Hubbell Anderson PW115V-HD User manual

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09
SERVICE AND OPERATION MANUAL
PW115/230V-HD HYDRAULIC POWER PUMP
ELECTRIC
TWO-STAGE HYDRAULIC PUMP
NOTE: Read and carefully follow these instructions. Most problems with
new equipment are caused by improper operation or installation.
To help avoid personal injury:
Hydraulic Hose
• 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ttings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uidcouldcauseserious
injury.
• Donotsubjectthehosetopotentialhazardsuchasre,sharpsurfaces,
extremeheatorcold,orheavyimpact.Donotallowthehosetokink,
twist,curl,orbendsotightlythattheoilowwithinthehoseisblocked
orreduced.Periodicallyinspectthehoseforwear,becauseanyofthese
conditionscandamagethehoseandresultinpersonalinjury.
• Donotusethehosetomoveattachedequipment.Stresscandamage
thehoseand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materials
suchascreosote-impregnatedobjectsandsomepaints.Consultthe
manufacturerbeforepaintingahose.Neverpaintthecouplers.Hose
deteriorationduetocorrosivematerialscanresultinpersonalinjury.
WARNING
!
Page 1 of 16Page 16 of 16
HMIS(US): HealthHazard 1
 FireHazard 1
 Reactivity 0
 PersonalProtection 8
NFPA(USA): HealthHazard 1
 FireHazard 1
 Reactivity 0
 SpecicHazard none
Rating 0 Insignicant
 1 Slight
 2 Moderate
 3 High
 4 Extreme
Section 16. Other Informations
Preparedby: SPXFluidPower
 588511thStreet
 Rockford,IL61109,USA
 Phone:815-874-5556
 Fax:815-874-7886
Dateofpreparation:November,2007
Theinformationpresentedhereinhasbeen
compiledfromsourceconsideredtobedepend-
ableandaccuratetothebestofSPXFluidPower
knowledge;however,SPXFluidPowermakes
nowarrantywhatsoever,expressedorimplied,
ofMerchantabilityorFitnessfortheParticular
Purpose,regardingtheaccuracyofsuchdataor
theresultstobeobtainedfromtheuserthereof.
SPXFluidPowerassumesnoresponsibilityforthe
injurytorecipientortothethirdpersonsorforany
damagetoanypropertyandrecipientassumesall
suchrisks.
Rev.2
Material Safety Data Sheet
Material Safety Data Sheet Page 3
AW Hydraulic Oil ISO 46
SAFETY PRECAUTIONS
HUBBELL®
Power Systems

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09
Pump
• DonotexceedthePSI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.
• Beforereplenishingtheoillevel,retractthesystemtopreventoverlling
thepumpreservoir.Anoverllcancausepersonalinjuryduetoexcess
reservoirpressurecreatedwhencylindersareretracted.
Cylinder
• Donotexceedratedcapacitiesofthecylinders.Excesspressurecan
resultinpersonalinjury.
• Donotsetpoorly-balancedoroff-centerloadsonacylinder.Theload
cantipandcausepersonalinjury.
Power Supply (Electric)
• IMPORTANT:Inordertomeetcertain
electricalsafetyrequirements,pumpsin
thisserieswiredfor115VoltAC60Hz
arerequiredtocontaina20AMPplug
asshowntotheright.Plugunitintothe
appropriate20AMPelectricalfemale
receptacle.Donotmodifythepump
powercordorpluginanyway-doingso
willVOIDtheproductwarrantyonany
electricalcomponents.
• Donotuseanungrounded(two-prong)extensioncordwiththisunit.
• Avoidanyconditionsthatcouldcreateanelectricalhazard.
• Anyelectricalworkmustbedonebyaqualiedelectrician.
• Ifthepowercordisdamagedorwiringisexposed,replaceorrepair
immediately.
• Disconnectthepowersupplybeforeremovingthemotorcontrolbox
coverorperformingrepairsormaintenance.
• Pumpmustbepluggedintocorrespondingvoltagepowersource.
• Branchcircuitmustbesizedproperlyforproperoperationofpump.For
bestperformance,plugpumpintoacircuitratedequaltoorgreaterthan
themaximumampratingorpump.
• Ifbranchcircuitbreakerorfuseopenscontinuously,donotattemptto
increasethepowerlinecapacitybyreplacingafuseorbreakerwith
anotherofhighervalue.Overheatingofthepowerlineandpossibilityof
arewillresult.
WARNING (cont’d)
!
Page 2 of 16 Page 15 of 16
Section 8. Exposure Control / Personal Protec-
tion
EngineeringControls:Fornormalapplication,
specialventilationisnotnecessary.Ifuser’s
operationsgeneratevaporsormists,useventila-
tiontokeepcontaminantsbelowexposurelimits.
Make-upairshouldalwaysbesuppliedtobalance
airremovedbyexhaust.Haveeyewashstationand
safety-showerclosetoworkstation.
PersonalProtection:
Eyes:Eyeprotectionshouldbedeterminedbased
onconditionsofuse.Ifproductisusedinapplica-
tionwheresplashingmayoccur,theuseofsafety
gogglesand/orafaceshieldshouldbeconsidered.
HandsandBody:Wearappropriatechemically
protectiveglovesandwearappropriateclothingto
preventskincontact.
Respiratory:NIOSHapprovedrespiratorsshould
beusedwhenairbornecontaminationisabove
exposurelimits.
Feet:Wearappropriatefootweartopreventproduct
fromcomingincontactwithfeetandskin.
Section 9. Physical and Chemical Properties
Appearance,PhysicalState:Clear,Blue,Viscous
Liquid
Odor:Mildpetroleum
Viscosity:41.4-50.6cSt@40degC
FlashPoint:>=200deg.C(392deg.F)
Vaporpressure:Negligibleatambienttemperature
andpressure
SpecicGravity:0.875kg/L@20deg.C(68deg.
F)
Watersolubility:Insolubleinwater
pH:Notapplicable
Section 10. Stability and Reactivity
Stability:Stableundernormalhandlingandstorage
condition
HazardousPolymerization:Willnotoccuratnormal
workingconditions.
IncompatibleSubstances/ConditionstoAvoid:
Reactivewithoxidizingagentsandacids.
DecompositionProducts:Combustioncanyield
carbon,nitrogen,sulfur,phosphorus,andzinc
oxides.
Section 11. Toxicological Information
Routesofentry:Skinandeyecontact,inhalation,
ingestion.
AcuteLethality:Basedontoxicityofcomponents.
Acuteoraltoxicity(LD50):>2000mg/kgrat.
ChronicorOtherToxicEffects.
DermaRoute:Prolongedorrepeatedcontactmay
causeskinirritationcharacterizedbydermatitisor
oilacne.
InhalationRoute:Negligiblebreathinghazardat
normaltemperature.Elevatedtemperaturesorme-
chanicalactionmayformvapors,mistsorfumes.
Material Safety Data Sheet
Material Safety Data Sheet Page 2
AW Hydraulic Oil ISO 46
Inhalationofoilmistsorvaporsfromhotoilmay
causeirritationoftheupperrespiratorytrack.
OralRoute:Lowtoxicity.
EyeIrritation/Inammation:Repeatedor
prolongedcontactmaycauseirritationbutnot
permanentdamage.
Immunotoxicity:Notavailable.
SkinSensitization:Notexpectedtobeskinsen-
sitizer.
RespiratoryTractSensitization:Notexpectedtobe
respiratorytractsensitizers.
Carcinogenicity:Thisproductisnotknowntocon-
tainanychemicalsatreportablequantitiesthatare
listedascarcinogensbyNTP,IARC,OSHA.
OtherConsiderations:Noadditionalremark.
Section 12. Ecological Information
EnvironmentalFate:Notavailable.
Persistence/BioaccumulationPotential:Not
available.
BOD5andCOD:Notavailable.
ProductofBiodegradation:Notavailable.
AdditionalRemarks:Noadditionalremarks.
Section 13. Disposal Considerations
WasteDisposal:Spent/usedwasteoilmaymeet
therequirementsofahazardouswaste.Con-
sultyourlocalorregionalauthorities.Preferred
wastemanagementprioritiesare:(1)recycleor
reprocess,(2)incineratewithenergyrecovery,(3)
disposalatlicensedwastedisposalfacility.Ensure
thatdisposalorreprocessingisincompliance
withgovernmentrequirementsandlocaldisposal
regulations.
Section 14. Transport Information
TDGClassication:NotcontrolledunderTDG
(Canada).
DOTShippingDescription:Notclassiedas
hazardous.
SpecialProvisionsforTransport:Notapplicable
Section 15. Regulatory Information
Thisproductisacceptableforuseunderthe
provisionsofWHMIS-CPR.Allcomponentsofthis
formulationarelistedontheCEPA-DSL.(Domestic
SubstancesList).
Allcomponentsofthisformulationarelistedonthe
USEPA-TSCAInventory.
Thisproducthasbeenclassiedinaccordance
withthehazardcriteriaoftheControlledProducts
Regulations(CPR)andtheMSDScontainsallof
theinformationrequiredbytheCPR.
Thisproductisnotknowntocontainanychemicals
atreportablequantitiesthatarelistedontheSARA
313and40CFR372.
ThisproductisnotcontrolledundertheHCS.

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09 Page 3 of 16
OPERATING PROCEDURE
Filling the Reservoir
NOTE: The pump has been shipped without oil in the reservoir. A high-
quality, approved hydraulic oil has been shipped with the pump in a
separate container. If additional oil is required, use an approved hydraulic
oil only.
1. Cleantheareaaroundthellercaptoremovealldustandgrit.Anydirtordust
intheoilcandamagethepolishedsurfacesandprecision-tcomponentsof
thispump.
2. Retractallcyclinder(s)totheirreturnposition.
3. Removethellercapandinsertacleanfunnelwithalter.Fillthereservoir
withahigh-quality,approvedhydraulicoiltowithin1”ofthecoverplate.
Replacethellercap.
4. Cyclethepump(withthecylinder(s)attached)severaltimes.Retractthe
cylinder(s)andchecktheoillevelinthepumpreservoir.
Electrical Hook-up and Operation
To help avoid personal injury:
• Allelectricalworkmustbedonebyaqualiedelectrician.
• Disconnectthepowersupplybeforeremovingmotorcasingcoveror
performingrepairsormaintenance.
• Allvoltagesmustbewiredforcounterclockwiserotationwhenviewed
fromtheleadendofthemotor.
• Changingthevoltageonthisunitisaninvolved,andifproperly
performed,hazardousprocedure.Consultthemanufacturerforspecic
informationbeforeattemptinganyrewiring.
WARNING
!
1. Theelectricmotorisasinglephase,60cycleandcanbewiredat115or230
volts.
Page 14 of 16
Material Safety Data Sheet
Section 1. Chemical Product and Company
Identifcation.
ProductName:AW Hydraulic Oil ISO 46
Code/PartNumber:9636,9637,9638,9616,
11360,9647
Manufacturer: SPXFluidPower
 588511thStreet
 Rockford,IL61109,USA
 Phone:815-874-5556
CHEMTREC 24 Hr. Emergency Number:
800-424-9300
MaterialUse: Theproductdesignedforusein
 heavydutyHydraulicuid
 applications.
ValidatedonJanuary,2007
Section 2. Composition and Information on
Ingredients.
Name:Hydrotreatedorseverelyrenedbaseoil
andproprietaryadditivesCAS#:Mixture
%(V/V):100
ExposureLimits:
TLV-TWA(8hr):5mg/cubicm(oilmist)
STLE:10mg/cubicm(oilmist)
ManufacturerRecommendation:Notapplicable
OtherExposureLimits:Consultlocal,state,
provincialorterritorialauthoritiesforacceptable
exposurelimits.
Section 3. Hazardous Identification.
Potentialhealtheffects:Notirritatingtoslightirrita-
tiontoskinandeyeswithnopermanentdamage.
Relativelynon-toxicviaingestion.Thisproducthas
alowvaporpressureandisnotexpectedtopres-
entaninhalationexposureatambientconditions.
Athightemperaturesormechanicalactionsmay
producevaporsormists.Inhalationmaycauseir-
ritationofthebreathingpassages.Seesection11.
Section 4. First Aid Measures
Eye contact:Immediatelyusheyeswithrunning
waterforatleast15minutes,keepingeyelids
open.Seekmedicalattention.
Skin Contact:Removecontaminatedclothing–
launderbeforereuse.Washcontaminatedskin
withrunningwaterandnon-abrasivesoap.Get
medicalattentionifirritationdevelopsorifproduct
isinjectedunderpressureintoorundertheskin.
Inhalation:Removetofreshair.Getmedicalat-
tentionifbreathingdifcultypersists.Ifvictimisnot
breathing,performarticialrespiration.
Ingestion:DONOTinducevomiting.Seekmedi-
calattention.
Section 5. Fire-Fighting Measures
Flammability:Maybecombustiveathightempera-
ture.
Flashpoint:>=200degC(392degF)(COC)
FlammableLimits:Notavailable
Auto-IgnitionTemperature:Notavailable
FireHazardinPresenceofVariousSubstances:
Lowrehazard.Thismaterialmustbeheated
beforeignitionwilloccur.
ExplosionHazardsinPresenceofVariousSub-
stances:Donotcut,weld,drillorpressurizeempty
container.Containersmayexplodeinheatofre.
ProductsofCombustion:variousoxidesofcarbon,
nitrogen,sulfur,smokeandirritatingvaporsfrom
incompletecombustion.
FireFightingMediaInstructions:NAERG96,Guide
171,Substances(lowtomoderatehazard).Iftank,
railcarortankisinvolvedinre,ISOLATEfor800
meters(0.5mile)inalldirections.Shutofffuelto
reifitispossibletodowithouthazard.ifitisnot
possible,withdrawfromareaandletreburnout
undercontrolledconditions.Withdrawimmediately
incaseofrisingsoundfromventingsafetydevice
oranydiscolorationoftankduetore.Coolcon-
tainingvesselswithwatersprayinordertoprevent
pressurebuild-up,autoignitionorexplosion.
SmallFire:useDRYchemicals,foam,waterspray
orCO2.
LargeFire:usewaterspray,fogorfoam.Forsmall
outdoorres,portablereextinguishersmaybe
used.Forallindoorresandsignicantoutdoor
resself-containedbreathingapparatusisre-
quired.Respiratoryandeyeprotectionarerequired
forreghtingpersonnel.
Section 6. Accidental Release Measures
MaterialReleaseorSpill:NAERG96,Guide171,
Substances(lowtomoderatehazard).ELIMINATE
ALLIGNITIONSOURCES.Avoidcontact.Stop
leakifwithoutrisk.Containspill.Absorbwithinert
absorbents.Placeusedabsorbentinclosedmetal
containersforlaterdisposalorburnabsorbentin
suitablecombustionchamber.DONOTFLUSH
TOSEWERS,STREAMSOROTHERBODIESOF
WATER.Checkwithapplicablejurisdictionforspe-
cicdisposalrequirementsofspilledmaterialsand
emptycontainers.Notifytheappropriateauthorities
immediately.
Section 7. Handling and Storage
Handling:Avoidinhalationandskincontact
especiallywhenhandlingusedoil.Keepawayfrom
sourcesofignition.Donotreuseemptycontain-
erswithoutcommercialreconditioning.Practice
goodpersonalhygiene.Washhandsafterhandling
oilandbeforeeating.Launderworkclothesfre-
quently.Discardsaturatedleathergoods.
Storage:Storeintightlyclosedcontainersincool,
dry,isolated,well-ventilatedarea,andawayfrom
incompatibles.
Material Safety Data Sheet Page 1
AW Hydraulic Oil ISO 46

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09
Pump Operation
Whenoperatingthepumpforthersttime:
1. Allvalveandhoseconnectionsshouldbesecure,andthereservoirshouldbe
lledtotheproperlevel.Connectthepowersupply.
2. Activatethepump,andadvancethecylinder(s)bypushingtheUPbutton
ontheremotecontrolswitch.ThemotorshutsoffwhentheUPbuttonis
released,andsystempressureisheld.PresstheDOWNbuttonorshiftthe
manualvalvetoallowthecylinder(s)toretract.
3. Refertothesectiontitled“BleedingAirfromtheSystem.”
4. Checktheoillevelinthereservoirandaddoilifnecessary.Thereservoiroil
levelshouldbewithin1”ofthepumpcoverplate.
PRESSURE REGULATING CONTROL ADJUSTMENTS
(NOTE: These options are not on all pump models.)
Adjusting the Pressure Regulating Valve
Thepressureregulatingvalvecanbeadjustedtobypassoilatagivenpressure
whilethepumpcontinuestorun.
IMPORTANT:
• Foreasyadjustmentofthepressureregulatingvalve,alwaysadjustthe
pressure by increasing it to a desired pressure setting.The pressure
range for this unit is from 1,000 PSI to 10,000 PSI.
1. Loosenthelocknutonthepressureregulatingvalve,andturntheadjusting
screwafewturnscounterclockwise(CCW)todecreasethepressuresetting
toalowerthandesiredpressure.
2. Connectthepumpcompletely.PlacethemotorcontrolswitchintheRun
positionandpushtheStartbutton.
3. Slowlyturntheadjustingscrewinaclockwise(CW)directiontogradually
increasethepressuresetting.Whenthedesiredpressuresettingisreached,
locktheadjustingscrewintopositionbytighteningthelocknut.
Page 4 of 16
OPERATING INSTRUCTIONS
Hydraulic Connections
1. Cleanalltheareasaroundtheoilportsofthepumpandcylinder(s).
2. Inspectallthreadsandttingsforsignsofwearordamage,andreplaceas
needed.
3. Cleanallhoseends,couplers,orunionends.
4. Removethethreadprotectorsfromthehydraulicoiloutlets.
5. Connectthehoseassemblytothehydraulicoiloutlets,andcouplethehoseto
thecylinder.
IMPORTANT: Seal all external pipe connections with a high-quality,
non-hardening thread sealant.Teflon tape can be used to seal hydraulic
connections if only one layer of tape is used. Apply the tape carefully,
two breads 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 oil or cause jamming of
precision-fit parts.
RECOMMENDED MINIMUM WIRE SIZE-AWG (mm2)
OF EXTENSION CORDS FOR ELECTRIC PUMPS
Current
At Full Load
(Amps)
Cord Size AWG (mm2) 3.2 Volt Drop
Length of Cord
0-25 feet
(0-8 m)
25-50 feet
(8-15 m)
50-100 feet
(15-30 m)
100-150 feet
(30-45 m)
6 18(.82) 16(1.33) 14(2.09) 12(3.32)
8 18(.82) 16(1.33) 12(3.32) 10(5.37)
10 18(.82) 14(2.09) 12(3.32) 10(5.37)
12 16(1.33) 14(2.09) 10(5.37) 8(8.37)
14 16(1.33) 12(3.32) 10(5.37) 8(8.37)
16 16(1.33) 12(3.32) 10(5.37) 8(8.37)
18 14(2.09) 12(3.32) 8(8.37) 8(8.37)
20 14(2.09) 12(3.32) 8(8.37) 6(13.30)
22 14(2.09) 10(5.37) 8(8.37) 6(13.30)
24 14(2.09) 10(5.37) 8(8.37) 6(13.30)
26 12(3.32) 10(5.37) 8(8.37) 6(13.30)
28 12(3.32) 10(5.37) 6(13.30) 4(21.29)
30 12(3.32) 10(5.37) 6(13.30) 4(21.29)
Page 13 of 16

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09
Cylinder(s) will not retract.  1.Checkthesystempres-
sure;ifthepressureis
zero,thesolenoidvalve
isreleasingpressure
andtheproblemmaybe
inthecylinder,(mechan-
icallinkageconnectedto
cylinders),orquick-
disconnectcouplings.
 2.Defectivevalve.
 1.Checkthecylindersfor
brokenreturnsprings
andcheckcouplers
toinsurethattheyare
completelycoupled.
Occasionallycouplers
havetobereplaced
becauseonecheckdoes
notstayopeninthe
coupledposition.
 2.Checkvalveoperation
andinspectparts.
Replaceifnecessary.
PROBLEM CAUSE SOLUTION
Pump delivers excess oil
pressure.
 1.Checkpressuregauge.
 2.Reliefvalvenotproperly
set.
 1.Calibrategauge.
 2.Resetthereliefvalve.
Automatic valve will not build
full pressure.
 1.Unloadingpressureis
toolow.
 2.Defectiveoroversize
seatonautomaticvalve.
 1.Increaseunloading
pressure.
 2.Replaceballandseat.
Page 12 of 16 Page 5 of 16
Pressure Regulating Valve
Apressureswitchcanbeadjustedtostopthepumpmotoratadesiredpressure
settingandrestartthemotorwhenthepressurefallsbelowthatsetting.
Itisrecommendedthatapressureswitchbeusedwithapressureregulating
valvetoinsureaccuracywhensettingamaximumPSIlevel.Apressure
switchalonewillbreakthemotor’senergysupplyataselectedsetting,butthe
hydraulicpumpwillcontinuebuildingpressureasitslowstoastop.Thepressure
regulatingvalveisadjustedatasettingslightlyabovethepressureswitchsetting
tocompensatebyreleasingthepressuredevelopedbythehydraulicpumpas
it“coasts”toastop.Asaresult,thepressurelimitrequirementcanbeheldto
approximately300PSI.
Adjusting the Pressure Switch Setting
1. Loosenthelocknutonthepressureswitch.Slowlyturnthepressureswitch
adjustingscrewinacounterclockwise(CCW)direction,decreasingthe
pressureswitchsettinguntilthepumpmotorshutsoff.Tightenthelocknutto
locktheadjustingscrew.
2. Releasethehydraulicpressure.Runthepumptocheckthepressuresetting
andautomaticshutoffofthemotor.Itmaybenecessarytomakeasecond
neadjustment.
To help avoid personal injury:
• Disconnectthepumpfromthepowersourcebeforeperforming
maintenanceorrepairprocedures.
• Maintenanceandrepairsmustbeperformedinadust-freeareabya
qualiedtechnician.
WARNING
!
Bleeding Air from the System
Uponinitialstartuporafterprolongeduse,aircanaccumulatewithinthe
hydraulicsystem.Thisentrappedaircancausethesystemtorespondslowlyor
behaveinanunstablemanner.Toremovetheair,loosenattingthatissituated
higherthantherestofthettingsinthesystem.Runthepumpuntilasteadyow
ofoilfreeofsuspendedairbubblesisobserved.Tightenthetting.
Inspecting the Hydraulic Fluid Level
Checktheoillevelinthereservoirperiodically.Theoillevelshouldcometo
within1”ofthepumpcoverplatewithallcylindersretracted.Drain,cleanand
replenishthereservoirwithahigh-quality,approvedhydraulicoilyearlyormore
oftenifnecessary.Thefrequencyofoilchangewilldependuponthegeneral
workingconditions,severityofuseandoverallcleanlinessandcaregiventhe
pump.
PREVENTIVE MAINTENANCE

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09 Page 11 of 16
PROBLEM CAUSE SOLUTION
Pump builds pressure but
cannot maintain pressure.
 1.Checktoseeifthereare
anyexternalleaks.Ifno
oilleakageisvisible,the
problemisinternal.
 2.Totestforaleaking
controlvalve,liftthe
pumpfromthereservoir
butkeepthelterinthe
oil.Removethedrain
linetoseeiftheoilis
leakingfromthevalve.If
thevalveisnotleaking,
theinternalcheckvalve
couldbeleaking.Refer
tothenoteconcerning
checkingforoilleaks
atthebeginningofthis
TroubleshootingGuide.
 1.Resealleakingpipet-
tingswithpipesealant.
 2.Clean,reseatorreplace
controlvalveparts.Ifthe
internalcheckvalveis
leaking,thecheckvalve
mustbedisassembled
andtheseatareare-
paired,poppetreplaced,
etc.
Pump will not build full
pressure.
 1.Faultypressuregauge.
 2.Checkforexternal
leakage.
 3.Checkthereliefvalve
setting.
 4.Checkforleaksinthe
solenoidvalve.
 5.Inspectthepumpfor
internalleakage.Check
highpressurepumpinlet
oroutletballchecks.
 6.Shearedkey(s).
 7.Automaticvalveleakage.
 1.Calibrategauge.
 2.Sealanyfaultypipet-
tingwithpipesealant.
 3.Liftthepumpfromthe
reservoirbutkeepthe
lterimmersedinoil.
Notethepressureread-
ingwhenthereliefvalve
beginstoopenup.If
functioningnormally,it
shouldstarttoleakoff
justpriortoreliefvalve
pressure.
 4.Cleanandreseator
replaceparts.
 5.Sameprocedureas
abovebutlookforleaks
aroundtheentireinner
mechanism.Ifthereare
novisibleleaks,thehigh
pressurepumpsubas-
semblymaybeleaking.
Removeallparts.Check
thevalveheadassembly
foranydamagetothe
seatarea.Cleanand
reseatifnecessary.
Inspectfordamageand
replacepartsifneces-
sary,thenreassemble.
 6.Replaceafterchecking
pumpcavityforbroken
pieces.
 7.Checkautomaticvalve
seat.
Adding Oil to the Reservoir
1. Cylinder(s)mustbefullyretractedandthepowersupplydisconnectedwhen
addingoiltothereservoir.
2. Cleantheentireareaaroundthellercapbeforeremovingthecap.
3. Useacleanfunnelwithlterwhenaddingoil.
4. Useonlyapprovedhydraulicuids.
Maintenance Cleaning
1. Keeptheoutersurfaceofthepumpasfreefromdirtaspossible.
2. Protectallunusedcouplers.
3. Keepallhoseconnectionsfreeofdirtandgrime.
4. Keepthebreatherholeinthellercapcleanandunobstructedatalltimes.
5. Equipmentconnectedtothepumpmustbekeptclean.
6. Useonlyapprovedhydraulicuidsinthispump.Changeasrecommended.
Draining and Cleaning the Reservoir
IMPORTANT: Clean the pump exterior before the pump interior is removed
from the reservoir.
1. Removethescrewsthatfastenthemotorandpumpassemblytothereservoir.
IMPORTANT: Lift the pump and motor off the reservoir carefully to avoid
damaging the gasket or any internal components.
2. Cleantheinsideofthereservoirandllhalffullwithcleanhydraulicuid.
3. Placethepumpandmotorassemblybackontothereservoirandsecure
withtwomachinescrewsassembledonoppositecornersofthehousing.
IMPORTANT: Connect a hose to the pressure port on the valve. Place the
other end of the hose into the oil filler hole.
4. Runthepumpforseveralminutes.Thendisconnectthemotorandpump
assembly,anddrainandcleantheinsideofthereservoir.
5. Fillthereservoirwithahigh-quality,approvedhydraulicuid.Placethepump
andmotorassembly(withgasket)onthereservoirandinstallallthescrews.
Tightensecurelyandevenly.
Page 6 of 16

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09 Page 7 of 16
TROUBLESHOOTING
To help prevent personal injury, any repair work or troubleshooting
must be done by qualified personnel familiar with this equipment.
WARNING
!
NOTE:
• Usethepropergaugesandequipmentwhentroubleshooting.
• Itisbesttocheckforleaksbyusingahandpumpandapplyingpressure
to the suspect area without the motor running. Watch for leaking oil and
follow it back to its source.
• Plugtheoutletportsofthepumpwhencheckingforleakageto
determine if the leak is in the pump or elsewhere in the system.
• Refertoyourpump’sappropriatepartslistandthehydraulicand
electrical schematics when using this troubleshooting guide.
North American & International Color Codes
Conductors North American International
Line................................Black......................Brown
Neutral...........................White.....................Blue
Ground.......................... Green.....................Green/Yellow
Page 10 of 16
Pump is not delivering oil or
delivers only enough oil to
advance ram(s) partially or
erratically.
 1.Oilleveltoolow.

 2.Loosettingcouplerto
ram.
 3.Airinthesystem.
 4.Airleakinsuctionline.
 5.Dirtinpumporlter
plugged.
 6.Coldoiloroilistoo
heavy(Hydraulicoilisof
ahigherviscositythan
necessary).
 7.Reliefvalveorlow
pressureunloadingvalve
outofadjustment.
 8.Reservoircapacityistoo
smallforthesizeofthe
ram(s)used.
 9.Defectivedirectional
valve.
10.Releasepoppetnot
seatinginsolenoid
valve.
11.Sheareddriveshaft
key(s).
12.Motorrotatinginwrong
direction.
13.Vacuuminreservoir.
14.Lowpressurepump
worn.
 1.Fillreservoirtowithin1”
ofllerplugwithallrams
retracted.
 2.Checkquick-disconnect
couplingstorams.
Inspectcouplersto
insurethattheyare
completelycoupled.
Occasionallycouplers
havetobereplaced
becausetheballcheck
doesnotstayopendue
towear.
 3.Bleedthesystem.
 4.Checkandtightenthe
suctionline.
 5.Pumpltershould
becleanedand,if
necessary,pumpshould
bedismantledandall
partsinspectedand
cleaned.
 6.Changetolighteroil.
 7.Readjustasneeded.
 8.Usesmallerram(s)or
largerreservoir.
 9.Inspectallpartscarefully
andreplaceifnecessary.
10.Disassemble,inspect,
andcleanpumpto
removeanydirt.
11.Replaceafterchecking
pumpcavityforbroken
pieces.
12.Refertoelectrical
schematiconmotor.
13.Checkforpluggedvent
inllerplug.
14.Repairorreplacegerotor
pump.
The force of escaping
hydraulic fluid could
cause serious injury.
Keep hands, face, etc.
clear of any hydraulic
leaks.
WARNING
!
PROBLEM CAUSE SOLUTION

Manual M-800 Rev. 6/09Manual M-800 Rev. 6/09
HYDRAULIC SCHEMATIC
MAX. PRESSURE
SAFETY RELIEF VALVE
REFER TO YOUR
PUMP’SNAMEPLATE
SUPERCHARGE
RELIEF VALVE
260 / 280 PSI
TO VALVE
Page 8 of 16
PROBLEM CAUSE SOLUTION
Electric motor does not run.  1.Unitisnotpluggedin.
 2.Novoltagesupply.
 3.Brokenleadwireorde-
fectivepowercordplug.
 4.Defectiveswitches.
 5.Defectivestartedrelay.
 6.Defectiveremoteswitch.
 7.Circuitbreakertripped
becausetotalamperage
drawtoohighforexisting
circuit.
 8.Overheatedmotor.
 9.Faultythermalprotector.
10.Defectivemotor
 1.Pluginunit.
 2.Checklinevoltage.
Checkresetbuttonon
powerpanel.
 3.Replacedefectiveparts.
 4.Replaceswitches.
 5.Replacedefectiveparts.
 6.Replaceremoteswitch.
 7.Addanadditionalcircuit
orusealternatecircuit.
 8.Waitformotortocool
beforerestarting.
Thermalprotectorwill
resetautomatically,or
pushredresetbutton
ontipofthemotor(ifso
equipped).
 9.Replace.
10.Replaceorrepairmotor.
Disconnect power sup-
ply before removing
cover. Any electrical
work should be per-
formed by a qualified
electrician.
WARNING
!
Page 9 of 16