Boss Hydraulics PE026 User manual

Model No.: PE026, PE075, PE090, PE0180
OPERATING INSTRUCTIONS
Electric Pumps- 690 Bar
(10,000 psi)
WARNING
Read and follow all Safety Instructions, Warnings, Cautions and
Important information provided in this manual before using the
equipment. They are provided for the safety of those operating the
equipment and to prevent personal injury and/or damage to property
when using this equipment.
THIS EQUIPMENT SHOULD ONLY BE USED BY OPERATORS
WHO HAVE BEEN TRAINED IN THE SAFE USE OF HIGH
PRESSURE HYDRAULIC EQUIPMENT
www.bosshydraulics.com.au
Form: BM009

BM009
2
WARNING:
• The following procedures must
be performed by qualied, trained
personnel who are familiar with
this equipment. Operators must
read and understand all safety
precautions and operating
instructions included with the
pump.
• 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. Consult your nearest
Authorised Boss Hydraulics
Dealer should you have enquiries
about product applications.
• Safety glasses must be worn
at all times by the operator and
anyone within sight of the unit.
Additional personal protection
equipment may include: gloves,
hard hat, safety shoes, and
hearing protection.
• Shut OFF the motor before
opening any connections in the
system.
• Do not exceed the hydraulic
pressure rating noted on the
pump name-plate or tamper with
the internal high pressure relief
valve. Creating pressure beyond
rated capacities can result in
personal injury.
• Retract the system before
adding uid to prevent overlling
the pump reservoir. An overll
can cause personal injury due
to excess reservoir pressure
created when cylinders are
retracted.
• The load must be under
supervision at all times.
• Do not connect pump to hydraulic
system powered by another
pump.
• 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.

BM009 3
WARNING:
• 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 counter-
clockwise 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.
• 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
o󰀨 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 creosote 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.

BM009
4
• 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 o󰀨-
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.
WARNING:
• 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.
• Do not exceed rated capacities
of the cylinders. Excess pressure
may result in personal injury.
• Avoid o󰀨-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.
• 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.
If Using With a Cylinder:

BM009 5
WARNING:
• Do not drop the load.
• Crib the load as you lift to avoid a
sudden drop.
• 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/ 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.
• Limiting the stroke and pressure
on all cylinders will prolong their
life.
IMPORTANT:
• 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.

BM009
6
Hydraulic Connections:
• Clean the areas around the uid
ports of the pump and cylinders
• Inspect all threads and ttings for
signs of wear or damage, replace
as needed
• Clean all hose ends, couplers or
union ends
• Remove the thread protectors
from the hydraulic uid outlets
• Connect the hose assembly to the
hydraulic uid outlet, and couple
the hose to the cylinder
• IMPORTANT: 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 o󰀨 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.
1. SETUP/ INSTALLATION
Inspection:
• Remove all packing materials
from the assembled unit
• 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 hy-
draulic uid in the reservoir. Hydraulic
uid may have been shipped in a
separate container, but if hydraulic
uid is needed, use only hydraulic
uid rated at AW 46 47 cSt @ 38°C
(215 SUS @ 100°F).
• Clean the area around the ller
cap to remove debris. Debris in
the hydraulic uid can damage the
polished surfaces and precision-t
components of this pump
• Remove the ller cap and insert a
clean funnel with a lter
• Fill the reservoir with hydraulic
uid to the specied usable
amount according to the
specications
• Replace the ller cap. Verify
the breather-hole is open, if
applicable
NOTE: If hydraulic uid foaming
occurs, reduce the hydraulic uid
level to 2” below the cover plate.

BM009 7
Electric Motor Operation:
Motor voltages are not changeable.
220 VAC - 190-240 VAC 50/60 Hz
380 VAC - 350-410 VAC 50/60 Hz
1) Verify the valve is in the neutral
or hold position
2) Connect the motor to a power
supply
3) Start the pump and shift as
required
4) Turn o󰀨 the pump when not in
use
1. SETUP/ INSTALLATION (CONT)
WARNING:
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 (see page 8).
Bleeding Air from the System:
After all connections are made, the
hydraulic system must be bled of any
trapped air. Refer to Figure 3. With
no load on the system and the pump
vented and positioned higher than
the hydraulic device, cycle the sys-
tem several times. If you are in doubt
about venting your pump, read the
operating instructions for your pump.
Check the reservoir uid level and ll
to proper level with the hydraulic uid
as necessary. If there is a problem
contact your local Boss Hydraulics
Authorised Service Centre.
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.

BM009
8
AMPS
At Maximum
Pressure
Electrical Cord Size AWG (mm2) 3.2 Volt Drop Length of Electrical Cord
mm2 AWG
0-8 m 8-15m 15-30 m 30-46 m 0-25  25-50  50-100  100-150 
60.75 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
1. SETUP/ INSTALLATION (CONT)
Table 2. Minimum Recommended Gauge Table

BM009 9
2. OPERATION:
FIGURE 7- Push button Remote
Electric Motor Control Operation:
• Connect the power cord to an
appropriate power source
• Place the motor control switch in
the ON position
• Depending on system
requirements Refer to Figure
7. This remote will start and
run the pump motor as long as
the button is pressed. Switch
will automatically return to OFF
position when button is released
and pump motor will turn o󰀨
Bleeding Air from the System:
• Cycle the hydraulic system
until operation is smooth and
consistent
• Check the pump reservoir level
• Add the hydraulic uid as
needed
Solenoid Valve Operation:
• Connect the power cord to an
appropriate power source
• Place the motor control box in
the ON position
• Operate the remote to either
advance or retract the cylinder.
When the button is released
the pump will cycle uid back to
reservoir

BM009
10
3. MAINTENANCE:
System Evaluation:
The components of your hydraulic
system — cylinders, pumps, hoses,
and couplings 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 Boss Hydraulics
Technical Support
Periodic Cleaning:
WARNING:
Contamination of the hydraulic uid
could cause the valve to malfunc-
tion. Loss of the load or personal
injury could result.
• Leaking hydraulic uid
• Scored or damaged piston rod
• Incorrectly functioning or
damaged heads and caps
• Loose bolts or cap screws
• Damaged, modied, welded
or incorrectly assembled
accessory equipment
• Bent or damaged couplers or
port threads
WARNING:
• Disconnect the unit from the
power supply before performing
maintenance or repair
procedures.
• Repairs and maintenance are to
be performed in a dust-free area
by a qualied technician.
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 insu󰀩cient thread
engagement
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 ller cap clean and
unobstructed
• Use only Powerram hydraulic
uid. Replace hydraulic uid as
recommended, or sooner if the
uid becomes contaminated.
Never exceed 300 hours of use
between uid changes

BM009 11
Hydraulic Fluid Level:
• Check the uid level in the
reservoir after each 10 hours of
use. The uid level should be 1.3-
3.8 cm (0.5-1.5 in.) from the top of
the ll hole when all cylinders are
retracted
• Drain, ush, and rell the reservoir
with a hydraulic uid after every
300 hours of use. The frequency
of uid 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
Adding Hydraulic Fluid To The
Reservoir:
• Retract the cylinder(s) devices
• Disconnect the power supply
• Clean the entire area around the
ller plug
• Remove the ller plug, and install
a clean funnel with a lter
• Use only hydraulic uid rated at
AW 46 47 cSt @ 38°C (215 SUS
@ 100°F). If low temperature
requirements are needed, use
hydraulic uid 5.1 cSt @ 100°C
(451 cSt @ -40°C)
3. MAINTENANCE: (CONT)
Sound Reduction - Electric Motor
• The electric powered hydraulic
pump operates in the 67-81 dBA
range
Hose Connections:
• IMPORTANT: 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 o󰀨 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.

BM009
12
4. TROUBLESHOOTING
• 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.
WARNING:
PROBLEM CAUSE SOLUTION
Electric motor does
not run
Unit is not plugged in Plug in unit
No voltage supply Check line voltage
Broken lead wire or
defective power cord/
plug
Replace defective parts
Defective motor Replace or repair motor
Automatic valve
will not build full
pressure
Unloading pressure is
too low
Increase unloading pressure
per chart, sheet 3 of 4
Defective or oversize
seat on automatic valve Replace ball and seat
Electric motor cuts
out
Extension cord is too
long and/ or not of
su󰀩cient gauge
Replace
Faulty motor Replace and repair
Overheated motor can
trip circuit breaker in
mains power panel
Allow motor to cool, reset
circuit breaker located in
mains power panel.
IMPORTANT:
• For a detailed parts list or to contact your local Boss Hydraulics
Authorised Service Centre
• 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.

BM009 13
PROBLEM CAUSE SOLUTION
Pump is not
delivering
hydraulic uid
or delivers
only enough
hydraulic uid
to advance
cylinder(s)
partially or
erratically
Hydraulic uid level too low Fill reservoir to 1-1/2" below
the cover plate, maximum
Air in system Bleed the system
Debris is in pump or lter is
plugged
Pump lter should be cleaned
and, if necessary, pump
should be dismantled and all
parts inspected and cleaned
Cold hydraulic uid or hydraulic
uid is too heavy (hydraulic
uid is of a higher viscosity)
Change to lighter hydraulic
uid
Relief valve or low pressure
unloading valve out of
adjustment.
Readjust as needed
Sheared motor drive shaft
key(s) Replace
Coupling not fully connected Connect couplings fully
Motor rotating in wrong
direction Reverse rotation
Pump will
not build full
pressure
Faulty pressure gauge Calibrate or replace gauge
Check for external leakage Seal any faulty pipe ttings
with Pipe sealant
Inspect the pump for internal
leakage
Same procedure as above
but for leaks around the entire
inner mechanism. If there are
no visible leaks the low-to-
high pressure ball check may
be leaking. Remove all parts.
Inspect the check body for
any damage to the seat areas.
Clean and reseat if necessary.
Inspect the ball for damages
and replace if necessary, then
reassemble
Sheared key(s) Replace
Pressure relief valve faulty or
incorrectly set Replace or adjust relief valve
High pressure pump inlet or
outlet check balls are leaking Ret or replace valve head
4. TROUBLESHOOTING (CONT)

BM009
14
PROBLEM CAUSE SOLUTION
Foaming hydraulic
uid
Hydraulic uid being
splashed by counter
weight
Lower hydraulic uid level to
approximately 38 mm (1.5
inches) below the cover plate
Cylinder(s) will not
retract
Check the system
pressure; if the pressure
is zero, the control valve
is releasing pressure
and the problem may
be in the cylinder(s),
mechanical linkage
connected to cylinder(s),
or quick- disconnect
couplings
Check the cylinders for
broken return springs and
check couplers to ensure that
they are completely coupled.
Occasionally couplers have
to be replaced because one
check does not stay open in the
coupled position
Pump delivers
excess hydraulic
pressure
Pressure gauge is not
accurate Calibrate gauge
Relief valve not properly
set Reset the relief valve
Automatic valve
will not release
pressure
Sticking piston Remove, clean and polish
High pressure hydraulic
uid is leaking past the
low-to-high pressure
check. This hydraulic
uid leaks back to the
piston in the automatic
valve, keeping the
piston closed
Seat the ball check. Inspect and
replace any faulty components
4. TROUBLESHOOTING (CONT)
Model
Reservoir
Cap.
(cc)
Reservoir
Useable
(cc)
Motor
Oil
delivery
(cc)
0 bar
Oil
delivery
(cc)
7 bar
Oil
delivery
(cc)
350 bar
Oil
delivery
(cc)
700 bar
PE026 series 3000 2400 0.45kw 220v 50/50hz 4000 2800 330 280
PE026-8 series 8000 7200 0.45kw 220v 50/50hz 4000 2800 330 280
PE075 series 11,000 9,500 1.12kw 220v 50/60hz 8,200 7,400 840 750
PE090 series 20,000 18,000 1.48kw 220v 50hz 9,500 1,020 980 900
PE180 series 20,000 18,000 2.2kw 415v 50Hz 3
phase 9500 2450 1950 1800
5. SPECIFICATIONS

BM009 15
6. CONTROL VALVE DIRECTORY
Model Valve funcon Valve Control Valve Model
PE026 2 Way 2 Posion Manual DVBB
PE026-8 2 Way 2 Posion Manual DVBB
PES026 2 Way 2 Posion Solenoid DVGB
PES026-8 2 Way 2 Posion Solenoid DVGB
PED026* 4 Way 3 Posion Manual DVE1B
PED026-8* 4 Way 3 Posion Manual DVE1B
PEDC026 4 Way 3 Posion Manual DVE2B
PEDC026-8 4 Way 3 Posion Manual DVE2B
PEDH026 4 Way 3 Posion Manual DVF1B
PEDH026-8 4 Way 3 Posion Manual DVF1B
PEDS026* 4 Way 3 Posion Solenoid DVK1B
PEDS026-8* 4 Way 3 Posion Solenoid DVK1B
PE075 2 Way 2 Posion Manual DVBB
PES075 2 Way 2 Posion Solenoid DVGB
PED075* 4 Way 3 Posion Manual DVE1B
PEDC075* 4 Way 3 Posion Manual DVE2C
PEDH075* 4 Way 3 Posion Manual DVF1B
PEDS075* 4 Way 3 Posion Solenoid DVK1B
PE090 2 Way 2 Posion Manual DVBB
PES090 2 Way 2 Posion Solenoid DVGB
PED090* 4 Way 3 Posion Manual DVE1B
PEDC090* 4 Way 3 Posion Manual DVE2C
PEDH090* 4 Way 3 Posion Manual DVF1B
PEDS090* 4 Way 3 Posion Solenoid DVK1B
PE180 2 Way 2 Posion Manual DVBB
PES180 2 Way 2 Posion Solenoid DVGB
PED180* 4 Way 3 Posion Manual DVE1B
PEDC180 4 Way 3 Posion Manual DVE2C
PEDH180 4 Way 3 Posion Manual DVF1B
PEDS180* 4 Way 3 Posion Solenoid DVK1B
* Suitable for both Single and Double Acting Cylinders.

BOSS HYDRAULICS:
Head Ofce: 19 Ricketts Road, Mt Waverley VIC 3149 I P: 1300 BOSS HYD (1300 267 749)
E: [email protected] I W: www.bosshydraulics.com.au