Power Team D Installation and operation manual

MODE D
TANDEM, TWO-STAGE, WITH CONTRO VA VE OR MANIFO D
AIR HYDRAU IC PUMP
Rated Capacity: 10,000 PSI at 100 PSI Air
•Carefully inspect the pump upon arrival. The carrier, not the manufacturer, is responsible for any damage
resulting from shipment.
•These instructions should be read and carefully followed. Most problems with new equipment are caused
by improper operation or installation.
•This instruction sheet is a condensed version intended for end-user application needs. A detailed parts
list for service repair can be obtained (if not already supplied) by calling our Technical Services
Department at 1-800-477-8326.
SAFETY PRECAUTIONS
•All WARNING statements must be carefully observed to help prevent personal injury.
Hydraulic Hose
•Before operating the pump, Tighten all hose connections using the proper tools. Do not overtighten the
connections. Connections need only be tightened securely and leak-free. Overtightening may cause
premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.
•Should a hydraulic hose ever burst, rupture, or need to be disconnected, immediately shut off the pump.
Never attempt to grasp a leaking hose under pressure with your hands. The force of the escaping
hydraulic fluid could cause serious injury.
•Do not subject the hose to potential hazard such as fire, extreme heat or cold, sharp surfaces, or heavy
impact. Do not allow the hose to kink, twist, curl or bend so tightly that the fluid flow within the hose is
blocked or reduced. Periodically inspect the hose for signs of wear because any of these conditions can
damage the hose and may 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. Never paint the couplers. Hose deterioration due to corrosive
materials may result in personal injury.
Pump
•Do not exceed the PSI hydraulic pressure rating noted on the pump nameplate or tamper with the internal
high relief valve. Creating pressure beyond rated capacities may result in personal injury.
•Before replenishing the fluid level, retract all cylinders to prevent overfilling the pump reservoir. An
overfill may cause personal injury due to excess reservoir pressure created when cylinders are retracted.
Cylinder
•Do not exceed rated capacities of the cylinders. Excess pressure may result in personal injury.
•Do not set poorly-balanced or off-center loads on a cylinder. The load may tip and cause personal injury.
Air Supply
•Shut off and disconnect the air supply when the pump is not in use or
before breaking any connection in the system.
Form No. 105006
PA60
PA64
Sheet No. 1 of 3
Rev. 2 Date: 28 May 2012
Operating & Maintenance
Instructions for:
Litho in USA
WARNING

Operating & Maintenance Instructions, Form No. 105006, Back sheet 1 of 3
PREPARATION & SET-UP
Air Supply Connections
Remove the thread protector from the air inlet of the pump. Select and install the thread fittings that are compatible
with your air supply fittings. The pumps air inlet has 1/4 NPT female threads. The air supply should be capable of
providing 20 CF at 100 PSI to obtain the rated hydraulic output. Shop air line pressure should never fall below 40
PSI and should be regulated to a maximum of 125 PSI. Secure your pump fitting to the air supply.
: To help prevent personal injury,
•Ensure that all hydraulic connections are secure and tight before building pressure in the system.
•After disconnecting the air supply, release all system pressure by shifting the two position, 3-way/4-way
valve twice before loosening any hydraulic connection in the system.
Hydraulic Connections
Clean areas around all fluid ports of the pump and cylinders. Inspect all threads and fittings for signs of wear or
damage and replace as needed. Clean all hose ends, couplers or union ends. Remove the thread protectors from the
hydraulic fluid outlets. anually fill the clamps (if so equipped) and hoses with fluid. Connect the hose assembly to
the hydraulic fluid outlet and couple the hose to the cylinder (if so equipped). See illustrations below.
IMPORTANT: Seal all external pipe connections with Power Team HTS6 thread sealant. PTFE tape can also
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 system. Any loose pieces of tape could travel
through the system and obstruct the flow of fluid or cause jamming of precision-fit parts.
Pump with a Manifold and Remote Valve
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.
3. Connect the fluid line from the fluid
return port on the manifold to the
pump return port on the valve.
4. Connect the clamp(s) or cylinder(s)
to the valve.
IMPORTANT: On all single pressure
line applications, plug one cylinder
port on the valve.
1. Connect the cylinder ports of the pump valve
to clamp(s) or cylinder(s). When cylinder port
"A" is pressurized, cylinder port "B" becomes
the return. When cylinder port "B" is
pressurized, cylinder 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.
WARNING

Operating & Maintenance Instructions Form No. 105006
OPERATION
Pump Operation and Adjustment
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 oil to the system. Continue to slowly turn the air
regulator control clockwise until gauge reads approximately 10,000 PSI. A reading of approximately 10,000 PSI
should be obtained if shop pressure is approximately 100 PSI.
NOTE: If shop air pressure is adequate but the 10,000 PSI hydraulic pressure cannot be reached, follow
the procedures outlined in the Trouble-shooting Guide.
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 the desired clamping pressure. When decreasing pressure, shift the valve
after each adjustment to measure actual system pressure.
NOTE:
•The minimum operating pressure at 100 PSI shop air line pressure is approximately 1,200 PSI
•The air pressure regulator that is mounted on the pump controls only the output from the high pressure stage
of this two stage pump. The output of the low pressure stage of the pump is determined by the shop air line
pressure coming from the remote regulator. A remote regulator is required to control the air pressure from the
shop air line. The independent functioning of the low and high pressure stages of this pump can best be
described as follows. At the minimum shop air line pressure of 40 PSI, the low pressure stage of the pump will
deliver 480 PSI oil pressure (with the pump regulator turned counterclockwise to prevent air pressure from
activating the high pressure stage of the pump.) At the minimum shop air line pressure of 40 PSI the high
pressure stage of the pump will deliver 4,000 PSI oil 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
counterclockwise when the pump is used to produce 1,200 PSI or less.
4. Shut off and disconnect air supply to the unit and shift pump valve (if so equipped) or external valve (if so
equipped) two times to release all system pressure. Recheck fluid level with cylinder(s) and clamp(s) retracted.
The unit is now ready for operation.
PREVENTIVE MAINTENANCE
NOTE: Any repairs or servicing that requires dismantling the pump must be performed in a dirt-free
environment by a qualified service technician.
ubrication
Set the air line oiler to feed 1 drop of oil per minute to the system. Use SAE No. 10 oil. For
servicing the air regulator, lubricator and filter system, see the operating and service instructions
provided.
Sheet No. 2 of 3
Rev. 2 Date: 28 May 2012
Note: Shaded areas reflect last revision(s) made to this form.
Next
Page

Operating & Maintenance Instructions, Form No. 105006, Back sheet 2 of 3
Bleeding Air from the System
Upon initial startup or after prolonged use, a significant amount of air may accumulate within the hydraulic system.
This entrapped air can 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 cylinders) free of any load. NOTE: The cylinder must
be at a lower level than the pump to allow air to be released through the pump reservoir.
Inspecting the Hydraulic Fluid evel
Check the fluid level in the reservoir periodically. With all cylinder(s) retracted, the fluid level should be 1-3/4" from the
filler hole. Drain, clean and replenish the reservoir with high-grade, approved Power Team hydraulic fluid yearly or
more often if necessary. The frequency of fluid change will depend upon the general working conditions, severity of
use and overall cleanliness and care given the pump.
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 filler/breather cap clean and unobstructed at all times.
5. Equipment connected to the pump must be kept clean.
6. Use only high-grade, approved Power Team hydraulic fluids 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 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. Refill half full with clean Power Team hydraulic fluid.
3. Place the pump assembly back onto the reservoir and secure with two machine screws assembled on opposite
corners of the housing.
4. Run the pump for several minutes. Remove the two cover screws and lift off the pump assembly again. Drain and
wipe out the reservoir with a clean, lint-free cloth.
5. Fill the reservoir with high-grade, approved Power Team hydraulic fluid to 1-3/4" from the fill hole. Place the pump
assembly (with gasket) on the reservoir and install the screws. Tighten securely and evenly.
Adding Fluid to the Reservoir
1. Cylinder(s) must be fully retracted and the air supply disconnected when adding fluid to the reservoir.
2. Clean the entire area around the filler/breather cap before removing the filler/breather cap.
3. Use a clean funnel with filter when adding fluid.
4. Use only approved Power Team hydraulic fluids.
5. Fill to 1-3/4" of the filler hole.
Priming the Pump Unit
1. Connect the fluid line to the pressure port and 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 valve 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.
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.
All unused couplers must be sealed with thread protectors. All hose connections must be free of grit and grime. Use
only high-grade, approved Power Team hydraulic fluid in this unit and change at least once a year.

Operating & Maintenance Instructions Form No. 105006
Gauges
:To help prevent personal injury, use a gauge of the proper rating for the pressure used.
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.
Refer to Figures 1 and 2.
2. Install male fitting into the tee adapter and securely tighten the hose to the male fitting.
Installing an In-line Hydraulic Pressure Gauge
1. Install a tee adapter, with gauge, between the valve and the cylinder. Refer to Figures 1 and 2.
2. Tighten all connections securely but do not overtighten.
Fire-Resistant Hydraulic Fluid
Flame Out 220™* fire-resistant hydraulic fluid is compatible with all Power Team 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.
* Flame Out 220™ is approved by Factory utual Research.
TROUB E-SHOOTING GUIDE
Sheet No. 3 of 3
Rev. 2 Date: 28 May 2012
Pump reciprocates but no fluid
delivery. (cylinder will not extend)
Cylinder(s) advance to desired
stroke but pump does not build
desired hydraulic pressure (air
motor running)
Pump will not build to maximum
pressure (air motor stopped
running)
1. Low fluid level.
2. Pump not primed.
3. Oil filter contamination.
1. Faulty gauge.
2. Reservoir not vented.
3.Fluid level too low.
4.Leaky connection or hose.
5. Excess air in fluid.
6. Defective 3-way/4-way valve
7. Leaking clamps.
1. Inadequate air supply.
2. Air regulator not set properly.
3. Leaking air line or connections.
1. Add fluid as instructed in
Preventive aintenance section.
2. Prime pump as instructed in
Preventive aintenance section.
3. Clean filter.
1. Replace gauge.
2. Vent reservoir by removing
shipping plug and installing
filler/vent cap.
3. Fill reservoir to 1-3/4" from the
filler hole.
4. Tighten connections or replace
hose.
5. Bleed unit as instructed in
Preventive aintenance section.
6. Replace valve.
7. Replace clamps.
1. Check air supply. inimum of 100
PSI air pressure is needed to
obtain 10,000 PSI hydraulic
pressure.
2. Increase or decrease hydraulic
pressure by turning regulator
clockwise or counterclockwise to
achieve desired pressure.
3. Repair or replace.
PROB EM CAUSE SO UTION
WARNING

Operating & Maintenance Instructions, Form No. 105006, Back sheet 3 of 3
Trouble-shooting Guide Cont'd
REP ACEMENT PARTS
PROB EM CAUSE SO UTION
ow fluid delivery (cylinder
extends slowly)
Pump builds pressure but will not
hold pressure.
Pump will continue to run slowly
even after desired pressure is
reached.
Excess oil spray from muffler.
1. Inadequate air supply.
2. Clogged fluid filter.
3. Air trapped in hydraulic system.
1. Loose or cross-threaded
connections.
2. Defective 3-way/4-way valve.
3. Defective clamps.
1. Defective 3-way/4-way valve.
2. Defective clamps.
1. Air lubricator is set too rich.
1. Check air supply -- 20 CF
minimum at 100 PSI is required
to achieve full speed.
2. Clean the filter.
3. Bleed system of air as instructed
in Preventive aintenance sec.
1. Check for leakage and re-fit if
necessary.
2. Replace valve.
3. Replace clamps.
1. Replace valve.
2. Replace clamps.
1. Turn adjuster clockwise until
closed and then open 1/8 turn.
160338WH2 1 Top Cover
224132S 1 Fill Plug
3209799 10 Screw (Torque to 35/40 in. lbs.)
447409 1 Gasket
561165 1 Reservoir
642382OR9 1 Front Panel
743481OR9 1 Back Panel
816492 1 ini Air Filter
915009 1 Air Lubricator
(Replacement bowl only -
#206264; for Wilkerson model
#251076; For Norgren model)
10 15010 1 Air Filter
(Replacement bowl only -
#206265; For Wilkerson model
#251082; For Norgren model)
11 29992 2 Foam Tube
Item Part No.
No. No. Req'd Description