SPX FLOW Power Team PB102-1 User manual

SP
X Hydraulic Technologies
5885 11th Street
Rockf
ord, IL 61109-3699 USA
Tech Ser
vices: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
powe
rteam.com
Parts List and Operating Instructions for:
PB102
PB102-0
PB102-1
PB102-2
PB102A
PB102A-0
PB102A-1
PB102A-2
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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
PB102P
PB102P-0
PB102P-1
PB102P-2
PB102R
PB102R-0
PB102R-1
PB102R-2
PB102-CP
PB104
PB104-0
PB104-1
PB104-2
BATTERY POWERED
HYDRAULIC PUMP

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
SAFETY SYMBOLS AND DEFINITIONS 4
SAFETY PRECAUTIONS 4
General 5
Power Supply 6
Hydraulic Hoses and Lines 6
Pump 7
Hydraulic Fluids 7
DESCRIPTION 8
SETUP INSTRUCTIONS 10
1. Hydraulic Connections. 10
2. Checking Hydraulic Fluid and Filling the Bladder. 10
3. Hydraulic Lines and Fittings. 11
4. 18VDC Battery & Charger 11
5. Bleeding The System 13
PUMP OPERATION 14
1. Operating The Pump For The First Time. 14
2. Attaching And Operating Hand Pendant 14
3. Lifting or lowering a load with a hydraulic cylinder. 16
DIRECTIONAL CONTROL VALVE OPTIONS 17
1. 2-Way Manifold 17
2. 2-Position, 2-Way Manual Valve 18
3. 3-Position, 4-Way Manual Valve 19
ADJUSTING THE PRESSURE REGULATING CONTROLS 21
1. Adjusting The Pressure Regulating Valve 21
PREVENTIVE MAINTENANCE 22
1. Checking Hydraulic Fluid and Filling the Bladder 22
2. Maintenance Cleaning 23
3. Draining and Cleaning the Bladder 23
TROUBLESHOOTING GUIDE 23
PARTS LIST 27
PB10 Series Hydrulic Pump 27
65187-18 (Pump Sub-assembly, Electric 18VDC) 30
350622 (Valve, Manual, 2-Position 2-Way) 34
420558 (Valve, Manual, 3-Position 4-Way) 35
350623 (Body, Valve Pressure Regulator) 37
350720 (Manifold Assembly) 39
3001123 (Manifold Assembly) 40
TABLE OF CONTENTS

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
ELECTRICAL SCHEMATIC 41
HYDRAULIC SCHEMATIC 42
POWER TEAM FACILITIES & CONTACT 43
MILWAUKEE ELECTRIC TOOL CORPORATION CONTACT 43
EC DECLARATION OF CONFORMITY 44
Table of contents continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
The safety signal word designates the degree or level of hazard seriousness.
: 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.
: 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 DEFINITIONS
WARNING The following procedures must be performed by qualied, trained personnel who
are familiar with assembling this equipment.
• Operators/installers 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/
installer’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 times 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.
• Disconnect the battery from the pump and relieve pressure before opening any connections
in the system.
• The guide cannot cover every hazard or situation so always do the job with SAFETY FIRST.
SAFETY PRECAUTIONS

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
General
To reduce the risk of re, personal injury, and product damage due to a short
circuit, never immerse your tool, battery pack or charger in uid or allow a uid
to ow inside them. Corrosive or conductive uids, such as seawater, certain industrial
chemicals, and bleach or bleach containing products, etc., can cause a short circuit.
• This unit is not suitable for use in explosive environments. Failure to comply may result in
damage, injury, or death.
• Always wear eye protection whenever operating hydraulic equipment.
• Always wear hearing protection as required. Refer to the sound level (dB[A]) chart.
• Operation, repair, or maintenance of hydraulic equipment should be performed by a
qualified person who understands the proper function of hydraulic equipment per local
directives and standards.
• Hydraulic equipment must be assembled correctly and then checked for proper function
before use. Use hydraulic components of the same hydraulic pressure ratings. An
appropriate hydraulic pressure gauge is recommended to monitor pressure.
• Never place your hands or other body parts near a hydraulic fluid leak. Never use your
hands or other body parts to check for a possible leak. High pressure fluid can be injected
under your skin causing serious injury and/or infection.
• High pressure fluid is present throughout a hydraulic system. Always use caution when
operating, repairing, or maintaining this equipment. Before beginning any work on any
hydraulic system component, stop the equipment, disconnect from its power source, and
relieve all pressure in all parts of the system. Do not tamper with the internal hydraulic relief
valve settings.
• Avoid exposing hydraulic equipment (especially hoses) to extreme high or low
temperatures. Damage to equipment or failure may result and cause loss of control or injury
to the operator.
• Exercise caution to avoid the risk of fire.
• Do not drop any hydraulic system components. Damage to the equipment and/or injury may
result.
• Avoid slipping or falling by cleaning up any oil spills.
• Avoid back injury by always lifting equipment carefully.
• It is strongly recommended to view the Power Team Hydraulic Safety video tape before
using hydraulic equipment.
Safety Precautions continued
WARNING

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Power supply
• Electrical Shock or Electrocution.
• Any electrical work must be done and tested by a qualified electrician per local directives
and standards.
• Disconnect the battery from the pump and relieve pressure before removing the motor case
cover or performing maintenance or repair.
• If wiring is exposed, replace or repair immediately.
• Do not attempt to increase the power capacity by replacing a fuse with another fuse of
higher value. Overheating of the power supply and the possibility of a fire will result.
• Electric pumps should never be exposed to rain or water which could cause personal
electrical hazard.
• Avoid conditions which can cause damage to the power supply such as abrasion, crushing,
sharp cutting edges, or corrosive environment. Damage to the power supply can cause an
electrical hazard.
Hydraulic hoses and lines
• 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. See diagrams in
“Set-up Instructions” section of this form.
• 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.
• Before operating the pump, all hose connections must be tightened with the proper tools. Do
not overtighten. Connections should only be tightened securely 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 ever rupture, burst, or need to be disconnected, immediately shut
off the pump and release all pressure. Never attempt to grasp a leaking pressurized hose
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, extreme heat or
cold, or heavy impact. Do not allow the hose to kink, twist, curl, crush, cut, 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. Never repair with tape.
• 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 materials such as creosote-impregnated
objects and some paints. Hose deterioration due to corrosive materials can result in
personal injury. Consult the manufacturer before painting a hose. Never paint a coupler.
Safety Precautions continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Pump
• 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.
• Before replenishing the uid level, retract the system to prevent overlling the pump
reservoir or bladder. An overll can cause personal injury due to excess reservoir or bladder
pressure created when accessories are retracted.
• Always shut off the motor and/or disconnect power supply and relieve pressure before
breaking any connections in the system.
• The motor is the major part of the weight of the pump. Always take this into consideration
when lifting or moving the pump.
Hydraulic uids
• Properly dispose of all uids, components, and assemblies at the end of their useful life.
• Hydraulic uid should be compatible with all hydraulic components.
Safety Precautions continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
• The PB10 Series hydraulic pump delivers hydraulic uid under pressure through the use of an electric
motor and18VDC Li-ION battery as a power source.
PUMP SPECIFICATIONS
Pump
Cat. No.
Max. Operating
Pressure Features Kw dB(A) Idle / 700 Bar
PB102-0 *
PB102-1
PB102-2 **
10,152 PSI
700 Bar 2P2W Valve .144 65/72
PB102P-0 *
PB102P-1
PB102P-2 **
10,152 PSI
700 Bar
2P2W Valve &
Hand Pendant .144 65/72
PB102R-0 *
PB102R-1
PB102R-2 **
10,152 PSI
700 Bar
2P2W Valve &
Pressure Regulator .144 65/72
PB102A-0 *
PB102A-1
PB102A-2 **
10,152 PSI
700 Bar 2W Manifold .144 65/72
PB102-CP 10,152 PSI
700 Bar
2W Manifold w/ 10K PSI
Pop-off Relief Valve .144 65/72
PB104-0 *
PB104-1
PB104-2 **
10,152 PSI
700 Bar 3P4W Valve .144 65/72
Pictured: PB102R
1. Valve control lever
2. Start button
3. Pressure regulator adjustment knob
1
3
4
5
2
DESCRIPTION
* Models designated with (-0) do not include battery charger.
** Models designated with (-2) include a 220-240V battery charger.
4. Battery Pack
5. Oil Bladder Fill Port

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Description continued
1. Contacts
2. Release buttons
3. Fuel Gauge button
4. Fuel Gauge
5. Electrical contacts
6. Bay
7. Vents
8. Light indicators:
*6 8
*5
7
6
5
1
2
4
3
2
Continuous red: Charging
Continuous Green: Charging is complete
Fast ashing red: Battery is too hot/cold - Charging will
begin when battery reaches correct
charging temperature
** Slow ashing red: Battery charge is pending -
Charging will begin when rst pack is
fully charged.
Flashing red/green: Damaged or faulty battery pack
*Items only on multi voltage charger models
** When charging M12 & M18 packs simultaneously
BATTERY & CHARGER SPECIFICATIONS
(Excerpt from Milwaukee Tool operator’s manuals)
Charger
SPX Cat. No.
AC Input
Volts
AC Input
Amps
DC Output
Volts
DC Output
Amps
Battery
SPX Cat. No. DC Volts
2009646 110-120 2.1 12 or 18V 3 3000973 18
2009647 220-240 1.15 12 or 18V 3
FUNCTIONAL DESCRIPTION
Volts Alternating Current
Volts Direct Current
Hertz
Double Insulated
Approximate Run Time
Remaining
Less than 10% if bottom light is ashing
10-32%
33-54%
55-77%
78-100%
SYMBOLOGY
IMPORTANT: For information regarding care, use,
recycling, or warranty of
batteries and/or chargers, contact
Milwaukee Electric Tool
Corporation or see original
manufacturers operating manual.

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
NOTE: Carefully inspect the pump upon arrival. The carrier, not the manufacturer, is responsible for
any damage resulting from shipment.
1. Hydraulic Connections
NOTE: Ensure areas are clean around uid ports, and inspect all threads and ttings for signs of wear
or damage before use, and replace as needed.
A. Remove plugs and/or thread protectors/dust covers from hydraulic ports if applicable.
B. Use an approved, high-grade pipe thread sealant to seal all hydraulic connections and connect ttings
and/or hose assemblies to the pump.
C. Tighten securely and leak-free but do not overtighten.
A. B. C.
PIPE THREAD SEALANT
2. Checking Hydraulic Fluid and Filling the Bladder.
NOTE: Most pumps with a bladder are shipped with hydraulic uid in the bladder. If hydraulic uid is
needed, use only approved Power Team hydraulic uid.
A. Remove the ller cap. (If there is no oil visible, continue to step B)
B. Insert a clean funnel with lter or strainer.
C. Fill the bladder completely with hydraulic uid.
D. Replace ller cap.
IMPORTANT: Tighten ller cap ONLY 1/2 - 1 turn (MAX) after O-ring contacts sealing surfaces.
Overtightening can cause pump damage on bladder equipped pumps.
HYDRAULIC
OIL
A. B. - C. D.
SET-UP INSTRUCTIONS

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Setup Instructions continued
3. Hydraulic Lines and Fittings.
• Hydraulic lines and ttings can restrict ow to a cylinder or hydraulically actuated device. The
restricting or slowing of the uid ow causes back pressure that slows the device’s return. Return speed
also varies because of the application, condition of the cylinder or device, inside diameter of hose or
tting, length of the hose, and the temperature and viscosity of the hydraulic uid.
• Tubes and Hoses should be routed in such a way that they can easily be serviced or removed as well
as provide the least resistance to uid ow. See below for recommended routing congurations.
TUBING
HOSES
CORRECT
INCORRECT
CORRECT
INCORRECT
4. 18VDC Battery & Charger
NOTE: New batteries must be charged before rst use. Approx. 60 minutes of charging = 100% battery
fuel.
A. Ensure battery charger is plugged in.
B. Slide battery pack into charger as shown and allow battery to charge.
C. Once battery is adequately charged it can be installed on pump unit as shown.
D. To remove the battery from the pump unit press the release buttons on the sides of the battery.
E. Slide the battery out of the pump unit as shown.
B.A.

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
C. D.
E.
Setup Instructions continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
5. Bleeding The System
• After all connections are made, the hydraulic system must be bled of any trapped air. Refer to the
diagrams below.
• With no load on the system and the pump vented and positioned higher than the accessory tooling,
cycle the system several times.
• To vent the Bladder, be sure the pump is positioned upright as shown below and slowly unscrew the
bladder plug. Check the bladder for possible low uid level and ll to proper level with approved, Power
Team hydraulic uid as necessary. Refer to “Checking Hydraulic Fluid and Filling The Bladder” section
under Set-up Instructions.
IMPORTANT: Some spring return cylinders or rams have a cavity in the rod which forms an air pocket.
This type of cylinder or ram should be bled when positioned upside down or lying on its
side with the port facing upward.
System with a single acting cylinder System with a double-acting cylinder
Setup Instructions continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
1. Operating The Pump For The First Time
A. Valve and hose connections must be tight, and the bladder must be lled to the proper uid level.
• Refer to “Hydraulic Connections” and “Checking Hydraulic Fluid and Filling the Bladder” under Set-
up Instructions.
B. Set valve to the neutral or return position and jog the pump on and off several times by pressing the
start button and allowing the pump to idle for 1 to 3 minutes.
C. Set valve to proper position / port to Advance and retract the accessory tooling (e.g. cylinder, torque
wrench, spreader, etc.) to its full travel. Do this several times to eliminate air from the system and build
pressure.
• For more complete instructions, refer to the section titled “Bleeding The System” under
Set-up Instructions.
D. With the accessory tooling retracted completely, check the uid level in the bladder and add uid if
necessary.
• Refer to “Checking Hydraulic Fluid and Filling The Bladder” under Set-up Instructions.
E. The pump is now ready to be put into regular operation.
2. Attaching And Operating Hand Pendant.
NOTE: Attaching a hand pendant can sometimes be a more effective way of controlling the pump unit
by allowing the user to operate the unit with a remote switch.
• The hand pendant has an 11 ft. cable and overrides the built in start button.
A. Notice the Alignment Pin in the cable tting on the end of the pendant cable.
B. Notice the Alignment Groove in the tting on the pump unit and insert the pendant cable as shown.
C. Secure the connection by threading (rotating clockwise) the cable tting into the pump unit tting.
D. To activate the pump unit press and hold the start button, release the start button and the pump unit will
stop running.
PUMP OPERATION
A.
Alignment
Pin

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
B.
Pump Operation continued
C.
D.
Start Button
Alignment
Groove

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Pump Operation continued
3. Lifting or lowering a load with a hydraulic cylinder.
A. The load must be under operator control at all times and other personnel must be clear of the load.
B. The use of blocking and cribbing is recommended to help prevent a falling load.
C. The use of a load lowering or metering valve is recommended in addition to the correct directional
control valve to help prevent a falling load.
C.B.

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
1. 2-Way Manifold Used With Single-acting Cylinders or Remote Mounted Valves (Figure 1)
A. Activate the pump unit by pressing the start button to advance the cylinder/accessory tooling.
B. When the cylinder or tool has advanced to the desired position the pump start button can be released
and the cylinder/tool will retract.
Pressure
Port
Return
Port
Manifold
Figure 1
Example of remote mounted valve:
Manifold
Remote mounted
3-position 4-way
manual valve
Single acting
cylinder
To prevent sudden, uncontrolled descent of a load as it is being lowered, use Load
Lowering Valve (No. 9596) or Counter Balance Valve (No. 9720) in conjunction with the
4-way manual valve in your application
DIRECTIONAL CONTROL VALVE OPTIONS

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
2. 2-Position, 2-Way Manual Valve Used With Single-acting Cylinder (Figures 2 & 3)
NOTE: Some valves return uid to the reservoir or bladder when the pump is not running or when the
valve control lever is shifted. The correct valve must be used per application, especially when
lifting a load.
WARNING Valve (No. 9561) works the same as a manifold if the pump is operated with the valve
in the RETURN position. In this position, the cylinder will advance when the pump is
running and retract when the pump is not running.
Never use valve (No. 9561) in the RETURN position when lifting a load!
9561
A. To HOLD pressure, turn the valve control handle counterclockwise (CCW), (See Figure 2)
B. Activate the pump unit to advance the cylinder/accessory tooling.
C. When the cylinder or tool has advanced to the desired position the pump start button can be released
and the cylinder will HOLD pressure.
D. To retract the cylinder, turn the valve control handle clockwise (CW) slowly, (See Figure 3)
Port
D.A. Valve control
lever
Figure 2 Figure 3

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
3. 3-Position, 4-Way Manual Valve used with Double-acting Cylinders (Figure 4)
P T
A B
9563
Gauge
(non posi-check)
HOLD
lever position
Valve control
lever
Stem
Port “B”
(Leave plugged if
using only
one port) Port “A”
Port “B”
Port “A”
Port “A”
Port “B”
45 °
(Ref.)
45 °
(Ref.)
Figure 4 Figure 5
NOTE: This valve is a low torque design for use with double-acting or single-acting cylinder(s).
• If this valve is to be used as a 3-way with single-acting cylinder(s), one port must remain
plugged (use steel plug). (Figure 5)
A. Position the valve control lever in the HOLD position.
B. Activate the pump unit.
C. Advance the cylinder by shifting the valve control lever to the ADVANCE (Port A) position.
D. When the cylinder has advanced to the desired position, turn the pump unit OFF, or shift the valve to
the HOLD position.
NOTE: Non “posi-check” valves will momentarily lose pressure when shifting to HOLD position.
E. Retract the cylinder by shifting the valve control lever to the RETRACT (Port B) position.
F. Activate the pump unit if using double-acting cylinders.
Directional Control Valve Options continued

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© SPX FLOW, Inc. Form No. 1001044
Rev. 2 Jan. 25, 2019
Examples of typical work holding applications:
Single-acting
Cylinders
Valve
Port is
Plugged
“Y” Manifold
Double-acting
Cylinders
Tees or
Manifolds
Valve
SINGLE-ACTING CYLINDER(S) IN THE CIRCUIT DOUBLE-ACTING CYLINDER(S) IN THE CIRCUIT
CONTROLLED BY A PUMP-MOUNTED VALVE CONTROLLED BY A PUMP-MOUNTED VALVE
Other valves are available.
Consult your dealer, catalog or valve
operating instructions for details of operation.
Directional Control Valve Options continued