PUMP-DHDA MANUAL-REVAJase

Hydratron – a Global supplier of high pressure equipment
DHDA AND DHDAX SERIES PUMP

Air Driven, High Pressure Liquid Pump
OPERATION AND MAINTENANCE MANUAL

December 2019
Table of Contents
SAFETY ................................................................................................................................................. 5
PIPES AND HOSES ................................................................................................................................................................... 6
INSTALLATION INSTRUCTIONS ................................................................................................................ 7
MOUNTING THE PUMP ........................................................................................................................................................... 7
HYDRAULIC SUPPLY CONNECTION / INLET CONNECTION ................................................................................... 7
PRESSURE PORT / OUTLET CONNECTION .................................................................................................................... 8
AIR SUPPLY CONNECTION .................................................................................................................................................... 9
OPERATING INSTRUCTIONS .................................................................................................................... 9
BEFORE OPERATING THE PUMP........................................................................................................................................ 9
BEGINNING OPERATION..................................................................................................................................................... 10
GENERAL MAINTENANCE ..................................................................................................................... 11
HYDRAULIC PUMP ................................................................................................................................................................. 11
FAULT FINDING ...................................................................................................................................................................... 11
PUMP WILL NOT STROKE......................................................................................................................... 11
LOSS OF HYDRAULIC PRESSURE ............................................................................................................... 11
PUMP RUNS ERRATICALLY ....................................................................................................................... 11
SERVICING INSTRUCTIONS .................................................................................................................... 12
REMOVING PUMP................................................................................................................................................................... 12
SERVICING THE HYDRAULIC CYLINDER ..................................................................................................................... 13
SERVICING THE INLET & OUTLET CHECK VALVE ................................................................................................... 15
SERVICING THE AIR MOTOR ............................................................................................................................................. 15
REMOVAL................................................................................................................................................. 15
INSTALLATION.......................................................................................................................................... 18
SERVICING THE PILOT VALVE SWITCH ....................................................................................................................... 21
REMOVAL................................................................................................................................................. 21
INSTALLATION.......................................................................................................................................... 22
SERVICING THE CHANGE OVER VALVE ....................................................................................................................... 23
REMOVAL................................................................................................................................................. 23
INSTALLATION.......................................................................................................................................... 24
SERVICING THE 5 WAY PILOT VALVE .......................................................................................................................... 26
REMOVAL................................................................................................................................................. 26
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December 2019
INSTALLATION.......................................................................................................................................... 27
PUMP COMPONENT LISTS .................................................................................................................... 28
AIR MOTOR ............................................................................................................................................................................... 28
CHANGE OVER VALVE (COV-T20-N) ............................................................................................................................. 30
PILOT VALVE (PV30400-BR-N-REV1)........................................................................................................................... 31
HYDRAULIC SECTION ............................................................................................................................ 32
DHDA33/4 HYDRAULIC END (Nitrile) .......................................................................................................................... 32
REMOVAL................................................................................................................................................. 32
INSTALLATION.......................................................................................................................................... 32
DHDA33X/4 HYDRAULIC END (Nitrile) ....................................................................................................................... 34
REMOVAL................................................................................................................................................. 34
INSTALLATION.......................................................................................................................................... 34
DHDA66/3.3 HYDRAULIC END (Nitrile) ...................................................................................................................... 36
REMOVAL................................................................................................................................................. 36
INSTALLATION.......................................................................................................................................... 37
DHDA66X/3.3 HYDRAULIC END (Nitrile) .................................................................................................................... 39
REMOVAL................................................................................................................................................. 39
INSTALLATION.......................................................................................................................................... 40
DHDA118/4 HYDRAULIC END (Nitrile) ....................................................................................................................... 42
REMOVAL................................................................................................................................................. 42
INSTALLATION.......................................................................................................................................... 43
DHDA118X/4 HYDRAULIC END (Nitrile) ..................................................................................................................... 45
REMOVAL................................................................................................................................................. 45
INSTALLATION.......................................................................................................................................... 46
DHDA158/4 HYDRAULIC END (Nitrile) ....................................................................................................................... 48
REMOVAL................................................................................................................................................. 48
INSTALLATION.......................................................................................................................................... 49
DHDA158X/4 HYDRAULIC END (Nitrile) ..................................................................................................................... 51
REMOVAL................................................................................................................................................. 51
INSTALLATION.......................................................................................................................................... 52
POWER PACKS ..................................................................................................................................... 55
HYDRAULIC POWER UNIT (HPU).................................................................................................................................... 55
BEFORE OPERATING THE POWER PACK .................................................................................................................... 55
OPERATING PRECEDURE ................................................................................................................................................... 55
RELEASE HYDRAULIC PRESSURE ................................................................................................................................... 56
Page 3 of 61
December 2019
HYDRAULIC POWER UNIT GENERAL MAINTENANCE .............................................................................. 57
TO DRAIN AIR FILTER/REGULATOR ............................................................................................................................. 57
TO CLEAN AIR FILTER/REGULATOR ELEMENT ...................................................................................................... 57
AIR LUBRICATOR OIL LEVEL ............................................................................................................................................ 57
TO CLEAN TANK STRAINER .............................................................................................................................................. 57
HYDRAULIC PUMP ................................................................................................................................................................. 58
HIGH PRESSURE GAUGE...................................................................................................................................................... 58
ATEX .................................................................................................................................................... 58
User Instructions Specific to Hazardous Area Installations ................................................................................. 58
(Reference European ATEX Directive 2014/34/EU) .............................................................................................. 58
TRANSPORT AND STORAGE .................................................................................................................. 59
INSPECTION ON RECEIPT OF GOODS ......................................................................................................................................... 59
INSPECT THE PACKAGE ............................................................................................................................................................... 59
INSPECT THE UNIT....................................................................................................................................................................... 59
LIFTING ......................................................................................................................................................................................... 59
LARGE UNITS WITH FORK TRUCK LIFTING POINTS ................................................................................................................. 59
UNITS WITH LIFTING EYES ......................................................................................................................................................... 60
LIFTING EQUIPMENT ................................................................................................................................................................... 60
LIFTING FROM TRANSPORT PALLET ......................................................................................................................................... 60
TRANSPORTATION GUIDELINES ................................................................................................................................................ 60
POSITION AND FASTENING ......................................................................................................................................................... 60
STORAGE GUIDELINES ................................................................................................................................ 60
STORAGE LOCATION .................................................................................................................................................................... 60
LONG-TERM STORAGE ................................................................................................................................................................ 60
FREEZING PRECAUTIONS ............................................................................................................................................................ 61
Decommissioning ................................................................................................................................. 61
PERSONNEL .................................................................................................................................................................................. 61
DISPOSAL/RECYCLING ............................................................................................................................................................... 61
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December 2019
Caution (Helps the user identify what can cause damage to the pump).
Warning (Helps the user reduce risk to personel, property and to the pump).
Assembly Tips (Helps the user to dismantle and reassemble the pump in a safest way).
SAFETY
Hydraulic equipment is precision made to extremely fine limits, it is therefore essential that
the servicing of this equipment is carried out by a competent person. The following
paragraphs detail general precautions.
Prior to commencing servicing or repairs, make sur the pump/ system is

depressurised.
If the pump(s) are not ATEX approved, it must NOT be used in a potentially explosive
environment.
Prior to commencing servicing or repair, liquid section(s) should be purged if

hazardous liquid was transferred.
In the event of an emergency the air supply must be turned off.
The end user must provide pressure indicators at the inlet and final outlet of the
pump.
Absolute cleanliness is necessary when servicing hydraulic systems and

components. Most hydraulic faults are caused by the ingress of dirt.
Before dismantling a component, drain al hydraulic and clean externally.
All parts dismantled should be laid on a clean, resilient surface. Special attention
should be made to the identification of parts and their dismantling sequence.
All metal parts with exception of sealed bearing should be washed in a mineral based
cleaning solvent and dried using compressed air or clean “non fluff” cloths. Oil seals
should be washed in clean hydraulic oil.
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December 2019
it is recommended that all oil seals disturbed should be renewed. If the seal is re-
used it should be closely examined for cuts, flaws or wear.
All internal metal parts and seal should be dripped in clean hydraulic oil or greased
before assembly. This assists in assembly and lessens the risk of seal damage.
Use only seals recommended for the equipment in use.
PIPES AND HOSES
Prior to commencing servicing or repairs, make sure the pump/ system is

dispressurised.
When removing and replacing rigid pipes and flexible hoses the following points
should be observed.
Use adjustableor open ended wrenches on fittings.

Do not use pipe wrenches, they damage fittings and protective coatings.
Ensure the the particular connection and its immediate surrounds are clean.
Ensure that the flexible hoses are not twisted when end fittings are tightened.
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December 2019
INSTALLATION INSTRUCTIONS
MOUNTING THE PUMP
• Pumps are supplied with 4-off 11mm diameter mounting slots. Firmly secure the pump
to a stable vibration free surface in the horizontal position using M10 bolts.
HYDRAULIC SUPPLY CONNECTION / INLET CONNECTION
• Make a suitable flexible or hard piped connection to the hydraulic inlet connections.
(see data sheets for connection sizes)
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December 2019
• Use a suitable thread anti-seize compound to prevent galling of the threads and ensure
all connections are leak free.
• Connections and tubing to the hydraulic inlet connections should be the same size or
larger. To prevent restricted flow supply.
• The installation of a 100-mesh screen (140 micron) fluid filter, or finer is recommended,
located between the fluid supply and the hydraulic inlet connections.
• If using a fluid reservoir position it level or above the pump hydraulic inlet connection to
ensure a flooded condition at the fluid inlet port.
Standard pumps are supplied with NITRILE hydraulic seals suitable for oil, water,
methanol and glycol service. Ensure that the fluid to be pumped is compatible with this
material prior to use.
• For other process applications Viton and Chemraz hydraulic seal kits are available.
PRESSURE PORT / OUTLET CONNECTION
• Make a suitably rated flexible or hard piped connection to the outlet connection. (see
data sheets for connection sizes)
• Where tapered threads are supplied use a suitable thread anti-seize compound to
prevent galling.
• Ensure connections are leak free.
• Connect a suitably rated gauge and a pressure release valve.
Hydraulic hoses or piping including adaptors or coupling must have a pressure rating
equal to or more than the maximum output pressure of the pump.
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December 2019
AIR SUPPLY CONNECTION
• Use 22mm (minimum) to 26mm inside diameter flexible or hard piped tube to the air
inlet connection located between the exhaust mufflers (Thread connection is 1”
NPT(F), connected to an air supply/compressor capable of delivering 100psi. For
optimum pump performance a flowrate of 200 SCFM is required.
• 100 PSI PILOT AIR SUPPLY - Use 1/4” outside diameter flexible or hard piped tube
and connect to the 1/8” BSPP(F) pilot air supply connection.
• Ensure all connections are leak free.
• To ensure maximum performance do not restrict air supply as this will affect the pumps
performance. It is recommended an air filter-regulator-lubricator is fitted on the air
supply as dirty and un-lubricated air can cause damage to the air motor.
• It is recommended an air isolation valve is fitted between the air supply and the air
filter-regulator-lubricator unit
DO NOT EXCEED 100 PSI AIR SUPPLY
OPERATING INSTRUCTIONS
BEFORE OPERATING THE PUMP
• Check sufficient clean liquid is present in the reservoir tank.
DO NOT RUN PUMP DRY

• Fill the air lubricator with light petroleum-based oil such as Kilfrost 400, Shell Tellus 27,
DTE light, Automatic Transmission Hydraulic Type A or any good grade of light oil
compatible with nitrile seals.
• Open the pressure release valve.
• Close the air Stop/Start isolation valve.
• Rotate air regulator control knob anti-clockwise until handle becomes free and air
gauge reads 0 PSI
• Connect to an air supply – 100 PSI maximum.
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December 2019
BEGINNING OPERATION
• Visually check air lubricator oil level. Top up with a light petroleum-based oil such as
Kilfrost 400, Shell Tellus 27, DTE Light, Automatic Transmission Fluid Type A, or any
good grade of light oil compatible with nitrile seals.
• Rotate air regulator control knob anti-clockwise until handle becomes free and air
gauge reads 0 PSI.
• Open the air supply isolation valve.
• Rotate air regulator control knob slowly until pump begins to reciprocate.
• Rotate air regulator control knob clockwise until 25 to 30 PSI is reached on the air
gauge and run pump until all air is purged out of the circuit.
When pressure testing, bleed all air out of the item being tested before pressurising by
fitting a bleed valve or vent plug at the highest point in the circuit. Care should be taken
to take account of any internal cavities that may trap air inside the circuit.
• Rotate air regulator control knob anti-clockwise until zero pressure is reached on air
gauge.
• Close the pressure release valve.
• Rotate air regulator control knob slowly until the required hydraulic pressure is reached
on the high-pressure gauge.
If the object being tested is large it will take a while before the pressure builds up in
the system and registers on the pressure gauge. Do not set the air driving pressure too
high if unattended as this may lead to the object under test being over pressurised. Do not
leave the pump running unattended.
Approximate hydraulic output pressure can be pre-set by air drive pressure. See
pump specification sheet.
Air pressure should be set slightly below the required setting so that it can be raised to
the correct setting once hydraulic pressure has built up and the pump has stalled out.
Once set the pump will maintain the set pressure indefinitely and make up any fluid
losses within the hydraulic system automatically.
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December 2019
GENERAL MAINTENANCE
HYDRAULIC PUMP
After prolonged service, the pump will require servicing and new seals may be required.
See pump servicing instructions.
Monthly checks for any lose connections and leaks.
FAULT FINDING
PUMP WILL NOT STROKE
Possible Cause Solutions

No air pressure Check air supply
Check air drive pressure gauge and regulator
Air Regulator not set correctly re-set
if necessary.
Pump Air Piston seal leaking Replace seal
5 Way Valve Stuck Replace Valve or Reseal
Pilot Valve Stuck Check Spring Loaded Plunger Moves
Change Over Valve Stuck or Leaking Check Spool and Lip Seals – Replace as
Required
LOSS OF HYDRAULIC PRESSURE

Insufficient Fluid Supply Check Tank Level
Hydraulic Check Valves Leaking Replace Seals

Hydraulic Seal Failure Replace Seal
Leak in the System Check for no Leakage
PUMP RUNS ERRATICALLY

Adjust to give about 1 drop of oil for every 20
Lubricator
strokes of the pump.
Air Filter Blocked Clean Filter
For maximum volume of flow, make sure that a sufficient flow of the air is supplied to
the pump. Hooking the pump up to a smaller pipe size than the “Air inlet” port will not allow
the pump to run at its full rated capacity. Long runs of relatively small pipe supplying air to
the pump will have the same effect.
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December 2019
SERVICING INSTRUCTIONS
Prior to commencing servicing or repairs, make sure the pump/system is

depressurised and the hydraulic cylinders are cleared of any potential hazardous liquid.
Absolute cleanliness is necessary. Most faults are caused by the ingress of dirt.
• Before dismantling a component, clean externally.

• Clean all parts prior to reassembly.
• It is recommended that all disturbed seals should be renewed. If the seal is re-used
check its condition prior to reassembly.
• Use only Hydratron seal kits.
• After servicing, pressurise the unit in accordance with the operating instructions and
leak check all joints.
• Check for no drop in hydraulic pressure.
REMOVING PUMP (if required)
• Isolate and Disconnect the air supply.

• Ensure all pressure is released from the system.
• Disconnect air supply pipe work to pump air inlet and pilot air supply.
• Disconnect pipe work to pump inlet and outlet check valves.
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December 2019
• Disconnect any additional pipe work to allow withdrawal of the pump.

• Unscrew mounting screws and withdraw complete pump.
• Re assembly is opposite procedure to disassembly.
SERVICING THE HYDRAULIC CYLINDER
Prior to commencing servicing or repairs, make sure the pump/system is

depressurised and the hydraulic cylinders are cleared of any potential hazardous liquid.
• Disconnect pipe work from inlet check valve and outlet check valve.
Note orientation of inlet and outlet check valve in respect to pump end plate and
port on hydraulic cylinder. (Note hydraulic inlet will always be on the air inlet port side).
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December 2019
• Unscrew complete hydraulic cylinder (including seal retainer or isolation chamber if
fitted) and carefully withdraw without damaging the piston or hydraulic seal.
DHDA SERIES
DHDAX SERIES
• Inspect condition of the piston, replace the piston if there are any signs of damage or
surface scratches.
• Service hydraulic cylinder according to pump model. See Pump components/ hydraulic
ends.
• Lubricate piston with a thin film of Hydratron SL grease.
• Carefully locate replacement seals (using guide bush where advised, not supplied, see
seal kit drawings).
• Ensure replacement O-rings are not twisted in the grooves.
• Ensure that the piston is fully retracted in the end plate (this can be achieved by slowly
putting air onto the air piston)
• Re-assemble if a two-piece hydraulic cylinder.
• Carefully locate the hydraulic cylinder up to the air motor end plate and screw in until
hydraulic piston engages with main seal. Continue to screw in until the check valves
are back in the original position. (Use pipe work as a reference for correct position) and
firmly tighten.
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December 2019
SERVICING THE INLET & OUTLET CHECK VALVE

• Unscrew check valve body from cylinder.
• Remove internal components. (See Hydraulic assembly drawing section in this manual
for the right pump model details).
• From inside the check valve body remove the O-ring and Discard.
• Check all remaining parts are clean and free of debris.
• install O-ring inside check valve body. Do Not grease.
• Ensure replacement O-rings are not twisted in the grooves.
• Re assembly is opposite procedure to disassembly.
• Re connect pipe work to the check valves.
SERVICING THE AIR MOTOR

REMOVAL
• Remove the pump if located inside a power pack or test rig (see pump removing).
• Remove the silencer/mufflers.
• Remove pilot air supply pipework and 5-way pilot valve.
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December 2019
• Remove hydraulic cylinders (if required and service) see hydraulic cylinder servicing.
• Remove 4-off screws locating the changeover valve mounting base located on top of
the pump and withdraw. Remove the O-Ring seals 4-off from the top of the end plates
and centre plate and discard.
• Undo 4-off nuts holding pump together and withdraw studs.

• Pull apart pump end plates from air cylinders taking care not to damage the hydraulic
pistons and the O-Ring seal.
• Remove air cylinders.

• Remove the O rings 2-off from the end plates and discard.
• Remove the hydraulic pistons by removing retaining rings, remove the O-rings and
discard.
• Remove the conrod piston retaining screw and withdraw from centre plate.
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December 2019
• Remove the air pistons from the conrod piston and conrod piston adaptor, remove the
O-rings and discard.
• Remove O-rings 4-off from centre plate and discard.
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December 2019
INSTALLATION
• Lubricate O rings OR-011 2-off with Hydratron SL grease and install to the centre plate.
• Lubricate O rings OR-016 2-off with Hydratron SL grease and install to the centre plate.
•
• Lubricate O rings OR-019 1-off and O ring OR-002 1-off (OR-018 for DHDA33 models)
with Hydratron SL grease and install to the conrod.
• Install the conrod assembly to the air piston, locating the pin with the hole on the air
piston and secure with the retaining ring.
• Lubricate O ring OR-002 1-off with Hydratron SL grease, install to the conrod adaptor,
install the assembly to the second air piston and secure with the retaining clip.
• Lubricate the conrod with Hydratron SL grease, install air piston/ conrod assembly
through the centre of the centre plate. Install the air piston/ conrod assembly to the
conrod and secure with the screw.
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December 2019
• Lubricate O ring OR-002 2-off with Hydratron SL grease, install to both hydraulic
pistons and install to the air pistons securing with the retaining clips. Note the O rings
are in the hydraulic seal kit.
• Lubricate O ring OR0015 2-off with Hydratron SL grease and install to the air pistons.
• Lubricate the internal surface of both air motor cylinders and install over the air pistons
and to the centre plate. When assembling the air cylinder back together place it at an
angle and then push it in place, taking care not to damage O-rings and avoiding
scratching the air cylinders.
• Lubricate O ring OR-016 2-off with Hydratron SL grease, install to the end plates and
install the end plates to the air motor cylinders. When reassembling the air motor
ensure the air cylinders are positioned square and tight against the pump end plates
BEFORE tightening the bolts.
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December 2019
• Install tie bars 4-off, feet (ensuring the pump securing holes are inboard), washer 4-off
and nuts 8-off. Secure all nuts hand tight, followed by an opposite tightening sequence
to a torque nuts to 60 Nm.
• Install O ring OR-067 4-off to the top of the air motor. Do Not apply grease.
• Install T20 COV/ manifold assembly to the top of the air motor ensuring the ports align
and secure with bolts 4-off.
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December 2019
• Install pilot air supply pipework and 5-way pilot valve.
• Install the silencer/mufflers.
• Install the pump if located inside a power pack or test rig.
• After servicing, pressurise the unit in accordance with the operating instructions and
leak check all joints.
• Check for no drop in hydraulic pressure.
SERVICING THE PILOT VALVE SWITCH

REMOVAL
• Undo the pipe work and fittings connected to the pilot valve.
• Unscrew pilot valve locknut.
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December 2019
• Withdraw the outer body containing the plunger and the spring.
• Remove the locknut and remove the inner body from the pump endplate using an M24
socket
• Remove O-rings from the main body, plunger and inner body discard.
INSTALLATION
• Check the plunger runs freely in outer and inner body.
• Lubricate O ring OR-079 1-off, O ring OR-137 1-off with Hydratron NLB grease, install
to the inner body, ensure Dowty seal is fitted and install inner body to the end plate
using an M24 socket.
• Install the locknut hand tight to the inner body ensuring the orientation (the groove
facing outwards).
• Lubricate O ring OR-014 1-off with Hydratron NLB grease, install to the plunger.
Lubricate the plunger with Hydratron NLB grease and install to the inner body.
• Install the spring over the plunger.
• Lubricate O ring OR-136 3-off with Hydratron NLB grease and install into the pilot valve
body.
• Install the pilot valve body to the inner pilot valve body hand tight until the body stops
on the locknut and then back the body off until the weep hole is facing the hydraulic
cylinder at the 3 o’clock position.
• Tighten the locknut to keep the pilot valve body in position.
• Install the fittings and pipework to the pilot valve.
The pilot valve plunger might stick out few millimetres, this is due to the air piston
pushing against it DO NOT force the plunger in.
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December 2019
SERVICING THE CHANGE OVER VALVE
REMOVAL
• Remove the pilot air pipe work.
• Unscrew 4-off screws retaining the valve body to the base block; Discard the gasket.
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December 2019
• Unscrew 8-off screws retaining the two end caps.
• Remove end bushes from both sides.
• Remove O-rings from end bushes and discard.

• Carefully withdraw spool, inspect condition of the spool, any signs of damage or
scratching and the spool will require replacement.
• Withdraw lip seals(x6) and lip seal spacers(x5). Discard the lip seals.
INSTALLATION
• Lubricate O-rings OR-017 4-off with Hydratron SL grease and install to the Change
Over Valve end caps. Ensure the plain side will face towards the end caps.
• Install 1 of the end cap assembly to the Change Over body with the end cap port hole
adjacent to the top of the body with retaining screws 4-off.
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December 2019
• Lubricate the lip-seals 6-off with Hydratron SL grease on install into the Change Over
Valve with the spacers 5-off.
• Lubricate the spool with Hydratron SL grease and install to the Change Over Valve.
• Install the other end cap assembly to the Change Over body with the end cap port hole
adjacent to the top of the body with retaining screws 4-off.
• Install the gasket to the base block and install the Change Over Valve Assembly to
the base block and secure with retaining screws 4-off
Page 25 of 61
December 2019
SERVICING THE 5 WAY PILOT VALVE

REMOVAL
• Remove end cap securing screws 4-off and end cap 2-off.
• Remove bushes from the end caps and remove O ring OR-029 from the bushes and
discard.
• Remove the spool and inspected.
• Remove large spacer 2-off, small spacer 5-off and OR-398 6-off and discard O rings.
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December 2019
INSTALLATION
• Lubricate O ring OR-029 2-off with Hydratron NLB grease, install to the bushes. Install
the bushes into the end caps.
• Install one end cap assembly and one large spacer to the PV-5 body and secure with
screws 2-off.
• Lubricate O ring OR-398 6-off with Hydratron NLB grease, install the O rings and small
spacers alternately.
• Lubricate the spool with Hydratron NLB grease and install to the PV-5.
• Install the larger spacer, end cap assembly and secure with screws 2-off.
Page 27 of 61
December 2019
PUMP COMPONENT LISTS
AIR MOTOR
Page 28 of 61
December 2019
DHDA118/4
DHDA33/4
DHDA66/3.3 DHDA118X/ DHDA158/4
Qt DHDA33X/4 DHDA66X
Item Description DHDA66X/3. 4 DHDA158X/
y DHDA33XC CP
3 DHDA118X 4
P
CP
1 2 END M45131 M45133 M45131 M45131 M48568
PLATE
AIR
2 2 M40373 M40114 M40114 M40114 M50531
PISTON
CONNECT
3 1 M40376 M40345 M40345 M40345 M40345
ING ROD
CONN
4 1 ROD END M40377 M40344 M40344 M40344 M40344
PIECE
INTERNAL CIR-N1300- CIR-N1300- CIR- CIR-N1300- CIR-N-1300-
5 4 N1300-175-
CIRCLIP 55 175-HTS 175-HTS 175-HTS
NITRILE SKDH33AIR SKDH66AIR HTS
SKDH66AI SKDH66AIR SKDH158/4-
6 1
SEAL KIT -00 -00 R-00 -00 HYD-N
Nitrile as standard.
Item Qty Part code Description

7 1 AIFIL-G1/8-AD 1/8”BSPP(F) FILTER-AUTO DRAIN
8 1 BR44924 FILTER MTG BRACKET
9 2 BR50581 MOUNTING BRACKET
10 2 BR50582 MOUNTING BRACKET
11 1 COV-T20-N T20 CHANGE OVER VALVE ASSY
12 2 DOWTY0.75SS 3/8” DOWTY SEAL – SS
13 2 DOWTY0.75SS ¾” DOWTY SEAL – SS
14 1 FAS-TP1/8X1/2-A2 TENSION PIN - SS
15 2 FIT-BP60PHEX-BR ¾” HEX BLANK PLUG – BRASS
16 2 M40106-ANOD AIR MOTOR CYLINDER
17 8 M40169 NUT
18 4 M40308 STUD
19 1 M42214-ANOD CENTRE PLATE
20 1 M48862-ANOD T20 VALVE BASE
21 2 PV30400-BR-N-REV1 PILOT VALVE
22 1 PV-5 5 – WAY PILOT VALVE
23 2 SIL-2901 1/8 VALVE SILENCER
24 2 SIL-M10 SILENCER
25 1 SCREWKIT-DHDA PUMP SCREW KIT
26A 1 FITKIT-DA-DHDA-L1-BRASS BRASS FITTING KIT (L1 OPTION)
26B 1 FITKIT-DHDA-L2-SS SS FITTING KIT (L2 OPTION)
27A 1 TU-CU-DHDA-SET PRE-BENT COPPER AIR TUBE SET
27B 1 TU-SS-DHDA-SET PRE-BENT SS AIR TUBE SET
Page 29 of 61
December 2019
CHANGE OVER VALVE (COV-T20-N)

1 1 M41067-ANOD SPOOL
2 2 M43083 END SEAL BUSH
3 5 M43084-ANOD SPACER
4 2 M43085-ANOD END CAP
5 1 M43086-ANOD BODY
6 8 SCM10SOC45-A2 M10 X 45 SOCKET CAP BOLT-SS
7 1 SKT20 ORING SEAL KIT
NITRILE AS STANDARD
Page 30 of 61
December 2019
PILOT VALVE (PV30400-BR-N-REV1)

1 1 DOWTY0.375SS 3/8” DOWTY SEAL – SS
2 1 M45203 PLUNGER
3 1 M50293-BR BODY 1/8”BSPP – BRASS
4 1 M50294-BR CONNECTOR – BRASS
5 1 M50296-BR LOCKNUT – BRASS
6 1 SKPV30400-N O-RING SEAL KIT
7 1 SPR43338-7 SPRING
NITRILE AS STANDARD
Page 31 of 61
December 2019
HYDRAULIC SECTION
DHDA33/4 HYDRAULIC END (Nitrile)
REMOVAL
• Remove the hydraulic cylinder (20) from the air motor end plate. Carefully withdraw
without damaging the piston or seal.
• Remove and discard the gasket G40379 (19) 1-off from the hydraulic cylinder (20).
• Remove and discard the main O ring seal OR-034 (18) 1-off and back up rings BU-
035 (17) 2-off from the hydraulic cylinder.
• Remove the inlet check valve assembly from the hydraulic cylinder (20).
• Remove the retaining clip (7), spring guide (6), spring (5), ball guide (4) and ball (3)
from the inlet check valve body (1).
• Remove and discard the O ring OR-005 (2) 1-off from the inlet check valve body
(1).
• Remove the outlet check valve assembly from the hydraulic cylinder (20).
• Remove the retaining clip (14), spring guide (13), spring (12), ball guide (11) and
ball (10) from the outlet check valve body (8).
• Remove and discard the O ring OR-005 (9) 1-off from the outlet check valve body
(8).
• Remove the hydraulic piston (16) if required. See air motor servicing.
INSTALLATION
• Install hydraulic piston (16) if removed. See air motor servicing.
• Lubricate the main seal O ring OR-34 (18)1-off with Hydratron SL grease and install
with back up ring BU-035 (17) 2-off into the hydraulic cylinder (20).
• Install gasket G40379 (19) 1-off to the hydraulic cylinder (20) and install the cylinder
(20) to the air motor end plate.
• Install the O ring OR-005 (2) 1-off (Do Not grease) inside the inlet check valve body
(1).
• Install the ball (3), ball guide (4), spring (5), spring guide (6) and retaining clip (7)
inside inlet check valve body (1).
• Install the inlet check valve assembly to the hydraulic cylinder (20).
• Install the O ring OR-005 (9) 1-off (Do Not grease) inside the outlet check valve
body (8).
• Install the ball (10), ball guide (11), spring (12), spring guide (13) and retaining clip
(14) inside outlet check valve body (8).
• Install the outlet check valve assembly to the hydraulic cylinder (20).
Page 32 of 61
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Item Part Code Description

16 M40375 HYDRAULIC PISTON
21 CIR-1300-55 EXTERNAL CIRCLIP
17 BU-035 PTFE BACKUP RING
20 M40374 HYDRAULIC CYLINDER
(CV30217-12) INLET CHECK VALVE
1 M49337 CV BODY
3 BALL-9/16”-G100 9/16” BALL
4 CV-P-1-34-2 BALL GUIDE
5 SPR-P-1-13 SPRING
6 CV-P-1-17 SPRING GUIDE
7 CIR-RRT68 INTERNAL CIRCLIP
(CV30217-10) OUTLET CHECK VALVE
8 CV-P-1-63 CV BODY
9 BALL-9/16”-G100 9/16” BALL
11 SPR-P-1-13 SPRING
SEAL KIT (O-RINGS ARE PART OF A COMPLETE SEAL KIT)
SKDH33-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH33-HYD-V (AVILABLE OPTION) VITON SEAL KIT
SKDH33-HYD-C (AVILABLE OPTION) CHEMRAZ SEAL KIT
Page 33 of 61
December 2019
DHDA33X/4 HYDRAULIC END (Nitrile)
REMOVAL
• Remove the hydraulic cylinder (23) by loosening the locknut (22) by turning anti-
clockwise then unscrewing the cylinder (23) from the isolation chamber (20).
Carefully withdraw without damaging the piston or seal.
• Remove locknut (22) 1-off from the hydraulic cylinder.
035 (17) 2-off from the hydraulic cylinder.
• Remove the retaining clip (7), spring guide (6), spring (5), ball guide (4) and ball (3)
from the inlet check valve body (1).
(1).
• Remove the retaining clip (14), spring guide (13), spring (12), ball guide (11) and
ball (10) from the outlet check valve body (8).
(8).
• Remove the isolation chamber (20) from the air motor end plate.
• Remove and discard O ring OR-034 (19) 1-off and gasket G40379 (18) 1-off from
the isolation chamber (20).
• Remove the hydraulic piston if required. See air motor servicing
INSTALLATION
• Lubricate O ring OR-34 (19) 1-off with Hydratron SL grease and install into the
isolation chamber (20).
• Install gasket G40379 (18) 1-off to the isolation chamber (20) and install the
isolation chamber (20) to the air motor end plate ensure the port is down 6 o’clock
position.
• Lubricate the main seal O ring OR-034 (19) 1-off with Hydratron SL grease and
install with back up ring BU-035 (21) 2-off into the hydraulic cylinder (23).
• Install locknut (22) 1-off to the hydraulic cylinder (23) and install the cylinder (23) to
the isolation chamber (20) and secure with the locknut (22).
(1).
• Install the ball (3), ball guide (4), spring (5), spring guide (6) and retaining clip (7)
inside inlet check valve body (1).
body (8).
• Install the ball (10), ball guide (11), spring (12), spring guide (13) and retaining clip
(14) inside outlet check valve body (8).
Page 34 of 61
December 2019
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December 2019

17 M40261-SSV HYDRAULIC PISTON
15 CIR-1300-55 EXTERNAL CIRCLIP
22 M41509 LOCK NUT
20 M41511 ISOLATION CHAMBER
1 M49337 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
8 CV-P-1-63 CV BODY
10 BALL-9/16”-G100 9/16” BALL
SKDH33X-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH33X-HYD-V (AVILABLE VITON SEAL KIT
SKDH33X-HYD-C
OPTION) (AVILABLE CHEMRAZ SEAL KIT
OPTION)
DHDA66/3.3 HYDRAULIC END (Nitrile)

REMOVAL
• Remove the hydraulic cylinder (28) from the air motor end plate. Carefully withdraw
without damaging the piston or seal.
• Remove and discard the gasket G40283 (27) 1-off from the hydraulic cylinder (28).
042 (25) 2-off from the hydraulic cylinder (28).
• Remove the seal insert (8) from the inlet check valve body (1).
• Remove and discard O rings OR-032 (7) 1-off and OR-033 (9) 1-off from the seal
insert (8).
• Remove the spring guide (6), spring (5), ball guide (4) and ball (3) from the inlet
check valve body (1).
(1).
insert (11).
Page 36 of 61
December 2019
• Remove the outlet check valve adaptor (20) from the outlet check valve body (13).
• Remove and discard O ring OR-032 (19) 1-off from the outlet check valve adaptor
(20).
• Remove the spring guide (18), spring (17), ball guide (16) and ball (15) from the
outlet check valve body (13).
(13).
• Remove the hydraulic piston (24) if required. See air motor servicing.
INSTALLATION
• Lubricate the main seal O ring OR-41 (26) 1-off with Hydratron SL grease and
install with back up ring BU-042 (25) 2-off into the hydraulic cylinder (28).
• Install gasket G40283 (27) 1-off to the hydraulic cylinder (28) and install the cylinder
(28) to the air motor end plate.
(1).
• Install the ball (3), ball guide (4), spring (5) and spring guide (6) inside inlet check
valve body (1).
• Lubricate O rings OR-032 (7) 1-off and OR-033 (9) 1-off with Hydratron SL grease
and install to the seal insert (8).
• Install the seal insert assembly (8) to the inlet check valve body (1).
body (13).
• Install the ball (15), ball guide (16), spring (17) and spring guide (18) inside outlet
• Lubricate O ring OR-32 (19) 1-off and install to CV adaptor (20).
• Install the CV adaptor assembly (20) to the outlet check valve body (13).
• Lubricate O rings OR-032 (12) 1-off and OR-033 (10) 1-off with Hydratron SL
grease and install to the seal insert (11).
• Install the seal insert assembly (11) to the outlet check valve body (13).
Page 37 of 61
December 2019
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December 2019
CIR-1300-175-HTS EXTERNAL CIRCLIP
1 M42088 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
8 M42090 SEAL INSERT
18 M42089 CV INNER BODY
14 BALL-9/16” 9/16” BALL
20 M49502 CV ADAPTOR
22 FIT-GL9M NUT
21 FIT-CL9M SLEEVE
SKDH66/3.3-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH66/3.3-HYD-V (AVILABLE VITON SEAL KIT
SKDH66/3.3-HYD-C
OPTION)
DHDA66X/3.3 HYDRAULIC END (Nitrile)
REMOVAL
• Remove the hydraulic cylinder (30) by loosening the locknut (29) by turning anti-
clockwise then unscrewing the cylinder (30) from the isolation chamber (27).
Carefully withdraw without damaging the piston or seal.
• Remove locknut (27) 1-off from the hydraulic cylinder (30).
042 (28) 2-off from the hydraulic cylinder (30).
insert (8).
(1).
insert (11).
Page 39 of 61
December 2019
(20).
(13).
• Remove the isolation chamber (27) from the air motor end plate.
• Remove and discard O ring OR-041 (26) 1-off and gasket G40283 (25) 1-off from
the isolation chamber (27).
• Remove the hydraulic piston if required. See air motor servicing
INSTALLATION
• Lubricate the O ring OR-41 (26) 1-off with Hydratron SL grease and install into the
isolation chamber (27) to the air motor end plate.
• Lubricate the main seal OR-041 (26) 1-off with Hydratron SL grease and install with
back up ring BU-042 (28) 2-off into the hydraulic cylinder (30).
• Install locknut (29) 1-off to the hydraulic cylinder (30) and install the cylinder (30) to
the isolation chamber (27) and secure with the locknut (29).
(1).
valve body (1).
body (13).
• Install the ball (15), ball guide (16), spring (17), spring guide (18) inside outlet check
valve body (13).
Page 40 of 61
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Page 41 of 61
December 2019
Part Code Description
M40524-SSV HYDRAULIC PISTON
M40522 ISOLATION CHAMBER
M50619-NIFLOR HYDRAULIC CYLINDER
M42088 CV BODY
BALL-9/16”-G100 9/16” BALL
CV-P-1-34-2 BALL GUIDE
SPR-P-1-13 SPRING
CV-P-1-17 SPRING GUIDE
M42090 SEAL INSERT
M42098 CV INNER BODY
BALL-9/16”-G100 9/16” BALL
CV-P-1-34-2 BALL GUIDE
SPR-P-1-13 SPRING
CV-P-1-17 SPRING GUIDE
M42090 SEAL INSERT
M49502 CV OUTER BODYADAPTOR
FIT-GL9M NUT
FIT-CL9M SLEEVE
SKDH66X/3.3-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH66X/3.3-HYD-V (AVILABLE VITON SEAL KIT
SKDH66X/3.3-HYD-C
OPTION)
REMOVAL
• Remove the hydraulic cylinder (29) and seal retainer (27) assembly from the air
motor end plate. Carefully withdraw without damaging the piston or seal.
• Remove and discard the gasket G40379 (25) 1-off from the seal retainer (27).
• Remove the seal retainer (27) from the hydraulic cylinder (29) using a C spanner.
• Remove and discard the main lip-seal LS-S002-2188-0 (28) 1-off from the hydraulic
cylinder (29).
insert (8).
(1).
insert (11).
Page 42 of 61
December 2019
(20).
(13).
• Remove the hydraulic piston if required. See air motor servicing.
INSTALLATION
Seal retainer (27).
• Lubricate the main Lip-seal LS-S002-2188-0 (28) 1-off with Hydratron SL grease
and using insert tool (Not Provided) install into the hydraulic cylinder (29).
• Install the seal retainer (27) to the hydraulic cylinder (29) and tighten with a C
spanner.
• Install gasket G40379 (25) 1-off to the seal retainer (27) and hydraulic cylinder (29)
assembly and install the assembly to the air motor end plate.
(1).
valve body (1).
body (13).
Page 43 of 61
December 2019
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December 2019
27 M47264 SEAL RETAINER
1 M42088 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
13 M42089 CV INNER BODY
15 BALL-9/16”-G100 9/16” BALL
20 M42107 CV OUTER BODY ADAPTOR
22 FIT-GL9H NUT
21 FIT-CL9H SLEEVE
SKDH118/4-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH118/4-HYD-V (AVILABLE VITON SEAL KIT
SKDH118/4-HYD-C
OPTION)
REMOVAL
• Remove the hydraulic cylinder (29) and isolation chamber (27) assembly from the
air motor end plate. Carefully withdraw without damaging the piston or seal.
• Remove and discard the gasket G40379 (25) 1-off from the isolation chamber (27).
• Remove the isolation chamber (27) from the hydraulic cylinder (29) using a C
spanner.
cylinder (29).
insert (8).
(1).
insert (11).
Page 45 of 61
December 2019
(20).
(13).
INSTALLATION
• Lubricate the main Lip-seal LS-S002-1288-0 (28) 1-off with Hydratron SL grease
and using insert tool (Not Provided) install into the hydraulic cylinder (29).
• Install the isolation chamber (27) to the hydraulic cylinder (29) and with a C
spanner.
isolation chamber/ hydraulic cylinder assembly to the air motor end plate.
(1).
valve body (13).
body (13).
Page 46 of 61
December 2019
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December 2019
29 M47560-NIFLOR HYDRAULIC CYLINDER
1 M42088 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
13 M42089 CV BODY
15 BALL-9/16”-G100 9/16” BALL
22 FIT-GL9H NUT
21 FIT-CL9H SLEEVE
SKDH118X/4-HYD-N (STANDARD) NITRILE SEAL KIT
SKDH118X/4-HYD-V (AVILABLE VITON SEAL KIT
SKDH118X/4-HYD-C
OPTION)
REMOVAL
• Remove the hydraulic cylinder (30) and seal retainer (27) assembly from the air
motor end plate. Carefully withdraw without damaging the piston or seal.
• Remove and discard the gasket G44021 (25) 1-off from the seal retainer (27).
• Remove the seal retainer (27) from the hydraulic cylinder (30) using a C spanner.
• Remove and discard the main lip-seal LS-S002-1885 (29) 1-off and O ring OR-202
(28) from the hydraulic cylinder (30).
insert (8).
(1).
insert (11).
Page 48 of 61
December 2019
(20).
(13).
INSTALLATION
Seal retainer (27).
• Lubricate the main Lip-seal LS-S002-1885 (29) 1-off with Hydratron SL grease and
using insert tool (Not Provided) install into the hydraulic cylinder (30).
• Lubricate O ring OR-202 (28) 1-off with Hydratron SL grease and install to the
hydraulic cylinder (30).
• Install the seal retainer (27) to the hydraulic cylinder (30) and tighten with a C
spanner.
• Install gasket G44021 (25) 1-off to the seal retainer (27) and hydraulic cylinder
assembly and install the assembly to the air motor end plate.
(1).
valve body (1).
body (13).
Page 49 of 61
December 2019
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December 2019
27 M51091 SEAL RETAINER
1 M42088 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
13 M42089 CV BODY
15 BALL-9/16”-G100 9/16” BALL
22 FIT-GL9H NUT
21 FIT-CL9H SLEEVE
SKDH158/4-HYD-N (STANDARD) NITRILE SEAL KIT

REMOVAL
• Remove the hydraulic cylinder (31) and isolation chamber (27) assembly from the
air motor end plate. Carefully withdraw without damaging the piston or seal.
• Remove and discard the gasket G44021 (25) 1-off from the isolation chamber (27).
• Remove the isolation chamber (27) from the hydraulic cylinder (29) using a C
spanner.
• Remove and discard the wear band (28) 1-off and O ring OR-453 (26) 1-off from the
cylinder (29).
insert (8).
(1).
Page 51 of 61
December 2019
insert (11).
(20).
(13).
INSTALLATION
• Install wear band (28) into the isolation chamber (27).
• Lubricate the main Lip-seal LS-S002-1885 (30)-off with Hydratron SL grease and
using insert tool (Not Provided) install into the hydraulic cylinder (29).
• Lubricate O ring OR-202 (29) 1-off with Hydratron SL grease and install to the
hydraulic cylinder (31).
• Install the isolation chamber (27) to the hydraulic cylinder (31) and with a C
spanner.
isolation chamber/ hydraulic cylinder assembly to the air motor end plate.
(1).
valve body (1).
body (13).
Page 52 of 61
December 2019
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December 2019
28 SB50412 WEAR BAND
31 M50409-NIFLOR HYDRAULIC CYLINDER
1 M42088 CV BODY
3 BALL-9/16”-G100 9/16” BALL
5 SPR-P-1-13 SPRING
13 M42089 CV BODY
15 BALL-9/16”-G100 9/16” BALL
22 FIT-GL9H NUT
21 FIT-CL9H SLEEVE
SKDH158X/4-HYD-N (STANDARD) NITRILE SEAL KIT
Page 54 of 61
December 2019
POWER PACKS
HYDRAULIC POWER UNIT (HPU)
BEFORE OPERATING THE POWER PACK

• Check sufficient clean liquid is present in the tank. Top up with water or suitable
hydraulic oil if required and replace tank cap.
DO NOT ALLOW TANK TO RUN DRY

• Visually check air lubricator oil level. Top up with a light petroleum-based oil such as
Kilfrost 400, Shell Tellus 27, DTE Light, Automatic Transmission Fluid Type A, or any
good grade of light oil compatible with nitrile seals.
• Open pressure let down needle valve. (if fitted, open pressure isolation needle
valve)
• Close air stop ball valve.
• Rotate air regulator control knob anti-clockwise until handle becomes free.
• Connect a suitable 100-PSI air supply to the air supply connection.
Maximum air pressure supplied must not exceed 100 PSI.

• Connect a suitably rated hydraulic hose or hard piped tubing to the outlet connection.
Hydraulic hoses or piping including adaptors or couplings must have a pressure rating
equal to or more than the maximum output pressure of the Power Pack.
OPERATING PRECEDURE
• Open air stop ball valve.
• Rotate air regulator control knob slowly clockwise until pump begins to reciprocate
(pump should start at 10 to 15 PSI under normal conditions).
• Rotate air regulator control knob clockwise until 25 to 30 PSI is reached on the air
gauge and run pump until all air is purged out of the circuit.
Page 55 of 61
December 2019
When pressure testing, bleed all air out of the item being tested before pressurising by
fitting a bleed valve or vent plug at the highest point in the circuit. Care should be taken
to take account of any internal cavities that may trap air inside the circuit.
• Bleed the air out of the system by closing the pressure let down valve on the power
pack and running the pump until all the air has been evacuated.
• Rotate air regulator control knob anti-clockwise until zero pressure is reached on air
pressure gauge.
• Close any vent valves external to the Power Pack once all air is purged from the
system.
• Rotate air regulator control knob slowly clockwise until required hydraulic pressure is
reached on the high-pressure gauge.
If the object being tested is large it will take a while before the pressure builds up
in the system and registers on the pressure gauge. Do not set the air driving pressure
too high if unattended as this may lead to the object under test being over pressurised.
Approximate hydraulic output pressure can be pre-set by air drive pressure. See
pump specification sheet.
Air drive pressure can be pre-set by closing air stop valve and rotating air regulator
valve clockwise until the required pressure is registered on air pressure gauge.
Air pressure should be set slightly below the required setting so that it can be
raised to the correct setting once hydraulic pressure has built up and the pump has
stalled out.
The pump can then be started and stopped by using air stop valve as it will go to the
pre-set output pressure each time it is started.
Once set the pump will maintain the set pressure indefinitely and make up any fluid
losses within the hydraulic system automatically.
RELEASE HYDRAULIC PRESSURE

• Close air stop ball valve.
• Rotate air regulator control knob anti-clockwise until air pressure gauge reads zero
pressure.
• Slowly open pressure let down needle valve until high pressure gauge reads zero (if
fitted, slowly open pressure isolation valve to ensure all pressure is released from
system).
• If necessary, disconnect hydraulic hose from high pressure outlet connection.
• If necessary, disconnect air supply from air supply connection
Page 56 of 61
December 2019
HYDRAULIC POWER UNIT GENERAL MAINTENANCE
TO DRAIN AIR FILTER/REGULATOR
• Isolate air supply from source.
• When water collects in the transparent bowl, open valve at base of filter and drain off
liquid. (If required a drain pipe can be fitted via the 1/8”NPT (M) thread to facilitate
draining – pipe not supplied)
TO CLEAN AIR FILTER/REGULATOR ELEMENT

• Regularly clean element as directed.
• Isolate air supply and bleed off trapped air pressure by rotating air regulator control
knob anti-clockwise until handle becomes free.
• Unscrew air filter bowl anti-clockwise ¼ turn and pull off.
• Unscrew retaining ring and withdraw filter element. (Recommend replacing the element
annually. Contact Hydratron for details).
• Clean filter element with paraffin and blow out with compressed air.
• Clean plastic bowl with soapy water only, solvents will damage the bowl beyond
repair.
• Do not over tighten retaining ring when re assembling as element damage may occur.
• Relocate air filter bowl and screw clockwise ¼ turn to lock in place.
• Turn on air supply and check for leaks.
AIR LUBRICATOR OIL LEVEL

• Regularly check lubricator oil level, do not allow to run dry. Re-fill as directed.
• Isolate air supply and bleed off trapped air pressure by rotating air regulator control
knob anti-clockwise until handle becomes free.
• Unscrew lubricator bowl anti-clockwise ¼ turn and pull off and fill to maximum level
indicated on transparent bowl using a light petroleum based oil such as Kilfrost 400,
Shell Tellus 27, DTE Light, Automatic Transmission Fluid Type A, or any good grade of
light oil compatible with nitrile seals.
• Relocate air filter bowl and screw clockwise ¼ turn to lock in place.
• Turn on air supply and check for leaks.
The adjustment screw located on the lubricator site dome is factory pre-set for
optimum performance and does not require any adjustment. To reset the factory setting,
rotate adjustment screw anti clockwise to minimum position (-) followed by a 1/4 turn
clockwise (+)
TO CLEAN TANK STRAINER

• Clean tank strainer at least every 6 months as directed.
• Remove the plug on the bottom of the tank to drain the tank. Close the suction supply
valve if fitted.
• Remove the plug from the Y strainer and remove the strainer.
Page 57 of 61
December 2019
←Plug
• Using compressed air directed internally and externally clean off any debris.
• Refit the strainer and plug.
• Flush tank out to remove any debris that has settled at the base of the tank.
• Replace PTFE tape on the plug and refit to the bottom of the tank.
• Re fill tank with clean liquid and check for leaks
HYDRAULIC PUMP
• After prolonged service, the pump will require servicing and new seals may be
required. See servicing instructions
HIGH PRESSURE GAUGE

• After prolonged service check gauge calibration.
ATEX
User Instructions Specific to Hazardous Area Installations
(Reference European ATEX Directive 2014/34/EU)
• The equipment may be used within a flammable gas (T5), vapour or dust (840C)
atmosphere -
certified for use in ambient temperatures in the range -20°C to +40oC and should not
be used outside this range.
• Installation shall be carried out by suitably trained personnel in accordance with the
applicable code of practice and in accordance with the installation, operating & service
manual supplied with this product.
• Inspection and maintenance of this equipment shall be carried out by suitably trained
personnel in accordance with the applicable code of practice and in accordance with
the installation, operating & service manual supplied with this product.
• Maintenance of this equipment shall be carried out by suitably trained personnel in
accordance with the applicable code of practice and in accordance with the installation,
operating & service manual supplied with this product.
• Components to be incorporated into or used as replacement parts of the equipment
shall be fitted by suitably trained personnel. Only parts referenced in the manual and
supplied by Hydratron or authorised representative can be used to ensure ATEX
certification is not invalidated.
• Putting into service, use, assembling, and adjustment of the equipment shall be carried
out by suitably trained personnel in accordance with the installation, operating &
service manual supplied with this product.
• The certification of this equipment relies upon the components as listed within the
installation, operating & service manual supplied with this product. If the equipment
supplied is likely to come into contact with aggressive substances, then it is the
Page 58 of 61
December 2019
responsibility of the user to take suitable precautions that prevent it from being
adversely affected, thus ensuring that the type of protection provided by the equipment
is not compromised.
• Aggressive substances: e.g. acidic liquids or gases not compatible with the materials of
construction as stated in the installation, operating & service manual supplied with this
product
• Suitable precautions: e.g. regular checks as part of routine inspections or establishing
from the materials data sheets that it is resistant to specific chemicals.
• It is the end user’s responsibility to ensure the product and its coding is suitable for its
intended application
• Regularly check the air outlet exhaust is clear of any obstructions or blockages.
• Regularly check the complete unit for dust build up and clean down accordingly.
• WARNING - Low conductive liquids may cause static generation and accumulate in the
plastic liquid tank versions (AZ Lightweight Hydraulic Power Unit only). It is advised
such liquids are not utilised. For guidance refer to purchasable document Cenelec Test
Report CLC/TR/50404.
• Ensure equipment supplied is suitably bonded to earth as necessary.
• The equipment bears the marking ;
• II 2G Ex h IIB T5 Gb II 2D Ex h IIIB T84C Db
• ATEX Certificate Number : Sira 06ATEX6143
TRANSPORT AND STORAGE

INSPECTION ON RECEIPT OF GOODS
INSPECT THE PACKAGE

1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the shipping documents and immediately
advise Hydratron
INSPECT THE UNIT

1. Remove packing materials from the product.
2. Dispose of all packing materials in accordance with local regulations.
3. Inspect the product to determine if any parts have been damaged or are missing.
4. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
5. Note any damaged or missing items and immediately advise Hydratron
LIFTING
WARNING: CRUSH HAZARD.
The unit and the components can be heavy. Use proper lifting methods
Lift and handle the product carefully, using suitable lifting equipment and in line with local
regulations.
LARGE UNITS WITH FORK TRUCK LIFTING POINTS

Always lift the unit using the fort truck lifting points.
Page 59 of 61
December 2019
UNITS WITH LIFTING EYES
Always lift the unit using the lifting points/eyes provided with suitably rated lifting slings and
in line with local safety regulations
LIFTING EQUIPMENT
Lifting equipment is always required when handling the unit. It must fulfil the following
requirements:
• Suitable certified in line with local regulations and correctly rated
• Capable of lifting the minimum height required.
• The lifting equipment must be able to lift the unit straight up and down, without the need
for resetting.
• The lifting equipment must support weight of the entire assembly and must only be used
by authorized competent personnel.
LIFTING FROM TRANSPORT PALLET

Remove all side and top packaging
Remove any stabilising/support strapping
Lift the unit by the lifting points provided ONLY
WARNING: Stay clear of suspended loads at all time.
TRANSPORTATION GUIDELINES
WARNING:
• Stay clear of suspended loads.
• Observe applicable local accident prevention regulations in force.
POSITION AND FASTENING

1. Make sure that the unit is securely fastened to an adequately strong pallet and suitably
protected from side or top damage during transportation.
2. Ensure the unit cannot roll, slide or topple over.
3. Ensure the fort truck lifting points on the pallet are correctly positioned to support the
unit with respect to its Centre of Gravity. (Note this may not be centralised)
STORAGE GUIDELINES
STORAGE LOCATION
The product must be stored in a covered and dry location free from extreme temperatures,
dirt, and vibrations.
NOTICE:
• Protect the product against humidity, extreme temperatures, and mechanical damage.
• Do not place heavy weights on the packed product.
LONG-TERM STORAGE
If the unit is stored more than 6 months, note the following:
• Before operating the unit, it must be inspected with special attention to seals, pipework,
joints, hosing and cables.
• All manual valves should be fully operated to ensure seizing has not occurred.
Page 60 of 61
December 2019
FREEZING PRECAUTIONS
The unit must be protected from freezing temperatures.
Decommissioning
PERSONNEL
All decommissioning work must be performed only by a qualified authorized service
technician.
It is the customer’s responsibility to verify correct qualifications and ensure they are in line
with local regulations
DISPOSAL/RECYCLING
The Unit must not be disposed of in domestic waste and should only be disposed of in accordance
with local regulations at authorized collection facilities.
Page 61 of 61

PUMP-DHDA MANUAL-REVAJase

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Hydratron – a Global supplier of high pressure equipment

DHDA AND DHDAX SERIES PUMP

OPERATION AND MAINTENANCE MANUAL

Prior to commencing servicing or repairs, make sur the pump/ system is

Prior to commencing servicing or repair, liquid section(s) should be purged if

In the event of an emergency the air supply must be turned off.

Absolute cleanliness is necessary when servicing hydraulic systems and

Before dismantling a component, drain al hydraulic and clean externally.

Use only seals recommended for the equipment in use.

PIPES AND HOSES

Prior to commencing servicing or repairs, make sure the pump/ system is

Use adjustableor open ended wrenches on fittings.

MOUNTING THE PUMP

HYDRAULIC SUPPLY CONNECTION / INLET CONNECTION

PRESSURE PORT / OUTLET CONNECTION

AIR SUPPLY CONNECTION

DO NOT EXCEED 100 PSI AIR SUPPLY

DO NOT RUN PUMP DRY

Monthly checks for any lose connections and leaks.

Possible Cause Solutions

LOSS OF HYDRAULIC PRESSURE

Hydraulic Check Valves Leaking Replace Seals

PUMP RUNS ERRATICALLY

Prior to commencing servicing or repairs, make sure the pump/system is

• Before dismantling a component, clean externally.

REMOVING PUMP (if required)

• Isolate and Disconnect the air supply.

• Disconnect pipe work to pump inlet and outlet check valves.

• Disconnect any additional pipe work to allow withdrawal of the pump.

• Re assembly is opposite procedure to disassembly.

SERVICING THE HYDRAULIC CYLINDER

Prior to commencing servicing or repairs, make sure the pump/system is

SERVICING THE INLET & OUTLET CHECK VALVE

SERVICING THE AIR MOTOR

• Undo 4-off nuts holding pump together and withdraw studs.

• Remove air cylinders.

• Remove O-rings 4-off from centre plate and discard.

SERVICING THE PILOT VALVE SWITCH

• Remove O-rings from end bushes and discard.

SERVICING THE 5 WAY PILOT VALVE

Item Qty Part code Description

Item Qty Part code Description

Item Qty Part code Description

Item Part Code Description

Item Part Code Description

DHDA66/3.3 HYDRAULIC END (Nitrile)

DHDA158X/4 HYDRAULIC END (Nitrile)

BEFORE OPERATING THE POWER PACK

DO NOT ALLOW TANK TO RUN DRY

Maximum air pressure supplied must not exceed 100 PSI.

RELEASE HYDRAULIC PRESSURE

TO CLEAN AIR FILTER/REGULATOR ELEMENT

AIR LUBRICATOR OIL LEVEL

TO CLEAN TANK STRAINER

HIGH PRESSURE GAUGE

(Reference European ATEX Directive 2014/34/EU)

• II 2G Ex h IIB T5 Gb II 2D Ex h IIIB T84C Db

• ATEX Certificate Number : Sira 06ATEX6143

TRANSPORT AND STORAGE

INSPECT THE PACKAGE

INSPECT THE UNIT

LARGE UNITS WITH FORK TRUCK LIFTING POINTS

LIFTING FROM TRANSPORT PALLET