SPX PE39 Series, PE39PED1BPR, PE39PED1PR, PE39YED1BPR, PE39YED1PR Operating Instructions Manual

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Page 1

SPX Bolting Systems Unit 4, Wansbeck Business Park Rotary Parkway Ashington Northumberland NE63 8QW

spxboltingsystems.com

Original Instructions

Compact Torque Wrench Pump

Tel: +44 (0) 1670 850580 Fax: +44 (0) 1670 850655

PE39 Series

Operating Instructions for:

PE39PED1BPR

PE39PED1PR

PE39YED1BPR

PE39YED1PR

Form No. 1000542

Rev. 2 November 14, 2014

Page 2

Table of Contents

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

Compact Electric/Hydraulic Torque Wrench Pumps .......................2

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

Safety Symbols and Denitions ............................................4

Safety Precautions .....................................................4

Initial Setup ...........................................................7

Operating Instructions ..................................................10

Performance Specications ..............................................12

General Maintenance ..................................................13

Troubleshooting Guide .................................................20

Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Parts List ............................................................28

Hydraulic Technologies Facilities ..........................................30

Declaration of Conformity ...............................................31

Rev. 2 November 14, 2014

Form No. 1000542

Page 3

Description:

The PE39 series hydraulic pump is designed to have a maximum of 690 bar (10,000 psi) at a

ow rate of 639 cc/min (39 cu. in/min). All pumps come fully assembled and ready for work.

Compact Electric/Hydraulic Torque Wrench Pumps

Description

Universal Motor

The universal motor pump, shown in Figure 1, offers a lightweight and portable hydraulic pump option. It is capable of vertical or horizontal operation. Weight can be up to 23 kg (50 lbs).

Universal motor pumps come with a 1.89L (0.5 Gal) capacity hydraulic reservoir.

The motor is a 0.8 kW (1.04 HP) average, 115/230 VAC (nominal), 50/60 Hz single-phase. Current draw can be up to 14.5 Amps at 115V (15A time delay 250VAC 5x20mm fuse) and 7.2 Amps at 230V (10A time delay 250VAC 5x20mm fuse) and the sound level is rated at 87-92 dB. Operating temperatures range is -25°C to +50°C (-13°F to 122°F). (If temperatures are at extremes of the

operating range, it is recommended to use hydraulic uids that are

rated for those temperatures.)

It is recommended that you use the cooling fan option for elevated ambient temperature or continuous duty.

Figure 1.

PE39 Series Pump

Rev. 2 November 14, 2014

Form No. 1000542

Page 4

Control Valves

Max. Capacity: 690 bar (10,000 psi)

2-position/

4-way

(Idle Valve)

2-position/

2-way

(Idle Valve)

Description Motor Control

Equipped with

2-position/4-way

solenoid valve.

Valve Function Diagrams

Advance Position:

(Solenoid "A") Pressure to "A" port, "B" port

Retract Position:

(De-energized Solenoid "A") Pressure to "B"

port, "A" port to tank

NOTE: All ports OPEN to tank during transi-

tion between valve positions.

Advance Position:

Idle Valve CLOSED

Pressure to "A" port, "B" port to tank

Retract Position:

Idle Valve CLOSED

Pressure to "B" port, Idle Valve port to tank

Idle Positon:

Idle Valve OPEN

"B" port to tank (through idle valve)

0.8 kW (1.04 HP

average) 50/60 Hz,

nominal 115 VAC,

single-phase

to tank

Switch

Remote

motor

Pendant Use with

Cylinder Type

See Figure

3. SPX

Part No.

3000554

Hydraulic

torque wrench

Valve No.

2002108

2-position/4-way,

pump mounted,

solenoid operated

Table 1. Pump Conguration

Rev. 2 November 14, 2014

Form No. 1000542

Page 5

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: To prevent personal injury,

• 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. Hydraulic Technologies will supply information necessary to help make these decisions. Consult your nearest Hydraulic Technologies 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.

Pump

WARNING: To prevent personal injury,

• 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 tools

are retracted.

Rev. 2 November 14, 2014

Form No. 1000542

Page 6

Electric Motor

WARNING: To prevent personal injury,

• 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.

Safety Precautions continued

• 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: To prevent personal injury,

• 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 result in personal injury.

Rev. 2 November 14, 2014

Form No. 1000542

Page 7

Safety Precautions continued

Tools

DANGER: To prevent serious personal injury or death,

• This pump is designed for torque wrench applications and should never be used for lifting.

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

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

• Inspect each component before each shift or usage to prevent unsafe conditions from developing.

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

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

FIRST.

IMPORTANT

• Use an approved, high-grade pipe thread sealant to seal all hydraulic connections. PTFE tape can be used if only one layer of tape is used and it is applied carefully (two threads back) to prevent the tape 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.

Rev. 2 November 14, 2014

Form No. 1000542

Page 8

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

Pumps are shipped with 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 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use hydraulic oil

5.1 cSt @ 100°C (451 cSt @ -40°C).

1. See Figure 2. Clean the area around the filler plug to remove debris. Debris in the hydraulic fluid can damage the polished surfaces and precision-fit components of this pump.

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

CAUTION: Do not ll reservoir with the unit in the horizontal position. Do not over ll reservoir.

3. Add hydraulic fluid to the bottom edge of the filler plug hole with the unit in the upright (vertical) position.

4. Replace the filler plug.

Hydraulic Connections

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

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

3. See Figure 3. Remove the protective covers from the hydraulic fluid outlets.

4. Connect the hose assembly to the hydraulic fluid outlet, and couple the hose to the tool.

Figure 2.

Filler Plug

Figure 3.

Hydraulic Fluid Outlets

Rev. 2 November 14, 2014

Form No. 1000542

Page 9

Initial Setup continued

Electric Motor

1. See Figure 4. Connect the motor control

pendant.

2. Refer to Table 2. Minimum Recommended

Gauge Table. See Figure 5. Connect the control box power cord to an appropriate power source. Never run the pump on long, light gauge extension cords.

Figure 4.

Motor Control Pendant

Figure 5.

Connected to Power Source

Caution: To prevent equipment damage,

• The correct voltage is required for the pump

to operate. Verify the voltage rating on the pump 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. The motor nameplate can be accessed by removing the shroud.

• Check the voltage at the motor with the

pump running at full pressure.

3. Start the pump and shift as required.

4. Turn off the pump when not in use.

5. Disconnect the motor control pendant.

6. See Figure 6. Disconnect power source.

Figure 6.

Disconnected from Power Source

Rev. 2 November 14, 2014

Form No. 1000542

Page 10

Initial Setup continued

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. With no load on the system and the pump positioned higher than the hydraulic device, cycle the system several times.

Check the reservoir uid level and ll to correct level with Power Team hydraulic uid as necessary.

If there is a problem contact Hydraulic Technologies Technical Support. To locate a Power Team Authorized Hydraulic Service Center, contact your nearest Hydraulic Technologies facility or www.SPXBOLTINGSYSTEMS.com.

Rev. 2 November 14, 2014

Form No. 1000542

Page 11

Operating Instructions

Pump Control Operation

1. See Figure 7. Connect the power cord to an appropriate power source.

2. See Figure 8. Press the START (green) switch. Lamp (white) will illuminate and electrical power is supplied to the control system. Press the STOP (red) switch to remove electrical power from the control system. As long as the lamp is illuminated, there is electrical power to the control system.

Figure 7.

Connected to Power Source

3. See Figure 9. Press the ON/OFF rocker switch to ON to start the motor. Press the ON/OFF rocker switch to OFF to stop the motor. This does not remove power from the control system.

4. Press and hold the ADVANCE/RETRACT/IDLE rocker switch to the ADVANCE position. Release when tool has reached the end of its stroke.

5. When the ADVANCE/RETRACT/IDLE is released, the rocker switch defaults to RETRACT. The pump is factory preset to 103 bar (1,500 psi) during RETRACT.

6. Pressing the ADVANCE/RETRACT/IDLE rocker

switch to IDLE allows hydraulic uid to cycle through

the pump back to the tank.

Item Description

1 Start (Green)

2 Lamp (White)

3 Stop (Red)

Figure 8.

Motor Control Switch

Item Description

1 OFF Position

2 ON Position

3 Idle Position

4 Retract Position

5 Advance Position

Figure 9.

Pendant Control

Form No. 1000542

Rev. 2 November 14, 2014

Page 12

Adjusting The Pressure Regulating Valve

1. The pump must be completely connected. Press the START (green) switch on the control box.

2. Using the pendant, press the ON/OFF rocker switch to ON.

3. Press and hold the ADVANCE/RETRACT/IDLE rocker switch to the ADVANCE position to start the motor and build pressure.

4. See Figure 10. Rotate pressure regulating valve to the desired pressure. Clockwise increases pressure, counterclockwise decreases pressure.

5. When the desired pressure is achieved, cycle the system again to verify correct pressure setting.

6. Using the pendant press the ON/OFF rocker switch to OFF.

7. Press the OFF (red) switch on the control box.

Operating Instructions continued

Figure 10.

Pressure Regulating Valve

Form No. 1000542

Rev. 2 November 14, 2014

Page 13

Performance Specications

Amp Draw at

Pump

PE39 4,500 14.5 7.2 92

Motor RPM

(Output)

690 Bar

(10,000 PSI)

(115V)

Amp Draw at

690 Bar

(10,000 PSI)

(230V)

dB A at Idle and 690 Bar (10,000 PSI)

Table 3. Drive Unit Requirements

Max. Pressure

Pump

PE39 690 (10,000) 0.90 (55) 0.80 (49) 0.64 (39)

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

Output Bar

(PSI)

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

70 Bar

(1,000 PSI)

345 Bar

(5,000 PSI)

690 Bar

(10,000 PSI)

Table 4. Fluid Pressure Chart

Form No. 1000542

Rev. 2 November 14, 2014

Page 14

General Maintenance

WARNING: To prevent personal injury,

• Disconnect the unit from the power source 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 — pump, 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 Hydraulic Technologies 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:

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

• Leaking hydraulic uid.

• Loose bolts, cap screws, or pipe plugs.

• Bent or damaged couplers or port threads.

Periodic cleaning

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

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.

• 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 level with the bottom of the fill hole when all cylinders are retracted and the unit is in the upright (vertical) position.

2. Drain, flush, and refill the reservoir with an approved Power Team hydraulic fluid after 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 when the system is not operated regularly indoors.

Form No. 1000542

Rev. 2 November 14, 2014

Page 15

General Maintenance continued

Adding Hydraulic Fluid to the Reservoir

1. See Figure 11. Disconnect the power source.

2. Clean the entire area around the filler plug.

3. See Figure 12. Remove the filler plug, and install a clean funnel with a filter.

4. Using a clean funnel with a filter, fill the reservoir

with Power Team hydraulic fluid 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use hydraulic Oil 5.1 cSt @ 100°C (451 cSt @ -40°C). Add hydraulic fluid to the bottom edge of the filler plug hole with the unit in the upright (vertical) position.

Figure 11.

Disconnected from Power Source

CAUTION: Do not ll reservoir with the unit in the horizontal position. Do not over ll reservoir.

Hose Connections

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

Pipe thread sealant 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 tape could travel through the system and

obstruct the ow of uid or cause interference of precision-t parts.

Storage

Figure 12. Filler Plug

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.

Form No. 1000542

Rev. 2 November 14, 2014

Page 16

General Maintenance continued

Draining and Flushing the Reservoir

1. Clean the filler plug.

2. See Figure 13. Remove the filler plug and drain the

fluid.

CAUTION: Do not ll reservoir with the unit in the horizontal position. Do not over ll reservoir.

3. Using a clean funnel with a filter, fill the reservoir

with Power Team hydraulic fluid 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use hydraulic oil 5.1 cSt @ 100°C (451 cSt @ -40°C). Add hydraulic fluid to the bottom edge of the filler plug hole with the unit in the upright (vertical) position.

4. Connect the hydraulic hoses to the fittings.

5. Bleed the air from the system. Refer to Bleeding Air

from the System.

6. Cycle the pump for 1–2 minutes.

7. Disconnect the hydraulic hoses from the motor and

pump assembly.

8. See Figure 14. Disconnect power cord from power source.

9. See Figure 15. Loosen the screw clamp.

Figure 13. Filler Plug

Figure 14.

Disconnected from Power Source

Figure 15.

Screw Clamp

Form No. 1000542

Rev. 2 November 14, 2014

Page 17

General Maintenance continued

10. See Figure 16. Remove the ller plug and drain the

uid from the reservoir.

Figure 16. Filler Plug

11. See Figure 17. Remove the 4 screws.

12. Remove the reservoir from the motor and pump

assembly.

13. Clean the mating surfaces.

14. Clean the inside of the reservoir.

15. See Figure 18. Replace the inlet suction filter.

16. Place the reservoir (with new o-ring) on the pump

and motor assembly. Tighten the screws to:

• 5 Nm (45 in/lbs).

Figure 17.

Reservoir Screws

17. Remove the filler plug and insert a clean funnel

with a filter. Fill the reservoir with Power Team hydraulic fluid 47 cSt @ 38°C (215 SUS @ 100°F) If low temperature requirements are needed, use hydraulic oil 5.1 cSt @ 100°C (451 cSt @ -40°C).

Figure 18.

Inlet Suction Filter

Form No. 1000542

Rev. 2 November 14, 2014

Page 18

18. See Figure 19. Tighten the screw clamp.

Checking Brushes on Universal Motors

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

General Maintenance continued

Figure 19.

Screw Clamp

1. See Figure 20. Disconnect power cord from power source.

2. Remove the motor covers. Refer to Motor Cover Removal and Installation.

3. See Figure 21. Use a screwdriver to remove the brush holder cap.

4. Remove the brush.

Figure 20.

Disconnected from Power Source

Figure 21.

Brush Holder

Form No. 1000542

Rev. 2 November 14, 2014

Page 19

General Maintenance continued

5. See Figure 22. The brush assemblies must be replaced if they are 4.7 mm (3/16 in.) or less.

6. See Figure 23. Install brush assemblies and brush holder caps.

Replace when

4.7 mm (3/16") or less

22 mm (7/8")

(new)

Figure 22.

Brush Inspection

Fuse Replacement

1. See Figure 24. Disconnect power cord from

power source.

Figure 23.

Brush

Figure 24.

Disconnected from Power Source

Form No. 1000542

Rev. 2 November 14, 2014

Page 20

2. See Figure 25. Remove the fuse holder.

3. Replace the fuse. On 115V (nominal) replace 15A time delay 250VAC 5x20mm fuse , 230V (nominal) replace 10A time delay 250VAC 5x20mm fuse.

4. To install, reverse the removal procedure.

General Maintenance continued

Figure 25.

External Fuse Holder

Form No. 1000542

Rev. 2 November 14, 2014

Page 21

Troubleshooting Guide

WARNING: To prevent personal injury,

• 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 Hydraulic Technologies 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 or in the tool.

Problem Cause Solution

Electric motor does not run.

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.

1. Control system not powered.

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. Pendant not plugged in.

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. Push START (green) switch.

2. Plug in unit.

3. Check line voltage.

4. Replace brushes.

5. Use an alternate circuit or have a qualied electrician add an additional circuit.

6. Connect pendant.

1. Disconnect unit from power

supply; contact a Hydraulic

Technologies 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 source; have qualied electrician review motor and circuit wiring.

1. Replace gauge.

2. Contact a Hydraulic Technologies Service Center.

Form No. 1000542

Rev. 2 November 14, 2014

Page 22

Troubleshooting Guide continued

Problem Cause Solution

Pump is not delivering

uid, or delivers only enough uid to advance

connected components partially or erratically or operation to slow.

Pump builds pressure but cannot maintain pressure.

Pump does not build to full pressure.

Erratic action 1. Air in system.

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. Cold uid or uid too heavy. (Hydraulic uid is of a higher

viscosity than necessary.)

7. Vacuum in reservoir.

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.

2. Internal leakage in attached components.

3. Attached component sticking or binding.

4. Malfunctioning valve.

1. Add uid, refer to lling the pump reservoir in Initial Setup section.

Verify quick-disconnect couplings

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 Hydraulic Technologies service center.

6. Drain, ush, and rell reservoir using a lighter weight uid. Refer to General Maintenance section.

7. Clean plugged vent in ller plug.

1. Look for external leaks. If no uid leakage is visible, the problem is internal. 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.

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.

Verify connections. Contact authorized Hydraulic Technologies Service Center.

Form No. 1000542

Rev. 2 November 14, 2014

Page 23

Repair Procedures

Motor Shroud Removal and Installation

1. See Figure 26. Disconnect power cord from power source.

2. See Figure 27. Remove the three motor shroud screws.

Figure 26.

Disconnected from Power Source

3. See Figure 28. Remove the two electric shroud screws and remove the motor shroud.

Figure 27.

Motor Shroud Screws

Figure 28.

Electric Shroud Screws

Form No. 1000542

Rev. 2 November 14, 2014

Page 24

4. See Figure 29. Remove the third electric shroud

screw and the electric shroud.

5. See Figure 30. If necessary, disconnect the three

wires from the motor.

Repair Procedures continued

Figure 29.

Electrical Shroud Screw

6. See Figure 31. If necessary, remove the nut and route the wires through the electrical shroud.

Figure 30.

Motor Wires

Figure 31.

Cover Nut

Form No. 1000542

Rev. 2 November 14, 2014

Page 25

Repair Procedures continued

7. See Figure 32. If necessary, route the wires through the electrical shroud and install the nut.

8. See Figure 33. If necessary, position the electrical shroud and connect the wires.

Figure 32.

Cover Nut

9. See Figure 34. Position the electrical shroud. Apply a small amount of Loctite® 243 or equivalent on end of the M6 bolt and install the bolt. Verify wires are not pinched or contacting the armature. Torque to 4.5-5 Nm (40-45 in/lbs).

Figure 33.

Motor Wires

Figure 34.

Electric Shroud Screw

Form No. 1000542

Rev. 2 November 14, 2014

Page 26

Repair Procedures continued

10. See Figures 35 and 36. Apply a small amount

of Loctite® 243 or equivalent on the end of the M4 bolts. Position the shroud cover and install the bolts. Torque the bolts to 2.8-3.3 Nm (25-30 in/lbs).

11. See Figure 37. Apply a small amount of

Loctite® 243 or equivalent on end of the M6 bolt and install the bolt. Torque to 3.3-3.9 Nm (30-35 in/lbs).

Figure 35.

Electric Shroud Screws

Figure 36.

Motor Shroud Screws

Figure 37.

Motor Shroud Screw

Form No. 1000542

Rev. 2 November 14, 2014

Page 27

Repair Procedures continued

Guard Removal and Installation

1. See Figure 38. Disconnect power cord from power source.

2. Disconnect any hydraulic hoses.

3. Disconnect the control pendant.

4. See Figure 39. Loosen but do not remove the four electrical box screws. Position the cover aside.

Figure 38.

Disconnected from Power Source

Figure 39.

5. See Figure 40. Remove the four electrical box screws.

Cover Screws

Figure 40.

Mounting Screws

Form No. 1000542

Rev. 2 November 14, 2014

Page 28

6. See Figure 41. Loosen the worm clamp.

7. See Figure 42. Remove the guard to motor bolts and remove the motor and pump assembly.

Repair Procedures continued

Figure 41.

Worm Clamp

8. If necessary, remove the worm clamp.

9. To install, reverse the removal procedure.

10. Install bolts and tighten to 7.5 Nm (65 in/lbs).

Figure 42.

Motor Bolts

Form No. 1000542

Rev. 2 November 14, 2014

Page 29

Parts List

Item

No.

1 1 9072 GAUGE, 10000 PSI, 4" DIA, CAL. (SPX)

3 2 2002095 MOTOR SHROUD KIT

4 5 1000371 DECAL, BURN HAZARD/HOT SURFACE. ISO

No.

Req'd

1 3000556 ASSY, PUMP/MOTOR (110/115V 50/60Hz)

1 3000584 ASSY, PUMP/MOTOR (220/230V 50/60Hz)

Part

No. Description Notes

5 1 G1-1074-27 O-RING (NOT SHOWN)

6 1 1000550 DECAL, TANK FILL LINE

Form No. 1000542

Rev. 2 November 14, 2014

Page 30

Parts List continued

Item

No.

8 2 2002075 SCREW, M8X1.25 X 16MM HHC C8.8 ST ZN

9 4 2002089 NUT, HEX M4-0.7

10 4 2002087 WASHER, LOCK 7.6MM X 4.4MM

11 1 2002073 GUARD, COMPACT PUMP

12 1 2002060 ELECTRICAL BOX, COMPACT PUMP

13 4 2002088 SCREW, M4X0.7 X 22MM SHC C12.9 ST

14 1 1000662 DECAL, PLAS CERT CE US RECT 2.24 IN

15 1 1000608 DECAL, PLAS INFO CAUT US RECT 3.0 IN

16 1 1000543 DECAL, SPX BOLTING SYSTEMS

No.

Req'd

8 3000834 SERVICE KIT RUBBER BUMPER

Part

No. Description Notes

SEE TECH. BULLITEN 121514

TORQUE TO

7.5 Nm (65 IN/ LBS)

17 1 1000616

1 1000617

1 1000618

1 1000619

18 1 2002324 CLAMP, HOSE, WORM GEARS 5-1/8" TO 6"

19 0.5 11360 OIL, HYDRAULIC 46AW (BLUE) (NOT SHOWN)

20 1 3000554 ASSY, PENDANT TORQUE WRENCH

21 1 2002391 DECAL, PLAST CERT CE US RECT 4.75IN

22 1 2001699 KNOB, ADJUSTMENT

23 1 251411 COUPLER, QUICK PLUG - 1/4 NPTF

2 2007886 MOTOR, BRUSH ASSEMBLY (not shown)

2 10806 CAP, BRUSH HOLDER (not shown)

DECAL, PLAS CERT CE US RECT 4.75 IN (PE39YED1PR)

DECAL, PLAS CERT CE US RECT 4.75 IN (PE39PED1PR)

DECAL, PLAS CERT CE US RECT 4.75 IN (PE39YED1BPR)

DECAL, PLAS CERT CE US RECT 4.75 IN (PE39PED1BPR)

Form No. 1000542

Rev. 2 November 14, 2014

Page 31

Hydraulic Technologies Facilities

UNITED

CER TIFIED

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

ST ATES

CHINA

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

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

infochina@powerteam.com

FAR EAST

7 Gul Circle Singapore 629563 Singapore

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

E-mail:

infoasia@powerteam.com

EUROPE

Albert Thijsstraat 12 6471 WX Eygelshoven The Netherlands

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

E-mail

infoeurope@powerteam.com

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

Form No. 1000542

Rev. 2 November 14, 2014

Page 32

Declaration of Conformity

Form No. 1000542

Rev. 2 November 14, 2014