Power Team PE10 Series User manual

Operating Instructions for:
PE10 Series
Electric-Powered
10 Series
Hydraulic Pump
© SPX
Form No. 1000573
Rev. 0 February 8, 2012

© SPX
Form No. 1000573
Rev. 0 February 8, 2012

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© SPX
Form No. 1000573
Rev. 0 February 8, 2012
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PE10-SeriesElectric/HydraulicPumps.....................................2
ControlValves.........................................................3
Safety Symbols and Denitions............................................4
SafetyPrecautions .....................................................4
InitialSetup...........................................................8
OperatingInstructions..................................................12
Performance Specications..............................................13
GeneralMaintenance ..................................................14
TroubleshootingGuide .................................................16
PowerTeamFacilities..................................................19

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© SPX
Form No. 1000573
Rev. 0 February 8, 2012
The 10 series hydraulic pumps are designed to have a maximum of 690 bar (10,000 psi) at
a ow rate of 164 cc/min (10 cu. in/min). A pump can be valved for use with either single- or
double-acting cylinders. All pumps come fully assembled, less uid, and ready for work.
PE10-Series Electric / Hydraulic Pumps
Electric Driven Motor
Motors are available in 0.186 kW (1/4 HP) in three voltages: 110/115VAC, 220/230 VAC, and 12 VDC.
Figure 1. PE10
Description

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Form No. 1000573
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Table 1. Pump Congurations
Control Valves
Max. Capacity: 690 bar (10,000 psi)
PE102
PE102-220
PR102
Valve Function Use with
Cylinder Type
Valve No.
HOLD
RETURN
Advance
Pump “ON”
Hold Position
Return
Pump “OFF”
Return Position
From
Pump
To
Tank
Single-acting 9561 2-way/auto dump,
advance return (auto)
Diagrams
PE102A
PE102A-220
PR102A
Valve Function Use with
Cylinder Type
Valve No.
Advance
Pump “ON”
Return
Pump “OFF”
From
Pump
To
Tank
Single-acting 9562 auto dump,
advance return
Diagrams
PE104
PE104-220
PR104
Valve Function Use with
Cylinder Type
Valve No.
P
Port “A” Port “B” Port “B”
TP
Port “A”
TP
Port “A” Port “B”
T
Position “A” Position “B”
Center
Position
From
Pump
To
Tank
From
Pump
To
Tank
From
Pump
To
Tank
Single- and
double-acting
9563 4-way,
advance hold return
Diagrams

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© SPX
Form No. 1000573
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The safety signal word designates the degree or level of hazard seriousness.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury.
CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
IMPORTANT: Important is used when action or lack of action can cause equipment failure, either
immediate or over a long period of time.
Safety Symbols and Denitions
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. If the operator cannot
read these instructions, operating instructions and safety precautions must be read
and discussed in the operator's native language.
• 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. Only the user can decide the suitability of this product in these conditions
or extreme environments. Power Team will supply information necessary to help make
these decisions. Consult your nearest Power Team facility.
• Safety glasses must be worn at all time by the operator and anyone within sight of
the unit. Additional personal protection equipment may include: face shield, goggles,
gloves, apron, hard hat, safety shoes, and hearing protection.
• The owner of this tool must ensure that safety-related decals are installed, maintained,
and replaced if they become hard to read.
• Shut OFF the motor before opening any connections in the system.
• The guide cannot cover every hazard or situation so always do the job with SAFETY
FIRST.
Pump
WARNING:
• Do not exceed the 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.
• 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 operator control at all times.
Safety Precautions

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• Do not connect pump to hydraulic system powered by another pump.
Electric-Driven Motor
WARNING:
• 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.
• 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 counterclockwise 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.
Hoses
WARNING:
• 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
off 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-
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.
Safety Precautions continued

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• 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.
Cylinder
DANGER:
• Do not exceed rated capacities of the cylinders. Excess pressure may result in personal
injury.
• Avoid off-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.
• 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 off-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.
• Do not drop the load.
• As the load is lifted, use blocking and cribbing to guard against a falling load.
• 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.
Safety Precautions continued

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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.
• 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.
• Limiting the stroke and pressure on all cylinders will prolong their life.
Safety Precautions continued

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Initial Setup
1. Remove all packing materials from the assembled unit.
2. Inspect the unit upon arrival. The carrier, not the manufacturer, is responsible for any damage
resulting from shipment.
Filling the Pump Reservoir/Bladder
Most pumps are shipped without hydraulic uid in the reservoir or bladder. Hydraulic uid may have
been shipped in a separate container, but if hydraulic uid is needed, use only approved Power Team
hydraulic uid rated at 47 cSt @ 38°C (215 SUS @ 100°F).
1. Clean the area around the filler cap to remove debris. Debris in the hydraulic fluid can damage the
polished surfaces and precision-fit components of this pump.
2. Remove the filler cap and insert a clean funnel with filter.
3. Fill bladder to the top of filler. All air must be out of bladder.
4. Replace the filler cap.
IMPORTANT: Tighten ller cap 1/2 - 1 turn after o-ring contacts sealing surface. Overtightening
can cause pump damage.
Hydraulic Connections
1. Clean the areas around the fluid ports of the pump and cylinders.
2. Inspect all threads and fittings for signs of wear or damage, replace as needed.
3. Clean all hose ends, couplers or union ends.
4. Remove the thread protectors from the hydraulic fluid outlets.
5. Connect the hose assembly to the hydraulic fluid outlet, and couple the hose to the cylinder.
CAUTION: 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 off 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.
Electric Motor Operation
Motor voltages are not changeable. They are:
12 VDC - 11-14 VDC
120 VAC - 90-130 VAC 50/60 Hz
220 VAC - 190-240 VAC 50/60 Hz
1. Verify the hydraulic valve is in the neutral or hold position.
2. Connect the motor to a power supply.
Caution:
• 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.

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Form No. 1000573
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Initial Setup continued
AMPS
at Maximum
Hyd. Pressure
Electrical Cord Size AWG (mm2) 3.2 Volt Drop
Length of Electrical Cord
mm2AWG
0-8 m 8-15 m 15-30 m 30-46 m 0-25 ft 25-50 ft 50-100 ft 100-150 ft
60.75 11.5 2.5 18 16 14 12
10 0.75 1.5 2.5 418 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 86
26 2.5 4 6 10 12 10 86
30 2.5 4 10 16 12 10 6 4
Table 2. Minimum Recommended Gauge Table
Bleeding Air from the System
After all connections are made, the hydraulic system must be bled of any trapped air. See Figure 2.
With no load on the system and the pump vented and positioned higher than the hydraulic device,
cycle the system several times. Check the reservoir uid level and ll to proper level with Power Team
hydraulic uid as necessary. If there is a problem contact Power Team.
• 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.
3. Start the pump and shift as required.
4. Turn off the pump when not in use.
Figure 2. System Bleeding

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Initial Setup continued
Figure 4. Gauge Port
IMPORTANT: Some spring return cylinders have a cavity in the rod which forms an air pocket. This type
of cylinder should be bled when positioned upside down or lying on its side with the port facing upward.
Hydraulic Pressure Gauge (optional)
Automatic Dump Valve
To monitor line pressure when using an automatic dump valve, a T-adapter is used between the valve
and the pressure switch to adapt a hydraulic pressure gauge.
Posi-Check Valve
If a Posi-Check valve is used, a hydraulic gauge shows zero pressure when the valve is switched to the
neutral (hold) position. Cylinder pressure, however, is held without loss. If reading the cylinder pressure,
a gauge must be installed in the outlet port of the valve.
To install a hydraulic pressure gauge (for PE104):
1. See Figure 4. Remove the pipe plug from the
valve’s gauge port.
1 2
3
To install a hydraulic pressure gauge (for PE102):
1. A T-adapter (PN 9760) is necessary. See
Figure 3. Install T-adapter.
2. Install sealant tape or non-hardening sealer to a
T-adapter. Install the T-adapter as shown.
3. Install sealant tape or non-hardening sealer to
the gauge.
4. Install the pressure gauge.
Figure 3. 10 Series Gauge
Item Description
1 Gauge
2 Hose
3 T-adapter

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Figure 5. Elbow Installation
Figure 6. Pressure Gauge
Installation
Initial Setup continued
2. See Figure 5. Install sealant tape or non
hardening sealer to a 45 degree elbow (PN
9678). Install the elbow as shown.
3. Install sealant tape or non hardening sealer to
the gauge.
4. See Figure 6. Install the pressure gauge.

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Operating Instructions
Bleeding Air from the System
1. Cycle the hydraulic system until operation is smooth and consistent.
2. Check the pump reservoir level. Add Power Team hydraulic uid as needed.
Motor Control Operation
1. If necessary, connect the power cord to an
appropriate power source.
2. See Figure 7. Place the motor control switch
located in the handle in the ON position.
Figure 7. PE10 Motor Control Switch

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Performance Specications
The information in the following charts can be used as a basis to determine if the system is performing
as expected during operation.
Pump RPM
Amp Draw at
690 bar (10,000
psi) (115V)
Amp Draw at
690 bar (10,000
psi) (230V)
dBa at Idle
and 690 bar
(10,000 psi)
Air Supply
Req'd bar (psi)
PE10 6 3 68-74 N/A
Pump Max. Pressure
Output bar (psi) Fluid Delivery** (cu. in./min. @)
0 bar (0 psi) 7 bar
(100 psi)
50 bar
(700 psi)
70 bar
(1,000 psi)
345 bar
(5,000 psi)
690 bar
(10,000 psi)
PE10 690 bar
(10,000 psi)
120 - - - - 10
** Typical delivery. Actual ow varies with eld conditions.
Table 3. Drive Unit Requirements
Table 4. Fluid Pressure Chart

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Form No. 1000573
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General Maintenance
System Evaluation
The components of your hydraulic system — cylinders, pumps, hoses, and couplings — all 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 Power Team Technical Support.
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 insufcient thread engagement.
• Leaking hydraulic uid.
• Scored or damaged piston rod.
• Incorrectly functioning or damaged heads and caps.
• Loose bolts or cap screws.
• Damaged or incorrectly assembled accessory equipment.
• Modied, welded, or altered equipment.
• Bent or damaged couplers or port threads.
Periodic cleaning
WARNING: Contamination of the hydraulic uid could cause the valve to malfunction. Loss
of the load or personal injury could result.
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 filler cap clean and unobstructed.
• Use only Power Team hydraulic fluid. Replace hydraulic fluid as recommended, or sooner if the fluid
becomes contaminated. Never exceed 300 hours of use between fluid changes.
Hydraulic Fluid Level
1. Check the fluid level in the reservoir after each 10 hours of use. The fluid level should be checked
when all cylinders are retracted.
2. Drain, flush, and refill the reservoir with an approved Power Team hydraulic fluid after every 300
hours of use. The frequency of fluid 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.
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.

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Adding Hydraulic Fluid to the Reservoir or Bladder
1. Retract the cylinder(s) devices.
2. Disconnect the power supply.
3. Clean the entire area around the filler plug.
4. Remove the filler plug, and install a clean funnel with a filter.
5. Use only Power Team hydraulic fluid 47 cSt @ 38°C (215 SUS @ 100°F).
General Maintenance continued
Sound Reduction - Electrically Powered Motor
The electrically powered hydraulic pump operates in the 90-95 dBA range. If further sound reduction is
desired, any of the following options will help reduce the sound level.
1. Install a pressure switch to automatically shut off the motor when maximum pressure is reached
(holding cycle).
2. Contact Power Team Hydraulic Technology technical support for products more suitable to your
application.
Hose Connections
CAUTION: 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 off 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.

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WARNING:
• 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.
Notes:
• For a detailed parts list or to locate a Power Team Authorized Hydraulic Service Center, contact your
nearest Power Team facility.
• 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.
Troubleshooting Guide
Problem Cause Solution
Electric motor does not
run.
1. Pump not turned ON. 1. Position switch to RUN position.
2. Unit is not plugged in. 2. Plug in unit.
3. No voltage supply. 3. Check line voltage. Check reset
button on power panel.
4. Worn brushes. 4. Replace brushes.
5. Circuit breaker tripped because
total amperage draw too high for
existing circuit.
5. Use an alternate circuit or have
a qualied electrician add an
additional circuit.
6. Overheated motor (single-
phase motor). Magnetic starter
disengaged (three-phase motor).
Thermal protector open.
6. Wait for motor to cool before
restarting. Reset thermal protector.
(Single-phase motor will reset
automatically.)
7. Faulty thermal protector (single-
phase motor). Faulty magnetic
starter (three-phase motor).
7. Replace defective parts.
Electric motor will not shut
off.
1. Defective motor controls. 1. Disconnect unit from power
supply; contact a Power Team
Service Center.
Electric motor stalls,
surges, overheats, or will
not start under load.
1. Low voltage 1. Refer to electric motor
information in Initial Setup section.
2. Electrical cord size too small. 2. Refer to electrical cord chart in
Initial Setup section.
Electrical overload
protector keeps tripping.
1. Wired incorrectly. 1. Disconnect unit from power
supply; have qualied electrician
review motor and circuit wiring.

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Troubleshooting Guide continued
Problem Cause Solution
Pump delivers excess uid
pressure.
1. Faulty pressure gauge. 1. Replace gauge.
2. Relief valve set incorrectly. 2. Contact a Power Team Service
Center.
Pump is not delivering
uid, or delivers only
enough uid to advance
connected components
partially or erratically or
operation to slow.
1. Fluid level too low. 1. Add uid, refer to lling the pump
reservoir in Initial Setup section.
2. Loose-tting coupler to
component.
2. Verify quick-disconnect couplings
to cylinders are completely coupled.
Couplers may need to be replaced
because ball check does not stay open
due to wear.
3. Air in system. 3. Refer to Initial Setup in this
manual to bleed air from system.
4. Air leak in suction line. 4. Check and tighten suction line.
5. Debris in pump or lter plugged. 5. Clean pump lter. If problem
persists, disconnect from power
supply contact authorized Power
Team service center.
6. Fluid bypasses through the
double-acting cylinder.
6. Remove cylinder; cap hoses.
Check pump and valve for leaks.
7. Cold uid or uid too heavy.
(Hydraulic uid is of a higher
viscosity than necessary.)
7. Drain, ush, and rell reservoir
using a lighter weight uid. Refer to
General Maintenance section.
8. External relief valve or low
pressure unloading valve out of
adjustment.
8. Refer to Adjusting the Pressure
Regulating Valve.
9. Power unit/reservoir capacity
is too small for the size of the
cylinder(s) used.
9. Use smaller cylinder(s) or larger
reservoir.
10. Vacuum in reservoir. 10. Clean plugged vent in ller plug.
Pump builds pressure but
cannot maintain pressure.
1. Fluid leakage. 1. Look for external leaks. If no uid
leakage is visible, the problem is
internal. If using a double-acting
cylinder, remove it from the system
to ensure the leak is not in the
cylinder. Seal leaking pipe ttings
with pipe sealant.
2. Leaking pressure switch seal. 2. Replace pressure switch.

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Troubleshooting Guide continued
Problem Cause Solution
Pump does not build to full
pressure.
1. Faulty pressure gauge. 1. Replace pressure gauge.
2. Check for external leakage. 2. Seal faulty pipe ttings with pipe
sealant.
3. Check external pressure
regulator. Check relief valve
setting.
3. Refer to Adjusting the Pressure
Regulating Valve.
4. Look for internal leakage in
double-acting cylinders.
4. Remove cylinder from pump. If
pump builds full pressure, cylinder is
defective.
5. Inadequate air pressure (air
motor only).
5. Refer to Initial Setup section.
Erratic action 1. Air in system. 1. Check for leaks. Refer to
bleeding procedure.
2. Internal leakage in attached
components.
2. Refer to manufacture's
information for attached component.
3. Attached component sticking or
binding.
3. Refer to manufacture's
information for attached component.
4. Malfunctioning valve. 4. Verify connections. Contact
authorized Power Team Service
Center.