ORIGINAL INSTRUCTIONS
Form No.102842
5
SPX Hydraulic Technologies
5885 11th Street
Rockford, IL 61109-3699
USA
Internet Address: http://www.powerteam.com
Tech. Services: (800) 477-8326
Fax: (800) 765-8326
Order Entry: (800) 541-1418
Fax: (800) 288-7031
SINGLE-STAGE AND TWO-STAGE
HYDRAULIC HAND PUMP
Max. Pressure: See Pump Data Plate
Operating Instructions for:
62072 (See P159) 201338-TID (See P12) P157 SERIES
62087 (See P55) P12 SERIES P175D SERIES
64122 (See P55) P19 SERIES P159 SERIES
64215 (See P59) P23 SERIES P159D SERIES
64372 (See P55) P30F SERIES P300 SERIES
66463 (See P59) P55 SERIES P300D SERIES
64662 (See P157) P59 SERIES P460 SERIES
64663 (See P157) P59F SERIES YM-01
© SPX Hydraulic Technologies
Page No. 1 of 14
Issue Date: Rev 14 1 Sep. 2012
Operating Instructions Form No. 102842
Contents
SAFETY EXPLANATIONS ...................................................................................................3
1. Pictogram Denition 3
SAFETY PRECAUTIONS .....................................................................................................4
SET-UP .................................................................................................................................7
1. Hydraulic Connections 7
OPERATION .........................................................................................................................7
1. Two-way Valve 8
2. Four-way Valve 8
PREVENTIVE MAINTENANCE ............................................................................................8
1. Bleeding Air From the System 8
2. Bleeding Air From The Pump 8
3. Hydraulic Fluid Level 9
4. Draining And Flushing The Reservoir 9
5. For models with Reservoir Type B & C: 10
6. For models with Reservoir Type D: 10
TROUBLESHOOTING GUIDE ........................................................................................... 11
POWER TEAM FACILITIES ...............................................................................................13
DECLARATION OF INCORPORATION .............................................................................14
Page No. 2
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
SAFETY EXPLANATIONS
Two safety symbols are used to identify any action or lack of action that can cause personal injury. Your reading and understanding of these safety symbols is very important.
DANGER
Danger is used only when your action or lack of action will cause serious human injury or
death.
WARNING
Warning is used to describe any action or lack of action where a serious injury can occur.
IMPORTANT
Important is used when action or lack of action can cause equipment failure, either immediate or over a long period of time.
1. Pictogram Denition
Do not remove this component. For service only. Pressure must be released.
WARNING
It is the operator’s responsibility to read and understand the following safety statements,
• Only qualied operators should install, operate, adjust, maintain, clean, repair, or transport this machinery.
• These components are designed for general use in normal environments. These components are not specically designed for lifting and moving people, agri-food machinery, certain types of mobile machinery or special work environments such as: explosive, ammable or corrosive. Only the user can decide the suitability of this machinery
in these conditions or extreme environments. Power Team will supply information
necessary to help make these decisions.
• Do not use equipment if damaged, altered, or in poor condition.
• All safety decals must be replaced when unreadable.
These instructions are intended for end-user application needs. Most problems with new equipment are caused by
improper operation or installation. Detailed service repair instructions or parts lists can be obtained from your nearest
Power Team facility.
Page No. 3
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
SAFETY PRECAUTIONS
WARNING
To help prevent personal injury,
• Before operating the pump, all hose connections must be tightened with the proper tools.
Do not overtighten. Connections need only be tightened securely and leak-free. Overtightening may cause premature thread failure or high pressure ttings to split at pressures lower than their rated capacities.
• Should a hydraulic hose ever rupture, burst, or need to be disconnected,
immediately shut off the pump and shift the control valve twice to release all
pressure. Never attempt to grasp a leaking hose under pressure with your
hands. The force of escaping hydraulic uid could cause serious injury.
• Do not subject the hose to any potential hazard such as re, extreme heat or cold, sharp
surfaces, heavy impact. Do not allow the hose to kink, twist, curl, or bend so tightly that
the uid ow within the hose is blocked or reduced. Periodically inspect the hose for
wear because any of these conditions can damage the hose and result in personal injury.
• Do not use the hose to move attached equipment. Stress may damage the hose and
cause personal injury.
• Hose material and coupler seals must be compatible with the hydraulic uid used. Hoses
also must not come in contact with corrosive materials such as creosote-impregnated
objects and some paints. Consult the manufacturer before painting a hose. Never paint
the couplers. Hose deterioration due to corrosive materials may result in personal injury.
• All components in the hydraulic system must match the maximum pressure rating of the
pump.
Pump
• Do not exceed the PSI rating noted on the pump nameplate or tamper with internal high
pressure relief valve. Creating pressure beyond rated capacities may result in personal
injury.
• Before adding hydraulic uid, retract the system to prevent overlling the pump reservoir. An overll may cause personal injury due to excess reservoir pressure created
when cylinders are retracted.
• The load must be under operator control at all times.
• Do not connect pump to hydraulic system powered by another pump.
Cylinder
• Do not exceed rated capacities of the cylinders. Excess pressure may result in personal
injury.
• Do not set poorly-balanced or off-center loads on a cylinder. The load may tip and cause
personal injury.
• Stay clear of lifted loads and keep others away.
• Extensions are not recommended for lifting applications.
Page No. 4
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
SINGLE-STAGE AND TWO-STAGE
HYDRAULIC HAND PUMP
Max. Pressure: See Pump Data Plate
Denition: A hydraulic hand pump delivers hydraulic uid under pressure by directly applied
anual effort.
Note: Illustrations depict general pump congurations.
P12
P19
P157D/P159D
P23
P30F
P30FP
P157/P159
64662/64663
P55
P59F
P59FP
P460
P300
Page No. 5
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
For Use
With
Single
Acting
Cylinders
(Pump
includes
2-Way
Valve)
Double
Acting
Cylinders
(Pump
includes
4-Way
Valve)
3/8 NPTF oil port(s) on all pumps.
Order
No.
Stage
P12 1 0.069 1.1 10000 700 75 34.0 A 12 197 9 148 5.7 2.6
P19 1
P23 1 0.160 2.6 3000 200 70 31.8 B 23.8 390 20.3 333 12.0 5.4
P30F 1
P30FP 1
P55 1 0.160 2.6 10000 700 145 65.8 B 55 901 45 738 15.8 7.2
P59 1
P59F 1
P59FP 1
P157 1
P159 1
P300 1
P460 1
P157D 1
P159D 1
P300D 1
P460D 1
2
2
pop-off
2
2
pop-off
2
2
2
2
2
2
2
2
Volume & Pressure
Volume per
stroke
3
In.
0.305
0.09151.5
0.216
0.054
0.216
0.054
0.662
0.160
0.550
0.130
0.550
0.130
0.650
0.160
2.600
0.160
2.600
0.160
7.350
0.294
0.650
0.160
2.600
0.160
2.600
0.160
7.350
0.294
cm
3.5
0.9
3.5
0.9
10.8
2.6
9.0
2.1
9.0
2.1
10.7
2.6
42.6
2.6
42.6
2.6
120.5
4.6
10.7
2.6
42.6
2.6
42.6
2.6
120.5
4.6
3
Maximum
Pressure
psi bar lbs. kg In.
325
1000022700
325
1000022700
325
1000022700
325
1000022700
325
1000022700
325
1000022700
1400
1000097700
325
1000022700
325
1000022700
325
1000022700
1400
1000097700
325
1000022700
325
1000022700
325
1000022700
Handle or Foot
Lever Effort
8.5
98.5
125 56.7 B 31 508 27 443 10.0 4.5
125 56.7 B 31 508 27 443 10.0 4.5
145 65.8 B 55 901 45 738 17.2 7.8
120 54.5 B 55 901 45 738 14.0 6.4
145 65.8 B 55 901 45 738 14.0 6.4
140 63.5 B 152 2491 137 2245 26.0 11.8
140 63.5 B 152 2491 137 2245 26.0 11.8
140 63.5 C 1.5 gal. 5.71 310 5081 55.3 25.1
90 40.8 D 2.5 gal. 9.51 460 7539 54.9 24.9
140 63.5 B 152 2491 137 2245 28.8 13.1
140 63.5 B 152 2491 137 2245 27.9 12.7
140 63.5 C 1.5 gal. 5.71 310 5081 57.0 25.9
90 40.8 D 2.5 gal. 9.51 460 7539 57.9 26.3
3.8
44.7
Type
B 24.4 400 20 328 6.6 3
Reservoir
Oil Capacity
3
cm3In.3cm3lbs. kg.
Usable Oil
Capacity
Product
Weight
Table 1
Page No. 6
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
SET-UP
1. Hydraulic Connections
IMPORTANT
Seal all hydraulic connections with a high grade, nonhardening thread sealant. PTFE tape
may also be used to seal hydraulic connections if only one layer of tape is used. Apply the
tape carefully, two threads back, to prevent it from being pinched by the coupler and broken
off inside the pipe end. Any loose pieces of tape could travel through the system and obstruct the ow of uid or cause jamming of precision t parts.
A. Clean all areas around the uid ports of the pump and cylinder. Clean all hose ends, cou-
plers, and union ends. Remove thread protectors from the hydraulic uid outlets, and connect the hose assembly. Couple hose to cylinder.
B. The use of a hydraulic pressure or tonnage gauge (not included) is strongly recommended.
Remove the pipe plug from the gauge port of the valve, thread the gauge into this port and
seal as noted above.
WARNING
To help prevent personal injury,
• The gauge must have the same pressure rating as the pump and cylinder. Personal injury can result if the wrong gauge is used.
• Release hydraulic pressure BEFORE removing or tightening hose couplings.
OPERATION
The P460 can be operated only in the horizontal position. All other hand pumps can be operated
in a horizontal position or in a vertical position with head pointing downward. Refer to Table 1 and
your pump name plate to determine your style of pump.
IMPORTANT
Figure 1 illustrates the normal drop of handle effort experienced when all (except P59) twostage pumps shift from low pressure stage to high pressure stage.
High Perssure Stage
Low Pressure Stage
Handle Effort
Pressure
Unloading
Pressure
Figure 1
Page No. 7
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
1. Two-way Valve
Pumps with a two-way valve are for use with singleacting cylinders.
A. 1. To extend the cylinder, turn the valve knob counterclockwise to a closed (seated) posi-
tion. Note: Hand tight only! Work the pump handle up and down to build pressure.
B. 2. To release pressure, open the valve slowly by turning the knob clockwise to control the
load.
2. Four-way Valve
Pumps with a three-position, four-way valve are for use with double-acting cylinders. The hose
connection for extending a cylinder can be made to either port. With the handle in the forward
position, the uid is directed to the top uid port. To maintain (hold) pressure, stop the pumping action. When the valve handle is in the center position, uid ow is blocked to both ports.
WARNING
The operator should always release the pressure slowly.
PREVENTIVE MAINTENANCE
IMPORTANT
Any repair or servicing that requires dismantling the pump must be performed in a dirt-free
environment by a qualied technician.
Lubrication
Apply lubricant regularly to all pivot and rubbing points.
Use a good grade of No. 10 motor oil or grease. Do not use dry lubricants.
1. Bleeding Air From the System
Air can accumulate in the hydraulic system during the initial set-up or after prolonged use,
causing the cylinder to respond slowly or in an unstable manner. To remove the air:
A. Position the cylinder at a lower level than the pump, and turn the cylinder rod end down.
B. Extend and retract the cylinder several times without putting a load on the system. Air will
be released into the pump reservoir. Follow the uid level instructions for your reservoir
type to release the air from the reservoir and top off the uid supply.
2. Bleeding Air From The Pump
When the pump is rst put into use, or after relling the pump’s reservoir it may be necessary
to bleed any trapped air from the pump. If this is not done the pump will not function properly
(will not build pressure or has very spongy operation).
Page No. 8
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
To bleed air from the pump, turn the pressure control knob counterclockwise (CCW) (turn lever
down or clockwise on P460 models) and operate the pump handle up and down approximately twenty times. Turn the pressure control knob clockwise (CW) to its full stop position (turn
lever up or CCW on P460 models). The pump should now be bled of air and ready to use.
3. Hydraulic Fluid Level
WARNING
Cylinder(s) must be fully retracted before checking the uid level. Release all system pressure before breaking any hydraulic connection in the system.
Check the hydraulic uid level in the reservoir periodically. Use a funnel with a lter to add hydraulic uid if needed. Refer to Table 1 for your reservoir type.
For models with Reservoir Type A: Place the pump in a vertical position with the pump head
facing upward. Unscrew and remove the pump head from the reservoir. The uid level within the
reservoir should come to the uid level mark indicated on the reservoir body decal. Before replacing the pump head, visually inspect the O-ring which seals the pump head/reservoir assembly.
Replace this O-ring if it is worn or damaged. Reinstall pump head to reservoir and tighten securely. Check for leaks.
For models with Reservoir Type B: Remove the ller cap. The uid level should come to the
bottom edge of the ller hole when the pump is level and resting horizontally on its base and the
cylinders are retracted (see Figure 2).
END VIEW
OIL
LEVEL
Figure 2
For models with Reservoir Type C: Remove the ller cap. The uid level should be 1/2 inch
(12.7 mm) from the ller hole when the pump is level and resting horizontally on its base and the
cylinders are retracted.
IMPORTANT
The pump sight gauge indicates the presence of hydraulic uid only. It does not determine
correct uid level.
For models with Reservoir Type D: Remove the ller cap. The uid level should be 1/2 inch
(12.7 mm) from the cover plate when the pump is level and resting horizontally on its base and the
cylinders are retracted.
4. Draining And Flushing The Reservoir
Drain, clean and replenish the reservoir with high-grade, approved Power Team hydraulic uid
yearly or more often if necessary. The frequency of uid change will depend upon the general
Page No. 9
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
working conditions, severity of use and overall cleanliness and care given the pump.
IMPORTANT
Clean the exterior of the pump rst. After draining and ushing the reservoir, drain and
clean the other hydraulic system components (hoses, cylinders, etc.) before connecting
them to the pump again. This will help prevent contaminated uid from entering the pump.
Refer to Table 1 for your reservoir type.
For models with Reservoir Type A:
A. Unthread and separate the pump head from the reservoir. Drain the reservoir of the used
hydraulic uid.
B. Flush out reservoir with a small amount of clean hydraulic uid. Clean the pump intake
lter.
IMPORTANT
Removing the lter from the pump assembly could result in its breakage. Attempt to clean it
as well as possible with it installed.
C. Rell the reservoir and reassemble the pump head to the reservoir. Tighten securely. Check
for leaks.
5. For models with Reservoir Type B & C:
A. Remove the ller cap. Drain the hydraulic uid through ller hole.
B. Remove the nut from the tie rod. Separate the reservoir from the pump body. Clean the
reservoir and lter.
IMPORTANT
Removing the lter from the pump assembly could result in its breakage. Attempt to clean it
as well as possible with it installed.
3. Reassemble and ll the reservoir with Power Team hydraulic uid. Replace the ller cap.
6. For models with Reservoir Type D:
A. Remove the ten screws fastening the reservoir cover to the reservoir, and lift the pump and
valve assemblies off.
B. Drain all hydraulic uid and ush reservoir with a small amount of clean hydraulic uid.
C. Remove the pump assembly lter, rinse it clean, and reassemble.
D. Rell the reservoir with Power Team hydraulic uid. Place the pump and valve assembly
(with gasket) on the reservoir, and thread the ten screws. Tighten securely and evenly.
Page No. 10
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
TROUBLESHOOTING GUIDE
WARNING
To help prevent personal injury, always release pump pressure and disconnect hose(s) from
pump before making repairs.
Refer to the appropriate pump parts list during troubleshooting. Repairs must be performed in a dirtfree environment by qualied personnel familiar with this equipment..
PROBLEM CAUSE SOLUTION
Pump losing pressure. 1. System components
leaking.
2. Directional control valve
leaks or not adjusted
properly.
3. Fluid leaking past outlet
check seat(s).
Handle rises after each
stroke.
Pump not delivering uid. 1. Low uid level in reservoir. 1. Check uid level per
Pump does not reach full
pressure.
Pump handle can be pushed
down (slowly) without raising the load.
1. Fluid leaking past outlet
check seat(s)
2. Intake lter is dirty. 2. Remove reservoir and
3. Seats worn and not seating
properly.
1. Low uid level in reservoir. 1. Check uid level per
2. System components
leaking.
3. Directional control valve
leaks or not adjusted
properly.
4. Improperly adjusted relief
valve.
5. Fluid leaking past inlet or
outlet checks or high
pressure piston seal
damaged.
1. Inlet checks are not seating. 1.* Check for dirt and/or reseat
2. Damaged piston assembly
or piston seals leaking,
1. Repair or replace as
necessary.
2.* Reseat, repair, or replace
directional control assembly
and correctly adjust.
3.* Check for dirt. Reseat pump
body and/or replace
poppet(s) or ball(s).
1.* Check for dirt. Reseat pump
body and/or replace
poppet(s) or ball(s).
instructions.
clean.
3.* Repair seats or replace
pump body.
instructions
2. Repair or replace as
necessary.
3.* Reseat, repair, or replace
directional control assembly
and correctly adjust.
4.* Readjust.
5.* Reseat or repair inlet or
outlet checks or replace
high pressure piston seal.
valve seats.
2. Damaged piston assembly
or piston seals leaking.
Page No. 11
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
PROBLEM CAUSE SOLUTION
Pump handle operates with a
spongy action.
1. Air trapped in system. 1. Position cylinder lower
than pump. Extend and
return cylinder several
times. Follow bleeding
instructions.
2. Too much uid in reservoir. 2. Check uid level per
instructions.
Pump handle effort drops
signicantly after some pressure has been obtained.
1. This is normal operation on
most two-stage hand
pumps.
*Power Team recommends these hand pump repairs be performed by an Authorized Hydraulic
Service Center.
Page No. 12
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
POWER TEAM FACILITIES
Page No. 13
Issue Date: Rev 14 28 May 2012
Operating Instructions Form No. 102842
DECLARATION OF INCORPORATION
Page No. 14
Issue Date: Rev 14 28 May 2012
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