-authorized personnel, modified, or damaged through misuse, abuse, accident, neglect, or mishandling. 4 Danger / Warning

BEFORE USE To prevent oil leaks during shipment, a metal knob is installed and tightened to ensure a good seal. Loosen it by turning counterclockwise before use. NOTE: Always secure threaded port connections with non-hardening pipe thread compound. Tighten securely to prevent accidental removal of components while in use. Take care not to introduce thread compound into port openings. Familiarize yourself with the specifications and illustrations in this operator s manual. Know your pump, its limitations and how it operates before attempting to use. Refer to Specification chart on the following pages for details of oil port thread size, usable oil capacity, and other information. OPERATION Operation of the pump as follow: 1. Connect the hose of the Air Hydraulic pump to the hydraulic coupling on the selected tool. 2. Connect the air supply line to the Air Hydraulic pump. The air line should be equipped with an air line filter/lubricator 3. Set the pressure to the corresponding hydraulic pressure for your product. See Pressure Chart on bottom of pg. 6. 4. To advance, hold or retract: Foot Pedal operated pumps: (See pg 9) a. Depressing the Pump end of pedal will pump hydraulic oil to the system. To maintain pressure over a period of time an accumlator should be added to the system. b. Stop depressing the pump end to stop and hold the pressure. In this position the pump will not start if there is loss of pressure. c. Depressing the Release end of pedal will release the pressure in the system. Hand Valve operated pumps. (See pg 8) a. Push lever forward and leaving it forward starts hydraulic pump. The pump will shut off at pre set pressure from chart (pg 6). it will re-start if pressure loss is decected. b. Retract the lever dumps the hydraulic pressure back to the tank and turns the pump off. Before Use / Operation 5

IMPORTANT: Keep the air hydraulic pump clean at all time. When the Air hydraulic pump is not in use, release the valve, remove hose and use rubber cap to recover the port. Do not drop objects on hose. Do not lift or carry hydraulic equipment by the hoses or couplers, use the handle or other means. Use hydraulic equipment in normal operating temperatures. Do not use equipment in temperatures of 65 C (150 F) or higher. Overheating will soften seals and weakens hose material, resulting in oil leaking or other equipment failure. DESCRIPTION Air Hydraulic Pump supplies hydraulic fluid pressure to selected clamps or vises. It consists of an in-line air and hydraulic cylinder. KHP5000PF Specifications FOOT HAND Pressure Rating (psi) 5,000 5,000 Usable Oil Capacity (cu. in.) 85 85 Hydraulic Oil #13 or DTE lite #13 or DTE lite Input Air Pressure (psi) 20-90 20-90 Input Port Threads (npt) 1/4-18 1/4-18 Output Port Threads (npt) 3/8-18 3/8-18 Oil Delivery (cu. in. / min.) No Load: 49.5 Load:7.6 Operational Manner Foot Pedal Hand Valve Weight (lbs) 19 22 Air Pressure (PSI) Pressure Chart Hydraulic Pressure (PSI) 14 1000 29 2000 43 3000 57 4000 71 5000 Note: This pump has a maxinum Hydraluic output pressure of 5000psi Any air pressure over 71PSI will only yeild 5000psi of hyd. pressure.v 6

Hydraulic Clamp Systems for your fixtures and machine tools. A full line of Hydraulic Swing Clamps, Pumps, valves. This new workholding system has been designed to increase productivity, reduce labor costs and scrap while improving part quality. 1 Treatment Hard chromed and polished for better wear resistance and smooth piston action Heat treated piston (HRC 60-63) to reduce abrasion and for better wear resistance 2 Flexible Mounting Type Upper and lower flange mounting styles for added flexibility Clamping force range from 475 lb to 6000 lb Max. pressure : 5000 psi 3 Guide Rod 3 guide slots design for larger sizes to ensure long life and reduces stress. Special guide slot design to reduce the wear and ensure long life (reduces stress) To change the direction (left 90 / right 90 / pull push) is easily done by rotating piston. 4 Cylinder Body Hardened to HRC 38-46 - reduces the wear of inner face of cylinder body, to ensure longer life (1,000,000 cycles) Polished to ensure longer life (reduces wear to the oil seal) 5 Pin Heat treated to HRC 38-40 gives strength to the pin and reduces breakage. 7

Hand lever operates pumps: a. Stroking the lever forward will pump hydraulic oil to the system. b. If there is a slight drop in pressure(approx. 200 pounds) the pump will start and pump back to the orginal pressure setting and then shut off and repeat as required. c. Stroking the lever back will release the pressure in the system. HAND PUMP 8 Operation

FOOT PUMP KHP5000PF-KIT Optional hydraulic hose assemblies include KURT TUFF #4 hose, a male pipe 3/8 NPT fitting on one end and a female #4 JIC fitting on the other end. The hose assemblies come in standard 3, 6, 12 lengths (Custom lengths are also available). Kurt Part # KT04036PM6JF4 KT04072PM6JF4 KT04144PM6JF4 Optional Hydraulic Hose (sold separately) 36 Kurt Tuff Hydraulic Hose w/fittings, #6 Male Pipe, #4 Female JIC 72 Kurt Tuff Hydraulic Hose w/fittings, #6 Male Pipe, #4 Female JIC 144 Kurt Tuff Hydraulic Hose w/fittings, #6 Male Pipe, #4 Female JIC Maintenance / Troubleshooting 9

MAINTENANCE Inspect the connections Inspect hoses and connections, tighten connections as needed. Use non-hardening pipe thread compound when servicing connections. Adding Hydraulic Fluid 1. Depressurize hydraulic hose from application. 2. With pump in its upright, horizontal position, remove the oil filler plug located on the top plate of the reservoir. 3. Use a small funnel to fill reservoir to within 3/4 (19mm) of the opening. 4. Wipe up any spilled fluid and reinstall the oil filler plug. NOTE: Use only approved hydraulic oil #13, DTE lite or equivalent. Never use brake fluid, transmission fluid, turbine oil, motor oil, alcohol, glycerin etc. Use of other than good quality hydraulic oil will void warranty and damage the pump, hose and application. Changing Hydraulic Fluid 1. For best results, change fluid once a year. 2. Repeat steps in Adding hydraulic Fluid section above. 3. Dispose of fluid in accordance with local regulations. 4. Fill with good quality hydraulic oil as recommended above. Reinstall vented oil filler plug. Lubrication Use a light machine oil to lubricate pivot points, hinges etc. Storage 1. Depressurize and disconnect hydraulic hoses from application. 2. Clean the pump and hose and couplers 3. Store in clean dry environment, avoid temperature extremes. TROUBLESHOOTING IMPORTANT: KURT air hydraulic pumps should be repaired only by KURT. Repairing hydraulic pumps without special tools and knowledge may result in personal injury. Always release pressure and disconnect hose(s) before making repairs. 10 Troubleshooting

SECONDS 40TO CHANGE With the InnerLock jaw plates, it takes only 40 seconds to change out your jaw plates. Increasing productivity over multiple jobs being run on the same vise. You can also view a tutorial video on this process at the Kurt Workholding YouTube Channel. www.youtube.com/user/kurtworkholding 11

Date: - - Model #: S/N: First Name: Last Name: Address: City: State: Zip: Phone: ( ) E-Mail: CUT OUT WARRANTY CARD Register On-Line now at Kurtworkholding.com and receive a FREE gift! 12

Symptom Possible Causes Corrective Action Application will not extend, move or respond to pressurized fluid Application responds to pressurized fluid, but system does not maintain pressure Application will not return fluid to pump (i.e. cylinder will not retract) Vise or clamp will not cycle fully Overload condition Release valve not closed Overload condition Release valve not closed Hydraulic unit malfunction Malfunctioning coupler Reservoir overfilled Fluid level low Remedy overload condition Ensure release valve closed Remedy overload condition Ensure release valve closed Secure load by other means. Open release valve, depressurize pump and hose, remove coupler then renew or replace Secure load by other means. Open release valve, depressurize pump and hose, remove coupler then drain fluid to proper level Follow symptom 3 procedure for securing load, depressurizing pump, then ensure proper fluid level Poor performance Air trapped in system Ensure proper fluid level Ensure vented oil filler plug let pressurized reservoir air escape (see page 6 BEFORE USE) Maintenance Log / Notes 13

Maintenance Log/Notes: Maintenance Log / Notes 14

1 YEAR LIMITED WARRANTY On all Kurt Hydraulic Workholding Products All Kurt Manufacturing Company industrial hydraulic workholding products and parts with the exceptions noted below, are warranted against defects in material and workmanship for a period of 1 year from date of purchase. Failure to properly maintain and/or properly operate the product or part that has been worn out, abused heated ground or otherwise altered, used for a purpose other than that for which it was intended, or used in a manner in consistent with any instructions regarding its use. The sole obligation of Kurt Manufacturing Company, Inc. (Kurt) and the purchaser s SOLE AND EXCLUSIVE REMEDY hereunder, shall be limited to the replacement or repair of any Kurt product or part (by an authorized Kurt technician) which are returned to Kurt Manufacturing Company s place of business, transportation, shipping and postal charges prepaid, and there determined by Kurt Manufacturing Company to be covered by the warranty contained herein. THE 1 YEAR LIMITED WARRANTY DESCRIBED HEREIN IS MADE EXPRESSLY IN LIEU OF ANY OTHER EXPRESSED OR IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. KURT MANUFACTURING COMPANY IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ITS PRODUCTS. KURT SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO, LOSS OF USE, REVENUE OR PROFIT. KURT ASSUMES NO LIABILITY FOR, AND MAKES NO WARRANTY REGARDING ANY PURCHASE ITEMS WHERE THE MANUFACTURER OF SUCH ITEM EXTENDS A SEPARATE WARRANTY. FORM WC05 9445 East River Road NW Minneapolis, MN 55433 Phone: 763-574-8309 Fax: 763-574-8313 kurtworkholding.com Manual Revision: 01.24.2014

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