SPX POWER TEAM PG554-AMKUS User manual

MODEL C
GAS DRIVEN
HYDRAULIC PUMP
SIDE VIEW
Form No. 102805
PG554-AMKUS
Parts List and
Operating Instructions for:
1, 2, 3
4
5
6
7
8
10,
22
11
12
13
14
15
16
17
18
19
20
21
Basic Pump
Assembly
See sheet
3 of 7
23
Sheet No. 1 of 7
Rev. 10 Date: 18 July 2000
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
®
© SPX Corporation

Parts List and Operating Instructions, Form No. 102805, Back sheet 1 of 7
Item Part No.
No. No. Req'd Description
126804 1 Stud
250243 2 Stud (Located on opposite side of engine.)
210246 3 Washer (For 5/16 bolt)
313116 3 Locknut (5/16-18 UNC;
Note: This nut should fully engage threads of studs [Item #1].)
458354BK2 1 Mount Plate
59500 1 Manual Valve (See Form No. 100623)
610268 1 O-ring (1/2 X 3/8 X 1/16)
711863 1 Backup Washer (1/2 X 3/8 X 1/16)
821484 1 Spacer
10 17586 1 Sight Gauge
11 20787 1 Valve Connector
12 350304 1 Filter
13 350995 1 Hose Clamp
14 64370YE3 1 Reservoir
15 250629 1 Shaft
16 421391 1 Gasket
17 40987 1 Gasket
18 18328 1 Soc. Hd. Cap Screw (5/16-18 X 2" Lg.)
19 250628 1 Sleeve
20 10281 2 O-ring (1-1/2 X 1-1/4 X 1/8)
21 420345 1 Gas Engine (4 H.P.)
22 253300 1 Seal Washer
23 200395 1 Gasket (Between valve & coverplate)
Note: Shaded areas reflect last revision(s) made to this form.

Parts List and Operating Instructions Form No. 102805
TOP VIEW AND SECTION B-B
"B"
"B"
T
R
O
P
B
T
R
O
P
A
Section B-B
1
2
3, 4
5
Fill counterbore
with sealant
where mounting
plate #58051
overlaps.
7
8
9
6
Sheet No. 2 of 7
Rev. 10 Date: 18 July 2000

Parts List and Operating Instructions, Form No. 102805, Back sheet 2 of 7
HYDRAULIC SCHEMATIC
Item Part No.
No. No. Req'd Description
LP
MHP AB
PT
TO CUSTOMER
SYSTEM
3-POSITION
MANUAL VALVE
L.P. UNLOADING
VALVE
SUPERCHARGE
RELIEF VALVE
CUSTOMER
RETURN
LINES
INTERNAL RELIEF
VALVE
10,850 P.S.I.
175 P.S.I. 2,050 P.S.I.
4-WAY
158207 1 Cover Plate
210177 10 Screw (1/4-20 X 3/4 Lg.;
Apply Loctite #242 and torque to 90/100 in. lbs.)
3252642 1 Breather/Filler Cap
4200415 1 O-ring (13/16 X 5/8 X 3/32)
510575 4 Drive Screw (#2 X 3/16 Lg.)
613273 2 Plug
7250630 2 Drain Tube (Note: One of these replaces the drain tube
on valve assembly.)
8209230 1 Tee Fitting
910621 1 Elbow

Parts List and Operating Instructions Form No. 102805
BASIC PUMP ASSEMBLY
.065
.075
.265
.275
1
2
3
4
5
6
7
8
9
8
7
10
11
12
13
14
15
16
17
18
21
22
23
24
25
26
27
28
29
24
22 30 33
31, 32
19
20
High Pressure Pump
Assembly #33113
See sheet 4 of 7.
Sheet No. 3 of 7
Rev. 10 Date: 18 July 2000

Parts List and Operating Instructions, Form No. 102805, Back sheet 3 of 7
OUTLET CHECK SECTION
110020 9 Cap Screw (1/4-20 UNC X 1-1/2 Lg.;
Torque to 170/180 in. lbs.)
210361 1 Compression Spring
(1/4 O.D. X 1" Lg.)
310375 1 Steel Ball (1/3 dia.)
423547 1 Bearing Top Plate
511814 1 Ball Bearing
623548 1 Top Plate
711228 2 Thrust Bearing
811813 3 Bearing Race
923549 1 Angle Plate
10 11955 1 Pin
11 11261 2 Retaining Ring
12 250631 2 Needle Bearing
13 23556 1 Shaft
14 420429 1 Pump Gear
15 11821 1 Woodruff Key
16 420430 1 Drive Gear
17 11199 2 Needle Bearing
18 10001 12 Cap Screw (1/4-20 UNC X 3/8 Lg.;
Torque to 50/60 in. lbs.)
19 251206 1 Coupling
20 10266 2 O-ring (3/4 X 19/32 X 1/32)
21 58198 1 End Plate
22 10425 2 Compression Spring
(3/8 O.D. X 3/4 Lg.)
23 250633 1 Compression Spring
24 20771 2 Poppet
25 64207 1 Body
26 23256 1 Spring Guide
27 23255 1 Spring Guide
28 10427 1 Pressure Guide
29 20849 1 Spool
30 10303 1 O-ring (7/8 X 3/4 X 1/16)
31 10271 1 O-ring (11/16 X 1/2 X 3/32)
32 12389 1 Backup Washer
(11/16 x 1/2 X 1/16)
33 10016 3 Cap Screw (1/4-20 UNC X 1" Lg.)
Item Part No. Item Part No.
No. No. Req'd Description No. No. Req'd Description
Item Part No.
No. No. Req'd Description
110015 2 Cap Screw (1/4-28 UNF X 1" Lg.; Torque to 130/180 in. lbs.)
210266 1 O-ring (3/8 X 1/4 X 1/16, -010)
310427 1 Pressure Plug (1/8 NPTF)
420771 1 Poppet
510425 1 Compression Spring (3/8 O.D. X 3/4 Lg.)
620770 1 Connector
7350306 1 Oil Line Tube
810430 2 Tube Sleeve
910431 2 Tube Nut
10 10261 1 Copper Washer (3/4 X 19/32 X 1/32)
11 20776 1 Valve Body
12 21278-105 1 Relief Valve Assembly (Set at 10,600/11,100 PSI)
1
234
56
7
8, 9
10
11
12

Parts List and Operating Instructions Form No. 102805
HIGH PRESSURE PUMP ASSEMBLY
Sheet No. 4 of 7
Rev. 10 Date: 18 July 2000

Parts List and Operating Instructions, Form No. 102805, Back sheet 4 of 7
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.)
3*24549 6 Valve Guide
4*10445 6 Compression Spring (5/32 O.D. x 3/4 Lg.)
5*12223 7 Steel Ball (3/16 dia.)
6*10023 7 Soc. Hd. Cap Screw (1/4-28 UNF x 1-1/2 Lg.;
Torque to 170/180 in. lbs.; See note below)
7*50411 1 Top Plate
810519 1 Soc. Set Screw (1/4-20 UNC x 3/8 Lg.;
Torque to 65/70 in. lbs.)
9*40630 1 Valve Head
10 *41062 1 Pump Barrel
11 *21628 3 Piston
Consult factory when replacing items marked with an asterisk (*).
Item Part No.
No. No. Req'd Description
NOTE: Assemble in sequence shown.
Lubricate under head and on threads.
Torque to 180 in. lbs.

Parts List and Operating Instructions Form No. 102805
NOTE:
•Carefully inspect the pump upon arrival. The carrier, not the manufacturer, is responsible for any damage
resulting from shipment.
•Read and carefully follow these instructions. Most problems with new equipment are caused by improper
operation or installation.
SAFETY PRECAUTIONS
WARNING: To help prevent 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.
•Always shut off the electric motor before breaking any connections 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. 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 the cylinders are retracted.
CYLINDER
•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.
SET-UP
Motor Hook-up and Operation
Refer to the instruction manual for the gasoline engine.
Hydraulic Connections
1. Clean all 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 union ends.
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. IMPORTANT: Seal all external pipe connections with a high quality,
nonhardening pipe sealant. Teflon tape can also be used to seal hydraulic connections if only one layer of tape
is used. Apply the tape carefully 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. Sheet No. 5 of 7
Rev. 10 Date: 18 July 2000

Parts List and Operating Instructions, Form No. 102805, Back sheet 5 of 7
Reservoir Venting
Before using the pump, remove the plastic shipping plug from the reservoir fill hole and replace with the breather cap
provided.
PUMP 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 oil level. Start the gas
engine.
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. Cycle the pump several times, extending and retracting the cylinder(s) fully, 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 for regular operation.
IMPORTANT: After eliminating trapped air from a large work-holding system, retract the cylinders and add oil
to the pump reservoir to within 1/2" from the fill hole.
PREVENTIVE MAINTENANCE
NOTE: Any repairs of servicing that requires dismantling the pump must be performed in a dirt-free
environment by a qualified technician.
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.
Inspecting the Hydraulic Fluid Level
Check the oil level in the reservoir periodically. With all cylinder(s) retracted, the oil level should come to within 1/2" of
the filler/breather cap. 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.

Parts List and Operating Instructions Form No. 102805
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 relief 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 within 1/2" of the top lip of the reservoir.
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 gas engine shut off 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 within 1/2" of the filler/breather cap.
TROUBLE-SHOOTING GUIDE
WARNING
•To help prevent personal injury, any repair work or trouble-shooting must be done by qualified personnel
familiar with this equipment.
•Use the proper gauges and equipment when trouble-shooting.
NOTE:
•It is 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.
•Plug the outlet ports of the pump when checking for leakage to determine if the leakage is in the pump or
in the cylinder or tool.
Pump is not delivering oil or delivers
only enough oil to advance
cylinder(s) partially or erratically.
1. Oil level too low.
2. Loose-fitting coupler to cylinder.
3. Air in system.
4. Air leak in suction line.
5. Dirt in pump or filter plugged.
1. With all cylinders retracted, fill
reservoir to within 1/2" of fill hole.
2. Check quick-disconnect couplings to
cylinders. Inspect couplers to ensure
that they are completely coupled.
Occasionally couplers have to be
replaced because the ballcheck does
not stay open due to wear.
3. Bleed the system.
4. Check and tighten suction line.
5. Pump filter should be cleaned and, if
necessary, pump should be
dismantled and all parts inspected
and cleaned.
PROBLEM CAUSE SOLUTION
Sheet No. 6 of 7
Rev. 10 Date: 18 July 2000

Parts List and Operating Instructions, Form No. 102805, Back sheet 6 of 7
Pump is not delivering oil or delivers
only enough oil to advance
cylinder(s) partially or erratically.
(continued)
Pump builds pressure but cannot
maintain pressure.
Pump will not build full pressure
6. Oil is bypassing through a
double-acting cylinder.
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) used.
10. Defective directional valve.
11. Sheared drive shaft key(s).
12. Vacuum in reservoir.
1. Check to see if there are an external
leaks. If no oil leakage is visible, the
problem is internal. If using a
double-acting cylinder remove it from
the system to ensure that the leak is
not in the cylinder.
2. To test for a leaking control valve lift
the pump from the reservoir but
keep the filter in the oil. Remove the
drain line to see if the oil is leaking
from the valve. If the valve is not
leaking, the internal check valve
could be leaking. Refer to the note
concerning checking for oil leak at
the beginning of this Trouble-
shooting Guide.
1. Check for external leakage.
2. Check the relief valve setting.
3. Look for internal leakage in
double-acting cylinders.
4. Check for leaks in the flow
control valve.
5. Inspect the pump for internal
leakage. Check high pressure
pump inlet or outlet ball checks
6. Sheared key(s).
7. Shifting spool seat and/or shifting
spool poppet (located under high
pressure pump assembly) worn.
8. Shifting spool O-ring (located within
shifting spool bore) worn or broken.
6. By removing the cylinder and
capping the hoses, the pump and
valve can be checked. Observe if
pump holds 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. Check for plugged vent in breather
cap.
1. Seal leaking pipe fittings with
pipe sealant.
2. Clean, reseat or replace flow
control valve parts. If the internal
check valve(s) are leaking, the
pump must be dismantled and
the seat areas repaired, poppets
replaced, etc.
1. Seal faulty pipe fitting with pipe
sealant.
2. Lift the pump from the reservoir,
but keep the filter immersed in
oil. Note the pressure reading
when the relief valve begins to
open. If functioning normally, it
should start to leak off at relief
valve pressure.
3. Remove the cylinder from the
pump. If the pump builds full
pressure, the cylinder is
defective.
4. Clean and reseat or replace
parts.
5. Same procedure as above, but
look for leads arouind the entire
inner mechanism. If there are
no visible leaks, the high
pressure pump subassembly
may be leaking. Remove all
parts. Check the valve head
assembly body for any damage
to the seat area. Clean and
reseat if necessary. Inspect for
damage and replace parts if
necessary, then reassemble.
6. Replace.
7. Clean and reseat or replace.
8. Remove and replace o-ring and
backup washer through low
pressure pump assembly end.
PROBLEM CAUSE SOLUTION

Parts List and Operating Instructions Form No. 102805
Cylinder(s) will not retract.
Pump delivers excess oil pressure
Gasoline engine.
1. Check the system pressure; if
the pressure is zero, the control
valve is releasing pressure and
the problem may be in the
cylinder(s), mechanical linkage
connected to cylinder(s), or
quick disconnect couplings.
2. Defective valve.
1. Relief valve not properly set.
1. Check the cylinders for broken
return springs, and check
couplers to ensure that they are
completely coupled.
Occasionally couplers have to
be replaced because one check
does not stay open in the
coupled position.
2. Check valve operation and
inspect parts. Replace if
necessary.
1. Adjust the relief valve.
1. Refer to instruction manual
included with gasoline engine.
PROBLEM CAUSE SOLUTION
Sheet No. 7 of 7
Rev. 10 Date: 18 July 2000