Power Team PG1200M-4 User manual

GAS HYDRAULIC PUMP
Max. Capacity: 10,000 PSI
NOTE:
●Read and carefully follow these instructions. Most problems with new equipment are caused by improper
operation or installation.
SAFETY PRECAUTIONS
WARNING: To help avoid personal injury,
Hydraulic Hose
●Before operating the pump, all hose connections must be tightened using the proper tools. Do not
overtighten. Connections should only be tightened securely and leak-free. Overtightening can cause
premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.
●Always shut off the electric motor before breaking any connection in the system.
●Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the pump.
Never attempt to grasp a leaking pressurized hose with your hands. The force of escaping hydraulic fluid
could cause serious injury.
●Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold, or heavy
impact. Do not let the hose kink, twist, curl or bend so tightly that oil flow within the hose is blocked or
reduced. Periodically inspect the hose for wear, because any of these conditions can damage the hose.
●Do not use the hose to move attached equipment. Stress can damage the hose, causing 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 can result in personal injury.
Pump
●Do not exceed the PSI hydraulic pressure rating noted on the pump nameplate or tamper with the internal
high pressure relief valve. Creatng pressure beyond the rated capacity can result in personal injury.
●Before replenishing the oil level, retract the system to prevent overfilling the pump reservoir. An overfill
can cause personal injury due to excess reservoir pressure created when cylinders are retracted.
Cylinders
●Do not exceed the 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 (Gasoline Engine)
●Read the instruction manual for the gasoline engine before using.
●Do not allow fuel to splash on the engine when refueling.
●Do not add fuel when the engine is running or very hot.
Form No. 102646
PG1200M-4
PG1200M-4D
Sheet No. 1 of 7
Issue Date: Rev. 7-20-94
Litho in USA
Parts List &
Operating Instructions for:
Tech. Services: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
SPX Corporation
5885 11th Street
Rockford, IL 61109-3699 USA
Internet Address:
http://www.powerteam.com
®

Parts List and Operating Instructions, Form No. 102646, Back sheet 1 of 7
SET-UP
Gasoline Engine
Refer to the instruction manual on the gasoline engine.
Hydraulic Connections
1. Clean all the areas around the oil ports of the pump and cylinders.
2. Inspect all threads and fittings for signs of wear or damage, and replace as needed.
3. Clean all hose ends, couplers or unions.
4. Remove the thread protectors from the hydraulic oil outlets. Connect the hose assembly to the hydraulic oil outlet,
and couple the hose to the cylinder. Although a high-grade, non-hardening thread sealant is preferred, teflon tape
can be used if only one layer of tape is used. Apply carefully to prevent the tape from being pinched by the
coupler and broken off inside the pipe end. Any loose pieces of tape could travel through the system and obstruct
the flow of oil.
Filling the Reservoir
NOTE: The pump has been shipped without oil in the reservoir. High-grade hydraulic oil has been shipped
with the pump in a separate container. If additional oil is required, use Power Team hydraulic fluids only.
1. Clean the area around the filler cap to remove all dust and grit. Any dirt or dust in the oil can damage the polished
surfaces and precision-fit components of this pump.
2. Retract all cylinders to the return position.
3. Remove the filler cap, and insert a clean funnel and filter. Fill with hydraulic oil to 1/2" from the top of the filler
hole. Replace filler cap with the breather-hole in the filler cap open.
4. Cycle the pump (with cylinders attached) several times. Retract the cylinders, and check the oil level in the pump
reservoir again.
OPERATION
Priming the Pump
When operating the pump for the first time:
1. Valve and hose connections must be tight, and the reservoir must be filled to the proper level. Start the motor.
2. Jog the pump several times to build pressure. If the pump doesn't build pressure, it may not be primed.
Disconnect a hose from the system and route it back to the pump reservoir. Run the pump until a steady flow of
oil is observed free of suspended air bubbles. Reconnect the hose to the system.
3. Run cylinder out to its full travel several times to eliminate air from the system. For more complete instructions,
refer to the section titled "Bleeding Air from the System."
4. The pump is ready to be put into regular operation.
IMPORTANT: After eliminating trapped air from a large work-holding system, retract the cylinders and refill
the pump reservoir to 1/2" from the top of the filler hole.
Adjusting the Pressure Regulating Valve
The pressure regulating valve can be adjusted to bypass oil at a given pressure setting while the pump continues to
run.
Figure 1
NOTE: For easy adjustment of the pressure regulating valve,
always adjust the pressure by increasing to the desired
pressure setting.
1. Loosen the locknut on the pressure regulating valve (B), and
back the adjusting screw (A) out a few turns with a
screwdriver by turning in a counterclockwise direction. This
will decrease the setting to a lower than desired pressure.
2. The pump must be completely connected. Set the motor
control toggle switch to "Run" and push the "Start" button.
3. With the screwdriver, slowly turn the adjusting screw (A) in a
clockwise direction. This gradually increases the pressure
setting. When the desired pressure is reached, lock the
adjusting screw in position by tightening the locknut.
AB

Parts List and Operating Instructions Form No. 102646
PREVENTIVE MAINTENANCE
WARNING: To help avoid personal injury,
●Repairs and maintenance are to be performed in a dust-free area by a qualified technician.
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 fitting that is
situated higher than the rest of the fittings in the system. Run the pump until a steady flow of oil free of suspended air
bubbles is observed. Tighten the fitting.
Inspecting the Hydraulic Fluid Level
Check the oil level in the reservoir periodically. The oil level should be 1/2" from the top of the filler hole with all
cylinders retracted. Drain, clean and replenish the reservoir with Power Team hydraulic fluid 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.
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/vent cap clean and unobstructed at all times.
5. Equipment connected to the pump must be kept clean.
6. Use only 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 ten 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 fill half full with clean Power Team hydraulic fluid.
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 plug 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 Power Team hydraulic fluid. Place the pump and motor assembly (with gasket) on the
reservoir and install all the screws. Tighten securely and evenly.
Adding Oil to the Reservoir
1. Cylinder(s) must be fully retracted and the gas engine off when adding oil to the reservoir.
2. Clean the entire area around the filler/vent cap before removing the filler/vent cap.
3. Use a clean funnel with filter when adding oil.
4. Use only Power Team hydraulic fluids.
Sheet No. 2 of 7
Issue Date: Rev. 7-20-94

Part List and Operating Instructions, Form No. 102646, Back sheet 2 of 7
SIDE VIEW
INLET
INLET
.010
.040
BOTTOM OF SLOT IN 21091.)
420052 SHAFT ADAPTER AND
(DISTANCE BETWEEN BOTTOM OF
123
4
5
678
91011
12, 13, 14
15
1617
1819
20
21
22, 4
23
24, 25
26
27
28
29
20
30, 13, 31, 14
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
22
4
48
49
50 51 52 53 54 55
56
13
57
58
59
60
Basic Pump Assembly
See back pg. 4 of 7
(Distance between bottom of
shaft adapter [Item #51] and
bottom of slot in nylon coupler
[Item #19 on sheet 6 of 7])
.010
.040
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List

Parts List and Operating Instructions Form No. 102646
1420202 1 Gasoline Engine (Honda 5.5 H.P.)
2250369 2 Conduit Clamp (3/4)
310009 2 Hex Cap Screw
(1/4-20 UNC x 3/4 Lg.)
410245 18 Lockwasher (1/4 I.D.)
510199 2 Hex Nut (1/4-20 UNC)
646647 1 Restrictor Valve
(See form #100666)
752515 1 Valve Assembly (3 position/3-way;
for PG1200M-4; see forms #100627 &
#102527)
52516 1 Valve Assembly (3 position/4-way;
for PG1200M-4D; see forms #100628
& 102527)
89052 1 Pressure Gauge (Liquid filled -
10,000 PSI
946244 1 Subplate (See form #102529)
10 12740 1 Straight Fitting
11 420076 1 Remote Metering Valve
(See form #101206)
12 10041 4 Hex Hd. Cap Screw (5/16-18 UNC
x 2-3/4 Lg.; for PG1200M-4)
250382 4 Hex Hd. Cap Screw (5/16-18 UNC
x 6" Lg.; for PG1200M-4D)
13 10257 10 Flat Washer (5/16 I.D.)
14 10201 8 Hex Nut (5/16-18 UNC)
15 9796 4 Quick Disconnect Coupler
(for PG1200M-4)
9796 8 Quick Disconnect Coupler
(for PG1200M-4D)
16 10666 1 90° Elbow Fitting
(for PG1200M-4D)
17 58055 1 Metering Valve Body
(for PG1200M-4D)
18 11946 3 O-ring Boss Plug (3/4-16 UNF;
for PG1200M-4D)
19 205956 1 Straight Fitting (for PG1200M-4D)
20 10673 2 Straight Hex Nipple Fitting
(for PG1200M-4D)
21 9575 1 Manual Directional
Control Valve (for PG1200M-4D)
22 209355 6 U-bolt with Nut
23 10648 1 45° Swivel Elbow Fitting
(for PG1200M-4)
10648 2 45° Swivel Elbow Fitting
(for PG1200M-4D)
24 10008 4 Soc. Hd. Cap Screw
(1/4-20 UNC x 3/4 Lg.)
25 12719 4 Plain Washer (1/4 I.D.)
26 250380 1 Hydraulic Hose (1/2 I.D. x 1-1/2 ft.
lg.; for PG1200M-4)
250380 2 Hydraulic Hose (1/2 I.D. x 1-1/2 ft.
lg.; for PG1200M-4D)
27 307968 1 Hydraulic Hose (1/4 I.D. x 2 ft. lg.)
28 250370 2 Barbed Hose Fitting (3/8 NPTF;
for PG1200M-4)
250370 4 Barbed Hose Fitting (3/8 NPTF;
for PG1200M-4D)
29 214488 1 Tee Fitting (for PG1200M-4D)
30 10039 4 Hex Hd. Cap Screw
(5/16-18 UNC x 2-1/2 Lg.)
31 10246 4 Lockwasher (5/16 I.D.)
32 40137OR9 1 Reservoir (5 gal.)
33 10049 4 Hex Hd. Cap Screw
(3/8-16 UNC x 1" Lg.)
34 10258 4 Washer
35 10204 4 Hex Nut (3/8-16 UNC)
36 60855BK2 1 Frame
37 10432 6 Snap Plug
38 211167 1 Decal (For manifold)
39 309221 2 Trade Name Decal
40 206737 2 Hub Cap
41 307004 1 Axle (3/4" dia.)
42 12330 6 Plain Washer (3/4 I.D.; NOTE: Use
one washer on each side of wheel
(both sides) & use remaining two
washers to take up any excessive
movement of wheels.)
43 10573 2 Cotter Pin (1/8 x 1-1/4 Lg.)
44 212876 2 Wheel (12" dia.)
45 206270 2 U-bolt with Nut (1/4)
46 10439 1 Radial Ball Bearing
47 15124 1 O-ring (1-3/8 x 1-1/4 x 1/16, -026)
48 40987 1 Gasket
49 *50384WH2 1 Motor Base
50 10945 1 Woodruff Key (No. 6)
51 420052 1 Shaft Extension
52 *251566 1 Cap Screw (5/16-24 UNF x 2” Lg.)
53 10556 1 Hex Soc. Hd. Set Screw
(1/4-20 UNC x 1/4 Lg.)
54 *420200 1 Gas Engine Mounting Plate
55 250427 4 Soc. Hd. Cap Screw
(5/16-18 UNC x 1/2 Lg.)
56 10948 2 Soc. Hd. Cap Screw
(5/16-18 UNC x 1-1/2 Lg.)
57 17596 1 Slide Control
58 46456BK2 1 Roll Cage Frame
60 202173 2 Decal
59 12367 2 Hose Clamp
PARTS INCLUDED BUT NOT SHOWN
10474 1 90° Elbow Fitting (for PG1200M-4)
Item Part No. Item Part No.
No. No. Req'd Description No. No. Req'd Description
Sheet No. 3 of 7
Issue Date: Rev. 7-20-94
*Note: If replacing any of these parts on a pump manufactured before 7-1-94,
order motor base replacement kit no. 251571.
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Drawing

Parts List and Operating Instructions, Form No. 102646, Back sheet 3 of 7
TOP VIEW
A
P
O
R
T
B
P
O
R
T
10,000 PSI MAX.
POWER TEAM 9644
I
L
L
E
R
E
A
T
H
E
F
R
B
1
2
3
4
5
6
7
8
9
10
11
12
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List

Parts List and Operating Instructions Form No. 102646
HYDRAULIC SCHEMATIC
1206731 2 Rubber Grip
246455BK2 1 Handle
310662 1 Straight Fitting (For PG1200M-4)
10662 2 Straight Fittng (For PG1200M-4D)
458122BK2 1 Mounting Bracket
5350234 1 Oil Line Tube (For PG1200M-4D)
610660 1 Straight Fitting
7350233 1 Oil Line Tube
8202120 1 Name Plate
99683 1 Straight Hex Nipple Fitting
10 10474 2 90° Elbow Fitting
11 250381 1 90° Elbow Fitting
12 10676 1 Straight Fitting
Sheet No. 4 of 7
Issue Date: Rev. 7-20-94
Item Part No.
No. No. Req'd Description
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Drawing

Parts List and Operating Instructions, Form No. 102646, Back sheet 4 of 7
GENERAL PUMP ASSEMBLY
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List

Parts List and Operating Instructions Form No. 102646
PRESSURE REGULATOR ASSEMBLY
110016 3 Soc. Hd. Cap Screw
(1/4-20 UNC x 1" Lg.)
245911 1 Manifold Body
320937 1 Filler Plug
410177 10 Machine Screw
(1/4-20 UNC x 3/4 Lg.)
550058WH2 1 Cover
658506 1 Gasket
721278 1 Relief Valve Assembly (Set at
10,100/10,700 PSI)
820776 1 Valve Body
920771 1 Poppet
10 10425 1 Compression Spring
(3/8 O.D. x 3/4 Lg.)
11 10261 1 Copper Washer
12 20770 1 Connector (Torque to 40/45 in. lbs.)
13 10015 2 Soc. Hd. Cap Screw (1/4-28 UNF
x 1" Lg.; Torque to 180 in. lbs.)
14 10266 1 O-ring (1/4 x 3/8 x 1/16, -010)
15 21484 1 Spacer
16 10268 1 O-ring (-012)
17 11863 1 Teflon Backup Washer (-012)
18 20787 1 Valve Connector
19 10430 2 Tube Sleeve
20 10431 2 Tube Nut
21 21495 1 Oil Line Tube
22 11342 1 Tube Nut
23 11174 1 Tube Sleeve
24 22399 1 External Pressure
Regulator Tube
25 11173 1 Straight Fitting
26 10479 2 Pipe Plug
27 10022 4 Soc. Hd. Cap Screw
(1/4-20 UNC x 1-1/2 Lg.)
28 200609 1 Drain Tube
Item Part No. Item Part No.
No. No. Req'd Description No. No. Req'd Description
122362 1 Adjusting Screw
(Set at 10,000/10,200 PSI)
210386 1 Hex Nut (3/8-24 UNF)
321305 1 Valve Cap
410268 1 O-ring (-012)
521306 1 Spring Guide
610495 1 Compression Spring
(.45 x 1-5/8 Lg.)
721046 1 Valve Stem
822361 1 Body
Item Part No.
No. No. Req'd Description
Sheet No. 5 of 7
Issue Date: Rev. 7-20-94
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Drawing

Parts List and Operating Instructions, Form No. 102646, Back sheet 5 of 7
BASIC PUMP ASSEMBLY
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List

Parts List and Operating Instructions Form No. 102646
NEEDLE BEARING INSTALLATION
SPECIFICATIONS
When replacing the needle bearings on the drive gear
of the basic pump, the dimensions shown must be as
specified.
110020 9 Soc. Hd. Cap Screw (1/4-20 UNC x 1-1/4 Lg.;
Torque to 170/180 in. lbs.)
233114 1 High Pressure Pump Assembly (See pg. 6 of 8)
310361 1 Compression Spring (1/4 O.D. x 1" Lg.)
410375 1 Steel Ball (1/4 dia.)
523547 1 Bearing Top Plate
623548 1 Top Plate
711228 2 Thrust Needle Bearing
811813 3 Needle Thrust Race Bearing
911814 1 Ball Bearing
10 23549 1 Angle Plate
11 11955 1 Roll Pin (1/4 dia. x 3/4 Lg.)
12 11064 2 Needle Bearing
13 11261 2 Retaining Ring
14 23556 1 Shaft
15 11821 1 Woodruff Key (No. 3)
16 23557 1 Gear
17 30533 1 Pump End Plate
18 10001 12 Soc. Hd. Cap Screw (#10-32 UNF x 1-3/4 Lg.;
Torque to 50/60 in. lbs.)
19 21091 1 Nylon Coupling
20 10528 1 Adapter Union
21 22033 1 Suction Line
22 11199 2 Needle Thrust Bearing (See note below)
23 10266 1 O-ring (1/4 x 3/8 x 1/16, -010)
24 21272 1 Drive Gear
25 10303 1 O-ring (3/4 x 7/8 x 1/16, -018)
26 10425 2 Compression Spring (3/8 O.D. x 3/4 Lg.)
27 20771 2 Poppet
28 40120 1 Pump Body
29 10427 1 Pipe Plug (1/8 NPTF)
30 10271 1 O-ring (11/16 x 1/2 x 3/32, -112)
31 12389 1 Teflon Backup Washer
32 20849 1 Spool
33 23255 1 Spring Guide
34 10426 1 Compression Spring (1" O.D. x 1-13/16 Lg.)
35 23256 1 Spring Guide
36 21345 1 Filter Assembly
Item Part No.
No. No. Req'd Description
Sheet No. 6 of 7
Issue Date: Rev. 7-20-94
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Drawing

Parts List and Operating Instructions, Form No. 102646, Back sheet 6 of 7
HIGH PRESSURE PUMP ASSEMBLY
6 PISTON -- 9/32 DIA.
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List

Parts List and Operating Instructions Form No. 102646
BOLT TIGHTENING SEQUENCE
110442 1 Copper Washer (3/8 x 1/4 x 1/32)
210002 1 Soc. Hd. Cap Screw (1/4-20 UNC x 3/8 Lg.;
Torque to 140/160 in. lbs.)
324549 12 Valve Guide
410445 12 Compression Spring (5/32 O.D. x 3/4 Lg.)
512223 13 Steel Ball (3/16 dia.)
610023 7 Soc. Hd. Cap Screw (1/4-28 UNF x 1-1/2 Lg.;
Torque to 170/180 in. lbs. See note below.)
750411 1 Top Plate
810519 1 Soc. Set Screw (1/4-20 UNC x 3/8 Lg.;
Torque to 65/70 in. lbs.)
941048 1 Valve Head
10 41063 1 Pump Barrel
11 21628 6 Piston
Item Part No.
No. No. Req'd Description
Sheet No. 7 of 7
Issue Date: Rev. 7-20-94
NOTE: Assemble in sequence shown.
Lubricate under head and on threads.
Torque to 180 in. lbs.
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Drawing