Form No. 102842 POWER TEAM Operating Instructions for: SPX Hy Teshoece Teck Senco: (800) 477-0925, Scour(seorsey” = prastnas” prevosomes 8885 11th Siot Fr (000) 769-8926 Griazfeeorss) SENS Prssaentes RecktorsIL 61108-9089 USA Ore Eni (000) 41-1418 certs (searsm) —PZSSERLES isto semies owerteam.com ‘ura (seerss) Path senes Panoseries beset ese fSoic/seorse) Passes anno Sees GiezlseePicn PaO SEMES Paso sens teen (Seeris) SBP SeAIES vent SINGLE-STAGE AND TWO-STAGE HYDRAULIC HAND PUMP ‘Max. Pressure: See Pump Data Plate hand pump delivers hydraulic fluid under pressure by directly applied manual effort. Definition: A hydrai Note: Mlustrations depict general pump configurations. f a Se pasriet 39 to6260669 wa) ooo] ume ae or vel over] [Ve Nein Vath | We louge| siese | 5S ear FETT aera po Pt [ame 8 | aes |e 2 [aoe | fs | i | Fea] fone pe” | 30 | an T yaa a6) see | ae POOF | 2 [oss | 08 | 1o000| 700 ‘fous es] a )ae PSOFFIpopon| 0.058 08 | 1oo00| 700 sege Pac Paseo oom 700 faim [oss | 1 Josse| tos | 22 | 2 onto] me | 2 [885 Be [Sto] i +[ossoy a0" a5 ae fume [oor |S [5885 24 | ito ts ‘Joss so] as | ee fave) |P5%P pepe ovo | 21 | sooo | 700 | ar] & [9550] 17 | won |g [e888 82 | iit | Bo wes] 1 | 200 [eae [as | 2 Leten| 2 | sco] i 1 /zeure] aes ae F900 | 2 |o160| 26 | 10000 | 700 1 aso] 05] sae Paso} 2 fo298| ‘a8 | so000| 700 TORE [oop tae OT |e aT rare [5] 2 [oo | 9s [reo cre nesol 2 [2000] 25 | 22] 2 7 P1580] 2 |0160| 26 | 10000| 700 we Kssoof fea] | 8 | 22 etuea|P9000] 2 | oveo| “26 | 1000] 100 ‘ey i” Praso wos | ae vawe) [P4800] 2 [ozo | 4s | 10000 | 700 ENF TF ou pore) anal ponge Tablet SheetNo. 1014 © SPX Hydraulic Technologies Rev12 Date: 19 OCT 2009Operating Instructions, Form No. 102842, Back sheet 1 of 4 SAFETY EXPLANATIONS Two safety symbols are used to identify any action or lack of action that can cause personal injury. Your reading and understanding of these safety symbols is very important. AX daNceR - Danger is used only when your action or lack of action wil cause gorious human injury or death, BA wosninc- warning is used to describe any action or lack of action where a serious injury can occur IMPORTANT - Important is used when action or lack of action can cause equipment failure, either immediate or over a long period of time. Pictogram Definition Do not remove this component. For service only. Pressure must be released. Ad waanina: itis the operator's responsi safety statements, ity to read and understand the following + Only qualified operators should install, operate, adjust, maintain, clean, repair, or transport this machinery. + These components are designed for general use in normal environments. These components are not specifically designed for lifting and moving people, agri-tood machinery, certain types of mobile machinery or special work environments such a: explosive, flammable or corrosive. Only the user can decide the suitability of this machinery in these conditions or extreme environments. Power Team will supply information necessary to help make these decisions. + Do not use equipment if damaged, altered, or in poor condition. * All safety decals must be replaced when unreadable. ‘These instructions are intended for end-user application needs. Most problems with new equipment are caused by improper operation or installation. Detailed service repair insiructons or pars lists can be obtained from your nearest Power Team facillyOperating Instructions Form No. 102842 SAFETY PRECAUTIONS BX sseeava: ro hop prover personal inary, + Before operating the pump, all hose connections must be tightened with the proper tools. Do not ‘overtighten. Connections need only be tightened securely and leak-froe. Overtightening may cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities. + Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the pump and shift the control valve twice to release all pressure. Never attempt to grasp a leaking hose under pressure with your hands, The force of escaping hydraulic fluid could cause serious injury. + Do not subject the hose to any potential hazard such as fire, extreme heat or cold, sharp surfaces, heavy impact. Do not allow the hose to kink, twist, curl, or bend so tightly that the fluid flow within the hos blocked or reduced. Periodically inspect the hose for wear because any of theso conditions can damage the hose and result in personal injury. + Do not use the hose to move attached equipment. Stress may damage the hose and cause personal injury. + Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must not come in contact with corrosive materials such as creosote-impregnated objects and some paints. Consult the manufacturer before painting a hose. Naver paint the couplers. Hose deterioration duo to corrosive materials may result in personal injury. + All components in the hydraulic system must match the ma lum pressure rating of the pump. Pump + Do not exceed the PSI rating noted on the pump nameplate or tamper with internal high pressure relief valve. Creating pressure beyond rated capacities may result in personal injury. + Before adding hydraulic fluid, retract the system to prevent overfilling the pump reservoir. An overfill ‘may cause personal injury due to excess reservoir pressure created when cylinders are retracted, + The load must be under operator control at all times. + Do not connect pump to hydraulic system powered by another pump. Cylinder + Donot exceed rated capacities of the cylinders. Excess pressure may result in personal injury. + Donot set poorly-balanced or off-center loads on a cylinder. The load may tip and cause personal injury. + Stay clear of lifted loads and keep others away. + Extensions are not recommended for lifting applications. SET-UP Hydraulic Connections IMPORTANT: Seal all hydraulic connections with a high grade, nonhardening thread sealant. Teflon tape may also be used to seal hydraulic connections if only one layer of tape is used. Apply the tape carefully, two threads back, to prevent it from being pinched by the coupler and broken off inside the pipe end. Any loose pieces of tape could travel through the system and obstruct the flow of fluid or cause jamming of precisian- {it parts. 1. Clean all areas around the fluid ports of the pump and cylinder. Clean all hose ends, couplers, and union ends. Remove thread protectors from the hydraulic fluid outlets, and connect the hose assembly. Couple hose to cylinder. 2, The use of a hycraulie pressure or tonnage gauge (not included) is strongly recommended. Remove the pipe plug from the gauge port of the valve, thread the gauge into this port and seal as noted above, AX warvuc: to tp prevent persona injury, ~The gauge must have th same pressure rating ae the pump and cinder. Personal njury can result he Wrong snuge sures. + Releate hydrate pressure BEFORE removing or igntening hose couplings Siesta, Bot Fev11 Date: 24 Sept 2007Operating Instructions, Form No. 102842, Back sheet 2 of 4 OPERATION The P460 can be operated only in the horizontal position. All other hand pumps can be operated in a horizontal position or in a vertical position with head pointing downward. Refer to Table 1 and your pump name plate to determine your style of pump. IMPORTANT: Figure 1 illustrates the normal drop of handle effort experienced when all (except P59) two-stage pumps shift from low pressure stage to high pressure stage. Handle Etfort Pressure Untoading Pressure Figure 1 ‘Two-way Valve Pumps with a two-way valve are for use with single- acting cylinders. 4. To extend the cylinder, turn the valve knob counterclockwise to a closed (seated) position. Note: Hand tight only! Work the pump handle up and down to build pressure, 2, Torelease pressure, open the valve slowly by turning the knob clockwise to control the load, Four-way Valve Pumps with a three-position, four-way valve are for use with double-acting cylinders. The hose connection for extending a cylinder can be made to either port. With the handle in the forward position, the fluid is directed to the top fluid port. To maintain (hold) pressure, stop the pumping action. When the valve handle is in the center position, fluid flow is blacked to bath ports, ba, WARNING: The operator should always release the pressure slowly. PREVENTIVE MAINTENANCE IMPORTANT: Any repair or servicing that requires dismantling the pump must be performed in a dittfree ‘environment by a qualified technician. Lubrication ', Apply lubricant regularly to all pivot and rubbing points, 1 Use a good grade of No. 10 motor oll or grease. Do not use dry lubricants, Bleeding Air From the System Air can accumulate in the hydraulic system during the initial set-up or after prolonged use, causing the oylinder to respond siowly or in an unstable manner. To remove the alr 1. Position the cylinder at a tower level than the pump, and turn the cylinder rod end down, 2. Extend and retract the cylinder several times without putting a load on the system. Air will be released into the Pump reservoir. Follow the fiuid level instructions for your reservoir type to release the air from the reservoir and {op off the fluid supply. Bleeding Air From The Pump ‘When the pump is first put into use, or after refiling the pump's reservoir it may be necessary to bleed any trapped air from the pump. If this I not done the pump will not function properly (wll not bulld pressure or has very spongy operation). ‘To bleed air from the pump, turn the pressure control knob counterclockwise (CCW) (tum lever down or clockwise on 460 models) and operate the pump handle up and dawn approximately twenty times. Tum the pressure control knob Clockwise (CW) to its full stop position (tum lever up or CCW on P460 models). The pump should now be bled of air and ready to use,Operating Instructions Form No. 102842 PREVENTIVE MAINTENANCE -CONTINUED Hydraulic Fluid Level the system ‘Check the hydraulic uid level in the reservoir periodically. Use a funnel with 2 filer fo add hydraule uid if needed. Refer to Table 1 for your reservoir type. For models with Reservoir Type A: Place the pump in a vortical position with the pump head fasing upward Unserew and remove the pump head from the reservoir. The fluid level within the reservoir should come to the fluid level mark indicated on the reservoir body decal. Before replecing the pump head, visually inspect the o-ring which seals the pump headireservoir assembly. Replace this o-ring fit is worn or damaged. Reinstall pump head to reservoir and tighten seourely, Check for leaks. For models with Reservoir Type B: Remove the filer cap. The fluid level should come to the bottom edge of the filer hole when the pump is level and resting horizontally on its base and the cylinders are retracted (see Figure 2) For models with Reservoir Type G: Remove the filer cap. The fluid level should be 1/2 inch (12.7 mm) from the filler hole when the pump Is level and resting horizontally on its base and the cylinders are retracted. IMPORTANT: The pump sight gauge indicates the presence of hydraulic fluid only. it does not determine correct fluid level. For models with Reservoir Type D: Remove the filer cap. The fluid fevel should be 1/2 inch (12.7 mm} from the cover plate when the pump is level and resting horizontally on its base and the cylinders are retracted. END VIEW OF P19 PUMPS Figure 2 Draining And Flushing The Reservoir Drain, clean and replenish the reservoir with high-grade, approved Power Team hydraulic fui yearly or more often it necessary. The frequency of luid change will depend upon the general warking conditions, severity of use and overall cleanliness and care given the pump. IMPORTANT: Clean the exterior of the pump first. After draining and flushing the reservoir, drain and clean the other hydraulic system components (noses, cylinders, etc.) before connecting them to the pump again. ‘This will help prevent contaminated fluid from entering the pump. Refer to Table 1 for your reservoir type. For models with Reservoir Type A: 1. Unthread and separate the pump head fom the reservoir Drain the reservoir of the used hydraulic tuid. 2, Flush out reservoir with a small amount of clean hydraulic fluid, Clean the pump intake fier. IMPORTANT: Removing the filter from the pump assembly could result in its breakage. Attempt to clean it ‘as woll as possible with it installed, 3, Refill the reservoir and reassemble the pump head fo the reservoir. Tighten securely. Check for leaks. For models with Reservoir Type B & C: 1. Remove the filer cap, Drain the hydraulic fuid through filer hole. 2, Remove the nut from the tie rod. Separate the reservoir from the pump body. Clean the reservoir and filter. IMPORTANT: Removing the filter from the pump assembly could result in its breakage. Attempt to clean it as well as possible with it installed. 3, Reassemble and fil the reservoir with Power Team hydraulic tld, Replace the filer cap. For models with Reservoir Type D: 1. Remove the ten screws fastening the reservoir cover to the reservoir, and it the pump and valve assemblies off. 2. Drain all hydraulic fuid and flush reservoir with a small amount of etean hydraulic uid 3. Remove the pump assembly fer, rinse it clean, and reassemble, 4, Refill te reservoir with Power Team hydraulic fluid. Place the pump and valve assembly (with gasket) on the reservoir, and thread the ten serews. ‘SheetNo. 3 of 4 Tighten seourely and evenly. Rev 11 Date: 24 Sept 2007Operating Instructions, Form No. 102842, Back sheet 3 of 4 TROUBLESHOOTING GUIDE BA ssswc: te natp prevent personal injury avaye relese pump pressure and dlaconnect hoses) from pump before making repairs. Refer to the appropriate pump parts list during trouble-shooting, Repairs must be performed in a dirtree environment by qualified personnel familiar with this equipment, PROBLEM CAUSE Pump losing pressure 1. Sysiem components leaking SOLUTION Repair or replace as necessary 2. Directional cantrol valve leaks or 2." Reseat, repair, or replace not adjusted properly directional control assembly anc correctly adjust 3. Fluid leaking past outlet check 3." Check for dirt, Reseat pump seats) body and/or replace poppet(s) or ball(s) Handle rises after each stroke 1. Fluid leaking past outlet check 1.” Check for dirt. Reseai pump seai(s) body and/or replace poppelis) or ball(s) Pump not delivering fluid 4. Low fluid level in reservoir 1. Check fluid level per instructions, 2. Intake filer is dirty 2. Remove reservoir and clean 3. Seats worn and not seating 8." Repair seats or replace pump property body Pump does not reach full pressure 1. Low fluid level in reservoir 4. Check fuid level per instructions 2, System components leaking 2. Repair or roplace as necessary 8. Directional contiol valve leaks or 3.* Reseat, repair, or replace not adjusted properly directional control assembly and correctly adjust 4. Impropery adjusted relief valve 4." Readjust 5. Fluid leaking past inlet or outlet §.* Reseat or repair inlet or outlet checks or high pressure piston ‘checks or replace high pressure seal damaged piston seal Pump handle can be pushed down 1. Inlet checks ara not seating 17 Check for dirt and/or reseat (slowly) without raising the load valve seats 2 Damaged piston assembly or 2." Replace piston assembly and/or piston seals leaking piston seals. Pump handle operates with a 1. Alrtrappedin system 1. Position cylinder lower than spongy action pump. Extend and return cylinder several times. Follow bleeding instructions. 2. Too much fluid in reservoir 2 Check fluid level per instructions Pump handle effort drops 1. This is normal operation on most icantly after some pressure two-stage hand pumps has been obtained “Power Team recommends these hand pump repairs be performed by an Authorized Hydraulle Service Center.Operating Instructions Form No, 102842 POWER TEAM FACILITIES POWER TEAM’ oe Bat Be ores Hcoungrens seikencee customer expopencusroven wenmuccurrs, anon as seen Teoria siraeet ee eer Sener Sica ese oncarone METERS, Scene SUSE ncaeaas sence ures Haren, GEetSlesserccoma oa eanwosuronomencon BE Gh EH seaeurne aa cs onsoresrowereucou cumwroaroneneancon Se spxeorauic reacts aay Ror Tssa HUA SHAN ROAD, SUR IERTONA eK, ‘Shanon a00ce9, PRC, ‘rieawen) 2908 sue rv) 2708 5682 Sheet No. 40f4 Rev tt Date: 24 Sept 2007