Power Team PE30-HOGEN, PE302, PE302-2, PE302S-CODHE, PE303 Operating Instructions Manual

Form No. 102838

Operating Instructions for:

PE30-HOGEN
PE302
PE302-2
PE302S-CODHE
PE303
PE303-2

PE304
PE304-2
PE304ML
PE302S-Tyco
PE302S-CODHE-115
PE302A-2-TRANS

ELECTRIC HYDRAULIC PUMP

Max. Capacity: 10,000 PSI

Read and carefully follow these instructions before installation and use of this pump. Most problems with new
equipment are caused by improper operation and installation.

SAFETY PRECAUTIONS

WARNING

●

All WARNING statements must be carefully observed to help prevent personal injury.

Hydraulic Hose

●

Before operating this pump, tighten all hose connections using the proper tools. Do not overtighten the
connections. Connections need only be tightened securely and leak-free. Overtightening may cause

premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.

●

Should a hydraulic hose ever burst, rupture, or need to be disconnected, immediately shut off the pump.
Never attempt to grasp a leaking hose under pressure with your hands. The force of the escaping

hydraulic fluid could cause serious injury.

●

Do not subject the hose to potential hazard such as fire, extreme heat or cold, sharp surfaces, or heavy
impact. Do not allow the hose to kink, twist, curl or bend so tightly that the oil flow within the hose is

blocked or reduced. Periodically inspect the hose for signs of wear because any of these conditions can
damage the hose and may 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 fluid 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.

Pump

●

Do not exceed the PSI hydraulic pressure rating noted on the pump nameplate or tamper with the internal
high pressure relief valve. Creating pressure beyond rated capacities may result in personal injury.

●

Before replenishing the oil level, retract the system to prevent overfilling the pump reservoir. An overfill
may cause personal injury due to excess reservoir pressure created when cylinders are retracted.

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.

Electrical Supply

●

Do not use an ungrounded (two-prong) extension cord.

●

Avoid conditions which could create an electrical hazard.

●

If the power cord is damaged or wiring exposed, replace or repair immediately.

Sheet No. 1 of 3

© SPX Corporation

Rev. 7 Date: 25 May 2012

Operating Instructions, Form No. 102838, Back sheet 1 of 3

Safety Precautions (Continued)

Electrical Supply

●

Check the voltage rating on the pump motor name plate to be certain the outlet you are using is of the
proper voltage.

●

Correct voltage is required for pump to operate properly.

●

Low voltage may cause the following:

■

motor surging when trying to start; ■motor stalls before maximum pressure is reached.

●

Always check the voltage at the motor with the pump running at full pressure.

●

Never run the motor on long, light gauge extension cords.

■

overheated motor;

■

motor fails to start under load;

SET-UP

Electric Motor

To help avoid possible personal injury

WARNING

●

Any electrical work must be done by a qualified electrician.

●

Disconnect the power supply before removing the motor casing cover or performing repairs or
maintenance.

●

Changing the voltage on this unit is an involved, and if improperly performed, hazardous procedure.
Consult the manufacturer for specific information before attempting any rewiring.

Hydraulic Connections

1. Clean all areas around the oil ports of the pump and cylinders.

2. Inspect all threads and fittings for signs of wear or damage, and replace as needed.

3. Clean all hose ends, couplers or unions ends.

4. Remove the thread protectors from the hydraulic oil outlets. Connect the hose assembly to the hydraulic oil outlet ,

and couple the hose to the cylinder. IMPORTANT: Seal all external pipe connections with a high quality,
nonhardening pipe thread sealant. PTFE tape can 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 system. Any loose pieces of tape could travel through the system and obstruct the flow of oil
or cause jamming of precision-fit parts.

Filling the Reservoir

NOTE: This pump has been shipped without oil in the reservoir. High-grade Power Team hydraulic fluid has
been shipped with the pump in separate containers. If additional oil is required, use only Power Team
hydraulic fluids.

1. Remove the filler cap and insert a funnel with a filter. Using the Power Team hydraulic fluid provided fill the
reservoir to 1" from the fill hole. Remove funnel and replace the filler cap.

PUMP OPERATION

Priming the Pump

When operating the pump for the first time:

1. After filling the pump reservoir and checking that the hose connections are secure, place the valve in the neutral
position, plug the electric motor into a sufficiant power supply and start the pump by switching the toggle to the run
position.

2. Disconnect a hose from the system and route it back to the pump reservoir. Run the pump until a steady flow of oil
is observed free of suspended air bubbles. Reconnect the hose to the system.

3. Cycle the pump several times, extending and retracting the cylinder(s) fully to eliminate air from the system. For
more complete instructions refer to the section section titled "Bleeding Air from the System."

4. Retract the cylinder(s) and check the reservoir oil level. It should be 1" from the filler vent cap. Add Power Team
hydraulic fluid if necessary.

Note: Shaded areas reflect last revision(s) made to this form.

Operating Instructions Form No. 102838

PREVENTIVE MAINTENANCE

NOTE: Any repairs of servicing that requires dismantling the pump must be performed in a dirt-free

environment by a qualified technician.

Bleeding Air from the System

Upon initial startup or after prolonged use, a significant amount of air may accumulate within the hydraulic system.
This entrapped air can cause the cylinder to respond slowly or behave in an unstable manner. To remove the air, run
the system through several cycles (extending and retracting cylinders) free of any load. NOTE: The cylinder must

be at a lower level than the pump to allow air to be released through the pump reservoir.

Inspecting the Hydraulic Fluid Level

Check the oil level in the reservoir periodically. With all cylinder(s) retracted, the oil level should be 1" from the filler
cap. Drain, clean and replenish the reservoir with Power Team hydraulic fluid yearly or more often if necessary. The
frequency of oil change will depend upon the general working conditions, severity of use and overall cleanliness and
care given the pump.

Maintenance Cleaning

1. Keep the outer surface of the pump as free from dirt as possible.

2. Protect all unused couplers.

3. Keep all hose connections free of dirt and grime.

4. Keep the filler cap clean and unobstructed at all times.

5. Equipment connected to the pump must be kept clean.

6. Use only Power Team hydraulic fluids in this pump. Change as recommended.

Draining and Cleaning the Reservoir

IMPORTANT: Clean the pump exterior before the pump interior is removed from the reservoir.

1. Remove the screws that fasten the pump assembly to the reservoir. Remove the pump assembly from the
reservoir. Do not damage the gasket, filter or relief valve.

2. Drain the reservoir of all fluid. Refill half full with clean Power Team hydraulic fluid.

3. Place the pump assembly back onto the reservoir and secure with two machine screws assembled on opposite
corners of the housing.

4. Run the pump for several minutes. Remove the two cover screws and lift off the pump assembly again. Drain and
wipe out the reservoir with a clean, lint-free cloth.

5. Fill the reservoir with Power Team hydraulic fluid to 1" from the filler cap. Place the pump assembly (with gasket)
on the reservoir and install the screws. Tighten securely and evenly.

Adding Oil to the Reservoir

1. Cylinder(s) must be fully retracted and the motor off when adding oil to the reservoir.

2. Clean the entire area around the filler cap before removing the filler cap.

3. Use a clean funnel with filter when adding oil.

4. Use only Power Team hydraulic fluids.

5. Fill to 1" from the filler cap.

Sheet No. 2 of 3

Rev. 7 Date: 25 May 2012

Operating Instructions, Form No. 102838, Back sheet 2 of 3

TROUBLE-SHOOTING GUIDE

WARNING

●

To help prevent personal injury, any repair work or trouble-shooting must be done by qualified personnel
familiar with this equipment.

●

Use the proper gauges and equipment when trouble-shooting.

NOTE:

●

It is best to check for leaks by using a hand pump and applying pressure to the suspect area without the
motor running. Watch for leaking oil and follow it back to its source.

●

Plug the outlet ports of the pump when checking for leakage to determine if the leakage is in the pump or
in the cylinder or tool.

PROBLEM CAUSE SOLUTION

Pump is not delivering oil or
delivers only enough oil to
advance cylinder(s) partially or
erratically.

1. Oil level too low.

2. Loose-fitting coupler to cylinder.

3. Air in system.

4. Air leak in suction line.

5. Dirt in pump or filter plugged.

6. Oil is bypassing through a
double-acting cylinder.

7. Cold oil or oil is too heavy
(Hydraulic oil is of a higher

viscosity than necessary).

8. Relief valve or low pressure
unloading valve out of
adjustment.

9. Reservoir capacity is too small
for the size of the cylinder(s)
used.

10. Defective directional valve.

11. Sheared drive shaft key(s).

12. Vacuum in reservoir.

1. With all cylinders retracted, fill
reservoir to 1" of fill hole.

2. Check quick-disconnect
couplings to cylinders. Inspect
couplers to ensure that they are
completely coupled.
Occasionally couplers have to be
replaced because the ballcheck
does not stay open due to wear.

3. Bleed the system.

4. Check and tighten suction line.

5. Pump filter should be cleaned

and, if necessary, pump should
be dismantled and all parts
inspected and cleaned.

6. By removing the cylinder and

capping the hoses, the pump
and valve can be checked.
Observe if pump holds pressure.

7. Change to lighter oil.

8. Adjust as needed.

9. Use smaller cylinder(s) or larger

reservoir.

10. Inspect all parts carefully and

replace if necessary.

11. Replace.

12. Check for plugged vent in

breather cap.

Operating Instructions Form No. 102838

PROBLEM CAUSE SOLUTION

Pump builds pressure but cannot
maintain pressure.

1. Check to see if there are any
external leaks. If no oil leakage
is visible, the problem is internal.
If using a double-acting cylinder,
remove it from the system to
ensure that the leak is not in the
cylinder.

2. To test for a leaking control
valve lift the pump from the
reservoir but keep the filter in
the oil. Remove the drain line to
see if the oil is leaking from the
valve. If the valve is not leaking,
the internal check valve could
be leaking. Refer to the note
concerning checking for oil leaks
at the beginning of this Trouble­shooting Guide.

1. Seal leaking pipe fittings with
pipe sealant.

2. Clean, reseat or replace flow
control valve parts. If the internal
check valve(s) are leaking, the
pump must be dismantled and
the seat areas repaired, poppets
replaced, etc.

Pump will not build full pressure

1. Check for external leakage.

2. Check the relief valve setting.

3. Look for internal leakage in
double-acting cylinders.

4. Check for leaks in the flow
control valve.

5. Inspect the pump for internal
leakage. Check high pressure
pump inlet or outlet ball checks.

6. Sheared key(s).

1. Seal faulty pipe fitting with pipe
sealant.

2. Lift the pump from the reservoir,

but keep the filter immersed in
oil. Note the pressure reading
when the relief valve begins to
open. If functioning normally, it
should start to leak off at relief
valve pressure.

3. Remove the cylinder from the

pump. If the pump builds full
pressure, the cylinder is
defective.

4. Clean and reseat or replace

parts.

5. Same procedure as above, but

look for leads around the entire
inner mechanism. If there are
no visible leaks, the high
pressure pump subassembly
may be leaking. Remove all
parts. Check the valve head
assembly body for any damage
to the seat area. Clean and
reseat if necessary. Inspect for
damage and replace parts if
necessary, then reassemble.

6. Replace.

Sheet No. 3 of 3

Rev. 7 Date: 25 May 2012

Operating Instructions, Form No. 102838, Back sheet 3 of 3

HYDRAULIC SCHEMATIC (REF.)

TO VALVE

UNLOAD IN G VALVE
500 P.S.I.

SUPERCHARGE
VALVE
160 P.S.I.

HIGH PRESSURE
REL IEF VALVE
10,400 P.S.I.

M

HP

LP

LP

PROBLEM CAUSE SOLUTION

Cylinder(s) will not retract.

1. Check the system pressure; if
the pressure is zero, the control
valve is releasing pressure and
the problem may be in the
cylinder(s), mechanical linkage
connected to cylinder(s), or
quick disconnect couplings.

2. Defective valve.

1. Check the cylinders for broken
return springs, and check
couplers to ensure that they are
completely coupled.
Occasionally couplers have to
be replaced because one check
does not stay open in the
coupled position.

2. Check valve operation and
inspect parts. Replace if
necessary.

Pump delivers excess oil
pressure

1. Relief valve not properly set.

HYDRAULIC SCHEMATIC

1. Adjust the relief valve.