SPX FLOW PQ60 Series User manual

Operating Instructions for:
1
© SPX FLOW, Inc.
SPX Hydraulic Technologies
5885 11th Street
Rockford, IL 61109-3699 USA
Tech Services: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
powerteam.com
PQ60 Series
Form No. 102371
Rev. 1 November 20, 2019
ELECTRIC
TWO-STAGE HYDRAULIC PUMP
Read and carefully follow these instructions. Most problems with new equipment are caused by improper operation
or installation. Warning statements must be carefully observed to help prevent personal injury.
SAFETY PRECAUTIONS
WARNING :To help avoid personal injury,
Hydraulic Hose
•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 fittings 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 shift the control valve twice to release all pressure. 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 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 wear because any of these conditions can damage
the hose and result in personal injury.
•Do not use the hose to move attached equipment. Stress may damage the hose and cause personal
injury.
•Hose material and couple 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. Creating pressure beyond rated capacities 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.
Cylinder
•Do not exceed 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.

2
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
WARNING Continued
Power Supply (Electric)
•Do not use an ungrounded (two-prong) extension cord with this unit.
•Avoid any condition that could create an electrical hazard.
•Any electrical work must be done by a qualified electrician.
•If the power cord is damaged or wiring is exposed, replace or repair immediately.
•Changing the voltage on jet motors is a complicated and, if not done correctly, dangerous procedure.
Consult the manufacturer for specific information before attempting any rewiring. Rewiring voids CSA
approval.
•Disconnect the power supply before removing the electrical box cover or performing repairs or
maintenance.
•All voltages must be wired for CCW rotation when viewed from the lead end (top) of the motor.
•The line voltage must be the same as the voltage for which the pump is wired. (Ex: 110/115 volt pump
plugged into 110/115 volt power source.)
•Check the total amperage draw for the electrical circuit you will be using. (Ex: Do not plug a motor or
motors that may draw 25 amps into a 20 amp fused electrical circuit.)
•Do not attempt to increase the power line capacity by replacing a fuse with another fuse of higher value.
Overheating of the power line and the possibility of a fire can result.
•To rewire a motor from one voltage to another, or to change the type of flow control valve (manual or
solenoid), consult the electrical schematic section in the Parts List #100384.
OPERATING PROCEDURE
Filling the Reservoir
NOTE: This pump has been shipped without oil in the reservoir. A high grade hydraulic oil has been
shipped with the pump, but if additional oil is required, use only an approved hydraulic oil.
1. Clean the area around the filler cap to remove all dust and grit. Any foreign material 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 with a filter. Fill the reservoir with hydraulic oil to within 1” of the
cover plate. Replace the filler cap with the breather-hole OPEN.
4. Cycle the pump (with the cylinders attached) several times. Retract the cylinders, and check the oil level in the
pump reservoir.
Hydraulic Connections
1. Clean all the areas around the oil ports of the pump and ram.
2. Inspect all threads and fittings for signs of wear or damage, and replace as needed.
3. Clean all hose ends, couplers, or union ends.
4. Remove the thread protectors from the hydraulic oil outlets.
5. Connect the hose assembly to the hydraulic oil outlet, and couple the hose to the cylinder. NOTE: Seal all
hydraulic connections with a high grade, non-hardening thread sealant, such as Power Team HTS6. Teflon
tape can be used to seal hydraulic connections if only one layer of tape is used. Apply carefully, two threads
back, 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 or cause jamming of precision fit parts.

3
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
Electrical Connections
WARNING
•To help avoid personal injury, all electrical work must be done by a qualified electrician.
•Disconnect the power supply before removing the electrical box cover.
•All voltages must be wired for counterclockwise (CCW) rotation viewed from the lead end of the motor.
1. This pump has been assembled with a single-phase 60 cycle motor that can be wired for 115 or 230 volts. The
pump is wired at the factory for 230 volts and is supplied with a power cord and plug. This pump may also be
ordered with a 50 cycle, 110 or 220 volt motor that is wired at the factory for 220 volts and is supplied with a
power cord but not a plug.
2. When installing a power supply, use a 14 gauge, four-strand copper electrical cable.
3. The line voltage must be compatible with the amperage draw required by the pump. Provide wiring as required.
To change the voltage of the motor, refer to the diagram on the motor nameplate or to the electrical schematic in
Parts List #100384.
WARNING : Changing the voltage on this unit is an involved and potentially hazardous procedure
if performed incorrectly. If assistance is required, consult the Technical Service Department.
4. Consult the electrical schematic in Parts List #100384 when wiring a solenoid valve into the electrical system.
5. When overheating occurs, the thermal overload will kick out. To start the pump again when the unit has cooled,
place the valve in neutral, and push the start button on the pump end panel.
6. If a power outage should occur while using the pump, when power has been restored the pump will need to be
started again. Place the valve in the neutral position, and push the start button on the pump end panel.
Conductors North American International
Line ........................... Black .................. Brown
Neutral ...................... White.................. Blue
Ground ......................Green ................. Green/Yellow
North American & International Color Codes

4
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
Valve Operation
3-Way Manual Valve
Neutral (Hold): Pressure to tank - cylinder port
blocked.
Advance: Pressure to cylinder port “A.”
Return: Pressure and cylinder port to
tank. Pressure holds without loss
when shifted from cylinder port to
“hold” position.
4-Way Manual Valve
Neutral (Hold): Pressure to tank, ports “A” and
“B” blocked.
Position “A”: Pressure to port “A”, port “B” to
tank.
Position “B”: Pressure to “B”, port “A” to tank.
Pressure holds without loss when
shifted from either cylinder port to
“hold” position.
3-Way Solenoid Valve
Neutral (Hold): When both solenoids are
deenergized, oil from the pump is
directed back to tank, and oil from
cylinder is checked in the cylinder.
Advance: When solenoid “B” is energized,
oil from the pump is directed
through the pressure port to the
cylinder.
Return: When solenoid “A” is energized,
oil from the pump and from the
cylinder is directed back to tank.
Pressure holds without loss when
shifted from the cylinder port to
the neutral “hold” position.
4-Way Solenoid Valve
Neutral (Hold): When both solenoids are
deenergized, oil from the pump
circulates at free flow from the
pressure port to the tank. Both
cylinder ports are blocked.
Solenoid “A”
Energized: Pressure to cylinder port “A”.
Cylinder port “B” to tank.
Solenoid “B”
Energized: Pressure to cylinder port “B”.
Cylinder port “A” to tank.
Pressure holds without loss when
shifted from either cylinder port to
the neutral “hold” position.
SOLENOID “B”
SOLENOID “A”
PORT “B”
PRESSURE
TO “A”
PRESSURE
TO “B”
PORT “A”
HOLD
NOT A PRESSURE PORT,
MUST REMAIN
PLUGGED
ADVANCE
PORT “A”
HOLD
RETURN
SOLENOID
“B”
SOLENOID
“A”
CYLINDER
PORT “A”
CYLINDER
PORT “B”

5
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
Pump Operation
1. All valve and hose connections should be secure, and the reservoir should be filled to the proper oil level.
Connect the power supply.
2. With the valve in the neutral or return position, jog the pump several times using the jog switch on the pump end
panel.
3. Place the switch in the run position and let the pump run at idle for two minutes.
4. Cycle the pump and cylinder several times to eliminate air from the system.
NOTE: If using a large cylinder, after eliminating the air from the system and with the cylinder in the
retracted position, refill the pump reservoir to 1” from the pump cover plate.
Pressure Regulating Valve
A pressure regulating valve can be adjusted to bypass oil at a desired pressure setting while the pump motor
continues to run. IMPORTANT: For easy adjustment of the pressure regulating valve, always adjust the
pressure by INCREASING it to a desired pressure setting. The pressure range for this unit is from 1000 PSI
to 10,000 PSI.
1. Loosen the locknut on the pressure regulating valve, and turn the adjusting screw a few turns counterclockwise
(CCW) to decrease the pressure setting to a lower than desired pressure.
2. Connect the pump power supply, and place the hydraulic control valve in the advance position. Place the motor
control toggle switch in the run position, and push the start button.
3. Slowly turn the adjusting screw in a clockwise (CW) direction to gradually increase the pressure setting. When
the desired pressure setting is reached, lock the adjusting screw into position by tightening the locknut.
Manifold/Pressure Switch Combination
When the pressure switch setting is reached, the switch
shuts off the motor. Once the pressure falls 300 PSI
below desired system pressure, the switch reactivates the
motor to sustain pressure.
Turn adjusting screw clockwise to increase pressure.
Turn adjusting screw counterclockwise to decrease
pressure. Refer to the section titled “Adjusting the
Pressure Switch” for further information.

6
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
OPTIONAL ACCESSORIES
Pressure Regulating Switch
A pressure switch can be adjusted to stop the pump motor at a desired pressure setting, and restart the motor when
the pressure falls below that setting.
It is recommended that a pressure switch be used with a pressure regulating valve to insure accuracy when setting
a maximum PSI level. A pressure switch alone will break the motor’s energy supply at a selected setting, but the
hydraulic pump will continue building pressure as it slows to a stop. The pressure regulating valve should be set
first at the desired maximum pressure. Then, with the pump running at that pressure, back the pressure switch
out until the motor stops. As a result, the pressure limit requirement can be held to approximately 300 PSI.
Adjusting the Pressure Switch Setting
Hydraulic Gauge
1. Remove the pipe plug from the gauge port located on the side of the hydraulic valve.
2. Thread the gauge into the gauge port.
3. All connections must be secure. Apply a small amount of pipe thread compound or teflon tape on all pipe thread
connections to insure proper sealing. DO NOT OVERTIGHTEN PIPE CONNECTIONS!
PREVENTIVE MAINTENANCE
WARNING : ALWAYS disconnect the pump from the power supply before attempting any maintenance
or repair procedures. Repairs and maintenance should be performed in a dust-free
environment by a qualified technician.
Bleeding Air from the System
This pump is equipped with a self-priming bleed valve that should eliminate the need to manually prime the pump
itself. However, air can accumulate within the hydraulic system during normal use causing the cylinder to respond
slowly or behave in an unstable manner.
1. Position the cylinder at a lower level than the pump to allow air to be released through the breather-hole in the
pump reservoir.
2. Run the system through several cycles of extending and retracting the cylinder free of any load. NOTE: Some
spring return rams have a cavity in the rod that can cause an air pocket. Position this type of cylinder
upside down or lying on its side with the port facing upward.
1. Connect the pump power supply, and place the control valve in
the advance position. Set the motor control toggle switch on run.
2. Loosen the Locknut on the pressure switch. Slowly turn the
pressure switch adjusting screw in a counterclockwise (CCW)
direction, decreasing the pressure switch setting until the pump
motor shuts off. Tighten the locknut to lock the adjusting screw.
See Figure 2.
3. Release the hydraulic pressure. Move the control valve
to advance again and check the pressure setting. It may be
necessary to make a second adjustment.
ADJUSTING
SCREW
LOCKNUT
Figure 2

7
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
Hydraulic Fluid Level
1. Check the oil level in the reservoir after each 10 hours of use. The oil should be 1” from the pump cover plate
when all cylinders are retracted.
2. Drain, flush, and refill the reservoir after approximately every 300 hours of use with an approved, high-grade
hydraulic oil. The frequency of oil changes will depend upon the general working conditions, severity of use, and
the overall cleanliness and care given the pump.
Draining and Flushing the Reservoir
1. Clean the pump exterior before the pump interior is removed from the reservoir.
2. Remove the fourteen screws that hold the motor and pump assembly to the reservoir. IMPORTANT: Do not
damage the gasket or bump the filter or hydraulic pressure regulating valves when lifting the pump
assembly off the reservoir.
3. After disposing of the used hydraulic fluid, clean the inside of the reservoir with a suitable flushing oil. Rinse the
filter clean.
4. Place the pump and motor assembly back onto the reservoir, and secure it with four of the machine screws
assembled on opposite corners of the housing.
IMPORTANT: The flow control valve MUST be in the neutral position for the following step. If the pump is
equipped with a valve that has only an advance or retract position, place the valve in the advance position
and connect a hose to the advance port on the valve. Place the other end of the hose into the oil filler plug
hole.
5. Run the pump for several minutes. Disconnect the motor and pump assembly, and drain and clean the inside of
the reservoir.
6. Fill the reservoir with an approved, high-grade hydraulic oil. Place the pump and motor assembly (with gasket) on
the reservoir with the fourteen machine screws. Tighten the machine screws securely and evenly.
Adding Oil to the Reservoir
1. The cylinder(s) must be fully retracted, and the power supply must be disconnected when adding oil to be
reservoir.
2. Clean the entire area around the filler plug. Remove the filler plug and insert a clean funnel with a filter.
3. Use only an approved, high-grade hydraulic oil (215 SSU @ 100°F). The oil level should come to within 1” of the
pump cover plate with all cylinders retracted.

8
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
TROUBLE-SHOOTING GUIDE
Refer to Parts List #100353 and the following hydraulic schematic when using this trouble-shooting guide.
IMPORTANT: Any repair work or trouble-shooting should be performed by qualified personnel familiar with
this equipment. Use the proper gauges and equipment when trouble-shooting.
NOTE: Depending on the type of pump, it is often best to check for leaks by using a hand pump and
applying pressure to the suspect area without the motor running. Watch for leaking oil and follow it back to
its source.
PROBLEM CAUSE SOLUTION
Motor Does Not Run
WARNING : Disconnect
power supply before removing
cover. Any electrical work should
be performed by a qualied
electrician.
1. Pump not tuned to “On” position
2. Unit is not plugged in
3. No voltage supply
4. Broken lead wire or defective
power cord plug
5. Defective switches
6. Defective motor
7. Thermal protector switch inside
motor housing is open.
8. Defective starter relay
1. Flip toggle switch to run position,
push start button
2. Plug in unit
3. Check line voltage
4. Replace defective parts
5. Check switches
6. Replace motor
7. Wait for motor to cool before
restarting
8. Replace defective parts
Pump is not delivering oil or
delivers only enough oil to
advance cylinder(s) partially or
erratically.
1. Oil level too low
2. Pump needs to be primed
3. Loose fitting coupler to cylinder
1. Fill reservoir to within 1" of filler
plug with all cylinders retracted
2. Prime pump
3. Check quick-disconnect couplings
to cylinders
Inspect couplers to insure that
they are completely coupled
Occasionally couplers have to be
replaced because the ball check
does not stay open due to wear
Bleed the system
TO VALVE
MAX. PRESSURE SAFETY
RELIEF VALVE
10,100/10,700 PSI
EXTERNAL PRESS.
REGULATOR VALVE
10,000/10,200 PSI
AIR
BLEED
VALVE
STRAINER
SUPER
CHARGE
VALVE
140/160 PSI
UNLOADING VALVE
850/950 PSI

9
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
PROBLEM CAUSE SOLUTION
Pump is not delivering oil or
delivers only enough oil to
advance cylinder(s) partially or
erratically (cont’d)
4. Air leak in suction line
5. Dirt in pump, or filter plugged
6. Oil is bypassing through the
double-acting ram
7. Cold oil or oil is too heavy
(Hydraulic oil is of a higher
viscosity than necessary)
8. Relief valve or low pressure
unloading valve out of adjustment
9. Reservoir capacity is too small for
the size of the cylinder(s)
10.Defective directional valve
11.Sheared drive shaft key(s)
12.Motor rotating in wrong direction
4. Check and tighten the suction line
5. Pump filter should be cleaned
and if necessary, pump should be
dismantled and all parts inspected
and cleaned
6. By removing the ram and capping
the hoses, the pump and valve
can be checked to see if they hold
pressure
7. Change to lighter oil
8. Adjust as needed
9. Use smaller cylinder(s) or larger
reservoir
10. Inspect all parts carefully and
replace if necessary
11. Replace
12. Reverse rotation
Pump builds pressure but cannot
maintain pressure
1. Check to see if there are any
external leaks. If no oil leakage
is visible, the problem is internal.
If using a double-acting ram,
remove it from the system to
insure that the leak is not in the
ram
2. To test for a leaking valve, lift the
pump from the reservoir keeping
filter in the oil. By removing the
drain line it is possible to see
the oil leaking from the valve. If
the valve is not leaking, one of
the internal check valves could
be leaking. Refer to the note
concerning checking for oil leaks
at the beginning of this trouble
shooting guide.
3. Check for sheared key
4. Leaking pressure switch seal
1. Seal leaking pipe fittings with pipe
sealant
2. Clean, reseat or replace valve
parts.
If the internal check valve(s)
are leaking, the pump must be
dismantled and the seat areas
repaired, balls replaced, etc.
3. Replace as needed
4. Replace as needed

10
© SPX FLOW, Inc. Form No. 102371
Rev. 1 November 20, 2019
PROBLEM CAUSE SOLUTION
Pump will not build full pressure 1. Faulty pressure gauge
2. Check for external leakage
3. Check the relief valve setting;
check the external pressure
regulator
4. Look for internal leakage in
double-acting cylinders
5. Check for leaks in the valve
6. Valve seat may be damaged.
Check for oil coming out the
return line (2-way valve)
7. Valve shear seals or O-rings
may be damaged. Check for oil
coming out the return line (3-way,
4-way)
8. Valve rotor lapped surface may
be damaged (3-way, 4-way
manual valves)
9. Inspect the pump for internal
leakage
10.Sheared key(s)
11.High pressure pump inlet or
outlet ball checks in the pump are
leaking
1. Calibrate gauge
2. Seal any faulty pipe fitting with
pipe sealant
3. Lift the pump from the reservoir
keeping the filter immersed in oil.
Note the pressure reading when
the relief valve begins to open up.
If functioning normally, it should
start to leak off at relief valve
pressure.
4. Remove the cylinder from the
pump. If the pump builds full
pressure, the cylinder is defective.
5. Clean and reseat parts
6. Replace the valve seat stem or
reseat pump body seat
7. Replace shear seals and/or
O-rings in valve section
8. Lap surface or replace rotor
9. Same procedure as above but
look for leaks around the entire
inner mechanism. If there are
no visible leaks, the low-to-high
pressure ball check (Item #16,
Sheet 3 of 4, Parts List #100384)
may be leaking. Remove all parts.
Check the end plate body for any
damage to the seat area. Clean
and reseat if necessary. Inspect
the ball for damage and replace if
necessary, then reassemble
10. Replace
11. Reseat or replace valve head
Electric motor cuts out 1. Insufficient power supply
2. Faulty motor and/or thermal
protector
1. Replace
2. Replace
Cylinders will not retract 1. Check the system pressure; if
the pressure is zero, the control
valve is releasing pressure and
the problem may be in the ram(s),
mechanical linkage connected
to ram(s), mechanical linkage
connected to ram(s), or quick-
disconnect couplings
2. Defective valve
1. Check the cylinders for broken
return springs and check couplers
to insure that they are completely
coupled. Occasionally couplers
have to be replaced because one
check does not stay open in the
coupled position
2. Test valve operation and inspect
parts. Replace if necessary
Pump delivers excess oil pressure 1. Relief valve not properly set
2. Check pressure gauge
1. Adjust the relief valve
2. Calibrate gauge