Page 1
Operating Instructions for:
Electric-Powered
18 Series
Hydraulic Pump
PE18 Series
© SPX
Form No. 1000572
Rev. 0 February 8, 2012
Page 2
© SPX
Form No. 1000572
Rev. 0 February 8, 2012
Page 3
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PE18-Series Electric / Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Symbols and Denitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Performance Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Team Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
© SPX
1
Form No. 1000572
Rev. 0 February 8, 2012
Page 4
Description
The 18 series hydraulic pumps are designed to have a maximum of 690 bar (10,000 psi) at
a ow rate of 295 cc/min (18 cu. in/min). A pump can be valved for use with either single- or
double-acting cylinders. All pumps come fully assembled, less uid, and ready for work.
PE18-Series Electric / Hydraulic Pumps
Electric Motor
The electric motor is available in a 0.4 kW (1/2 HP).
The motor is in single-phase conguration.
The electric motor offers a low noise level due
to moderate speed. This motor is ideal for long
service, xed applications.
The 1/2 hp, 110/115 or 220/230 VAC, 60/50 Hz
single phase motor starts under load, even at
reduced voltage.
The weight can be up to 29 kg (63 lbs).
Figure 1. Electric Motor
© SPX
2
Form No. 1000572
Rev. 0 February 8, 2012
Page 5
Control Valves
Position “A” Position “B”
P
Port “A”
T
P
Port “A”
T
P
Port “A”
T
From
PumpToTank
From
PumpToTank
From
PumpToTank
Position “A”
Release
Position
Center
Position
Max. Capacity: 690 bar (10,000 psi)
Valve Function Use with
Port “A”
Port “A”
PE182
T
P
From
PumpToTank
T
P
From
PumpToTank
NOTE: All ports OPEN to tank during transition between valve positions.
Valve Function Use with
PE183
PE183-2
Valve No.
Cylinder Type
Single-acting 2-way advance return
Diagrams
Valve No.
Cylinder Type
Single-acting 3-way advance hold return
Diagrams
NOTE: All ports OPEN to tank during transition between valve positions.
Valve Function Use with
Advance
Pump “ON”
Port “A”
PE183A
P
T
To
From
Tank
Pump
NOTE: All ports OPEN to tank during transition between valve positions.
Cylinder Type
Retract
Pump “OFF”
Port “A”
T
To
Tank
P
From
Pump
Single-acting Auto/dump pump, advance
Table 1. Pump Congurations
Valve No.
return
Diagrams
© SPX
3
Rev. 0 February 8, 2012
Form No. 1000572
Page 6
Control Valves continued
Tank
Pump
Tank
Pump
Tank
Pump
Center
Position “A” Position “B”
Valve Function Use with
PE183C
Advance
Pump “ON”
Solenoid “ON”
Port “A”
P
T P
From
To
Hold
Pump “OFF”
Solenoid “ON”
Port “A”
T P
To
From
Retract
Solenoid “OFF”
Port “A”
Pump “OFF”
T
To
From
NOTE: All ports OPEN to tank during transition between valve positions.
Valve Function Use with
Position “A”
Position Position “B”
PE184
PE184-2
Port “A” Port “B” Port “B”
Port “A”
Port “A” Port “B”
Valve No.
Cylinder Type
Single-acting Special, for crimping only,
advance hold return
Diagrams
Valve No.
Cylinder Type
Single and
4-way advance hold return
double-acting
Diagrams
P
From
T
To
P
From
T
To
NOTE: All ports OPEN to tank during transition between valve positions.
Valve Function Use with
Port “A” Port “B”
P
From
Valve Port
T
To
Tank
Port “A” Port “B”
T
P
From
Valve Port
To
Tank
PE184C
Advance
Pump “ON”
Solenoid “ON”
PT PT PT
To
From
Tank
Pump
Tank
To
Hold
Pump “OFF”
Solenoid “ON”
From
Pump
Tank
To
Retract
Solenoid “OFF”
From
Pump
P
From
Pump “OFF”
T
To
Valve No.
Cylinder Type
Single and
4-way advance return
double-acting
Diagrams
NOTE: All ports OPEN to tank during transition between valve positions.
Table 1. Pump Congurations (continued)
© SPX
4
Rev. 0 February 8, 2012
Form No. 1000572
Page 7
Safety Symbols and Denitions
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 qualied, 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.
© SPX
• Retract the system before adding uid to prevent overlling the pump reservoir. An
overll 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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Form No. 1000572
Rev. 0 February 8, 2012
Page 8
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 qualied 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 specic 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.
© SPX
• 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
result in personal injury.
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Form No. 1000572
Rev. 0 February 8, 2012
Page 9
• 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.
© SPX
• 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.
• Never use extreme heat to disassemble a hydraulic cylinder or ram. Metal fatigue and/
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Form No. 1000572
Rev. 0 February 8, 2012
Page 10
Safety Precautions continued
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.
© SPX
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Form No. 1000572
Rev. 0 February 8, 2012
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 (237 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 cm (0.5 in.) from the cover plate.
4. Replace the filler cap. Verify the breather-hole is open, if applicable.
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
The electric motor is wired for nominal 115 or nominal 230 volts, 50/60 Hz. Some motors can be
rewired. Consult Power Team technical support.
1. Verify the hydraulic 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
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.
Form No. 1000572
Rev. 0 February 8, 2012
© SPX
9
Page 12
Initial Setup continued
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
2
mm
AWG
Table 2. Minimum Recommended Gauge Table
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:
1. Open the ller plug two full turns.
2. See Figure 2. Place the cylinder at a lower level than the pump.
3. Extend and retract the cylinder several times without putting a load on the system. Air will be released
through the pump reservoir.
4. Cycle the hydraulic system until operation is smooth and consistent.
5. Check the pump reservoir level. Add Power Team hydraulic uid as needed.
Figure 2. System Bleeding
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.
© SPX
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Form No. 1000572
Rev. 0 February 8, 2012
Page 13
Initial Setup continued
Hydraulic Pressure Gauge (optional)
Note: Hose can thread directly into pump body.
To install a hydraulic pressure gauge:
1. See Figure 3. For 18-series pumps not equipped
with a gauge port a T-adapter (PN 9760) is
necessary. Install Tee fitting.
2. Install sealant tape or non-hardening sealer to a
T-adapter. Install the T-adapter as shown.
3. Install sealant tape or non hardening sealer to
the gauge.
4. Install the pressure gauge.
1
2
3
Item Description
1 Gauge
2 Hose
3 T-adapter
Figure 3. 18-Series Gauge
© SPX
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Form No. 1000572
Rev. 0 February 8, 2012
Page 14
Operating Instructions
1. Open the filler plug two full turns to vent the reservoir.
2. Place the control valve in the neutral position.
3. Insert the power cord into an outlet.
WARNING: To help prevent personal injury, check the voltage rating on the motor
nameplate to be sure the outlet has the right voltage.
Priming the Pump (if equipped)
1. Back the priming screw out two complete turns.
2. Cycle the pump three times.
3. Tighten the priming screw to 2–3 Nm (15–25 in. lbs.)
Electric Motor Control Operation
1. Connect the power cord to an appropriate power
source.
2. See Figure 5. Place the motor control switch in the
ON position or the REMOTE position, if applicable.
3. Depending on system requirements:
See Figure 6. This remote will start and run the pump
motor as long as the switch is pressed. The switch will
automatically return to OFF position when switch is
released and pump motor will turn off.
Figure 4. PE18 Priming Screw
Figure 5. Motor Control Switches
© SPX
12
Figure 6. Momentary ON-OFF Push
Button Remote Motor Control
Form No. 1000572
Rev. 0 February 8, 2012
Page 15
Operating Instructions continued
See Figure 7. This remote will start and run the pump
motor to advance or retract the cylinder when released
it allows the pressure to be held.
1. Press the rocker switch toward the Advance side of
the switch and hold to extend the cylinder.
2. Press the rocker switch toward the Retract side of the
switch and hold to retract the cylinder.
3. Release the rocker switch and the pump will stop
but the system will hold. Generally used on 4-Way2-Position valves.
Figure 7. Advance-Hold-Retract Remote
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 switch.
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.
© SPX
13
Form No. 1000572
Rev. 0 February 8, 2012
Page 16
Operating Instructions continued
Adjusting The Pressure Switch (for Electric Units)
Generally, the pressure switch should be used with the pressure regulating valve and used in a
hydraulic circuit where system pressure must be “held”. It automatically (electrically) turns off the pump
motor when the predetermined system pressure is reached. It either attaches directly to the control
valve manifold or can be mounted “in-line” to read system pressure. It has a 1/4" NPTF male thread,
and a 1/4" NPTF tting for gauge mounting, if required, and is adjustable from 69 to 690 bar (1,000
to 10,000 psi). This can also be used to actuate other electrical devices in the system and is wired
“normally open” and held closed by spring pressure.
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).
© SPX
14
Form No. 1000572
Rev. 0 February 8, 2012
Page 17
Performance Specications
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
PE18 12,000 10.2 N/A 85/90 N/A
690 bar (10,000
psi) (115V)
Table 3. Drive Unit Requirements
Pump
PE18 690 bar
* Typical delivery. Actual ow varies with eld conditions.
Max. Pressure
Output bar (psi)
(10,000 psi)
Fluid Delivery* (cu. in./min. @)
0 bar (0 psi) 7 bar
(100 psi)
230 190 - - 25 18
Table 4. Fluid Pressure Chart
Amp Draw at
690 bar (10,000
psi) (230V)
50 bar
(700 psi)
dB A at Idle
and 690 bar
(10,000 psi)
70 bar
(1,000 psi)
345 bar
(5,000 psi)
Air Supply
Req'd bar (psi)
690 bar
(10,000 psi)
© SPX
15
Form No. 1000572
Rev. 0 February 8, 2012
Page 18
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 qualied
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. 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 insufcient 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.
• Modied, 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 cm (0.5
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
use, the overall cleanliness and care given to the pump. Fluid should be changed more frequently
Form No. 1000572
Rev. 0 February 8, 2012
© SPX
16
Page 19
General Maintenance continued
1
2
3
4
when the system is not operated regularly indoors.
Draining And Flushing The Reservoir
1. Clean the pump exterior before the pump interior is
removed from the reservoir.
2. Remove the screws fastening the motor and pump
assembly to the reservoir. If equipped with a 2-gallon
reservoir the screws need to be discarded.
3. Remove the motor assembly and place aside.
Caution: Do not damage the pump lter or pressure
regulating valves when lifting the pump and motor off
the reservoir.
4. Clean the inside of the reservoir, and fill with Power
Team hydraulic fluid. Rinse the filter clean.
5. Place the pump and motor assembly back onto
the reservoir, and secure with two machine screws
assembled on opposite corners of the housing.
6. Place the hydraulic flow control valve in the neutral
position. If the pump is equipped with a valve that has
only an advance or retract position.
7. Run the pump for several minutes.
Item Description
1 Accumulator (Not used on
all models)
2 High Pressure Relief Valve
3 Filter
4 Pressure Regulating Valve
Figure 8. Pump Assembly
8. Disconnect the motor and pump assembly, and drain
and clean the inside of the reservoir.
9. Fill the reservoir with Power Team hydraulic fluid.
10. For pumps with 2-gallon reservoir, use new screws: Place the pump and motor assembly (with new
gasket) on the reservoir, and install the new screws. Tighten screws securely and evenly.
For pumps with small reservoirs: Place the pump and motor assembly with clean gasket on the
reservoir, and install the screws. Tighten screws securely and evenly.
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 AW 46 47 cSt @ 38°C (247 SUS @ 100°F). If low temperature
requirements are needed, use hydraulic fluid 5.1 cSt @ 100°C (451 cSt @ -40°C).
Form No. 1000572
Rev. 0 February 8, 2012
© SPX
17
Page 20
General Maintenance continued
4.7 mm (3/16") or less
Sound Reduction - Electrically Powered Motor
The electrically powered hydraulic pump operates in the 85-90 dB A 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. Install casters (7.5L (2 Gallon) reservoir only).
3. Contact Power Team Hydraulic Technology technical support for products more suitable to your
application.
Hose Connections
CAUTION: Contamination of the hydraulic uid could cause the valve to malfunction.
Loss of the load or personal injury could result.
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.
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 Electric Motors
To help prevent premature failure of the armature, check the brushes every 100 hours or 100,000
pressure cycles:
1. Remove the brush holder caps and brush assemblies.
2. The brush assemblies must be replaced if they are 4.7mm (3/16") long or less. See Figure 9.
3. Install brush assemblies and brush holder caps.
Replace when
© SPX
Figure 9. Brush Inspection
22 mm (7/8")
(new)
18
Form No. 1000572
Rev. 0 February 8, 2012
Page 21
Troubleshooting Guide
WARNING:
• Repair work or troubleshooting must be performed by qualied personnel who are
familiar with this equipment.
• Disconnect the power supply before removing the electrical cover. Electrical work
should be performed by a qualied 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.
1. Pump not turned ON.
2. Unit is not plugged in.
3. No voltage supply.
4. Worn brushes.
5. Circuit breaker tripped because
total amperage draw too high for
existing circuit.
6. Overheated motor (singlephase motor). Magnetic starter
disengaged (three-phase motor).
Thermal protector open.
7. Faulty thermal protector (singlephase motor). Faulty magnetic
starter (three-phase motor).
1. Position switch to RUN position.
2. Plug in unit.
3. Check line voltage. Check reset
button on power panel.
4. Replace brushes.
5. Use an alternate circuit or have
a qualied electrician add an
additional circuit.
6. Wait for motor to cool before
restarting. Reset thermal protector.
(Single-phase motor will reset
automatically.)
7. Replace defective parts.
© SPX
19
Form No. 1000572
Rev. 0 February 8, 2012
Page 22
Troubleshooting Guide continued
Problem Cause Solution
Electric motor will not shut
off.
Electric motor stalls,
surges, overheats, or will
not start under load.
Electrical overload
protector keeps tripping.
Pump delivers excess uid
pressure.
Pump is not delivering
uid, or delivers only
enough uid to advance
connected components
partially or erratically or
operation to slow.
1. Defective motor controls.
1. Low voltage
2. Electrical cord size too small.
1. Wired incorrectly.
1. Faulty pressure gauge.
2. Relief valve set incorrectly.
1. Fluid level too low.
2. Loose-tting coupler to
component.
3. Air in system.
4. Air leak in suction line.
5. Debris in pump or lter plugged.
6. Fluid bypasses through the
double-acting cylinder.
7. Cold uid or uid too heavy.
(Hydraulic uid is of a higher
viscosity than necessary.)
8. External relief valve or low
pressure unloading valve out of
adjustment.
9. Power unit/reservoir capacity
is too small for the size of the
cylinder(s) used.
10. Vacuum in reservoir.
1. Disconnect unit from power
supply; contact a Power Team
Service Center.
1. Refer to electric motor
information in Initial Setup section.
2. Refer to electrical cord chart in
Initial Setup section.
1. Disconnect unit from power
supply; have qualied electrician
review motor and circuit wiring.
1. Replace gauge.
2. Contact a Power Team Service
Center.
1. Add uid, refer to lling the pump
reservoir in Initial Setup section.
2.
Verify quick-disconnect couplings
to cylinders are completely coupled.
Couplers may need to be replaced
because ball check does not stay open
due to wear.
3. Refer to Initial Setup in this
manual to bleed air from system.
4. Check and tighten suction line.
5. Clean pump lter. If problem
persists, disconnect from power
supply contact authorized Power
Team service center.
6. Remove cylinder; cap hoses.
Check pump and valve for leaks.
7. Drain, ush, and rell reservoir
using a lighter weight uid. Refer to
General Maintenance section.
8. Refer to Adjusting the Pressure
Regulating Valve.
9. Use smaller cylinder(s) or larger
reservoir.
10. Clean plugged vent in ller plug.
© SPX
20
Form No. 1000572
Rev. 0 February 8, 2012
Page 23
Troubleshooting Guide continued
Problem Cause Solution
Pump builds pressure but
cannot maintain pressure.
Pump does not build to full
pressure.
Erratic action 1. Air in system.
1. Fluid leakage.
2. Leaking pressure switch seal.
1. Faulty pressure gauge.
2. Check for external leakage.
3. Check external pressure
regulator. Check relief valve
setting.
4. Look for internal leakage in
double-acting cylinders.
5. Inadequate air pressure (air
motor only).
2. Internal leakage in attached
components.
3. Attached component sticking or
binding.
4. Malfunctioning valve.
1. Look for external leaks. If no uid
leakage is visible, the problem is
internal. If using a double-acting
cylinder, remove it from the system
to ensure the leak is not in the
cylinder. Seal leaking pipe ttings
with pipe sealant.
2. Replace pressure switch.
1. Replace pressure gauge.
2. Seal faulty pipe ttings with pipe
sealant.
3. Refer to Adjusting the Pressure
Regulating Valve.
4. Remove cylinder from pump. If
pump builds full pressure, cylinder is
defective.
5.
Refer to Initial Setup section.
1. Check for leaks. Refer to
bleeding procedure.
2. Refer to manufacture's
information for attached component.
3. Refer to manufacture's
information for attached component.
4.
Verify connections. Contact
authorized Power Team Service
Center.
© SPX
21
Form No. 1000572
Rev. 0 February 8, 2012
Page 24
Power Team Facilities
EUROPE
Albert Thijsstraat 12
6471 WX Eygelshoven
The Netherlands
Tel: 31 (45) 5678877
FAX: 31 (45) 5678878
E-mail
infoeurope@powerteam.com
Singapore
Singapore 629563
Tel: (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
Tel: 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
Tel: 86 (21) 2208-5888
FAX: 86 (21) 2208-5682
FAR EAST
7 Gul Circle
E-mail
infochina@powerteam.com
© SPX
22
Form No. 1000572
Rev. 0 February 8, 2012
Page 25
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