SPX PE39 Series User manual

Form No. 1000542
Rev. 2 November 14, 2014
© SPX
Operating Instructions for:
PE39PED1BPR
PE39PED1PR
PE39YED1BPR
PE39YED1PR
PE39 Series
Compact Torque Wrench Pump
SPX Bolting Systems
Unit 4, Wansbeck Business Park
Rotary Parkway
Ashington
Northumberland NE63 8QW
spxboltingsystems.com
Tel: [phone]
Fax: [phone]
Original Instructions

1
© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Compact Electric/Hydraulic Torque Wrench Pumps.......................2
Control Valves .........................................................3
Safety Symbols and Denitions............................................4
Safety Precautions .....................................................4
Initial Setup ...........................................................7
Operating Instructions ..................................................10
Performance Specications..............................................12
General Maintenance ..................................................13
Troubleshooting Guide .................................................20
Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Parts List ............................................................28
Hydraulic Technologies Facilities..........................................30
Declaration of Conformity ...............................................31

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Description:
The PE39 series hydraulic pump is designed to have a maximum of 690 bar (10,000 psi) at a
ow rate of 639 cc/min (39 cu. in/min). All pumps come fully assembled and ready for work.
Compact Electric/Hydraulic Torque Wrench Pumps
Description
Figure 1.
PE39 Series Pump
Universal Motor
The universal motor pump, shown in Figure 1, offers a lightweight
and portable hydraulic pump option. It is capable of vertical or
horizontal operation. Weight can be up to 23 kg (50 lbs).
Universal motor pumps come with a 1.89L (0.5 Gal) capacity
hydraulic reservoir.
The motor is a 0.8 kW (1.04 HP) average, 115/230 VAC (nominal),
50/60 Hz single-phase. Current draw can be up to 14.5 Amps at
115V (15A time delay 250VAC 5x20mm fuse) and 7.2 Amps at
230V (10A time delay 250VAC 5x20mm fuse) and the sound level
is rated at 87-92 dB. Operating temperatures range is -25°C to
+50°C (-13°F to 122°F). (If temperatures are at extremes of the
operating range, it is recommended to use hydraulic uids that are
rated for those temperatures.)
It is recommended that you use the cooling fan option for elevated
ambient temperature or continuous duty.

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Table 1. Pump Conguration
Control Valves
Max. Capacity: 690 bar (10,000 psi)
Description Motor Control
Switch
Pendant Use with
Cylinder Type
Valve No.
Equipped with
2-position/4-way
solenoid valve.
0.8 kW (1.04 HP
average) 50/60 Hz,
nominal 115 VAC,
single-phase
Remote
motor
See Figure
3. SPX
Part No.
3000554
Hydraulic
torque wrench
2002108
2-position/4-way,
pump mounted,
solenoid operated
Valve Function Diagrams
2-position/
4-way
(Idle Valve)
Advance Position:
(Solenoid "A") Pressure to "A" port, "B" port
to tank
Retract Position:
(De-energized Solenoid "A") Pressure to "B"
port, "A" port to tank
NOTE: All ports OPEN to tank during transi-
tion between valve positions.
S1
2-position/
2-way
(Idle Valve)
Advance Position:
Idle Valve CLOSED
Pressure to "A" port, "B" port to tank
Retract Position:
Idle Valve CLOSED
Pressure to "B" port, Idle Valve port to tank
Idle Positon:
Idle Valve OPEN
"B" port to tank (through idle valve)
S2

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
WARNING: To prevent personal injury,
• The following procedures must be performed by qualied, trained personnel who
are familiar with this equipment. Operators 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 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. Hydraulic Technologies will supply information necessary
to help make these decisions. Consult your nearest Hydraulic Technologies facility.
• Safety glasses must be worn at all time 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.
• Shut OFF the motor before opening any connections in the system.
Pump
WARNING: To prevent personal injury,
• 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.
• Retract the system before adding uid to prevent overlling the pump reservoir. An
overll can cause personal injury due to excess reservoir pressure created when tools
are retracted.
Safety Precautions
The safety signal word designates the degree or level of hazard seriousness.
DANGER: 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.
CAUTION: 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 Denitions

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Electric Motor
WARNING: To prevent personal injury,
• Electrical work must be performed and tested by a qualied electrician per local
directives and standards.
• Disconnect the pump from the power supply and relieve pressure before removing the
motor case cover or performing maintenance or repair.
• Check the total amperage draw for the electrical circuit you will be using. For example:
Do not connect a pump that may draw 25 amps to a 20 amp fused electrical circuit.
• Never use an ungrounded power supply with this unit.
• Changing the voltage is an involved and, if incorrectly performed, hazardous procedure.
Consult the manufacturer for specic information before attempting rewiring.
• Wire pump motors for counterclockwise rotation when viewed from the shaft end of
the motor.
• Do not attempt to increase the power line capacity by replacing a fuse with another
fuse of higher value. Overheating the power line may result in re.
• Exposing electric pumps to rain or water could result in an electrical hazard.
• Avoid conditions that can cause damage to the power cord, such as abrasion, crushing,
sharp cutting edges, or corrosive environment. Damage to the power cord can cause
an electrical hazard.
Hoses
WARNING: To prevent personal injury,
• Before operating the pump, tighten all hose connections using the correct tools. Do
not overtighten. Connections should be only secure 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 rupture, burst, or need to be disconnected, immediately shut
off the pump and shift the control valve twice to release pressure. Never attempt to
grasp a leaking hose under pressure 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, heavy impact,
or extreme heat or cold. Do not allow the hose to kink, twist, curl, 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.
• 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 material 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.
Safety Precautions continued

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Tools
DANGER: To prevent serious personal injury or death,
• This pump is designed for torque wrench applications and should never be used for
lifting.
• Do not exceed rated capacities of the tools. Excess pressure may result in personal
injury.
• Read and understand all safety and warning decals and instructions for devices
attached.
• Inspect each component before each shift or usage to prevent unsafe conditions from
developing.
• Do not use tools if they are damaged, altered or in poor condition.
• The guide cannot cover every hazard or situation so always do the job with SAFETY
FIRST.
IMPORTANT
• Use an approved, high-grade pipe thread sealant to seal all hydraulic connections.
PTFE tape can be used if only one layer of tape is used and it is applied 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 ow of uid or cause jamming of precision-t parts.
Safety Precautions continued

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Initial Setup
1. Remove all packing materials from the assembled unit.
2. Inspect the unit upon arrival. The carrier, not the manufacturer, is responsible for any damage
resulting from shipment.
Filling the Pump Reservoir
Pumps are shipped with hydraulic uid in the reservoir. Hydraulic uid may have been shipped in a
separate container, but if hydraulic uid is needed, use only approved Power Team hydraulic uid rated
at 47 cSt @ 38°C (215 SUS @ 100°F). If low temperature requirements are needed, use hydraulic oil
5.1 cSt @ 100°C (451 cSt @ -40°C).
1. See Figure 2. Clean the area around the filler plug to remove
debris. Debris in the hydraulic fluid can damage the polished
surfaces and precision-fit components of this pump.
2. Remove the filler plug and insert a clean funnel with a filter.
CAUTION: Do not ll reservoir with the unit in the horizontal
position. Do not over ll reservoir.
3. Add hydraulic fluid to the bottom edge of the filler plug hole with
the unit in the upright (vertical) position.
4. Replace the filler plug.
Figure 2.
Filler Plug
Hydraulic Connections
1. Clean the areas around the fluid ports of the pump
and tools.
2. Clean all hose ends, couplers or union ends.
3. See Figure 3. Remove the protective covers from the
hydraulic fluid outlets.
4. Connect the hose assembly to the hydraulic fluid
outlet, and couple the hose to the tool.
Figure 3.
Hydraulic Fluid Outlets

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Initial Setup continued
Electric Motor
1. See Figure 4. Connect the motor control
pendant.
Figure 4.
Motor Control Pendant
Figure 5.
Connected to Power Source
Figure 6.
Disconnected from Power Source
2. Refer to Table 2. Minimum Recommended
Gauge Table. See Figure 5. Connect the control
box power cord to an appropriate power source.
Never run the pump on long, light gauge
extension cords.
Caution: To prevent equipment damage,
• The correct voltage is required for the pump
to operate. Verify the voltage rating on the
pump name plate matches the outlet or
power source you are using. Low voltage
may cause: an overheated motor; a motor
that fails to start under load; motor surging
when trying to start; or a stalled motor before
maximum pressure is reached. The motor
nameplate can be accessed by removing the
shroud.
• Check the voltage at the motor with the
pump running at full pressure.
3. Start the pump and shift as required.
4. Turn off the pump when not in use.
5. Disconnect the motor control pendant.
6. See Figure 6. Disconnect power source.

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
AMPS
at Maximum
Hyd. Pressure
Electrical Cord Size AWG (mm2) 3.2 Volt Drop
Length of Electrical Cord
mm2AWG
0-8 m 8-15 m 15-30 m 30-46 m 0-25 ft 25-50 ft 50-100 ft 100-150 ft
6 0.75 1 1.5 2.5 18 16 14 12
10 0.75 1.5 2.5 4 18 14 12 10
14 1 2.5 4 6 16 12 10 8
18 1.5 2.5 6 6 14 12 8 8
22 1.5 4 6 10 14 10 8 6
26 2.5 4 6 10 12 10 8 6
30 2.5 4 10 16 12 10 6 4
Table 2. Minimum Recommended Gauge Table
Bleeding Air from the System
After all connections are made, the hydraulic system must be bled of any trapped air. With no load on
the system and the pump positioned higher than the hydraulic device, cycle the system several times.
Check the reservoir uid level and ll to correct level with Power Team hydraulic uid as necessary.
If there is a problem contact Hydraulic Technologies Technical Support. To locate a Power Team
Authorized Hydraulic Service Center, contact your nearest Hydraulic Technologies facility or
www.SPXBOLTINGSYSTEMS.com.
Initial Setup continued

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Operating Instructions
Figure 8.
Motor Control Switch
Item Description
1 Start (Green)
2 Lamp (White)
3 Stop (Red)
Item Description
1 OFF Position
2 ON Position
3 Idle Position
4 Retract Position
5 Advance Position
Figure 9.
Pendant Control
Pump Control Operation
1. See Figure 7. Connect the power cord to an
appropriate power source.
3. See Figure 9. Press the ON/OFF rocker switch to
ON to start the motor. Press the ON/OFF rocker
switch to OFF to stop the motor. This does not
remove power from the control system.
4. Press and hold the ADVANCE/RETRACT/IDLE
rocker switch to the ADVANCE position. Release
when tool has reached the end of its stroke.
5. When the ADVANCE/RETRACT/IDLE is released,
the rocker switch defaults to RETRACT. The pump
is factory preset to 103 bar (1,500 psi) during
RETRACT.
6. Pressing the ADVANCE/RETRACT/IDLE rocker
switch to IDLE allows hydraulic uid to cycle through
the pump back to the tank.
Figure 7.
Connected to Power Source
2. See Figure 8. Press the START (green) switch.
Lamp (white) will illuminate and electrical power
is supplied to the control system. Press the STOP
(red) switch to remove electrical power from the
control system. As long as the lamp is illuminated,
there is electrical power to the control system.

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Adjusting The Pressure Regulating Valve
1. The pump must be completely connected. Press
the START (green) switch on the control box.
2. Using the pendant, press the ON/OFF rocker
switch to ON.
3. Press and hold the ADVANCE/RETRACT/IDLE
rocker switch to the ADVANCE position to start
the motor and build pressure.
4. See Figure 10. Rotate pressure regulating valve
to the desired pressure. Clockwise increases
pressure, counterclockwise decreases pressure.
5. When the desired pressure is achieved, cycle
the system again to verify correct pressure
setting.
6. Using the pendant press the ON/OFF rocker
switch to OFF.
7. Press the OFF (red) switch on the control box.
Figure 10.
Pressure Regulating Valve
Operating Instructions continued

12
© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Performance Specications
Pump Motor RPM
(Output)
Amp Draw at
690 Bar
(10,000 PSI)
(115V)
Amp Draw at
690 Bar
(10,000 PSI)
(230V)
dB A at Idle
and 690 Bar
(10,000 PSI)
PE39 4,500 14.5 7.2 92
Pump
Max. Pressure
Output Bar
(PSI)
Fluid Delivery* L/min (cu. in./min. @)
70 Bar
(1,000 PSI)
345 Bar
(5,000 PSI)
690 Bar
(10,000 PSI)
PE39 690 (10,000) 0.90 (55) 0.80 (49) 0.64 (39)
* Typical delivery. Actual ow varies with eld conditions.
Table 3. Drive Unit Requirements
Table 4. Fluid Pressure Chart

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
General Maintenance
System Evaluation
The components of your hydraulic system — pump, hoses, and couplings — all must be:
• Rated for the same maximum operating pressure.
• Correctly connected.
• Compatible with the hydraulic uid used.
A system that does not meet these requirements can fail, possibly resulting in serious injury. If you are
in doubt about the components of your hydraulic system, contact Hydraulic Technologies Technical
Support.
Inspection
Keep a dated and signed inspection record of the equipment. Before each use, the operator or other
designated personnel should visually inspect for the following conditions:
• Excessive wear, bending, damage, or insufcient thread engagement.
• Leaking hydraulic uid.
• Loose bolts, cap screws, or pipe plugs.
• Bent or damaged couplers or port threads.
Periodic cleaning
WARNING: Contamination of the hydraulic uid could cause the valve to malfunction.
Establish a routine to keep the hydraulic system as free from debris as possible.
• Seal unused couplers with dust covers.
• Keep hose connections free of debris.
• Use only Power Team hydraulic fluid. Replace hydraulic fluid as recommended, or sooner if the fluid
becomes contaminated. Never exceed 300 hours of use between fluid changes.
Hydraulic Fluid Level
1. Check the fluid level in the reservoir after each 10 hours of use. The fluid level should be level with
the bottom of the fill hole when all cylinders are retracted and the unit is in the upright (vertical)
position.
2. Drain, flush, and refill the reservoir with an approved Power Team hydraulic fluid after 300 hours of
use. The frequency of fluid changes depends upon general working conditions, severity of use, the
overall cleanliness and care given to the pump. Fluid should be changed more frequently when the
system is not operated regularly indoors.
WARNING: To prevent personal injury,
• Disconnect the unit from the power source before performing maintenance or repair
procedures.
• Repairs and maintenance are to be performed in a dust-free area by a qualied
technician.

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Adding Hydraulic Fluid to the Reservoir
1. See Figure 11. Disconnect the power source.
2. Clean the entire area around the filler plug.
Figure 11.
Disconnected from Power Source
Figure 12.
Filler Plug
3. See Figure 12. Remove the filler plug, and install a
clean funnel with a filter.
4. Using a clean funnel with a filter, fill the reservoir
with Power Team hydraulic fluid 47 cSt @
38°C (215 SUS @ 100°F). If low temperature
requirements are needed, use hydraulic Oil 5.1 cSt
@ 100°C (451 cSt @ -40°C). Add hydraulic fluid to
the bottom edge of the filler plug hole with the unit
in the upright (vertical) position.
CAUTION: Do not ll reservoir with the unit in the
horizontal position. Do not over ll reservoir.
Hose Connections
CAUTION: To prevent personal injury from leaking hydraulic uid, seal all hydraulic
connections with a high-quality, non-hardening, pipe thread sealant.
Pipe thread sealant tape can be used to seal hydraulic connections if only one layer of tape is
used. Apply tape carefully, two threads back, to prevent it from being pinched by the coupler
and broken off inside the system. Loose pieces of tape could travel through the system and
obstruct the ow of uid or cause interference of precision-t parts.
Storage
Store the unit in a dry, well-protected area where it will not be exposed to corrosive vapors, dust, or
other harmful elements. If a unit has been stored for an extended period of time, it must be thoroughly
inspected before it is used.
General Maintenance continued

15
© SPX
Form No. 1000542
Rev. 2 November 14, 2014
Draining and Flushing the Reservoir
1. Clean the filler plug.
2. See Figure 13. Remove the filler plug and drain the
fluid.
CAUTION: Do not ll reservoir with the unit in the
horizontal position. Do not over ll reservoir.
3. Using a clean funnel with a filter, fill the reservoir
with Power Team hydraulic fluid 47 cSt @
38°C (215 SUS @ 100°F). If low temperature
requirements are needed, use hydraulic oil 5.1 cSt
@ 100°C (451 cSt @ -40°C). Add hydraulic fluid to
the bottom edge of the filler plug hole with the unit
in the upright (vertical) position.
4. Connect the hydraulic hoses to the fittings.
5. Bleed the air from the system. Refer to Bleeding Air
from the System.
6. Cycle the pump for 1–2 minutes.
7. Disconnect the hydraulic hoses from the motor and
pump assembly.
General Maintenance continued
Figure 13.
Filler Plug
Figure 14.
Disconnected from Power Source
8. See Figure 14. Disconnect power cord from power
source.
9. See Figure 15. Loosen the screw clamp.
Figure 15.
Screw Clamp

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
10. See Figure 16. Remove the ller plug and drain the
uid from the reservoir.
11. See Figure 17. Remove the 4 screws.
12. Remove the reservoir from the motor and pump
assembly.
13. Clean the mating surfaces.
14. Clean the inside of the reservoir.
15. See Figure 18. Replace the inlet suction filter.
16. Place the reservoir (with new o-ring) on the pump
and motor assembly. Tighten the screws to:
• 5 Nm (45 in/lbs).
17. Remove the filler plug and insert a clean funnel
with a filter. Fill the reservoir with Power Team
hydraulic fluid 47 cSt @ 38°C (215 SUS @ 100°F)
If low temperature requirements are needed, use
hydraulic oil 5.1 cSt @ 100°C (451 cSt @ -40°C).
General Maintenance continued
Figure 16.
Filler Plug
Figure 17.
Reservoir Screws
Figure 18.
Inlet Suction Filter

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
18. See Figure 19. Tighten the screw clamp.
General Maintenance continued
Figure 19.
Screw Clamp
Checking Brushes on Universal Motors
To help prevent premature failure of the armature,
check the brushes periodically.
1. See Figure 20. Disconnect power cord from power
source.
2. Remove the motor covers. Refer to Motor Cover
Removal and Installation. Figure 20.
Disconnected from Power Source
3. See Figure 21. Use a screwdriver to remove the
brush holder cap.
4. Remove the brush.
Figure 21.
Brush Holder

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
General Maintenance continued
5. See Figure 22. The brush assemblies must be
replaced if they are 4.7 mm (3/16 in.) or less.
6. See Figure 23. Install brush assemblies and
brush holder caps.
Figure 22.
Brush Inspection
Figure 23.
Brush
Fuse Replacement
1. See Figure 24. Disconnect power cord from
power source.
Figure 24.
Disconnected from Power Source
22 mm (7/8")
(new)
Replace when
4.7 mm (3/16") or less

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© SPX
Form No. 1000542
Rev. 2 November 14, 2014
General Maintenance continued
Figure 25.
External Fuse Holder
2. See Figure 25. Remove the fuse holder.
3. Replace the fuse. On 115V (nominal) replace 15A
time delay 250VAC 5x20mm fuse , 230V (nominal)
replace 10A time delay 250VAC 5x20mm fuse.
4. To install, reverse the removal procedure.