SPX POWER TEAM® Operating Instructions for:
Contents
1. Klarenanstelerweg 5 D POWER TEAM Pea pE stearic RN OIC Netherlands Telephone 31 45 5463030 Fax 31 45 5461633 EC Declaration of Incorporation as defined by European Communities Directive 89 392 EEC Annex II B MANUFACTURER S ADDRESS 5885 llth Street Telephone 815 874 5556 Rockford Illinois 61109 Fax 815 874 7853 USA TYPE or eouIpMENT RECIPROCATING AIR PISTON HYDRAULIC PUMP ORDER NUMBER OR PART NUMBER PA4 Series PA6 Series PA5O Series PAGO PA64 52431 58356 203641 OTC 203641 PF APPLICATION OF EC COUNCIL DIRECTIVES 89 392 EEC as amended by 91 368 EEC 93 44 EEC and 93 68 EEC STANDARDIS TO WHICH CONFORMITY IS DECLARED EN292 1 and EN292 2 I the undersigned hereby declare that the equipment specified above conforms to the above European Communities Directive s and Standard s This product is not to be put into service until the machine has been declared in conformity with the provisions of the European Communities Directive s r ta ap SL US ers Signature DATE 1 JAN 1995 Michael S O Brien idate month year Director Quality Technical Services price Owatonna Minnesota USA Ne Nee Se See SN ES eS ESSN Sr Sn OR mt ty er OE nen unc Se sy Arne min Sty Wes Ed ny Sens SEE sy sons Ne mune wanes tro me uy sna meal ea I l I l l I l l l l l l I l l I l l l l I I I I I I l l l I l l l l l I l l l l2. 3 Connect the fluid line from the fluid return port on the manifold to the pump return port on the valve 4 Connect the cylinder s to the valve IMPORTANT On al single pressure line applications plug one port on the valve 1 Connect the ports of the pump valve to cylinder s When port A is pressurized port B becomes the return When port B is pressurized port A becomes the return 2 Place the valve into the A or B position in order to pressurize the cylinder s or start the pump Operating Instructions Form No 105001 OPERATION PICTOGRAM DEFINITIONS x Activating the pump with the pedal end marked with this pictogram ery the flow of fluid is directed out of the reservoir Activating the pump with the pedal end marked with this pictogram I the flow of fluid is directed back to the reservoir Priming The Pump Unit Under certain circumstances it may be necessary to prime the pump unit To accomplish this perform the following procedure For Hand Foot Operated Pumps 1 Press the release end of the pedal while holding down the air intake valve with a flathead screwdriver The air intake valve is located directly under the pedal in the area marked me The valve is depressed simultaneously with the cH area of the pedal during priming 2 Allow the pump to cycle approximately 15 seconds 3 Remove the screwdriver and press the mal end of the pedal once Filler more
3. Normal operation 2 Repair or replace 1 Set at one drop per minute rr Sheet No 5o0f5 Rev 3 Date 30 April 2003 Operating Instructions Form No 105001 Back sheet 5 of 5 POWER TEAM FACILITIES AUSTRALIA SC SOR FAR KOREA 28 Clayton Road Eert EAST So Anyang P O Box 50 Clayton North 19 Joo Koon Road Kyounggi Do Victoria Singapore 628978 Korea 430 600 Australia Singapore Tel 82 31 391 0209 Tel 61 3 95628800 Tel 65 265 3343 FAX 82 3 396 5373 FAX 61 3 95625080 FAX 65 265 6646 E mail ptkor hitel net E mail E mail sales powerteam com au powerteam pacific net sg Be 190G UNITED Ferrit STATES SPX Corporation Fluid Power 5885 Hth 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 SO 002 JAPAN MEXICO FAX 1 800 288 7031 Eikai EUROPE 2 5 53 Minowacho Gustavo Baz 15 E mail l Klarenanstelerweg 5 D Kohoku Ku Yokohama Col Echegaray C P 53310 pwrteam fluidpower px com 7 6468 EP Kerkrade Kanagawen 223 0051 Naucalpan Edo de Mexico k Netherlands Japan Mexico Technical Services Tel 31 45 5678877 Tel 81 45 562 7700 Tel 52 55 53603645 Tel 1 800 477 8326 FAX 31 45 5678878 FAX 81 45 562 7800 FAX 52 55 53658711 FAX 1 800 765 8326 E mail spx powerteam nl E mail tecnoherramienta aol com For more information Internet address http www powerteam com or http www hytec com
4. Pumps 1 To extend the cylinder shift the valve handle to the advance position and depress the end of the foot pedal inscribed with ma to activate the pump ee 2 To hold the cylinder in position release the end of foot pedal inscribed with to deactivate the pump 3 To retract the cylinder shift the valve handle to the retract position and depress the end of the foot pedal inscribed with ma to activate the pump For Pumps With Air Regulators 1 Open the air shut off valve if so equipped or connect the air quick coupler if so equipped NOTE under certain circumstances the pump may need to be primed before operation Refer to the method described in the section entitled Priming the Pump Unit 2 Slowly turn the air regulator control on unit clockwise to increase pressure counterclockwise to decrease pressure As air is admitted to the pump unit it will begin to deliver fluid to the system Continue to slowly turn the air regulator control clockwise until gauge reads the maximum hydraulic pressure rating as stated on the pumps data plate A maximum hydraulic pressure reading should be obtained if air pressure is approximately 100 PSI 7 BAR 3 Cycle the system several times by manually shifting the 3 way 4 way valve if so equipped or the remote valve if so equipped Set the air regulator to obtain the desired hydraulic pressure When decreasing pressure shift the valve after each adjustment before measuring act
5. Vent 4 If the cylinder extends or pressure builds the pump has been Cap successfully primed If the pump does not respond repeat the procedure jogging the air intake valve while holding the pedal in the CEP position ADVANCE RETRACT Pressure lt Pressure For Manual Valve Operated Pumps to Port A Disconnect the hose end at the advance port of the cylinder Direct the hose end into a suitable container or back into the pump reservoir Shift the valve to the ADVANCE position and depress the end of the foot pedal inscribed with m Allow the pump to cycle until fluid begins to flow freely into the Filler container or reservoir Reconnect the hose end to the cylinder advance port Vent Shift the valve to the ADVANCE position and reactivate the pump If the Cap cylinder extends or builds pressure the pump has been successfully primed If not refer to the Trouble shooting Guide of these instructions For Remote Controlled Pumps Depress the m AND CES buttons on the remote hand control simultaneously and allow the pump to cycle for approximately fifteen seconds Release both buttons and then depress the faim 3 button once more If the cylinder extends or pressure builds the pump has been successfully primed If the pump does not respond repeat the procedure If pump still does not respond tip pump upside down and repeat procedure For Tandem Pumps 1 Connect the fluid line to the pressure port and
6. keep the return port plugged Place the other end of the fluid line in the pump filler hole NOTE If the fluid lines are connected to a remote valve shift the valve into the center position and plug both cylinder ports on the valve This lets fluid circulate through the vaive and back to the pump reservoir thereby allowing the pump to prime 2 Attach air line with shut off valve to the pump 3 Open the air valve Pump will begin to reciprocate and fluid will advance through the hose or fluid line and return to the pump reservoir Allow the pump to cycle approximately 15 seconds 4 Plug the manifold pressure port or shift the valve to pressurize the circuit If the pump builds pressure it has been successfully primed Sheet No 3o0f5 Rev 3 Date 30 April 2003 a Ete Operating Instructions Form No 105001 Back sheet 3 of 5 Pump Operation For Hand Foot Operated Pumps 1 To extend the cylinder depress the pedal on the end marked gt 2 To hold the cylinder in position release the end of foot pedal marked with ma 5 to deactivate the pump 3 To retract the cylinder depress the pedal on the end marked I For Remote Controlled Pumps 4 To extend the cylinder depress the button on the remote hand control marked mia 2 To hold the cylinder in position release the fm 4 button 3 To retract the cylinder depress the button on the remote hand control marked EE For Manual Valve Operated
7. the fluid flow 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 hose and possibly 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 Hose deterioration due to corrosive materials can result in personal injury Never paint the couplers inspect machine for wear damage and correct function before each use Do not use machinery that is not in proper working order but repair or replace it as necessary Replace worn or damaged safety decals Modification of a product requires written Power Team authorization Use only components with the same pressure rating when assembling a system or machine Do not exceed the hydraulic pressure rating noted on the pump data plate or tamper with the internal high pressure relief valve Creating pressure beyond the rated pressure can result in personal injury Before replenishing the fluid ievel retract the system to prevent overfilling the pump reservoir An overfill can cause personal injury due to excess reservoir pressure created when cylinders are retracted Air Supply Shut off and disconnect the air supply
8. when the pump is not in use or before breaking any connections in the system PREPARATION amp SET UP Air Supply Hook Up Remove the thread protector from the air inlet of the pump Select and install the threaded fittings which are compatible with your air supply fittings The air supply should be 20 CFM 57 M3 min and 100 PSI 7 BAR at the pump to obtain the rated hydraulic pressure Air pressure should be regulated to a maximum of 140 PSI 9 BAR Secure your pump fitting to the air supply See illustrations on following pages aA WARNING If improperly used pressurized equipment can be potentially hazardous Therefore e Hydraulic connections must be securely fastened before building pressure in the system Release all system pressure before loosening any hydraulic connection in the system Venting The Reservoir To improve hydraulic fluid delivery and increase useable hydraulic fluid capacity remove shipping plug and install filler vent cap before using the pump Operating Instructions Form No 105001 Hydraulic Connections Clean all the areas around the fluid ports of the pump and cylinder Inspect all threads and fittings for signs of wear or damage and replace as needed Clean all hose ends couplers and union ends Remove the thread protectors from the hydraulic fluid outlets Connect the hose assembly to the hydraulic fluid outlet and couple the hose to the cylinder See illustrations below IMP ORTANT Seal all e
9. Form No 105001 POWER TEAM Operating Instructions for PA4 SERIES 52431 PA6 SERIES 58356 PASO SERIES 203641 OTC PA6O 203641 PF PA64 c MODELS C D E F amp G AIR HYDRAULIC PUMP Max Pressure See Pump Data Plate Workstation Sound Pressure Level 83 dB A at Rated Capacity Definition An air hydraulic pump delivers hydraulic fluid under pressure through the use of compressed air as a power source 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 DANGER Danger is used only when your action or lack of action will cause serious human injury or death A WARNING 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 A WARNING Itis the operator s responsibility to read and understand the following safety statements e Only qualified operators should install operate adjust maintain clean repair or transport this machinery e These components are designed for general use in normal environments These components are not specifically designed for lifting and moving people agri food machinery certain types of mobile machinery or special work environments such as explosive flammable or corrosive On
10. Instructions Form No 105001 PREVENTIVE MAINTENANCE IMPORTANT Any repair or servicing that requires dismantling the pump must be performed in a dirt free environment by a qualified technician Dispose of machine and fluids properly Lubrication For Hand Foot Manual Valve and Remote Control Operated Pumps if the pump is operated on a continuous duty cycle for extended periods the manufacturer recommends installing an automatic air line oiler in the air inlet line as close to the pumping unit as possible Set the unit to feed approximately one drop of oil per minute into the system Use SAE grade oil 5W to 30W For Tandem Pumps These models have an integral air pressure regulator air filter and lubricator Set the lubricator to feed one drop of oil per minute to the system Use SAE grade oil 5W to 30W For servicing the air regulator lubricator and filter system see the operating and service instructions provided Bleeding Air From The System During the first moments of operation or after prolonged use a significant amount of air may accumulate within the hydraulic system This entrapped air may cause the cylinder to respond slowly or behave in an unstable manner To remove the air run the system through several cycles extending and retracting the cylinder free of any load The cylinder must be at lower level than the pump to allow air to be released through the pump reservoir inspecting The Hydraulic Fluid Level Check th
11. auge must be of the proper rating for the pressure used Use only Power Team approved accessories hydraulic fiuid and repair parts Installing An In line Air Pressure Gauge 1 Remove the male fitting from the air filter and install a tee adapter with gauge between the hose and air filter 2 Install male fitting into the tee adapter and securely clamp the hose to the male fitting Installing An In line Hydraulic Pressure Gauge 1 Remove the thread protector from the hydraulic outlet port and inspect the threads and fittings for signs of wear 2 Install a tee adapter with gauge between the hose coupling and the pump hydraulic outlet port 3 Tighten all connections securely DO NOT OVERTIGHTEN HOSE CONNECTIONS Fire Resistant Hydraulic Fluid Flame Out 220 fire resistant hydraulic fluid is compatible with all Power Team hydraulic equipment The use of this fluid does not require the changing of seals in any Power Team pump or cylinder and is available through your local Power Team distributor p88 PR Operating Instructions Form No 105001 OPERATOR TROUBLESHOOTING GUIDE If this guide does not resolve your pump problem contact an authorized hydraulic service center or a company headquarters listed on back sheet 5 of 5 PROBLEM Pump reciprocates but no fluid delivery cylinder will not extend Low fluid delivery cylinder extends slowly CAUSE 1 Low fluid level 2 Pump not primed 3 Fluid intake filter c
12. e fluid level in the reservoir after every 10 hours of use Drain and replenish the reservoir with Power Team hydraulic fluid after every 300 hours of use approximately For pumps with a 105 cubic inch 1 7 reservoir capacity The fluid level should be 1 2 inch 12 7 mm from the filler vent cap with all cylinders retracted For pumps with a 2 gallon 7 6 I reservoir capacity The fluid level should be 1 3 4 inch 44 5 mm from the filler vent cap with all cylinders retracted Draining And Flushing The Reservoir IMPORTANT Wipe the pump exterior completely clean before attempting this procedure 1 Remove the screws that fasten the pump assembly to the reservoir Remove the pump assembly from the reservoir Do not damage the gasket filter or safety valve 2 Drain the reservoir of all fluid and refill half full with clean hydraulic fluid Rinse the filter clean 3 Place the pump assembly back onto the reservoir and secure with two of the machine screws assembied in opposite corners of the housing 4 Run the unit for several minutes Use the same method described in the section titled Priming the Pump Unit 5 Drain and clean the reservoir once more 6 Refill the reservoir with Power Team hydraulic fluid and replace the pump assembly with gasket on the reservoir and install the screws Torque the screws as follows For 105 cubic inch 1 7 I reservoirs torque to 25 to 30 inch pounds 2 8 to 3 4 Nem for 2 gallon 7 6 reservoir
13. l l l Lam Appendix to 105001
14. ly 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 These instructions are intended for end user application needs Most problems with new equipment are caused by improper operation or installation Detailed service repair instructions or parts lists can be obtained from your nearest Power Team facility see listing Sheet No 1of5 Rev 3 Date 30 April 2003 Operating Instructions Form No 105001 Back sheet 1 of 5 SAFETY PRECAUTIONS a WARNING General Operation e Pum All WARNING statements must be carefully observed to help prevent personal injury Before operating the pump all hose connections must be tightened with the proper tools Do not overtighten Connections should only be tightened securely and leak free Overtightening can 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 release all pressure Never attempt to grasp a leaking pressurized hose with your hands The force of escaping hydraulic fluid could cause serious injury Do not subject the hose to potential hazard such as fire sharp surfaces extreme heat or cold or heavy impact Do not allow the hose to be altered or kink twist curl crush cut or bend so tightly that
15. n using a double acting cylinder attach one hose to port A of valve and the other end of the hose to the advance port C of cylinder Attach the second hose to valve port B and the other end of the hose to return port D of cylinder S Sheet No 2of5 Rev 3 Date 30 April 2003 Operating Instructions Form No 105001 Back sheet 2 of 5 For Remote Controlled Pumps Remote we Hand Control Hydraulic Three strand amp Boe Air Hose i i i Tee Air a Adapter Filter 2 Filler Vent Inline Hydraulic Inline Air J ee High Pressure Gauge Pressure ft Gauge YN Single acting I 7 Cylinder Coupler Lubricator Filter Tee Adapter Male Fitting To Hydraulic a Hose And Cylinder Union Adapter swivel connector For Tandem Pumps With Remote Valve Air Filter Wee Inlet Port 1 4 NPTF Air Lubricator Position A Air Pressure Regulator Pressure Oil Fill and Vent Valve and Manifold Port Ports are 3 8 NPTF With Pump Mounted Valve Position A Pressure to cylinder port A cylinder port B to tank Ae Inlet Port 1 4 NPTF Hold Neutral all ports blocked Postion B Pressure to cylinder port B cylinder port A to tank Position A Position B Hold 1 Connect the pump to a remote 3 way 4 way valve 2 Connect the fluid line from the fluid pressure port on the manifold to the pump pressure port on the valve
16. ontaminated 1 Inadequate air supply a Check air input supply b Contamination check air side of pump plugged air inlet screen 2 Hydraulic failure a Check the fluid inlet filter for contamination b Air in hydraulic system SOLUTION 1 Add fluid as instructed in Preventive Maintenance section 2 Prime pump as instructed in Operation section 3 Remove reservoir and clean intake filter and reinstall 1 a Should be 20 CFM 57 M3 min minimum b Clean and reassemble 2 a Remove reservoir and clean intake filter and reinstall b Bleed the system as described in the Preventive Maintenance section i a Pump will not build to maximum pressure no visible leakage 1 Check the air supply 2 Pressure regulator improperly adjusted if so equipped 1 100 PSI 7 BAR is required to obtain maximum pressure 2 Adjust according to instructions in Operation section renee eee a UU Pump builds pressure but will not hold system pressure Pump will continue to run slowly even after desired pressure is reached Excess oil spray from muffler 1 Check the hydraulic connections and other system components for leakage including 3 way 4 way valve if so equipped 1 Output pressure equal to or higher than relief vaive setting 2 Defective 3 way 4 way vaive or other components leaking 1 Air lubricator is set too rich if so equipped 1 Refit or repair as needed 1
17. s torque to 35 to 45 inch pounds 4 0 to 5 0 Nem IMPORTANT Drain and clean the other hydraulic system components hoses cylinders etc before reconnecting them to the pump This will prevent contaminated fluid from entering the pump again Sheet No 4of5 Rev 3 Date 30 April 2003 Operating Instructions Form No 105001 Back sheet 4 of 5 Refilling The Reservoir If additional fluid must be added to the reservoir use only Power Team hydraulic fluid 215 SSU 100 F 38 C Clean the entire area around the filler plug before adding fluid to the reservoir Remove the filler plug and insert a clean funnel with filter The cylinder must be fully retracted and the air supply disconnected when adding the fluid to the reservoir Periodic Cleaning IMPORTANT The greatest single cause of failure in hydraulic pumps is dirt Keep the pump and attached equipment clean to prevent foreign matter from entering the system A routine should be established to keep the pump as free from dirt as possible All unused couplers must be sealed with thread protectors All hose connections must be free of grit and grime Any equipment hooked up to the pump should also be kept clean Use only Power Team hydraulic fluid in this unit and change as recommended every 300 hours ACCESSORIES Gauges and accessories may not be included with the pump However a hydraulic gauge is strongly recommended whenever the pump is used a WARNING The g
18. ual hydraulic pressure 4 Shut off and disconnect air supply to the pump and shift pump valve if so equipped or remote valve if so equipped two times to release all system pressure Check fluid level with hydraulic system retracted The pump is now ready for operation NOTE The hydraulic pressure is increased or decreased by adjusting the air inlet pressure at the regulator e On two stage pumps the air pressure regulator that is mounted on the pump controls only the output from the high pressure stage The output of the low pressure stage of the pump is determined by the air line pressure coming from the remote regulator A remote regulator is required to control the air pressure from the air line The independent functioning of the low and high pressure stages of this pump can best be described as follows At the minimum air line pressure of 40 PSI 3 BAR the low pressure stage of the pump will deliver 480 PSI 33 BAR hydraulic pressure with the pump regulator turned counterclockwise to prevent air pressure from activating the high pressure stage of the pump At the minimum air line pressure of 40 PSI 3 BAR the high pressure stage of the pump will detiver 4 000 PSI 275 BAR hydraulic pressure with the pump regulator turned clockwise to allow air pressure to reach the high pressure stage Always remember that the pump regulator must be turned fully counterclockwise when the pump is used to produce 1 200 PSI 83 BAR or less Operating
19. xternal pipe connections with a high grade nonhardening thread sealant Teflon tape may also be used to seal hydraulic connections provided only one layer of tape is used Apply the tape carefully two threads back to prevent it from being pinched by the coupler and broken off inside the system Any loose pieces of tape could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts For Hand Foot Operated Pumps x 2 p P Union Adapter Inline Hydraulic swivel connector or High Pressure Gauge Hydraulic Hose Air Inline Air EA Pressure Gauge T Hose Coupler Lubricator Supply Filter Coupler For Manual Valve Operated Pumps Hydraulic t High Pressure Gauge g Lubricator inline Air Pressure Gauge Coupler Filter Tee Adapter Hydraulic Hydraulic Hose s r Hose al ingle Acting lt Double Air Supply Cylinder Acting Cylinder This pump is equipped with a two position 3 way 4 way control valve for operating single or double acting hydraulic cylinders and requires attaching the hoses in the following manner When using a single acting cylinder attach one end of a hose to port A of valve and the end of the hose to the advance port C of the cylinder Then install a pipe plug in valve port B If the hoses are frequently connected and disconnected quick couplers should be used to prevent wear and tear on the fittings Whe
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