Pre-Pressurization Checks

Check for any loose connections on the hydraulic pump unit. A visual inspection should indicate any issues.

Make sure the operator has performed the before and after connecting air supply see also Before and After Connecting Air Supply, before proceeding to step 3.

On the pressure filter regulator (See also Hydraulic Pump Assembly for part 7), pull up the adjustment cap . Rotate the cap in a clockwise direction, until an air pressure of 1 – 2 bar is shown on the gauge.

Make sure the pressure release valve (See also Hydraulic Pump Assembly for part 12) is in the open position. This is achieved by rotating the clutch mechanism (designed to protect the nipple in the pressure release valve) in a anti-clockwise direction. When the valve is open, the clutch mechanism will slip, preventing excessive torque on the pressure release valve.

Make sure oil is present in the tank (oil reservoir), prior to hydraulic pump activation. A minimum level of 5 litres is standard.

To activate the hydraulic pump, pull the dead-mans handle down. The hydraulic pump will begin to operate, forcing hydraulic oil around the pump unit and back to the tank (oil reservoir). This process will remove any air bubbles in the system. Continue to hold the dead-mans handle for 30 seconds. After this period, release and hydraulic pump will stop pumping.

To perform a pressurisation test, rotate the pressure release valve in a clockwise direction. The clutch mechanism will slip, when the correct closing torque on the nipple has been reached.

Hold down the dead-mans handle, the pump will activate, building up a hydraulic pressure. Increase until the oil gauge reading is 750 bar, release the dead-mans handle and monitor if the pressure drops. If no pressure drop is indicated (i.e. the pressure gauge remains at 750 bar), the hydraulic pump is ready for tensioning set-up.

To release the pressure, rotate the pressure release valve in an anti-clockwise direction. The pressure in the system will reduced to zero.