ELECTRIC/HYDRAULIC PUMPS

UP-45SV（G）-2・-4 Series
Operation and maintenance manual

NITTOH ZOHKI CO.,LTD.
102,4-10,2-Chome,Kamezawa,Sumida-ku,
Tokyo 130,Japan
Telephone.03-3625-6551
Facsimile. 03-3625-6553

INDEX
1.

Safety information ---------------------------- 2

2.
3.
4.
5.
6.

Description of components ------------------ 4
Instructions before use ------------------------ 5
Operation --------------------------------------- 5
Maintenance ------------------------------------ 6
Circuits ------------------------------------------ 9

7.
8.
9.

Construction drawings ------------------------10
Parts lists ----------------------------------------12
Trouble shooting guide ------------------------14

10.

Warranty -----------------------------------------15

1

page

1 Safety Information
Read and follow all WARNINGS,CAUTIONS and INSTRUCTIONS included with eachproduct to use the products correctly and to avoid personal injury or property damage duringsystem operation. NITTOH ZOHKI CANN NOT BE RESPONSIBLE FOR DAMAGE ORINJYRY RESULTING FROM UNSAFE USE OF PRODUCTS, LACK OF MAINTENANSE
OR INCORRECT SYSTEM APPLICATION.
Cautions remarks used in this manual are classified as follows;

DANGERIn case as the result of incorrect use in disregard of this remarks,
imminent danger may happen, causing the risk of death or serious
injury.

WARNING

In case as the result of incorrect use in disregard of this remarks,
there will be s possibility that an operator will die or receive aserious wound.

CAUTION

In case as the result of incorrect use in disregard of this remarks,
there will be a possibility that and operator will receive an injury or
material damage only will happen.

Cautions when installed
WARNING■Install a pump unit for better balance.
Since the reservoirs of totally emclosed rubber structure are used in this series pumps, thepumps can be placed for use in every direction (slant, inversion or perpendicular).
However, the pumps should be installed on stable places. When a pump is used aslant, fix
it firmly with. Otherwise, it slide down, causing an injury.
■Prepare good working environment.
Make sure all system components are protected form external sources of damage such as
excessive heat, flame, moving machine parts, sharp edges, corrosive chemicals.

CAUTION■Do not use the pump in the rain or on such wet or dusty places.
■Do not expose hydraulic system to the direct rays of the summer’s sun.
Be careful with unacceptable rise in hydraulic oil temperature, causing trouble ofhydraulic equipment.
■In case the pumps are used outdoors in the extremely cold regions, exchange oil forhydraulic oil of proper viscosity.
Increased viscosity due to drop in oil temperature, there is the possibility that equipment
gets out of order.

2

Caution when used
WARNING■Take safety measures.
When hydraulic equipment is operated, protect yourself with a personal safeguard,
working clothes and shoes, safety spectacles, etc.
■Always check pressure limitations of hydraulic circuit.
Always confirm in advance that max. permissible working pressure of a hydraulic pump islower than the pressure rating of the lowest rated component connected in the system.
■Be careful to avoid electric shock.
Do not pull power plug out with a wet hand. Use a grounded outlet or a plug adapter witha grounding attachment in order to protect the operator from electric shock. Do not operate
the pump by the side of electric welder or do not place it on the earthed materials or
equipment.

CAUTION■Power supply is AC220V 50/60Hz single phase.
Make sure your line voltage must be the same as the voltage your pump is wired for.
Wrong voltage connection or voltage drop of your line shall cause burning or heating.
Be careful about voltage drop when used with an electric generator.
■When the power supply is disconnected, always grasp the power plug and pull it out.
Disconnection by grasping the cord and pulling it out will cause breaking of a wire or ashort circuit.
■When a supplement cord is used, use only three-wire grounded cords of such sufficientgauge as 1.25mm2 or more, its length of max. 10M, in order to avoid voltage drop or
damage of the solenoid valves or electric motors.

Specifications
Model,No

UP-45SV
G-2(L)
G-4(L)

Electric motor
Hydraulic pumpCommutator
Max,
Flow Rateand open type,
Work pressure
0.45KW 220V
MPa
L/min(50Hz)
50/60Hz
1st stage
2nd stage
1st stage
2nd stage
single phase,“E” insulation,
2000rpm,
7
70
2.5
0.35
Max. 4.5A

3

Reservoir
Capacity
3.0L(5.0L)
Usable
2.0L(4.0L)

2 Description of components
UP-45SVG-4
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
⑫

Erectric motor
Metal plug socket
Power supply plug
HP relief valve
Oil feeding plugReservoir
Oil gauge
Delivery port block
Pressure gauge
Pendant switch 2.5m
Power cable 2.5m
2-way solenoid valve

①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
⑫

Erectric motor
Metal plug socket
Power supply plug
HP relief valve
Oil feeding plugReservoir
Oil gauge
Delivery port block
Pressure gauge
Pendant switch 2.5m
Power cable 2.5m
2-way solenoid valve

UP-45SVG-2

4

3 Instructions before use
3-1

Confirmation of all components for shipping damage or oil leakage. If any shipping
damage is found, notify carrier at once. Shipping damage is not covered by warranty.
The carrier is responsible for all repair or replacement costs resulting from damage inshipment.

3-2

Oil feeding plug
CAUTION
Use it after 2～3 turns loosens a plug.

3-3 Confirmation of your power supply
WARNING
Power supply is 220V 50/60Hz single phase. Make sure that a grounded outlet or a plug
adapter with a grounding attachment must be used.
3-4 Confirmation of hydraulic oil
WARNING
Always check oil level before operation, with the connected cylinders fully retracted(extended if pull cylinders). In case oil is added with cylinders fully extended and thencylinders are retracted, the returned oil will overflow in the reservoirs, causing
generation of high pressure in the reservoirs, confirm required oil volume in a reservoir
as follows;① Retract the connected cylinder fully.
② Check the oil gauge and confirm if oil is feeded up to half of the gauge. If oil is short,
not reaching the half of the level gauge, replenish oil. (See 5-1 kind of hydraulicworking oil).

4 Operation“UP-45SVG-4” with 2-way nomally closed solenoid valve.
1 Plug in the pump.
2 Depress “ON” switch to run the motor to advance the cylinder. If the “ON” switch isreleased, the motor stops and cylinder’s piston remains stopped for pressure holding.
3 Depress “OFF” switch to retract the cylinder.

“UP-45SVG-2” with SVS-2H 2-way normally open solenoid valve. Advance/auto retract.
12
3Plug in the pump.
Depress “ON” switch to run the motor to advance the cylinder.
Release “ON” switch to stop the motor, and the cylinder retracts.

55Maintenance

5-1 Hydraulic working oil① Kind of oil
Use only Nittoh NHO-32 hydraulic oil or an approved, high-grade oil (ISO #32, viscosity :32 cSt @40°C) with these pumps to promote long pump life.
② Oil temperature
Aptitude temperature for use of hydraulic oil is max. 55 ° C. In case it happens
unacceptable rise in oil temperature, stop working so as to decrease oil temperature or
take such a measure as installation of an oil cooler.
③ Oil exchange

CAUTION

The frequency of oil change will depend upon general working conditions, severity of use
and overall cleanliness. 300 hours (working time) of use or about 3 months is considered
as a standard change interval. Periodically compare samples oh the reservoir oil with newoil and inspects oil color for contaminants or differences.
Remove oil feeding plug and tilt the pump to drain out old oil. Be careful that such
impurities as dusts do not enter info the reservoir and new oil is filled up to the gauge
level mark shown on pump. Precautions when oil changed are;
● Retract all cylinders fully to the return position.
● Do not fill with even a small quantity of replenishment of different kinds of oil.
● Be careful that impurities or foreign matter do not enter info new oil.

④ Others

WARNING

When oil enters into a eye, wash it away fully with clean water and consult a doctor
immediately. In case oil enters into the skin of such a wound, wash it away with soapy
water and consult a doctor without delay.

5-2 Pressure and piping① Composition of hydraulic equipment system

WARNING

When a pump, high-pressure hose(s), cylinder, valve, couplings are connected together,always check product limitations regarding pressure ratings and load capacities. The
system operating pressure must not exceed the pressure rating of the lowest rated
component in the system.
② Pressure gauges
Always install or prepare a pressure gauge in-line form the pump in order to checkpressure developed.
6

③ Piping

CAUTION

Use wrapping of Teflon tape on hoses fittings, valves and couplers. Make sure all hoseconnections are tight-use proper tools to tighten connections with reference to thefollowing table. Do not over tighten the connections.
NPT,PT sizes
1/8”
1/4”
3/8”
1/2”

Tightening torque N-m(kgf-m)
13-14 (1.3-1.4)
30-40 (3.0-4.0)
60-70 (6.0-7.0)
100-110 (10.0-11.0)

Make sure that tape not shed into hydraulic system, causing damage. Trim loose ends.
5-3 High pressure hoses① Hose installation

WARNING

Install hoses, leaving something in reserve, because high-pressure hoses expand andcontract more or less when full pressure is applied. Be careful that the hoses do not rub
against other solid materials.
Never allow the hoses to kink, twist, curl or bend so tightly that oil flow within hoses areblocked or restricted. Do not clamp the hoses, causing troubles.
② Hose handling

DANGER

Never drop heavy things against the hoses, causing bursting of hoses or serious accident.
Do not subject the hoses to any potential hazard (fire, extreme heat or cold, heavy impact
or sharp surfaces), which might rupture or weeken the hoses. Never pull hoses to move or
lift equipment connected with hoses.
Should a hose ever burst or ruptured, immediately stop operating the pump before
attempting to remedy the situation. Never attempt to grasp a leaking hose underpressure with your hands. The force of the escaping hydraulic fluid could cause serious
and permanent injury.
5-4 Quick couplers① Connections
Make sure that all couplers are connected properly. Incomplete coupling connections
might cause partial or complete blockage of oil flow, resulting in trouble of hydraulicsystem.
② Handling

WARNING

Stop operating of the pump with a hose and coupler, but without a cylinder. The damaged
coupler will cause accident. Do not disconnect the coupler sets, which are under pressure.

7

5-5 Bleeding air from the system

CAUTION

In case a new cylinder and/or a hose is connected with the pump or hydraulic oil is
exchanged, air may accumulate in the hydraulic system. This air will cause the pump notdeliver oil or the cylinder to respond in an unstable or slow manner. To remove this air;(a) The cylinder(s) must be positioned on their side with the couplers located upward.
(b) Remove any load from the cylinder(s) and cycle the hydraulic system through several
cycles (fully extend and retract the cylinders) or intermittently 2 to 3 minutes.

5-6 Carbon brushes① Cautions when in use

WARNING

Always check the wearing condition of the carbon brushes. When the carbon brushes havebeen worn down and exchanging time has come, the motor will stop automatically.
Replace when a carbon brush has been worn down to 6mm in length as shown below or
working time of the motor is 150 hours or more subject to the conditions of their uses. Use
only NITTOH carbon brushes with these pumps to promote long pump life. When they
have been worn down, the spring exerts insufficient pressure to hold brush against thecommutator.

② How to changeFirstly disconnect the power supply. Remove rubber caps on two places and loosen andremove fitting screws inside with a screw driver, so the carbon brushes can be taken out.
Replace with new ones and fix the screws and rubber caps.

5-7 Relief valve adjustment
Range of standard pressure adjustment available is form 58.8 to 68.6MPa. different kindof a spring is needed to adjust and set at lower pressure than the standard. Contact
NITTOH authorized distributor.
Loosen lock screw on the relief valve and turn the adjusting screw a few turns
counter-clockwise to decrease pressure setting to a lower desired pressure. Clockwise
rotation of the adjusting screw will increase pressure.

86 Circuits
UP-45SVG-4 Hydraulic Circuit

Electric Circuit

UP-45SVG-2 Hydraulic Circuit

Electric Circuit

97 Construction drawings
The pump part is an attached sheet (Drawing attachment).
The valve part mentions it according to a model as follows.
UP-45SVG-2

10

UP-45SVG-4

11

8 Parts list
No.

Part No.

Description

HL valve portion

Driving portion

2-1

φ5

Steel ball

1-1

1P50155

Pump body2-2

WY5-10Spring

1-2

TLA1616Z

Bearing

2-3

4P53854

Retainer

1-3

AC0687A0

Oil seal

2-4

φ7

Steel ball

1-4

4P53051

Low pres, piston

2-5

WF6-25

Spring

1-5

4P53052

High pres, piston

2-6

4P53855

Retainer

1-6

UF-8.5-20

Spring

2-7

4P50636

Copper packing

1-7

4P50636

Copper packing

2-8

MSWA12Blind plug

1-8

4P52942Blind plug

2-9

PT1/8×PS1/4

L fitting

1-9

MSWA12Screw plug

2-10

4P50664

Filter

1-10

4P52943

Eccentric collar

2-11

φ5

Steel ball

1-11

RNAF253517

Bearing2-12

WY5-10Spring

1-12

NTB1629

Thrust bearing

2-13

4P53854

Retainer

1-13

AS1629Thrust washer

2-14

φ7

Steel ball

1-14

φ4×30

Spring pin

2-15

WF6-25

Spring

1-15

4P52944

Driving shaft

2-16

4P53855

Retainer

1-16

G-16

G type ring

2-17

4P50636

Copper packing

1-17

Key

2-18

MSWA12Blind plug

1-18

2 Gear

2-19

MB700-070

Expander

1-19

MUM-S8-1

Electric motor

Unloader portion

1-20

Carbon brush

3-1

φ1/4

Steel ball

1-21

Screw cap

3-2

TB8-15

Spring

1-22

4P52995

Rubber plug

3-3

4P52949

Adjusting screw

1-23

M6

Spring washer

3-4

M10

Lock nut

1-24

M6×15

Fitting bolt

3-5

SL-M5

Air filter

1-25

SCK2003R

Metal plug socket

3-6

4P53050

Push pin

1-26

M3×10

Screw

3-7

φ4×15.8

Needle roller

1-27

OA-05

Cap cone

3-8

P-4

O ring

1-28

M4

Spring washer

3-9

P-4

Back-up ring

1-29

M4×10

Fitting bolt

3-10

4P50636

Copper packing

1-30

MB700-040

Expander3-11

4P52951

Blind plug

1-31

MB700-050

Expander

3-12

MSWA12Blind screw

1-32

PT1/16Blind plug

3-13

USA-4-10

Spring

1-33

P-8

O ring

1-34

4P53053

Return pipe

4-1

φ2.5

Steel ball

1-35

UHP-16

Hole plug

4-2

4P51889

Ball receiver

1-36

4P53055

Guide plate

4-3

TB8-15

Spring

1-37

M5×10

Fitting bolt

4-4

4P51980

Spring pusher

1-38

M5

Spring washer

4-5

P-6

O ringRelief valve portion

12

4-6

MSWA12

Pushing screw

7-23

P-15

O ring4-7

M4×10

Lock screw

7-24

W-22B

Solenoid

7-25

P-7B

O ringTank portion
5-1

1P50156

Reservoir 3L

7-26

4P52908

Back-up ring

5-2

KCM-20Oil gauge

7-27

P-8

O ring5-3

G-140

O ring

7-28

M8×50

Fitting bolt

5-4

M6

Spring washer

5-5

M6×10

Fitting bolt

5-6

4P54343

Feeding plug

7-1

3P50802

Manifold

5-7

P-16

O ring7-2

7-1

Gauge adaptor

5-8

PT3/8

Blind screw

7-3

φ63-100MPa

Pressure gauge

5-9

1P50165

Reservoir 5L

7-4

PT1/4

Blind plug

Electrical parts portion

7-5

M6×25

Fitting bolt

UP-45SVG-4 Valve portion

6-1

Power cord

7-6

M5×25

Fitting bolt

6-2

SCK2003P Plug socket

7-7

P-8

O ring6-3

COB61

Pendant control switch

7-8

4P52976

Gauge cover

6-4

DC power supply

7-9

M5×5

Fitting bolt

6-5

Printed board Assy

7-10

3P50803

Valve body

Fitting bolt

7-11

4P50821SleeveUP-45SVG-2 Valve portion

7-12

P-9

Back-up ring

7-1

3P50802

Manifold

7-13

P-9

O ring7-2

7-1

Gauge adaptor

7-14

P-5

Back-up ring

7-3

φ63-100MPa

Pressure gauge

7-15

P-5

O ring7-4

PT1/4

Blind plug

7-16

4P51210

Collar7-5

PT1/8

Blind plug

7-17

4P51083

Spring7-6

M6×40

Fitting bolt

7-18

4P51105

Spring receiver

7-7

M5×40

Fitting bolt

7-19

4P50770

Poppet7-8

P-8

O ring

7-20

4P51080

Valve seat

7-9

Gauge cover

7-21

P-10A

O ring

7-10

Spacer

7-22

P-10A

Back-up ring

6-6

M3×6

7-11

M5×15

Fitting bolt

7-23

4P52972

Valve seat retainer

7-12

3P51014

Valve body

7-24

φ3×23.8F

Push pin 1

7-13

PT1/16Blind plug

7-25

φ4×10

Spring pin

7-14

M4

Washer

7-26

W-32A

Solenoid

7-15

4P53506

Spool shaft

7-27

4P52973

Push pin 2

7-16

4P52957

Spring

7-28

4P52975

Dummy cover

7-17

4P52516

Spring nut

7-29

P-8

O ring

7-18

P-3

O ring

7-30

M8×50

Fitting bolt

7-19

4P52539

O ring collar

7-31

PT1/16Blind plug

7-20

4P52538

Stopper pin

7-21

φ3×10

Spring pin

7-22

Push pin13

9 Trouble shooting guide
WARNING●To prevent injuries, any repair work or trouble-shooting must be done by qualified personelfamiliar with this kind of equipment. Use the proper gauges and device.
Problems
Motor does not run

Possible Causes(1) No supply voltage.
(2) Broken lead wire or defective
WARNINGpower cord plug.
Disconnect power(3) Defective switches.
supply before(4) Worn carbon brushes.
disassembly or repair. (5) Defective motor.
(6) Defective remote switch.
(7) Unit is not plugged in.
Abnormal noise of (1) Damage or pump or motor.
motor.
(2) Damage of ball bearings, etc.
Motor
runs,
but (1) Damage of release valve.
cylindersdonot (2) Oil level is too low.
advance or retract.

Cylinders works, but
full pressure is not
built up.

Cylinders works, but
their speed too slow,
partially or erratically.

Cylindersretract.
Oil leaks.
Short circuit.

do

not

Remedies(1) Check line voltage.
(2) Replace defective partd.

(3) Check switches.
(4) Replace carbon brushes.
(5) Repair or replace motor.
(6) Repair or replace switch.
(7) Plug in unit.
(1) Repair or replace unit.
(2) Replace ball bearings.
(1) Repair or replace it.
(2) Fill reservoir to 1/2 of level
gauge with all cylinders
retracted.
(3) Air in system.
(3) Bleed the system.
(4) Filter plugged or dirt in pump. (4) Pump filter should becleaned and if necessary,pump should be dismantled
and cleaned.
(5) Repair pump.
(5) Damage of pump body.
(6) Damage or out of adjustment (6) Repair or readjust as needed.
of relief valve.
(1) Damage of release valve.
(1) Repair or replace.
(2) Air in system.
(2) Bleed the system.
(3) Damage of pump body.
(3) Repair pump.
(4) Lowering of set pressure or (4) Readjustment of set pressuredamage of relief valve.
or repair of relief valve.
(1) Damage of release valve.
(1) Repair or replace.
(2) Air in system.
(2) Bleed the system.
(3) Unacceptable rise in oil (3) Stop operation or install oil
temperature.
cooler. (max. 55℃)
(4) Damage of pump body.
(4) Repair pump.
(1) Damage of release valve.
(1) Repair or replace.
(2) Damage of return springs of (2) Repair or replace springs or
cylinders or quick couplers.
couplers.
Damage seals, seats or steel Replace them.
balls.
(1) Damage cords.
(1) Replace.
(2) Bad insulation of electric (2) Replace.
parts.

14

10 Warranty
9-1 Warranty period
It is for one year from purchase.
9-2 Warranty
All NITTOH products and parts, with the exception mentioned below, are warranted
against defects in materials and workmanship, which results in damage to products andparts. This warranty shall cover repair and/or replacement of the products orcomponents/parts free of charge. To qualify for warranty consideration, return the
NITTOH product, freight prepaid, to a NITTOH factory. Refer to the NITTOH
STANDARD EXPRESS WARRANTY for the details.
9-3 Warranty exceptions
No warranty claim will be accepted for damage or breakdown arising for any of thefollowing reasons.
“Abuse or improper use, fair wear and tear, faulty or negligent operation, improper
storage, chemical/ electrical influences or climatic or other effects which can not be
related specially to faults in manufacture”
No liability is accepted for packing seals, springs, and/ or the like, and the following:◎ Alterations or remodeling on the products undertaken by the purchasers without any
prior notice and agreement to NITTOH.
◎ Severe and very highly frequent use, deviating from product specifications.
◎ Damage due to faulty installation or assembly by purchasers or third parties.
◎ Damage from natural disaster.
◎ Damage from such accidents as fire, submersion, dropping, etc.

15