HPP20-4 INSTRUCTION MANUAL Page 1

INSTRUCTION MANUAL

HPP20-4
HYDRAULIC PRESSURE PUMP

This manual was prepared to present the correct methods and procedures of operating and
maintaining your ALMEX Hydraulic Pressure Pump.

At the time of writing this manual, the instructions were up to date. However, some of the
information or appearance of the component parts may vary slightly from the product
delivered to you.

Read this manual carefully before operating your vulcanizer.

SHAW-ALMEX INDUSTRIES LIMITED

P.O. Box 430
Parry Sound, Ontario, Canada P2A 2X4

Phone: 705-746-5884 or 1-800-461-4351

Fax: 705-746-9484
E-Mail: sail@almex.com
Web Site: www.almex.com

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 2

Table of Contents

1. RECORD OF PURCHASE ...............................................................................................................3

2. SAFETY .............................................................................................................................................4
2.1. Definition of Pictograms .................................................................................................4
2.1.1. Safety Alert .................................................................................................................4
2.1.2. Electrical Hazard.........................................................................................................4
2.1.3. Crushing Hazard.........................................................................................................4
2.2. Limitation of use .............................................................................................................4
2.3. Hazardous Materials and Products ................................................................................5
2.4. Safe Handling .................................................................................................................5
3. ASSEMBLY .......................................................................................................................................6
3.1. Functional Diagram ........................................................................................................6
3.2. Assembly ........................................................................................................................6
4. OPERATION......................................................................................................................................7
4.1. Pressurizing the Vulcanizer............................................................................................7
4.2. De-Pressurizing the Vulcanizer ......................................................................................7
5. MAINTENANCE ................................................................................................................................7
5.1. Routine Maintenance .....................................................................................................7
6. TROUBLESHOOTING......................................................................................................................8
6.1. Pump will not Start..........................................................................................................8
6.2. Vulcanizer will not Pressurize or Loses Pressure ..........................................................8
7. Service ...............................................................................................................................................8
7.1. Emergency Service ........................................................................................................8
7.2. Return of Goods Authorization .......................................................................................8
7.3. Guarantee.......................................................................................................................8

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 3

1. RECORD OF PURCHASE

Job Number
Date of Purchase
Model Number HPP20-4
Serial Number
Weight Dry 100 lb. [45 kg]
Full 300 lb [135 kg]
Operating Pressure 200 psi [1380 kPa]
Voltage
Phase
Cycle/Hertz
Amperage
Calibration Pressure
Spare Parts
Operating Instructions 49904-002
Supplements
Service Bulletins
Warranty Card
Drawings MWD573
Parts Diagrams D7

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 4

2. SAFETY

The following safety precautions should be read carefully and understood thoroughly before you set-up or
operate your vulcanizer. Failure to follow these precautions may result in personal injury and/or equipment
damage. All operating personnel should be trained in the proper method of handling and operating the
vulcanizer.
The risks associated with operating the vulcanizer with the Hydraulic Pressure Pump Control are identified
throughout this manual with pictograms.

2.1. Definition of Pictograms

Safety Alert Electrical Hazard Crushing Hazard

2.1.1. Safety Alert

1. The operating pressure of the Hydraulic Pressure Pump Control must match the operating pressure
indicated on the vulcanizer serial plate.
2. Never operate the press while unattended.
3. The upper frame must be securely assembled to the lower frame before pressurizing vulcanizer. Do not
lean against or over top of the vulcanizer during operation. Since high stress levels are resident in the frame
and assembly members during operation, component failure can result in parts being projected upward or
outward.
4. Do not connect the vulcanizer to a continuous pressure supply. In the event of component failure, it is
important for the pressure to drop to a safe level.
5. Do not tamper with the Pop Safety valve. It is factory preset to prevent the vulcanizer from operating at
unsafe pressures.

2.1.2. Electrical Hazard

1. A qualified electrician should perform all maintenance of the electrical components of the Hydraulic
Pressure Pump.
2. All of the electrical components contain live circuits. Do not service any of the electrical equipment
without disconnecting the main power supply.
3. Incorrect voltage and phase may result in component damage and create a fire hazard.
4. Equipment power supplies must be properly grounded or a severe shocking hazard may result.
5. Avoid using equipment in wet surroundings or a severe shocking hazard may result.
6. If any cable or connectors are damaged, they must be replaced or a fire and shock hazard may result.

2.1.3. Crushing Hazard

1. Fingers must not be placed between platen surfaces when the vulcanizer is pressurized or injury will result.

2.2. Limitation of use

The HPP20-4 has been designed to indicate and regulate the liquid pressure of ALMEX conveyor belt
vulcanizing presses. The process of vulcanizing is done by applying a combination of heat and pressure on the
product for a certain period of time. The HPP20-4 generally operates at various pressures within a range of 0-
200 psi (1380 kPa). There is a pop safety valve that must be used. A continuous pressure supply must not be

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 5

connected to the pump or the vulcanizer. The press must never be allowed to operate while unattended. A hose
is attached to the pressure pump for connecting to the vulcanizer. Other use is not allowed without the written
permission of Shaw-Almex.

2.3. Hazardous Materials and Products

It is recommended that the hydraulic pressure pump reservoir be filled with water and glycol. Refer to the
safety precautions for the glycol.
The pump will supply liquid at pressures up to 200 psi (14 kg/cm2). If a leak should develop, the liquid may
spray workers in the surrounding area.

2.4. Safe Handling

Handling the pump does present some residual hazard. Weight is listed in the record of purchase. The pump is
mounted on wheels for moving and care must be taken so the pump does not upset and fall on the operator.
Hoisting provision is provided on the top of the pump reservoir and hoisting equipment can be used to move
the pump into position.
Wear protective footwear when handling the pump.
Connection of cables and hoses must be made in such a way that no tripping hazard is created.

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 6

3. ASSEMBLY

3.1. Functional Diagram

8
9 1. Drain Cock

10 2. Strainer
3. Motor
4. Pump
5. 2-way Pressure Release Valve
5
6. Safety Relief Valve
7
11 (hidden) 7. Check Valve

6 8. Pressure Relief Valve

3 9. Pressure Gauge

10. Start/Stop Switch

11. Sight Gauge

1, 2

3.2. Assembly
Safety: The operating pressure of the Hydraulic Pressure Pump must match the operating pressure
indicated on the vulcanizer serial plate.

Safety: The pump should be operated on a flat, level and stable surface so there is no danger of falling.

Safety: Ensure the voltage phase and cycle on the hydraulic pressure pump serial plate is the same as the
power supply.
1. Fill the pump reservoir with a 50-50 mix of water and ethylene glycol (anti-freeze). The fill level is visible
through the sight gauge.
Note: If there is no danger of freezing and commercial pump lubricants are not available, a mixture of water
and 10% glycerin should be used to provide lubrication for the pump.
2. Locate the pump near the vulcanizer. Avoid placing the pump higher than the vulcanizer or the pressure
bag may not drain properly.
3. Connect the pump pressure hose to the pressure bag fitting or the bag hose manifold on the vulcanizer.
4. If your pump has been supplied with an additional reservoir, there will be a quick connect fitting at the
drain cock. Connect the Reservoir hose to this fitting.
5. Connect the pump power supply cord. There may be a connector on the temperature control panel for the
pump. Check the serial plate for the correct voltage and phase.
Important: Before disconnecting the pump hose from the vulcanizer, ensure the pressure has been released.
Failure to do this will result in a sudden uncoupling of the hose from the vulcanizer and pressure will be
trapped in the bag. It is very difficult to reconnect the fittings while under pressure, and it will be very
difficult to release the pressure from the bag without the fittings connected.

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 7

4. OPERATION

4.1. Pressurizing the Vulcanizer

Safety: Do not lean against the vulcanizer when pressurizing. Component failure can result in
components being projected upward or outward. People must stay clear of the area when press is in operation.

Safety: The safety relief valve is preset to blow off at a pressure slightly higher than the operating
pressure shown on the serial plate. Do not override this safety device or injury could result.

Safety: Fingers must not be placed between platen surfaces when the vulcanizer is pressurized or injury
will result.
Important: Make sure fluid is entering the pressure bag and the pressure is rising before beginning to heat the
vulcanizer.
1. Close the pressure release valve by turning the handle to the horizontal position.
2. Press the starter switch and pressurize to desired pressure. The pressure gauge may not read an accurate
pressure while the pump is running so it is recommended that the pump be switched off occasionally to
read an accurate pressure. Do not exceed the operating pressure indicated on the vulcanizer serial plate.
3. The pressure relief valve can be adjusted to the required operating pressure. When the pump reaches this
pressure, the fluid will bypass the pressure bag hose and return to the tank. This helps to prevent over
pressurization and is very useful when operating the pump at pressures less than 200 psi. (1380 kPa).
4. When the pump reaches operating pressure, press the stop switch.

4.2. De-Pressurizing the Vulcanizer

1. To de-pressurize the vulcanizer, slowly open the pressure release valve by turning the handle to the
vertical position. Opening this valve fast will cause undue pressure in the reservoir.
2. When the pressure has dropped to zero and the fluid has stopped flowing, the pump can be disconnected.

5. MAINTENANCE

There are no special tools required to maintain this equipment.

5.1. Routine Maintenance

The following items should be checked after every thirty cures.
1. Check the fluid level in the reservoir.
2. Without connecting the Hydraulic Pressure Pump to the vulcanizer, switch the pump on and ensure that the
Pop Safety valve operates approximately 10% above the pressure indicated on the serial plate.
3. Remove and clean the strainer.
4. Tighten any loose fittings.
5. Check hoses and pressure bag for signs of wear that might cause a leak. Repair or replace any worn parts.

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001
HPP20-4 INSTRUCTION MANUAL Page 8

6. TROUBLESHOOTING

6.1. Pump will not Start

FAULT CORRECTION
1. Power supply not correct. 1. Check power supply.
2. If connecting pump power 2. Check and replace fuses in the temperature controller.
supply to temperature Refer to temperature controller manual.
controller, fuses in the
controller may be open.

6.2. Vulcanizer will not Pressurize or Loses Pressure

FAULT CORRECTION
1. No fluid in the reservoir. 1. Fill reservoir with correct mixture of water and antifreeze.
2. Pressure release valve in the 2. Turn the pressure release valve to the pressure position.
wrong position.
3. Pressure relief regulating valve 3. Raise the pressure setting on the pressure relief valve.
set too low.
4. Broken hose or leaking valves 4. Tighten fittings, clean or replace leaking valves. Note:
or fittings. Do not disassemble the safety relief valve. If it is leaking
it must be replaced.
5. Leaking pressure bag. 5. Remove and replace the pressure bag.
6. Strainer plugged. 6. Remove strainer and clean or replace.
7. Pump defective. 7. Repair or replace pump.

7. Service

7.1. Emergency Service

Contact: Service Department
Telephone: 705 746 5884 or Toll Free 1 800 461 4351
Fax: 705 746 9484
Mail: SHAW-ALMEX INDUSTRIES LIMITED
P.O. Box 430
Parry Sound, Ontario
Canada, P2A 2X4

7.2. Return of Goods Authorization

The service department of Shaw-Almex Industries Limited MUST be contacted for the necessary authorization
and documentation prior to returning goods to the factory.
The service department may be reached at the above numbers.

7.3. Guarantee
Your ALMEX equipment is guaranteed against defective parts, material and workmanship for a period of 12
months from the date of purchase. For complete details, refer to the Warranty Card.

SHAW-ALMEX INDUSTRIES LIMITED 49904-002 December 97

Rev. Feb 1999, Jun 2001