SPX PE8 Series, PE17 Series User Manual

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Page 1

User Manual for:

Electric-Powered

8 & 17 Series

Two-Stage Hydraulic Pump

PE8 Series

PE17 Series

Form No. 1000559

Rev. 0 February 3, 2012

Page 2

Form No. 1000559

Rev. 0 February 3, 2012

Page 3

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PE8/17-Series Electric / Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Safety Symbols and Denitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Performance Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Power Team Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Form No. 1000559

Rev. 0 February 3, 2012

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Description

The 17 series hydraulic pumps are designed to have a maximum of 690 bar (10,000 psi) at

a ow rate of 278 cc/min (17 cu. in/min). A pump can be valved for use with either single- or double-acting cylinders.

The 8 series pump all the same features as the 17-series. The 8-series is equipped with a 1.9 kW (½ HP) 1,725 RPM electric motor where the 17-series is equipped with a 1.9 kW (½ HP) 3,450 RPM electric motor. All pumps come fully assembled, less uid, and ready for work.

PE8/17-Series Electric / Hydraulic Pumps

The 17 series uses an induction motor. Refer to the Performance section of this manual for motor ratings.

Electric Motor

The PE17-series pumps are equipped with .4 kW (1/2 hp), 3,450 rpm, single-phase, thermal protected induction motor; 10 ft. remote control cord. Low amperage draw; small generators and low amperage circuits can be used as power source. Extremely quiet noise level (67-81 dBA).

The PE8-series pumps are equipped with 1,725 rpm, single-phase, thermal protected induction motor.

Figure 1. PE172SM Figure 2. PE84

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Page 5

Control Valves

Max. Capacity: 690 Bar (10,000 PSI)

PE84

PE174

PE172

PE172M

Valve Function Use with

CENTER

HOLD

POSITION

Port “A”

From

Pump

Tank

Valve Function Use with

ADVANCE

PUMP “ON”

HOLD POSITION

Port “A” Port “B”

From

Pump

RETURN

PUMP “OFF”

RETURN POSITION

HOLD

Tank

POSITION “A” POSITION “B”

Port “A” Port “B” Port “B”

From

Pump

Tank

HOLD

PUMP “OFF”

HOLD POSITION

Valve No.

Cylinder Type

Single-and

double-acting

9500 4-way, 3-position, pump

mounted manual detented

Diagrams

Valve No.

Cylinder Type

Single acting 9517 2-way, 2-position, pump

mounted manual detented

Diagrams

RETURN

PE172S

PE172SM

ADVANCE

PUMP “ON”

SOLENDOID

DE-EMERGIZED

From

Pump

From

Pump

Tank

Valve Function Use with

Cylinder Type

Single acting 9579 3-way, 2-position,

HOLD

PUMP “OFF” SOLENDOID

DE-EMERGIZED

RETURN

PUMP “OFF” SOLENDOID

EMERGIZED

Tank

Table 1. Pump Congurations

Valve No.

pump mounted solenoid

operated, normally closed

Diagrams

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Control Valves continued

ADVANCE

RETURN

PE172A

PE172AM

PUMP “ON”

From

Pump

Valve Function Use with

Cylinder Type

Single acting 45554 Auto/Dump

PUMP “OFF”

Tank

Table 1. Pump Congurations (continued)

Valve No.

manifold advance return

Diagrams

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Page 7

Safety Symbols and Denitions

The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death

or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor

or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

IMPORTANT: Important is used when action or lack of action can cause equipment failure, either immediate or over a long period of time.

Safety Precautions

WARNING:

• The following procedures must be performed by qualied, trained personnel who

are familiar with this equipment. Operators must read and understand all safety precautions and operating instructions included with the pump. If the operator cannot

read these instructions, operating instructions and safety precautions must be read

and discussed in the operator's native language.

• These products are designed for general use in normal environments. These products are not designed for lifting and moving people, agri-food machinery, certain types of mobile machinery, or in special work environments such as: explosive, ammable, or

corrosive. Only the user can decide the suitability of this product in these conditions

or extreme environments. Power Team will supply information necessary to help make

these decisions. Consult your nearest Power Team facility.

• Safety glasses must be worn at all time by the operator and anyone within sight of the unit. Additional personal protection equipment may include: face shield, goggles, gloves, apron, hard hat, safety shoes, and hearing protection.

• The owner of this tool must ensure that safety-related decals are installed, maintained,

and replaced if they become hard to read.

• Shut OFF the motor before opening any connections in the system.

• The guide cannot cover every hazard or situation so always do the job with SAFETY

FIRST.

Pump

WARNING:

• Do not exceed the hydraulic pressure rating noted on the pump nameplate or tamper

with the internal high pressure relief valve. Creating pressure beyond rated capacities can result in personal injury.

• Retract the system before adding uid to prevent overlling the pump reservoir. An overll can cause personal injury due to excess reservoir pressure created when

cylinders are retracted.

• The load must be under operator control at all times.

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Safety Precautions continued

• Do not connect pump to hydraulic system powered by another pump.

Electric Motor

WARNING:

• Electrical work must be performed and tested by a qualied electrician per local

directives and standards.

• Disconnect the pump from the power supply and relieve pressure before removing the motor case cover or performing maintenance or repair.

• Check the total amperage draw for the electrical circuit you will be using. For example: Do not connect a pump that may draw 25 amps to a 20 amp fused electrical circuit.

• Never use an ungrounded power supply with this unit.

• Changing the voltage is an involved and, if incorrectly performed, hazardous procedure. Consult the manufacturer for specic information before attempting rewiring.

• Wire pump motors for counterclockwise rotation when viewed from the shaft end of

the motor.

• Do not attempt to increase the power line capacity by replacing a fuse with another fuse of higher value. Overheating the power line may result in re.

• Exposing electric pumps to rain or water could result in an electrical hazard.

• Avoid conditions that can cause damage to the power cord, such as abrasion, crushing, sharp cutting edges, or corrosive environment. Damage to the power cord can cause

an electrical hazard.

Hoses

WARNING:

• Before operating the pump, tighten all hose connections using the correct tools. Do not overtighten. Connections should be only secure and leak-free. Overtightening can cause premature thread failure or high pressure ttings to split at pressures lower

than their rated capacities.

• Should a hydraulic hose rupture, burst, or need to be disconnected, immediately shut

off the pump and shift the control valve twice to release 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 potential hazard, such as re, sharp surfaces, heavy impact, or extreme heat or cold. 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 possibly result in

personal injury.

• Do not use the hose to move attached equipment. Stress can damage the hose and possibly 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 material such as creosoteimpregnated objects and some paints. Consult the manufacturer before painting a hose. Never paint the couplers. Hose deterioration due to corrosive materials may

Form No. 1000559

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Page 9

result in personal injury.

• Avoid straight line tubing connections in short runs. Straight line runs do not provide for expansion and contraction due to pressure and/or temperature changes.

• Eliminate stress in the tube lines. Long tubing runs should be supported by brackets or clips. Tubes through bulkheads must have bulkhead ttings. This makes easy

removal possible and helps support the tubing.

• Carefully inspect all hoses and ttings prior to use. Before each use, check entire hose for cuts, leaks, abrasion or bulging of cover, or damage or movement of couplings. If any of these conditions exist, replace the hose immediately. NEVER attempt to repair

the hose.

Cylinder

DANGER:

• Do not exceed rated capacities of the cylinders. Excess pressure may result in personal

injury.

• Avoid off-center loads that could damage the cylinder and/or cause loss of the load.

• Read and understand all safety and warning decals and instructions for devices

attached.

Safety Precautions continued

• Inspect each cylinder and coupler before each shift or usage to prevent unsafe conditions from developing.

• Do not use cylinders if they are damaged, altered or in poor condition.

• Do not use cylinders with bent or damaged couplers or damaged port threads.

• Under certain conditions, the use of an extension with a hydraulic cylinder may not be

advisable and could present a dangerous condition.

• Avoid pinch points or crush points that can be created by the load or parts of the cylinder.

• To help prevent material fatigue if the cylinder is to be used in a continuous application, the load should not exceed 85% of the rated capacity or stroke.

• Cylinder must be on a stable base which is able to support the load while pushing or

lifting.

• To help prevent personal injury, use shims, friction material or constraints to prevent

slippage of the base or load.

• Do not set poorly-balanced or off-center loads on a cylinder.

• The load can tip or the cylinder can “kick out” and cause personal injury.

• Do not use the locking collar on a threaded piston as a stop. The threads may shear

resulting in loss of the load.

• If this component is used to lift or lower loads, be certain that the load is under operator

control at all times and that others are clear of the load.

• Do not drop the load.

• As the load is lifted, use blocking and cribbing to guard against a falling load.

• To help prevent personal injury, do not allow personnel to go under or work on a load before it is properly cribbed or blocked. All personnel must be clear of the load before

lowering.

Form No. 1000559

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Safety Precautions continued

• Never use extreme heat to disassemble a hydraulic cylinder or ram. Metal fatigue and/

or seal damage will result and can lead to unsafe operating conditions.

IMPORTANT

• Keep the cylinder clean at all times.

• While at a job site, when the cylinder is not in use, keep the piston rod fully retracted

and upside down.

• Always use protective covers on disconnected quick couplers.

• When mounting cylinders or rams using the internal piston rod threads, collar threads, threaded tie rods or base mounting holes, the threads must be fully engaged. Always

use SAE grade 8 or better fasteners when attaching components to cylinders or rams and tighten securely.

• Limiting the stroke and pressure on all cylinders will prolong their life.

Form No. 1000559

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Page 11

Initial Setup

1. Remove all packing materials from the assembled unit.

2. Inspect the unit upon arrival. The carrier, not the manufacturer, is responsible for any damage resulting from shipment.

Filling the Pump Reservoir

Most pumps are shipped without hydraulic uid in the reservoir. Hydraulic uid may have been shipped in a separate container, but if hydraulic uid is needed, use only approved Power Team hydraulic uid

rated at AW 46 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use

hydraulic uid 5.1 cSt @ 100°C (451 cSt @ -40°C).

1. Clean the area around the filler cap to remove debris. Debris in the hydraulic fluid can damage the polished surfaces and precision-fit components of this pump.

2. Remove the filler cap and insert a clean funnel with a filter.

3. Fill the reservoir with hydraulic fluid to 1.3–3.8 cm (0.5–1.5 in.) from the cover plate.

4. Replace the filler cap. Verify the breather-hole is open, if applicable.

NOTE: If hydraulic uid foaming becomes a problem, reduce the hydraulic uid level to 2" below

the cover plate.

Hydraulic Connections

1. Clean the areas around the fluid ports of the pump and cylinders.

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

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

4. Remove the thread protectors from the hydraulic fluid outlets.

5. Connect the hose assembly to the hydraulic fluid outlet, and couple the hose to the cylinder.

CAUTION: To prevent personal injury from leaking hydraulic uid, seal all hydraulic connections with a high-quality, non-hardening, pipe thread sealant.

IMPORTANT: Sealant tape or non hardening sealer tape can be used to seal hydraulic

connections if only one layer of tape is used. Apply tape carefully, two threads back, to prevent it from being pinched by the coupler and broken off inside the system. Loose pieces of sealant could travel through the system and obstruct the ow of uid or cause jamming of precision-t parts.

Electric Motor Operation

Motor voltages are not changeable. They are:

12 VDC - 11-14 VDC

120 VAC - 90-130 VAC 50/60 Hz

220 VAC - 190-240 VAC 50/60 Hz

1. Verify the valve is in the neutral or hold position.

2. Connect the motor to a power supply.

Caution:

• The correct voltage is required for the pump to operate. Verify the voltage rating on the pump

motor name plate matches the outlet or power source you are using. Low voltage may cause: an overheated motor; a motor that fails to start under load; motor surging when trying to

Form No. 1000559

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Page 12

Initial Setup continued

start; or a stalled motor before maximum pressure is reached.

• Check the voltage at the motor with the pump running at full pressure.

• Never run the motor on long, light gauge extension cords. Refer to Table 2. Minimum

Recommended Gauge Table.

3. Start the pump and shift as required.

4. Turn off the pump when not in use.

AMPS

at Maximum

Hyd. Pressure

0-8 m 8-15 m 15-30 m 30-46 m 0-25 ft 25-50 ft 50-100 ft 100-150 ft

6 0.75 1 1.5 2.5 18 16 14 12

10 0.75 1.5 2.5 4 18 14 12 10

14 1 2.5 4 6 16 12 10 8

18 1.5 2.5 6 6 14 12 8 8

22 1.5 4 6 10 14 10 8 6

26 2.5 4 6 10 12 10 8 6

30 2.5 4 10 16 12 10 6 4

Electrical Cord Size AWG (mm2) 3.2 Volt Drop

Length of Electrical Cord

AWG

Table 2. Minimum Recommended Gauge Table

Bleeding Air from the System

After all connections are made, the hydraulic system must be bled of any trapped air. Refer to Figure 3. With no load on the system and the pump vented and positioned higher than the hydraulic device, cycle the system several times. If you are in doubt about venting your pump, read the operating instructions

for your pump. Check the reservoir uid level and ll to proper level with Power Team hydraulic uid as

necessary. If there is a problem contact the Power Team.

IMPORTANT: Some spring return cylinders or rams have a cavity in the rod which forms an air pocket. This type of cylinder or ram should be bled when positioned upside down or lying on its side with the port

facing upward.

Figure 3. System Bleeding

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Page 13

Hydraulic Pressure Gauge (optional)

Automatic Dump Valve

To monitor line pressure when using an automatic

dump valve, a tee tting is used between the

valve and the pressure switch to adapt a hydraulic pressure gauge.

Posi-Check Valve

If a Posi-Check valve is used, a hydraulic gauge shows zero pressure when the valve is switched to the neutral (hold) position. Cylinder pressure, however, is held without loss.

To install a hydraulic pressure gauge:

1. Refer to Figure 4. Remove the pipe plug from the valve’s gauge port.

Initial Setup continued

Figure 4. Gauge Port

2. Refer to Figure 5. Install sealant tape or non hardening sealer to a 45 degree elbow (PN

9678). Install the elbow as shown.

3. Install sealant tape or non hardening sealer to the gauge.

4. Refer to Figure 6. Install the pressure gauge.

Figure 5. Elbow Installation

Figure 6. Pressure Gauge Installation

Rev. 0 February 3, 2012

Form No. 1000559

Page 14

Operating Instructions

Bleeding Air from the System

1. Cycle the hydraulic system until operation is smooth and consistent.

2. Check the pump reservoir level. Add Power Team hydraulic uid as needed.

Electric Motor Control Operation

1. Connect the power cord to an appropriate power source.

2. Place the motor control switch in the ON position or the REMOTE position, if applicable.

3. Depending on system requirements:

Refer to Figure 7. This remote will start and run the pump motor as long as the button is pressed. Switch will automatically return to OFF position when button is released and pump motor will turn off.

Figure 7. Momentary ON-OFF Push

Button Remote Motor Control

Refer to Figure 8. This remote will start and run the pump motor as long as the button is held in the ON position. Switch will automatically return to OFF position when button is released and pump motor will turn off. Generally used with 2-Way, 2-Position valves.

Refer to Figure 9. This remote will start and run the pump motor to advance or retract of the cylinder when released it allows the pressure to be held.

4. Press the rocker switch toward the Advance side of the switch and hold to extend the cylinder.

5. Press the rocker switch toward the Retract side of the switch and hold to retract the cylinder.

6. Release the rocker switch and the pump will stop but the system will hold. Generally used on 4-Way2-Position valves.

Figure 8. Momentary ON-OFF Remote

Figure 9. Advance-Hold-Retract

Remote

Form No. 1000559

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Page 15

Operating Instructions continued

Pressure Regulating Controls

To ensure accuracy and low pressure differential (approx. 20 Bar 300 PSI) throughout the pressure range (69-690 Bar (1,000-10,000 PSI) depending on the pump model), the pressure switch should be used with the pressure regulating valve. The pressure switch must be set at a pressure lower than the pressure regulating valve to work correctly.

• The pressure regulating valve can be adjusted to bypass uid at a given pressure setting while the

pump continues to run.

• The pressure switch can be adjusted to stop the pump at a given pressure setting.

Adjusting The Pressure Regulating Valve (if equipped). All others are factory preset.

Note: For easy adjustment of the pressure regulating valve, always adjust the pressure by increasing to the

desired pressure setting.

1. Loosen the locknut on the pressure regulating valve.

2. Use a screwdriver to back out the adjusting screw a few turns in a counterclockwise direction. This decreases the setting to a lower-than-desired pressure.

3. The pump must be completely connected. Set the motor control toggle switch on RUN, and push the START button.

4. With the screwdriver, slowly turn the adjusting screw in a clockwise direction. This gradually increases the pressure setting. When the desired pressure is reached, lock the adjusting screw in position by tightening the locknut.

Notes:

• The pressure range is from 69-690 Bar (1,000-10,000 PSI), depending on the pump model.

• The pressure switch must be set at a higher pressure than working range to prevent shut down during

adjustment. It is also possible to bypass the pressure switch contacts by holding the start switch or remote control switch so the motor runs continuously.

Adjusting The Pressure Switch

Generally, the pressure switch should be used with the pressure regulating valve. A pressure switch can be used alone for operating electrical devices such as motors, solenoids, and relays, which are located elsewhere in the circuit.

1. Loosen the locknut on the pressure switch, and turn the adjusting screw in a clockwise direction. This increases the pressure setting to a higher than desired pressure.

2. Adjust the pressure regulating valve to the desired pressure setting by using the procedure previously outlined.

3. With the pump running and bypassing fluid at the desired pressure, slowly turn the pressure switch adjusting screw in a counterclockwise direction, decreasing the pressure switch setting until the pump motor shuts off.

4. Lock the adjusting screw in position by tightening the locknut.

5. Release pressure. Run the pump to check the pressure setting and cut-out of the motor. It may be necessary to make a second adjustment.

Note: When the pressure switch setting is reached, the motor shuts off. However, the “coast” of the motor continues to deliver uid for a brief period. The pressure regulating valve bypasses this surplus uid, preventing it from going into the system. As a result, the pressure differential can be held to approximately 20 Bar (300 PSI).

Form No. 1000559

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Page 16

Performance Specications

The information in the following charts can be used as a basis to determine if the system is performing as expected during operation.

Amp Draw at

Pump RPM

PE8 1,725 10 15 67/81

PE17 3,450 10 15 67/81

690 Bar (10,000

PSI) (115V)

Table 3. Drive Unit Requirements

Max. Pressure

Pump

PE8

PE17 690 Bar (10,000

** Typical delivery. Actual ow varies with eld conditions.

Output Bar

(PSI)

690 Bar (10,000

PSI)

Fluid Delivery** (cu. in./min. @)

0 Bar (0 PSI) 7 Bar (100

PSI)

145 95 - - 10 8

290 190 - - 20 16

Table 4. Fluid Pressure Chart

50 Bar (700

PSI)

Amp Draw at

690 Bar (10,000

PSI) (230V)

70 Bar

(1,000 PSI)

dB A at Idle

and 690 Bar (10,000 PSI)

345 Bar

(5,000 PSI)

690 Bar

(10,000 PSI)

Form No. 1000559

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Page 17

General Maintenance

WARNING:

• Disconnect the unit from the power supply before performing maintenance or repair

procedures.

• Repairs and maintenance are to be performed in a dust-free area by a qualied

technician.

System Evaluation

The components of your hydraulic system — cylinders, pumps, hoses, and couplings — all must be:

• Rated for the same maximum operating pressure.

• Correctly connected.

• Compatible with the hydraulic uid used.

A system that does not meet these requirements can fail, possibly resulting in serious injury. If you are in doubt about the components of your hydraulic system, contact Power Team Technical Support.

Inspection

Keep a dated and signed inspection record of the equipment. An inspection checklist (Form No.

105503) is available on request from your nearest Power Team facility. Before each use, the operator or

other designated personnel should visually inspect for the following conditions:

• Cracked or damaged cylinder.

• Excessive wear, bending, damage, or insufcient thread engagement.

• Leaking hydraulic uid.

• Scored or damaged piston rod.

• Incorrectly functioning or damaged heads and caps.

• Loose bolts or cap screws.

• Damaged or incorrectly assembled accessory equipment.

• Modied, welded, or altered equipment.

• Bent or damaged couplers or port threads.

Periodic cleaning

WARNING: Contamination of the hydraulic uid could cause the valve to malfunction. Loss

of the load or personal injury could result.

Establish a routine to keep the hydraulic system as free from debris as possible.

• Seal unused couplers with dust covers.

• Keep hose connections free of debris. Equipment attached to a cylinder must be kept clean.

• Keep the breather-hole in the filler cap clean and unobstructed.

• Use only Power Team hydraulic fluid. Replace hydraulic fluid as recommended, or sooner if the fluid

becomes contaminated. Never exceed 300 hours of use between fluid changes.

Hydraulic Fluid Level

1. Check the fluid level in the reservoir after each 10 hours of use. The fluid level should be 1.3–3.8 cm (0.5–1.5 in.) from the top of the fill hole when all cylinders are retracted.

2. Drain, flush, and refill the reservoir with an approved Power Team hydraulic fluid after every 300 hours of use. The frequency of fluid changes depends upon general working conditions, severity of

Form No. 1000559

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General Maintenance continued

use, the overall cleanliness and care given to the pump. Fluid should be changed more frequently when the system is not operated regularly indoors.

Draining And Flushing The Reservoir

IMPORTANT: Clean the pump exterior before the

pump interior is removed from the reservoir.

1. Remove the ten screws that fasten the motor and pump assembly to the reservoir.

IMPORTANT: Do not damage the gasket or bump the lter or pressure regulating valves

when lifting the pump and motor off the reservoir. See Figure 10.

2. Drain fluid and clean the inside of the reservoir. Fill with a suitable nonflammable flushing fluid. Rinse the filter clean.

3. Place the pump and motor assembly back onto the reservoir and secure with four corner screws.

IMPORTANT: Connect a hose to the advance/ retract port of the pump manifold. Place the

other end of the hose into the uid ller plug

hole.

4. Run the pump for several minutes. Then disconnect the motor and pump assembly, and drain and clean the inside of the pump reservoir.

5. Fill the reservoir to 1.3–3.8 cm (0.5–1.5 in.) below the cover plate with an approved, high-grade hydraulic fluid. Place the pump and motor assembly (with gasket) onto the reservoir. Thread in ten screws and tighten securely and evenly.

Item Description

1 Pressure Regulating Valve

2 Accumulator (not used on all models)

3 High Pressure Relief Valve

4 Filter

Figure 10. Pump Assembly

Adding Hydraulic Fluid To The Reservoir

1. Retract the cylinder(s) devices.

2. Disconnect the power supply.

3. Clean the entire area around the filler plug.

4. Remove the filler plug, and install a clean funnel with a filter.

5. Use only Power Team hydraulic fluid rated at AW 46 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use hydraulic fluid 5.1 cSt @ 100°C (451 cSt @ -40°C).

Form No. 1000559

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Page 19

General Maintenance continued

22 mm (7/8")

(new)

Replace when

4.5 mm (1/8") or less

Sound Reduction - Electrically Powered Motor

The electrically powered hydraulic pump operates in the 67–81 dBA range. If further sound reduction is desired, any of the following options will help reduce the sound level.

1. Install a pressure switch to automatically shut off the motor when maximum pressure is reached (holding cycle).

2. Contact Power Team Hydraulic Technology technical support for products more suitable to your application.

Hose Connections

CAUTION: To prevent personal injury from leaking hydraulic uid, seal all hydraulic

connections with a high-quality, non-hardening, pipe thread sealant.

IMPORTANT: Sealant tape or non-hardening sealer tape can be used to seal hydraulic

Storage

Store the unit in a dry, well-protected area where it will not be exposed to corrosive vapors, dust, or other harmful elements. If a unit has been stored for an extended period of time, it must be thoroughly inspected before it is used.

Checking Brushes on Universal Motors

To help prevent premature failure of the armature, check the brushes periodically:

1. Remove the metal brush cover plates.

2. Remove the brush holder caps and brush assemblies.

3. The brush assemblies must be replaced if they are 4.5mm (1/8") long or less. See Figure 11.

4. Install brush assemblies, brush holder caps, and metal brush cover plates.

Figure 11. Brush Inspection

Form No. 1000559

Rev. 0 February 3, 2012

Page 20

Troubleshooting Guide

WARNING:

• Repair work or troubleshooting must be performed by qualied personnel who are

familiar with this equipment.

• Disconnect the power supply before removing the electrical cover. Electrical work should be performed by a qualied electrician.

• Check for system leaks by using a hand pump to apply pressure to the suspect area. Watch for leaking uid and follow it back to its source. Never use your hand or other

body parts to check for a possible leak.

Notes:

• For a detailed parts list or to locate a Power Team Authorized Hydraulic Service Center, contact your nearest Power Team facility.

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

Problem Cause Solution

Electric motor does not run.

Pump is not delivering

hydraulic uid or delivers

only enough hydraulic

uid to advance cylinder(s)

partially or erratically.

1. Unit is not plugged in.

2. No voltage supply.

3. Broken lead wire or defective power cord plug.

4. Defective motor.

1. Hydraulic uid level too low.

2. Air in system.

3. Debris is in pump or lter is

plugged.

4. Cold hydraulic uid or hydraulic uid is too heavy (hydraulic uid is of a higher viscosity than

necessary).

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

6. Sheared drive shaft key(s).

7. Motor rotating in wrong direction.

1. Plug in unit.

2. Check line voltage.

3. Replace defective parts.

4. Replace or repair motor.

1. Fill reservoir to 1-1/2" below the cover plate, maximum.

2. Bleed the system.

3. Pump lter should be cleaned

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

and cleaned.

4. Change to lighter hydraulic uid.

5. Readjust as needed.

6. Replace.

7. Reverse rotation.

Form No. 1000559

Rev. 0 February 3, 2012

Page 21

Troubleshooting Guide continued

Problem Cause Solution

Pump will not build full pressure.

1. Faulty pressure gauge.

2. Check for external leakage.

3. Inspect the pump for internal leakage.

4. Sheared key(s).

5. High pressure pump inlet or outlet ball checks in the pump are leaking.

Automatic valve will not

1. Unloading pressure is too low.

build full pressure

2. Defective or oversize seat on automatic valve.

Electric motor cuts out. 1. Extension cord is too long and/

or not of sufcient gauge.

2. Faulty motor.

3. Overheated motor can trip circuit breaker in shop power panel.

Foaming hydraulic uid. 1. Hydraulic uid being splashed

by counter weight.

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 quickdisconnect couplings.

2. Inadequate air pressure (air motor only).

Pump delivers excess hydraulic uid pressure.

1. Pressure gauge is not accurate.

2. Relief valve not properly set.

1. Calibrate gauge.

2. Seal any faulty pipe ttings with pipe sealant.

3. Same procedure as above but

for leaks around the entire inner

mechanism. If there are no visible

leaks the low-to-high pressure ball

check may be leaking. Remove all parts. Inspect the check body for any damage to the seat areas. Clean and reseat if necessary.

Inspect the ball for damages and replace if necessary, then

reassemble.

4. Replace.

5. Reseat or replace valve head.

1. Increase unloading pressure per chart, sheet 3 of 4.

2. Replace ball and seat.

1. Replace.

2. Replace and repair.

3. Allow motor to cool, reset circuit

breaker located in shop power

panel.

1. Lower hydraulic uid level to approximately 38 mm (1.5 inches) below the cover plate.

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. Increase air pressure.

1. Calibrate gauge.

2. Reset the relief valve.

Form No. 1000559

Rev. 0 February 3, 2012

Page 22

Troubleshooting Guide continued

Problem Cause Solution

Automatic valve will not release pressure.

1. Sticking piston.

2. High pressure hydraulic uid

is leaking past the low-to-high pressure check. This hydraulic

uid leaks back to the piston in

the automatic valve, keeping the piston closed.

1. Remove, clean and polish.

2. Seat the ball check. Inspect and replace any faulty components.

Form No. 1000559

Rev. 0 February 3, 2012

Page 23

Power Team Facilities

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Te l: 31 (45) 5678877 FAX: 31 (45) 5678878

E-mail

infoeurope@powerteam.com

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Singapore 629563

Te l: (65) 6265-3343 FAX: (65) 6265-6646

E-mail:

infoasia@powerteam.com

UNITED ST ATES

SPX Hydraulic Technologies 5885 11th Street

Rockford, IL 61109-3699 USA Telephone: 1-815-874-5556

FAX: 1-815-874-7853

Cust. Service/Order Entry Te l: 1-800-541-1418 FAX: 1-800-288-7031

E-mail:

info@powerteam.com

Technical Services Tel: 1-800-477-8326 FAX: 1-800-765-8326

For more information, Internet address: http://www.powerteam.com

C E R T I F I E D

CHINA

No. 1568 Hua Shan Road International Park Center Shanghai 200052, China

Te l: 86 (21) 2208-5888 FAX: 86 (21) 2208-5682

FAR EAST

7 Gul Circle

E-mail

infochina@powerteam.com

Form No. 1000559

Rev. 0 February 3, 2012

Page 24