Powerx PA6 Series User manual

D0136 RevC 1 C19-01-01
INSTRUCTION SHEET
Model PA6 Family
Air/Hydraulic Pump 10,000 PSI Capacity
Safety/Warning - Set-up - Operating - Maintenance Instructions
IMPORTANT - READ CAREFULLY
This manual contains important information about the correct installation, operation and maintenance
of this equipment. All persons involved in the installation, operation and maintenance of this equipment
must be thoroughly familiar with the contents of this manual. To safeguard against the possibility of
personal injury or property damage, follow the recommendations and instructions of this manual. Keep
this manual for reference.
WARRANTY STATEMENT
PowerX products are warranted to be free of defects in materials and workmanship under normal use,
please go to www.powerxinternational.com to review our complete warranty policy. This warranty does
not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper lubrication, or
use in a manner for which they are not intended. If the customer believes a product is defective, the
product must be delivered, or shipped freight prepaid, to the nearest PowerX Authorized Service Center
for evaluation and repair.
RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify
carrier at once. Shipping damage will not be covered by warranty. The carrier is responsible for all loss
associated with shipping damage.
CONTENTS
SECTION
Receiving Instructions...............................................................................................................................1.0
Safety ........................................................................................................................................................2.0
Technical Specifications ............................................................................................................................3.0
Basic Operation and Function...................................................................................................................4.0
Basic Operation.........................................................................................................................................4.1
After Completing the Job..........................................................................................................................4.2
Periodic Maintenance ...............................................................................................................................5.0
Maintain Oil Level .....................................................................................................................................5.1
Troubleshooting........................................................................................................................................6.0

D0136 RevC 2 C19-01-01
1.0 RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found,
notify carrier at once. Shipping damage will not be covered by warranty. The carrier is responsible
for all loss associated with shipping damage.
2.0 SAFETY
Make sure to read the instructions, warnings and precautions carefully. Follow all recommended
safety precautions to avoid personal injury or damage to the unit. PowerX cannot be responsible for
any damage or injury from unsafe use, lack of maintenance, or incorrect operation. In the event any
questions or concerns arise, contact PowerX or a local PowerX Distributor for clarification.
The pump’s maximum working pressure is 10,000 PSI (700 bar). Make sure that all hydraulic
equipment such as rams, hoses, etc. used with this pump are rated at 10,000 PSI (700 bar) operating
pressure.
If you have never been trained on high-pressure hydraulic safety, consult your distributor or service
center. Failure to comply with the following cautions and warnings could cause equipment damage,
property damage, or personal injury.
DANGER: is only used when your action or lack of action may cause serious injury or even death.
WARNING: indicates a potential danger that requires correct procedures or practices to avoid
personal injury.
CAUTION: is used to indicate correct operating or maintenance procedures and practices to
prevent damage to, or destruction of equipment, or other property.
WARNING: Wear proper personal protective gear when operating hydraulic equipment.
WARNING: The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install pressure gauges in the system to monitor operating
pressure. Gauges help the user see what is happening with the hydraulic pressure in the
system.
WARNING: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing
hydraulic hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and
kinks will internally damage the hose, leading to premature hose failure. Do not drop heavy
objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying
handle or other means of safe transport.
CAUTION: Keep hydraulic equipment away from flames and heat. Excessive heat will soften
seals, resulting in fluid leaks. Heat also weakens hose materials. For optimum performance do

D0136 RevC 3 C19-01-01
not expose equipment to temperatures of 65° C (170° F) or higher. Protect hoses and cylinders
from weld spatter.
WARNING: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the
skin, causing serious injury. If oil is injected under the skin, see a doctor immediately.
Untreated oil injection could be fatal, but normally just causes severe injury.
WARNING: Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised or
lowered, it must always be blocked mechanically.
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. Carefully select steel or wood blocks that
are capable of supporting the load. Never use a hydraulic cylinder as a shim or spacer in any
lifting or pressing application.
3.0 TECHNICAL SPECIFICATIONS
Model
Cylinder
Type
Operator
Useable Oil
Volume
(in3)
No Load
Flow
(cu.in/min)
Flow at
10,000 psi
(cu.in/min)
Air Pressure
(psi)
Wt.
(lbs.)
PA6-98C
S/A
Foot Pedal
98
82
13
60-150
16
PA6-122
S/A
Foot Pedal
122
82
13
60-150
20
PA6-98R
S/A
Pendant
98
82
13
60-150
23
PA6-231
S/A
Foot Pedal
231
82
13
60-150
32
PA6-122D
D/A
Valve
122
82
13
60-150
22
PA6-231D
D/A
Valve
231
82
13
60-150
32
PA6-460D
D/A
Valve
460
82
13
60-150
44
4.0 BASIC OPERTION AND FUNCTION
1. Locate and remove the shipping plug and discard. Ensure the oil level is just below the oil filler
plug hole, see the chart in section 5-B. Install the vent / oil fill / dip stick plug.
2. Remove air inlet shipping plug and discard. Pour a teaspoon of good quality, air tool #10 wt. non-
detergent oil into the air inlet port. Install the appropriate air supply coupler and a 3/8” NPT
hydraulic connection which is rated for 10,000 psi. The air quick disconnect configuration of your
choice can be installed in the threaded hole underneath the foot pedal labeled “PUMP”. An in-line
filter/ regulator/lubricator should be installed close to pump. Add a few drops of SAE 10 oil to the air
intake weekly if no lubricator is used or when pump will be idle for a long time.
3. Remove the pressure port shipping plug and discard. Use at least 1-1/2 wraps of Teflon tape (or
suitable sealant) on the hose fitting threads. Make sure the first complete thread is free from tape
or sealant so they do not enter and contaminate the hydraulic system. Thread the hose fitting or
coupler into the pump manifold’s outlet port and turn until snug - make sure the fitting threads are
not cross-threaded.

D0136 RevC 4 C19-01-01
4.1 OPERATION
1. Make sure the pump is on a level surface.
2. Connect Foot Pump to an external air source that is capable of supplying 90 PSI @ 10 CFM. Next
connect a 3/8” NPT quick disconnect coupler or hose to the oil outlet side that is rated for 10,000
psi. (PowerX recommends that a gauge adaptor and 10,000 PSI gauge be used during operation).
Connect the pump to tooling (I.e. cylinder, bender, or cutter)
3. Check for leaks in system and repair as needed. Before repairs are made, disconnect air source
and application, then release the pressure from the hydraulic system. Do so simply by pressing the
pedal or pendant button for three seconds (see figure 1).
4. To build pressure, depress the pedal or pendant button where “PUMP” is located. Operate pump
until desired position is reached and/or pressure is obtained (see figure 1).
5. To retract a cylinder, simply press down on the RELEASE valve or pendant button portion of the
pump. Fully depressing pedal will LOCK the DETENT feature to “on” (see figure 1).
6. For double acting pumps model “D”, to build pressure depress were indicated (see figure 1).
When the handle is in the center position, the load will not move even if the pump is running. To
actuate the load, start the pump, rotate the handle in either direction to extend or retract the load.
Move the handle back to the center position and release the treadle to stop the pump. Always move
the valve handle to the center position before stopping the pump.
WARNING: If the pump is stopped and the valve is not in the center position it is possible for
the load to drift or lower. See section 2.0, Safety.
Figure 1
4.2 AFTER COMPLETING THE JOB
Before disconnecting hoses, fittings, etc., be sure the ram is unloaded and retracted, then
disconnect air source and hydraulic connections. Store the pump in a clean, dry area.
5.0 PERIODIC MAINTENANCE
A) MAINTENANCE

D0136 RevC 5 C19-01-01
1. Inspect hose and connections daily. Replace damaged components immediately with PowerX
Authorized replacement parts only.
2. Tighten connections as needed. Use pipe thread Teflon when servicing connections. NOTE:
DO NOT OVER TIGHTEN CONNECTIONS.
3. When not in use or during storage:
• Disconnect pump from air source, depressurize and disconnect hydraulic hoses from
application.
• Wipe clean, throughout.
• Shelter the pump with protective cover.
• Store in clean, dry environment.
• Avoid temperature extremes.
B) HOW TO FILL THE RESERVOIR
1. Disconnect hydraulic hose from application, remove air source from pump.
2. With reservoir horizontal, remove the vent / oil filler plug.
3. Use a small funnel to fill reservoir so the oil level remains the distance stated below in the
table, distances are measures from the top of the fill hole.
Model
Recommended Oil Level from the Top of Fill Hole
Minimum Fill Lever
Maximum Fill Level
PA6-98C, PA6-122, PA6-98R, PA6-122D
1.25"
.5"
PA6-231, PA6-231D, PA6-460D
2.25"
1.5"
4. Use PowerX oil only (Model PL-1, 1 gallon). Using oil other than PowerX Brand may void the
pump warranty.
5. Wipe up any spilled fluid and install oil filler screw.
6. Return pump to original position (parallel to a flat level surface), reconnect application and air
source. Operate for a few seconds, and then check for leaks.
C) CHANGING THE OIL
1. For best results, change fluid once a year.
2. Repeat steps (B) “How to Fill Reservoir”, and then pour used fluid into a sealable container.
3. Fill with PowerX oil. Reinstall oil filler plug.
D) LUBRICATION (When no in-line oiler is used)
1. When used daily, pour a teaspoon of good quality air tool oil #10 non-detergent oil into the
air source inlet of pump. Connect hydraulic hose to application, connect air source to pump and
operate pump a few seconds to evenly distribute fluid.

D0136 RevC 6 C19-01-01
2. Use light machine oil to lubricate pivot points, hinges etc.
WARNING: Never operate the pump while it is disconnected from the application. If operated
in this condition, the hoses and connections become pressurized. This increases the burst
hazard and damage may occur to the pump, hoses, connections or other components.
5.1 MAINTAIN OIL LEVEL
Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in
oil when all tools are retracted. Add PowerX oil (Model PL-1 –1 gallon) when necessary. Oil level
should be no more than 1/2” from top of reservoir plate (see chart in 5-B) –with cylinders retracted
and motor off.
6.0 TROUBLESHOOTING
UNIT OPERATES, BUT TOOLING DOES NOT MOVE: NO HYDRAULIC FLOW / LOW FLOW
Reservoir not vented, causing a vacuum.
Unclog vent plug.
No oil, reservoir empty or low.
Check oil level once the tooling is fully retracted,
should be ½” from top (see 5-B above) of oil tank
cover or check that your tooling requirement
does not exceed the foot pump oil capacity.
Defective coupler, not allowing flow.
Coupler is not fully seated or ball seats are
defective, replace coupler.
Oil entrance valve clogged.
Oil inlet is clogged with foreign matter or seat is
defective.
UNIT DOES NOT OPERATE AND AIR BY PASSES: AIR CYLINDER DRY OR DAMAGED AIR VALVE
Insufficient air supply.
Ensure you have 90 PSI @ 10 CFM supplied.
Air supply does not have ample lubrication.
Use a recommend premium air tool lubrication.
Apply 1 drop per minute into foot pump.
Air entrance plunger has defective seals or is
damaged.
O-rings are damaged; replace seal or damaged
components.
Air piston is frozen, worn seals or air valve is
defective.
Replace O-ring and/or air piston assembly or
lubricate.
Muffler are completely clogged, not allowing air
to pass.
Remove and clean or replace mufflers. Check for
water and or rust in air supply.