IMPORTANT

Follow this procedure or you may get an airlock in your pump and it will not work.

To install a CG420-6 pressure gauge mounting adaptor, CG420-5C pressure gauge, CG420-3-1 hose assembly, CG420-4-2 hose coupler or any other accessory on a CG420-2A or CG420-2S hydraulic hand pump, the following steps should be followed to prevent air from entering the hydraulic system and causing the pump to fail.

If this pump was shipped from the manufacturer with a black 3/8” NPT pipe plug in the outlet port where you need to hook your hose, coupler, gauge or other accessory, or if you need to disconnect the hose from the pump for any reason. Close the round plated shutoff hand wheel, (turn clockwise), tip the pump so that the 3/8” pipe plug you are removing is facing upward, (you can hold the in a vise by clamping on the flat foot on the pump head). Fill the threaded hole that you remove the pipe plug from with hydraulic oil. The hose or other accessories you are installing should be filled with oil if possible before connecting it to the pump. Connect your hose or accessory with the pump still in the upright position, the pump can then be laid flat to finish tightening the connection. When possible, the other end of the hose accessory should be bled by leaving the pump hand wheel closed and with the added hose or accessory held pointing up (air will rise to the highest point) and pumping hydraulic oil through until a steady stream of oil comes out. At this time you should connect your coupler, ram or accessory to close the system. You should then release the hand wheel, ( a half of a turn counter clockwise is enough) and refill your pump reservoir thru the filler plug located on the opposite end of the pump from the hose. With the hose end pointed down, fill the reservoir to the bottom of the filler plug.

IF YOU DO GET AN AIRLOCK IN THE CG420-2S HYDRAULIC HAND PUMP

Make sure the oil reservoir is completely full of hydraulic oil. Close the shutoff hand wheel (turn clockwise), then using a 1/4" hex head Allen wrench, loosen the two 3/8” pipe plugs on the right side of the need a cheater bar on the Allen wrench to break them loose. Do not remove the plugs completely. (This in the raised position), until the pipe plug is almost completely out of the head. At this point, push the pump handle down so that oil and air is forced out around the threads of the plug. The screw the plug in, raise the handle, and repeat the process a couple of times. Repeat this same procedure with the second plug. The oil is forced out will probably look black; this is normal because of the cast mehanite pump head. By the flushing oil out past the pipe plugs, (the ball checks are located behind the pipe plugs), any trapped air or foreign material should be removed from the pump. Tighten the plugs securely. The pump should now work properly. Repeat if necessary.

HYDRAULIC HAND PUMPS

OPERATING THE CG4-2A, CG420-2A, AND CG420-2S HYDRAULIC HAND PUMPS

THESE HAND OPERATED HYDRAULIC PUMPS ARE EQUIPPED WITH RELIEF VALVES WHICH OPEN UP AT THE RATED PRESSURE OF THE HYDRAULIC RAM BEING USED. THIS PROTECTS THE RAM, PUMP, HOSE AND PRESS OR PULLER FROM A DANGEROUS OVERLOAD.
EXAMPLE: WHEN A CG420-1A RAM REACHES 20 TONS OF FORCE, THE RELIEF VALVE IN THE PUMP WILL OPEN, AND THEN RESEAT ITSELF UNTIL 20 TONS IS REACHED AGAIN.
TO OBTAIN HYDRAULIC PRESSURE, TURN THE RELIEF VALVE NEAR THE HOSE END OF THE PUMP. ALL THE WAY CLOCKWISE AND THEM PUMP THE HANDLE. TO RELEASE THE PRESSURE, TURN THE VALVE ABOUT ONE TURN COUNTER CLOCKWISE AND THE RAM WILL AUTOMATICALLY RETRACT. SINCE THE PUMP HAS AN ACCUMULATOR SACK, IT CAN BE HELD IN ANY POSITION WHILE BEING USED AS LONG AS IT IS FULL OF OIL. A CHECK VALVE IN THE QUICK COUPLER PREVENTS LOSS OF OIL WHEN THE HOSE IS REMOVED FROM THE RAM.
TO REFILL THE PUMP, PUT THE HANDLE IN THE DOWN POSITION AND OPEN THE RELIEF VALVE. REMOVE THE REFILL PIPE PLUG AT THE END OPPOSITE THE HOSE OUTLET, AND FILL TO THE TOP OF THE REFILL HOLE WITH HYDRAULIC JACK OIL. THE USE OF ANY FLUID EXCEPT HYDRAULIC JACK OIL MAY DAMAGE THE PUMP OR RAM AND VOID THE WARRANTY. ALWAYS MAINTAIN PROPER FLUID LEVEL TO PREVENT POSSIBLE PROBLEMS WITH THESE HYDRAULIC UNITS.
WE RECOMMEND THE USE OF THE CG420-5C HYDRAULIC PRESSURE GAUGE AND CG420-6 MOUNTING ADAPTER. THIS GAUGE READS TONNAGE ON OUR 6, 10, 20, 35 AND 50 TON RAMS. THIS GAUGE IS ESPECIALLY IMPORTANT IF ANY PUMP OTHER THAN THE CG4-2A, CG420-2A OR CG420-2S IS USED. AIR OVER HYDRAULIC, OR ELECTRONIC PUMPS MAY BE USED SAFELY WITH OUR RAMS WHEN THE CG420-5C GAUGE IS USED. PUMPS OTHER THAN OURS MAY HAVE THE BY-PASS VALVES SET HIGHER WHICH COULD OVERLOAD THE RAM BEFORE BY-PASSING.