SPX FLOW Power Team AP02528 User manual

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© SPX FLOW, Inc. Form No. 102696
Rev. 2 Sept. 21, 2016
MODELS D & F
AIR HYDRAULIC PUMP
with Automatic Valve
Max. Capacity: 10,000 PSI
lCarefully inspect the pump upon arrival. The carrier, not the manufacturer, is responsible for any damage
resulting from shipment.
lThese instructions should be read and carefully followed. Most problems with new equipment are caused by
improper operation or installation.
SAFETY PRECAUTIONS
WARNING
lAll WARNING statements must be carefully observed to help prevent personal injury.
Hydraulic Hose
l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.
l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.
l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 oil 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.
lDo not use the hose to move attached equipment. Stress may damage the hose and cause personal injury.
l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
l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.
lBefore replenishing the oil 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
lDo not exceed rated capacities of the cylinders. Excess pressure may result in personal injury.
lDo not set poorly-balanced or off-center loads on a cylinder. The load may tip and cause personal injury.
Air Supply
lShut off and disconnect the air supply when the pump is not in use or before breaking any connection in the
system.
Operating Instructions for:
AP02528
AP02529
AP03715
PA4-ADV
PA4-HOL
PA4-MBI
PA6R-MBI
PA50-MBI
SPX Hydraulic Technologies
5885 11th Street
Rockford, IL 61109-3699 USA
Tech Ser
vices: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
powerteam.com

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© SPX FLOW, Inc. Form No. 102696
Rev. 2 Sept. 21, 2016
PREPARATION & SET-UP
Air Supply
The air supply should be capable of providing 20 CFM at 90 PSI to obtain the rated hydraulic output. Shop air line
pressure should be regulated to a maximum of 90 PSI.
Hydraulic Connections
Clean areas around all oil 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 oil outlets.
IMPORTANT: Seal all external pipe connections with a high-quality, nonhardening thread sealant. Teflon 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 oil or cause jamming of precision-fit parts.
WARNING: To help prevent personal injury,
lEnsure that all hydraulic connections are secure and tight before building pressure in the system.
OPERATION
Pump Operation
1. Connect air supply to pump air quick coupler.
NOTE: Under certain circumstances the pump may need to be primed before operation. Refer to the
method described in the Preventive Maintenance section entitled “Priming the Pump Unit.”
2. Close the door after inserting the filter. The pump will continue to run until the system pressure stalls the pump.
3. The automatic dump valve is activated and the cylinder returns upon opening the door.
PREVENTIVE MAINTENANCE
NOTE: Any repair or servicing that requires dismantling the pump must be performed in a dirt-free
environment by a qualified service technician.
Lubrication
A high quality auto-drain filter/regulator/lubricator has been mounted as close to the pump as possible. Set the
lubricator to feed not more than one drop of non-detergent hydraulic oil per 3 crushing cycles.
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.

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© SPX FLOW, Inc. Form No. 102696
Rev. 2 Sept. 21, 2016
Inspecting the Hydraulic Fluid Level
Check the oil level in the reservoir periodically. With all cylinder(s) retracted, the oil level should come to 1/2” from the
filler/breather cap hole. Drain, clean and replenish the reservoir with high-grade, approved 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/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 1/2” from the filler/breather cap hole. Place
the pump assembly (with gasket) on the reservoir and install the screws. Tighten securely and evenly.
Adding Oil to the Reservoir
1. Cylinder(s) must be fully retracted and the air supply disconnected when adding oil 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 oil.
4. Use only approved Power Team hydraulic fluids.
5. Fill to 1/2” from the filler/breather cap hole.
Priming the Pump Unit
1. Connect the oil line to the pressure port and keep the return port plugged. Place the other end of the oil line in the
pump filler hole.
2. Attach air line with shut-off valve to the pump.
3. Open the air valve. Pump will begin to reciprocate, and oil will advance through the hose or oil 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.

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© SPX FLOW, Inc. Form No. 102696
Rev. 2 Sept. 21, 2016
Gauges
WARNING: 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.
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.
2. Tighten all connections securely but do not overtighten.
TROUBLE-SHOOTING GUIDE
Pump reciprocates but no oil
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)
Low oil delivery (cylinder
extends slowly)
Excess oil spray from muffler.
1. Low oil level.
2. Pump not primed.
3. Oil filter contamination.
1. Faulty gauge.
2. Reservoir not vented.
3. Oil level too low.
4. Leaky connection or hose.
5. Excess air in oil.
1. Inadequate air supply.
2. Air regulator not set properly.
3. Leaking air line or connections.
1. Inadequate air supply.
2. Clogged oil filter.
3. Air trapped in hydraulic system.
1. Air lubricator is set too rich.
1. Add oil as instructed in
Preventive Maintenance section.
2. Prime pump as instructed in
Preventive Maintenance section.
3. Clean filter.
1. Replace gauge.
2. Vent reservoir by removing
shipping plug and installing filler/
vent cap.
3. Fill reservoir to 1/2” from filler/
breather cap hole.
4. Tighten connections or replace
hose.
5. Bleed unit as instructed in
Preventive Maintenance section.
1. Check air supply. 90 PSI air
pressure is needed to obtain
correct hydraulic pressure.
2. Increase or decrease hydraulic
pressure by turning regulator
clockwise or counterclockwise to
achieve desired pressure.
3. Repair or replace.
1. Check air supply -- 20 CFM
minimum at 100 PSI is required
to achieve full speed.
2. Clean the filter.
3. Bleed system of air as instructed
in Preventive Maintenance sec.
1. Turn adjuster clockwise until
closed and then open 1/8 turn.
PROBLEM CAUSE SOLUTION