How to Pump a Hydraulic Press of 20 Tons

How to pump the jack: jacking jack and bottle jack

One of the most common devices for weight lifting, has a compact and, at the same time, very reliable design. But even the most robust components and durable materials tend to wear and tear, reducing the overall efficiency of the mechanism. Popular symptoms of jack failures, such as a decrease in maximum load or a decrease in piston rod extension. Fortunately, the causes of these troubles are quite trivial and can be solved with a minimum of effort, almost on the knee. Briefly about the design and in detail about the pumping of the hydraulic jack, tell further.

• Piston. Sturdy base for the stopper that moves with it.
• Cylinder. Sealed reservoir where fluid is pumped.
• Pump piston. Pumping oil from one chamber to another.
• Pump chamber. Intermediate link, between the working fluid chamber and the cylinder.
• Oil reservoir. Also called working fluid chamber. Contains liquid reserve, to be pumped into cylinder block.
• Return valve. Controls the motion of the fluid being pumped, allowing it to travel in one direction only. Through it, the oil enters the cylinder, but can no longer escape.
• Lever. Exerts pressure on the pump piston. Increases the thrust force by several times due to a clever fastening method.
• Relief valve. Opens and closes passages between cylinder and oil reservoir. Serves to normalize pressure and deflate the piston rod.

The essence of the hydraulic mechanism is based on displacing a piston from a sealed chamber. Medium viscosity oil acts as filler, pushing out the thrust. Unlike air, the fluid is not compressed, making sure that the weights are firmly seated at the proper level. The movement of the pump lever, gradually introduces oil into the hermetically sealed cylinder block, where it starts to press against the only moving element, the piston, forcing it to move out and making space for the fluid to flow in. This is how hydraulic jacks work, lifting multi-ton loads by smoothly pumping fluid into the reservoir.

When pumping is necessary

The period of careless use of any tool and equipment is limited, and even the strongest samples of devices sooner or later require maintenance or repair. Jacks are highly reliable appliances, but even they are not immune to failure. The most common faults that reduce the effectiveness of a hoist to a minimum include a decrease in rod lift and a decrease in the loads held. Both have similar causes and solutions.

The specifics of such a malfunction do not have a specific time frame for the decrease in jack effectiveness. The tool may decrease its performance gradually or do so abruptly, dropping its efficiency to zero. It is in such cases that the unit requires pumping, which involves filling the reservoirs with oil and completely evacuating the air from the system. To understand why your hydraulic jack does not pump fluid, you should know the basic causes of this malfunction. Precise identification of the weak point in the system, significantly increases the chances of successful repair.

Design and function of a hydraulic press

A hydraulic press is equipment designed specifically for pressurizing parts and workpieces with high pressure. This press works by applying liquid pressure to the elements of its design.

Most hydraulic jacks are designed with the operating cylinder in a vertical position, but there are also models with the operating cylinder in a horizontal position. Different models of presses can produce working forces ranging from several tens to several thousand tons.

Factory-made hydraulic press version

The operating principle of the hydraulic press is based on Pascal’s law, familiar from school physics. Two different sized operating chambers, or cylinders as they are called, are the heart of the press. The principle of the hydraulic press, in a few words, is as follows.

In its smaller cylinder a high pressure of working liquid is created, which is fed through a connecting channel to the chamber of larger diameter and acts on a piston, connected to a working tool. The latter exerts pressure on the workpiece, which is placed on a rigid support to prevent it from moving under its action. Special oils are used as working fluid in all hydraulic presses.

Hydraulic presses are most widely used for such operations on metal parts as stamping, forging, straightening, bending, extrusion of pipes and other profiles. These presses are also used for briquetting, baling and compacting various materials (usually a mini-press is used for this purpose).

The design of the hydraulic press allows its active use in the manufacture of rubber, plastic and wood products, as well as in other areas. The variety of functions and applications of this equipment determine the existence of its various modifications. You can find, for example, table hydraulic press, mini press, floor hydraulic press, hand hydraulic press, press with and without pressure gauge.

How to use it in the home

The use of the hydraulic press in the garage or home workshop is quite common. This small size press is suitable for use in car repairs, but also for other applications.

This compact machine lets you press out or press in new parts like bearings or silent blocks. In addition to automotive repair, the hydraulic press can be used for bending metal parts, creating the required pressure when gluing surfaces, briquetting waste, for squeezing oil and liquid. Factory equipment for this purpose (even a manual hydraulic press) costs a lot of money, and not everyone can afford it. Meanwhile, you can make such a press with your own hands, spending money only on acquiring the necessary materials.

Using the press as a juicer

What is noteworthy, the design of a home-made hydraulic press can be immediately adapted to solve a specific problem with a particular part or workpiece. Self-made press will not take up much space, for its placement will be enough to allocate a little space in the workshop or garage. Detailed instructions on how to make a hydraulic press are given below. At the end of the article there is also a video on this topic.

Options how to pump the hydraulic jack

A hydraulic jack is a mechanism that allows you to lift an object to a certain height. Most often used in maintenance services.

Pumping of the hydraulic jack is required in cases of: pollution and ingress of air into the working area of the jack, corrosion formation in the mechanism and its damage, deformation of the hydraulic piston rod due to heavy loads. Also depending on the type of jack and frequency of use.

There are several types of hydraulic jacks:

The purchase of a hydraulic jack should be based on the purpose for which it will be used. Select the type of jack to be used depending on these requirements.

For individual use, it is better to purchase a jack with a capacity of 3 tons, for cars this is enough. For service stations, it is required to install a jack with a lifting capacity of at least 5 tons, and for heavy vehicles. from 20 tons.

Pumping

The technology of pumping a hydraulic jack consists in cleaning the hydraulic mechanism. Because during operation dirt can get into various parts of the mechanism and disrupt the operation of the equipment.

After removal of working liquid, the hydraulic system should be flushed with a special liquid to clean the mechanism from impurities. Pumping is used to transfer the oil from the reservoir to the working area.

Pumping causes the accumulated air in the jack to be gradually forced out of the jack’s working area.

The purging process should be continued until the air is completely expelled from the working area.

Liquid replacement and cleaning should be carried out in strict accordance with the instruction, which has a step-by-step photo. It is usually included with the equipment.

Or you can use the modern method and see a video on the Internet about how to properly pump a particular type of hydraulic jack.

This process is not complicated and does not take much time. To pump the hydraulic jack is possible, with your own hands. The pumping technique may vary, depending on which type of jack is used.

How to properly pump a hydraulic jack

The hydraulic jack is particularly popular because of its high load capacity, which can reach dozens of tons, and its ease of use. This type of jack is considered the most reliable. However, even the best hydraulic jack may lose its initial efficiency over time, so it is necessary to pump it.

As it was already mentioned above, the main reason for pumping the hydraulic system is pollution and air in the working area. There are several ways to pump the hydraulic jack.

The first method is to open the valve and the oil tank plug and quickly pump the jack pump. After which all the air is removed from the working area.

Then close the valve and oil reservoir cap.

The other pumping options are used in cases where, with the help of the first one, it was not possible to fully evacuate air from the working area. How to find out if there is air left in the working area after the pumping? If you use a jack, the air left inside is sure to make itself felt, because if it is present, the equipment will not work at all or work incorrectly.

In this case, it is necessary to find such detail as a blocking needle included in the construction of any hydraulic jack. It should be unscrewed two or three turns, then lift as far as the design allows and lower. Repeat this procedure several times until all air is purged from the working area.

Pumping methods for other types

Pump the bottle-type hydraulic jack with your own hands. Jacks of this variety have a very simple structure and principle of operation. Installed in trucks designed to transport heavy loads. The minimum capacity of a bottle jack is 3 tons, and the maximum capacity is up to 200 tons.

There are 2 types of vertical hydraulic jack: single-rod and double-rod. The first has a simple design and is very easy to use, it is mainly used for installation work in construction, auto repair and other purposes. The working principle of the second one is based on the installation of two rods, due to which a high lifting capacity is achieved.

How to pump a hydraulic jack by yourself?

The question of how to pump a hydraulic jack is asked by many people who have this type of equipment. In order to know the technology of performing and performing this operation, it is required to study the device of the hydraulic jack and the reasons for the decrease in its effective functioning.

The hydraulic jack is a device that is used for a wide variety of tasks. The most common are hydraulic jacks in service stations and car repair shops. These devices allow you to lift a decent load to the required height.

However, over time, the effectiveness of the equipment decreases and this is due to a number of reasons.

Before you start pumping hydraulic equipment, you need to determine the causes of the deterioration of its work.

Normal operation of the jack may be impaired as a result of contamination and air ingress into the working cavity of the tool.

Corrosion that damages the surface of the working cylinder can limit the jack’s capabilities. The most common reasons for the need to pump the jack are:

• appearance of air bubbles;
• Internal corrosion of the device;
• high load, causing bending of the hydraulic rod;
• contaminated oil filled in the jack, causing damage to the mechanism.

In order to get rid of these defects, you should perform a certain list of works in the following sequence:

• Loosen the fasteners carefully and completely.
• Remove the valve responsible for the process of draining the working liquid.
• Remove primary piston and inspect surface for damage.
• Inspect the equipment to check the condition of the gaskets, balls on the valves, and replace components if they are not in good condition.
• Clean all contaminants and foreign bodies from the jack’s mechanisms.
• After reassembling the mechanism, pour in new oil and flush the jack.

For the proper functioning of the hydraulic mechanism it is necessary to use only specific types of oil, because otherwise the equipment will not be able to operate at its full capacity.

Pumping of the hydraulic system is required in the event of malfunctions. In addition, regular pumping of the jack is recommended for stable operation of the equipment.

Frequency and frequency of pumping and priming depends on how often the machine is used.

In case the equipment is used very often, pumping should be performed almost monthly for stable operation, and in case the equipment is rarely used, pumping should be performed at least 2-3 times a year.

To keep the jack for long periods of time, it is necessary to monitor the oil level in the jack as well as the condition of the oil seal and the valves.

Oil and flushing fluid should be purchased to perform the work on filling and pumping of hydraulic equipment. Hydraulic equipment is characterized by high reliability in operation, but even such mechanism requires regular care and maintenance. Preventive maintenance is required in the following cases

• When the capacity of the device decreases;
• When the indicator of the lifting capacity of the mechanism decreases and it is not possible to perform operations that were previously performed without problems;
• If large quantities of air bubbles appear in the unit’s oil;
• contaminant ingress in the device.

Performing preventive maintenance in accordance with a maintenance schedule prevents the jack from having problems with its operation. Regular flushing and de-aerating of oil helps return power to the operating mechanism.

Procedure of changing the liquid in the hydraulic jack

In order to perform pumping of the hydraulic jack, the following materials and tools should be prepared:

Hydraulic jack pumping diagram.

Jack filling begins with unscrewing filling plug and drainage of old operational fluid. System is flushed with a special flushing fluid. Flushing the hydraulic mechanism to remove contaminants. Flush the implement several times to remove all contaminants.

After each flushing, the fluid is drained into a specially prepared container. After flushing, fill jack with oil. The device is positioned as low as possible during the filling process, which allows you to fill up to the maximum level.

While filling with oil, the jack can be easily lowered by turning the special screw into the “drain” position.

After the jack is filled with the functional liquid, it must be pumped and then the jack must be refilled. Filling and priming should be carried out until the oil has fallen below the maximum mark. Pouring does not require complex manipulation or work.

Selection of the right oil for pumping of the hydraulic devices is important. For example, a special frost-resistant synthetic oil should be used that meets the technical requirements for winter operation of the unit to the maximum extent possible.

Before pumping, it is necessary to learn the pumping technology and to know how to pump hydraulic jacks.

Pumping the jack

Pumping of the jack is a preventive measure that can help prevent tool breakage. Preventive maintenance must be carried out at regular intervals.

Why is pumping needed??

The number of maintenance pumpings depends only on how often the jack is used. In the car service centers pumping may be performed once every few weeks, but in the conditions of the garage or infrequent use of the device it is possible to reduce the number of preventive measures to 2 times a year.

• If there are too many contaminants in the oil. Foreign impurities can reduce the construction efficiency and lead to a serious breakdown.
• Bubbles. Bubbles in the oil indicate that air has entered the system. Although air rarely enters the piston, it is also necessary to check its condition.
• Reduced real lifting capacity. If the jack is unable to lift the declared mass, it is worth carrying out preventive work or taking it to a workshop for reassembly of the device.

Modern jacks come in one piece, so it is not always possible to overhaul it. Even if repair of the unit is not possible, pumping the system is an excellent solution.

Procedure for Performing the Work

Pumping is performed in several steps. First unscrew the valve and remove the plug from the oil reservoir. It is recommended that the oil be changed before pumping, so the old oil must be drained.

The oil should be drained until only air remains in the unit. This operation prevents further damage that could be caused by residual contaminants.

Depending on the owner’s request, the inner surfaces may be cleaned with special compounds. Special flushing removes deposits and prolongs jack life.

The next step is to fill the jack with grease. There are two types of oil for hydraulic jacks. Summer oil performs well in warm weather but may not perform as well in winter. If the jack is constantly used indoors, where the average temperature does not drop below freezing, you can safely pour in summer oil. When operating a hydraulic jack in harsh operating conditions, take care of the safety of the structures and fill up with winter oil.

The oil is poured until the cylinder is completely filled and the piston is at its lowest point.

At this stage it is considered that the work is completed, but it is better to pump the jack immediately. For this purpose, the oil valve is opened and the unit is pumped intensively using a lever or pedal.

Since faulty cuff gaskets are often the cause of malfunctions that lead to air in the system, they should be replaced immediately. Do not rely on their integrity, as minor defects on them are almost impossible to notice.

Some last tips

The performance of the jack depends on the quality of the lubricant that is poured into it. Do not skimp on oil, as this can lead to serious breakdowns that will not be repairable in the future. If the device will be used in various conditions with temperature fluctuations, it is better to fill the jack with a frost-resistant synthetic lubricant that will preserve the functionality of the system.

In winter it is better to refrain from using the device for a long time in freezing temperatures, because all gaskets and seals are very sensitive to low temperatures.

Procedure of changing the liquid in the hydraulic jack

In order to perform pumping of the hydraulic jack, the following materials and tools should be prepared:

Filling of the jack begins with unscrewing the filling plug and draining of the old operating-liquid. The jack is topped up with a special flushing fluid. The hydraulic device mechanism is flushed to remove impurities. The unit should be flushed several times to remove all contaminants. After each flushing, the fluid is poured into a specially prepared container. After flushing, fill jack with oil. During filling the device is placed in as low a position as possible to allow filling up to the maximum level. While filling with oil, the unit stem can be easily lowered by turning the special screw into the “drain” position.

After the filling of the functional liquid, the jack is pumped and then the additional priming must be performed. Dosing and pumping should be carried out until the oil has fallen below the maximum mark. Flushing does not require complex manipulation or work.

Read also: How to Find a Phase with a Multimeter

To perform pumping of hydraulic implements, select the correct oil. For example, in the winter period it is necessary to use special frost-resistant synthetic oil that meets to the maximum the technical requirements during the work of the tool in the winter period.

Before flushing, you must learn about flushing techniques and know how to flush hydraulic jacks.

Hydraulic jack pumping technology

Flushing the hydraulic system begins with flushing the mechanism of the hydraulic system.

Flushing the tool ensures that the tool operates properly. During operation, dirt can penetrate into the jack and cause serious damage, up to and including machine malfunction.

After the working fluid has been drained the reservoir is filled with flushing fluid. The flushing process removes all impurities from the device. After all contaminants have been removed, the flushing fluid is drained out and the reservoir is refilled with bath fluid. During the flushing process, the operating-liquid is transferred from the reservoir to the operating-cavity, this process is carried out quickly and does not take long.

During this procedure air is gradually forced out of the working cavity. Repeat the pumping operation until all air bubbles have been displaced from the reservoir. Always follow the operating instructions supplied with the implement when changing the operating-liquid and flushing it. The point is that differently designed hydraulic tools have different technology of changing the working fluid.

After completing the work, close the overflow valve and the oil reservoir opening.

A hydraulic jack is a mechanism that allows you to lift an object to a certain height. Most often used in service stations.

Purging of hydraulic jack is required in cases of: contamination and air penetration into working area of jack, corrosion formation in mechanism and its damage, deformation of hydraulic piston rod because of heavy loads. Also depending on jack type and frequency of use.

Hydraulic jack pumping technology

Flushing the hydraulic attachment begins with flushing the hydraulic attachment mechanism.

Tool flushing ensures normal operation of the tool. During operation, contamination enters the various parts of the mechanism, which can cause serious damage, up to and including the failure of the unit to work.

After draining the bath fluid, fill the reservoir with flushing fluid. In the process of flushing with a special liquid all impurities are removed from the device. After flushing, the flushing fluid is drained out and the reservoir is filled with service fluid. The flushing process is sufficiently fast and does not require much time to shift from the oil reservoir to the operating pressure tank.

During this procedure air is gradually forced out of the working cavity. Repeat the flushing process until all air bubbles have been evacuated from the reservoir. Always follow the operating-liquid change and flushing instructions supplied with the device. The matter is that differently designed hydraulic devices have different technology of change of working liquid.

Once work is complete, the overflow valve and oil reservoir opening must be closed.

A hydraulic jack is a mechanism that allows you to lift an object to a certain height. Most often used in maintenance services.

Purging of the hydraulic jack is required in cases of: contamination and ingress of air in the jack’s working area, corrosion in the mechanism and its damage, deformation of the hydraulic piston rod due to heavy loads. Also depending on jack type and frequency of use.

Design of the hydraulic elevator

The main components of the system are the housing, the mobile piston and the fluid medium (machine oil). Casing made of solid metal in the form of a cylinder. It serves both as a guide for the piston rod and as a reservoir for the hydraulic oil. Additional elements that drive the device in operation:

Use of valves can increase the force applied to the lever tenfold. The plunger is needed to move the piston by transporting the working fluid into the reservoir underneath. The valve prevents the fluid from flowing back into the general container. The plunger gradually pumps more and more fluid under the piston, raising it. And for the load to go down, you only need to allow the oil to return to the common container by opening the valve.

Construction of a hydraulic elevator

The main components of the system are the housing, the moving piston and the liquid medium (machine oil). The body is made of durable metal in the shape of a cylinder. It serves both as a guide for the piston rod and as a reservoir for the service fluid. Additional elements that drive the device in operation:

The use of valves increases the force exerted on the lever tenfold. The plunger is needed to move the piston by transporting the working fluid into the vessel below. A valve prevents fluid from flowing back into a common container. The plunger gradually pumps more and more fluid under the piston, raising it. And in order to lower the load, you only need to let the oil return to the common tank by opening the valve.

Hydraulic jack

The hydraulic jack comes in several varieties:

When buying a hydraulic jack, you should be guided by the purpose for which it will be used. So based on these requirements you need to choose the type of jack.

For individual use, it is better to purchase a jack with a capacity of 3 tons, for cars this is enough. For service stations you need to install a jack with a lifting capacity of at least 5 tons, and for heavy vehicles. from 20 tons.

Other malfunctions of the self-made hydraulic cylinder press

If there is an insufficient level of effort manual hydraulic press, with their own hands made, or the mechanism works intermittently, this problem is associated with possible ingress of air into the cavity of the jack, which negatively affects the work of the piston. To repair the damage, the operating-liquid should be added to the cylinder and the air removed through the tubes.

Low pressure of the mechanism is due to a damaged valve that has moved away from the compartments, soiled or its springs are loose. In the first two cases, the element is repaired or replaced. Clean the valve with a damp cloth and then dry the element. If heavily soiled, the mechanism is flushed with kerosene or gasoline and dried with compressed air. If the cause is wear of the springs, they must be replaced with new elements.

If air enters the jack cavity, the press is under-pressurized.

Note! If the jack has a damaged body or piston, it is necessary to replace the entire mechanism, which cannot be repaired.

After disassembling the jack for repair work, the mechanism must be assembled under certain conditions. Valves must fit snugly in the seating. It is essential that there is a sufficient quantity of liquid in the hydraulic cylinder. There must be no air in the system.

A hydraulic press is multifunctional and versatile equipment that can be used for a variety of tasks where you need to exert effort. The tool can be purchased in a specialized store or make a press with your own hands from a hydraulic jack, which will save you money. For this it is important to choose the correct material and stick to the algorithm of assembling elements.

Useful tips for proper operation

If you have chosen the right solution for you and now begin to learn the basic features of operating the press, be very careful.

To begin with, carefully study the supplied instructions and then begin installing the equipment, taking into account the layout and installation requirements stated by the manufacturer.

The first thing a worker does is to assemble the structure, checking that the connections shown in the diagram are correct. Then it remains to assess the condition of the device and proceed to the tasks. However, in order to extend the service life, you should pay attention to a few valuable recommendations. If you follow the advice given below, your baler will operate for a long time without breakdowns.

Here are a few things to watch out for:

• assessing the volume of the working fluid. If it is not high enough, the maximum pressure values in the cylinder can not be expected;
• regular maintenance of parts and moving mechanisms by means of periodical lubrication. In this case, it is necessary to use special fluids offered by the manufacturer;
• regularly check the condition of the packings and rams. It’s no secret that as they are used, they lose elasticity values, which, in turn, entails deterioration of the sealing properties of the entire system;
• before starting the press, make sure the workpiece is securely clamped. It is important to ensure that the pressure is evenly distributed without exceeding the permissible values. It will not prevent the use of nozzles to increase the functionality. At the same time the device must cope with its main duties;

If you intend to move the construction to another place, or such action will occur regularly, observe the level of the working table. Fixing reliability is checked every time after successful implementation of the assigned task.

when looking for the operating-liquid solution, give priority to those recommended by the manufacturer. Replacement and supplementation of such a substance can be carried out with a special valve. If you are not ready to buy the factory model of the hydraulic press, you can try to create such a device yourself. There are special instructions and manuals for this.

The number of cars on the roads is increasing every day. This leads to more modern vehicle repair shops. Whoever provides fast, high-quality car repair services earns. A prerequisite for a well-organized service station is the presence of a hydraulic press.