Val-Tex QS-5000-C User manual

QS-5000-C
OPERATING MANUAL
CONTENTS:
-PARTS LIST
-QS-5000-C REQUIREMENTS
-USING THE VAL-TEX #8607 AIR REGULATOR
-BEFORE OPERATING THE PUMP
-LOADING AND OPERATING THE QS-5000-C
-DETATCHING THE LUBRICATION CYLINDER
-PERIODIC MAINTENANCE FOR HYDRAULIC PUMP AND CART
-RECOMMENDED STORAGE PROCEDURES
-RECOMMENDED REPLACEMENT FLUIDS
-OPERATING INSTRUCTIONS FOR HYD. PUMP
-HYDRAULIC PUMP PARTS
-AUTHORIZED REPAIR CENTERS
-MATERIAL SAFETY DATA SHEET

Options Available
• Sight glass modification to the metal hydraulic pump reservoir allows the operator to monitor the amount
of material being pumped.
• Air regulator (8607) rated for 3,000 PSI input and gauge (2052L160) rated to 160 PSI. Be sure to refer
to your company’s policies before using anything other than compressor air for your power
source.
• Moisture separator (5604-2) and airline lubricator (5904-2) for protection of the pump.
Part No. Item No. Description Qty.
5001A 1 Cylinder Assembly Complete 1
5001A-1 2 Sealant Cap Assembly Complete 1
5001A-1A 3 Sealant Cap 1
5001-1B 4 Air Return Fitting 1
328034 5 Air Quick Disconnect-Male 1
5001A-1C 6 Lube Pack Extension 1
5001-1D 7 Dowel Pin 6
5001-1E 8 Hydraulic End Cap O-ring 1
5001A-1F 8A Sealant Cap O-rings 1
5001A-2 9 Cylinder Body 1
5001-3 10 Piston Assembly Complete 1
Consists of:
5001-3A .11 Piston Body 1
5001-3B .12 Snap Ring 2
5001-3C .13 Piston Seal Retainer 2
5001-3D .14 Upper & Lower Seal Sets 2
1408-A 15 Cap Screw Bleeder 5/16"-24NF 1
1408-BA 16 Copper Washer 1
5001A-4 17 Hydraulic End Cap 1
BB-12 18 1/2" NPT Body Bleed Fitting 1
5002-1-C Hydraulic Hose Assembly 1
HQD-14-N-M Hyd. Quick Disc. Nipple 1/4" (M) 1
HQD-14-C Hyd. Quick Disc. Coupler 1/4" (F) 1
PA-6-M-2 Hydraulic Pump - Metal Reservoir .. 1
328030 Air Quick Disconnect (F) .1
Part No. Description Qty.
328034 Air Quick Disconnect (M) 1
5016 Sealant Hose Assembly 1
Consists of:
6.Giant Buttonhead Coupler 1
321320 Straight Swivel 1/4" X 1/4" 1
15MGF 15,000 PSI Gauge 1
GC-250 Gauge Guard 1
.25 TEE 1/4" Tee 1
38-120 Hose - 10' X 3/8" 1
331107 .High Pressure Z-Swivel 1
319700 .Shut-off / Bleeder Valve 1
1/4 IN CPLG 1/4"X1/4" Coupling 1
5020-C Compact Cart
Consists of:
5020-1-C Sealant Cap Wrench 1
MINI-QS-5000 Compact Cart 1
5020-3 Pneumatic Tire 2
5020-4 Handle Grips - 1" 3
SC-14 1/4" G.B. Lube Fitting 1
OPTIONS
2052L160 0-160 PSI Gauge 1
5035 O Shaped Sight Glass 1
5040 Hydraulic Fluid - 1 Gallon 1
8607 Air Regulator 1
Delivery: 8 oz. / 30-60 seconds
Weight: 153 Lbs.
Lube Sealant Size: V, P-4
PSI Rating: 10,000
Overall Dimensions: 46" H X 20" W X 26" L
Priming: Self-Priming Air / Hydraulic
CFM Required: 20
Air Pressure Required: 75 - 100 PSI
Pressure Delivered through a 10 foot hose at 100 PSI:
Lube Sealant - 8,000 PSI
Valve Flush - 10,000 PSI
Gauge: Included
Lube Pack Compatible: Yes
Internal Relief Valve: Yes
Val-Tex QS-5000-C
10600 FALLSTONE ROAD • HOUSTON, TEXAS 77099-4390 • ORDER 1-800-627-9771 • PHONE [phone] • FAX [phone] • WWW.VALTEX.COM
REV. 8/03 18
Val-Tex QS-5000-C
The Val-Tex QS-5000-C is a compact, easy to transport, fast, versatile, heavy
duty lubrication unit that will pump large volumes of stick lube sealant, lube
packs, and Valve Flush.The QS-5000-C is quickly separated into two parts by
removing the cylinder for easy loading and unloading by one person.
Assembly is as simple as inserting the two catch pins to secure the cylinder
clamps to the frame.
The QS-5000-C has the largest stick lube sealant capacity in the valve lubrication industry.The Val-Tex five pound V-stick, four pound P-4 Lube
Pack, and one gallon Valve Flush (VF-GAL) are designed to drastically reduce the frequency of loading.
The QS-5000-C’s four inch pneumatic tires allow the unit to be maneuvered easily by one person.The rugged sealant cap wrench has 16 ounce
graduations to allow the operator to control the amount of material being loaded.The unit comes complete with a 10 foot, 3/8 inch I.D. high
pressure hose, quarter turn shut-off / bleeder valve, 15,000 PSI gauge, Gauge Guard, dual swivels, giant buttonhead coupler, and metal hydraulic
fluid reservoir.The hydraulic pump requires only periodic maintenance and has an internal safety relief valve set at approximately 10,000 PSI to
prevent over-pressuring.
Air / Hydraulic Lubrication Gun
EASIER TO TRANSPORT
SAME LARGE CAPACITY

QS-5000-C Requirements
A minimum of 20 CFM is required to operate the unit. The unit should be run with
100 to 125 PSI input pressure. Exceeding 125 PSI input pressure is not recommended
and could damage the hydraulic pump.
To obtain 10,000 PSI output requires 100 to 125 PSI of input air at 20 CFM.
Moisture separator, oiler, and air line filter (these items are not included) are
recommended on the air supply line to prolong the life of the pump.
If using the Val-Tex #8607 Air Regulator
1. Install 160 psi air gauge (2052L160) in one of the LP ports on the regular.
2. Regulator Specifications:
A. Regulator inlet capacity 3000 psi maximum
B. Output Adjustable 1-160 psi
C. Regulator preset at factory for 100 psi.
One (1) air inlet port is marked HP (High Pressure)
Two (2) air outlet ports are marked LP (Low Pressure)
Before Operating the Pump
1. Remove shipping plug from hydraulic pump and install vent filler cap (20937S)
provided on the opposite end.
2. Remove shipping plug from sealant cap (5001A-1A) and install sealant hose
assembly (5016).

Loading and Operating the QS-5000-C
1. Move pump control lever to "release" position. (as marked on pedal)
2. Disconnect air supply from pump.
3. Close relief valve (319700) on material hose. (|) open (-) close
4. Close body bleed fitting on sealant cap.
5. Attach air supply to quick disconnect (328034) on sealant cap (5001A-1A). Allow
approximately 60 seconds for piston to return to the bottom.
6. Disconnect the air supply from sealant cap.
7. Open the body bleed fitting on the sealant cap. Place a rag under and in front of
the bleeder hole on the body bleed fitting to catch bleeding material. DO NOT
place your hand in front of or stand in front of the bleeder hole. After the material
passes through the bleeder hole, the trapped air pressure will vent. This allows
the sealant cap to be more easily removed.
8. Close the body bleed fitting after the pressure has vented.
9. Using the sealant cap wrench supplied (5020-1-C), remove sealant cap. DO NOT
attempt to remove the allen screw on the side of the sealant cap at any time!!!
10. Determine piston (5001-3) is all the way down. If not, replace sealant cap and
proceed from step 5 above.
11. When less then full capacity is required, use the 16 ounce markings on the sealant
cap wrench (5020-1-C) and activate the Hydraulic Pump (PA6-M-2) until the piston
assembly reaches the proper position. WARNING! Piston Assembly (5001-3) can
be pumped out of the cylinder.
12. Load Val-Tex lube sealant or Valve Flush as required. Remember to remove
cellophane wrapper on sticks or cut the top of the bag open for the P-4 lube packs.
13. Replace sealant cap. Snugly tighten with sealant cap wrench provided. The cap is
securely tightened when you cannot see any threads on the sealant cylinder.
14. Close the relief valve (319700) on material hose. (|) open (-) close
15. Open the body bleed fitting on the sealant cap.
16. Reattach air supply to hydraulic pump (PA6-M-2).

17. Activate pump by moving the pump control lever to "pump" position (as marked on
pedal). Place a rag under and in front of the bleeder hole on the body bleed
fitting to catch bleeding material. * DO NOT place your hand in front of or stand in
front of the bleeder hole. As material passes through the bleeder hole, any
trapped air should vent. Stop the pump when the air is vented.
18. Close the body bleed fitting on the sealant cap.
19. Open the relief valve (319700) on material hose. (|) open (-) close
20. The QS-5000-C is now ready to service your valves.
21. Before removing the coupler from the valve or when the hydraulic pump is not in
use, release the pressure on the hydraulic pump and close relief valve (319700) on
material hose.
22. When the cylinder is empty the pump will begin to stall. Stop the pump. Please
refer to step 1.
* Dispose of any expelled material properly.
Detaching the Lubrication Cylinder
One of the unique features of the QS-5000-C is that you can detach the lubrication
cylinder so one person can load and unload the entire unit. Note: Only perform this
procedure when there is no pressure on the cylinder.
1. Disconnect the female hydraulic quick disconnect from the bottom of the lubrication
cylinder.

2. Pull the two push pins holding each of the two bracket pins in place.
3. Pull both of the bracket pins to disengage the cylinder from the frame.
4. Carefully remove the cylinder. This will now allow you to more easily load or unload
the unit from your vehicle.

Periodic Maintenance For Pump and Cart
1. If automatic air line oiler is not installed, periodically lubricate air line using SAE No.
10 oil.
2. Lubricate wheel bearings using quality wheel bearing grease.
3. Refer to the OTC Form 105001 and 100424 included with your hydraulic pump
(5012) for periodic maintenance requirements on the PA6-2-M.
4. Slowness or difficulty in returning piston assembly (5001-3) to the bottom of the
cylinder indicates the need to change hydraulic fluid and clean filter assembly
(29682) referred to in Form 100424 item 12.
Recommended Storage Procedures
Follow the steps below for proper storage when the QS-5000-C is out of service for an
extended period of time.
1. It is recommended to remove any product from the sealant cylinder.
2. Blow the piston down to the bottom of the sealant cylinder.
3. Coat the inside of the cylinder with a light oil. This should allow the piston to run
smoothly when you take it out of storage. When you are ready to use the unit, make
sure the hydraulic fluid is clean before you operate it. If it is not, change the
hydraulic fluid.

RECOMMENDED REPLACEMENT FLUIDS FOR QS-5000
Plant Eng. ISO Viscosity Viscosity SUS
Designation Grade Lubricant Type at 100o F
GRADE-215-HP 46 High-pressure 194-236
(anti-wear)
hydraulic oil
Company Name Product Number
Allube (Far Best Corp.) Moly-Shield HM 215
Amalie Refining Co. (Div. of Witch Chemical) AMA Oil 200
Anderson Oil & Chemical Co. Windsor Hyd. Oil 45AW
Ashland Oil Inc. Valvoline Oil Div. AW Oil #20
American Lubricants, Inc. (AmLube) 200 AW Hyd. Oil
Amoco Oil Co. (Standard Oil of Indiana) Rykon Rykon Oil #46 or Amoco AW 46
Bel-Ray Co., Inc. Raylene AW Hyd. Fluid #1
Benz Oil, Inc. Petraulic 46-LC
Brooks Technology Co. Versalene 610
Cato Oil & Grease AW/AL Hyd. Oil 10
Davis-Howland Oil Corp. DSL 46
Delta Resins & Refractories, Inc. Deltalene Med. Hyd. Oil #931
Conoco, Inc. Super Hyd. Oil 46
Darmex Industrial Corp. Darmex Hyd. 100/200
Exxon Co. USA Nuto 46
G & M Lubricants, Ltd. 330 Hydralube-Med.
Gard Oil Products, Inc. HydraGard AW 46
Union Oil Company of Unax AW 46
California Western Region
Union Oil Company of Unax AW 46
California Eastern Region
United Refining Company Emblem AW-200
World-Wide Lubricants, Ltd. Moly Hyd. AW 225
White & Bagley of Michigan Penn-Mar EP Hyd. Oil 225
Arthur C. Withrow Company H Med. AW Hyd. Oil
Georgia-Carolina Oil Co. G-C Hy-Press 15
International Refining & Manufacturing Co. Imco HL-21
The Inter-State Oil Co. Inter-State Resistal EP H-215
E.F. Houghton & Co. Hydro-Drive HP-200
Imperial Oil & Grease Molub-Alloy 602
Lubrication Analysis, Inc. Hyd. Oil AW 250
Lubriplate Div. Fiske Brothers Refining Co. HO-1
A. Margolis & Sons Corp. Silogram TIP 100-20-7
Metal Lubricants Co. Meltran AW-410
Mobil DTE 25
Phillips Petroleum Co. Magnus A Oil 46
Phoenix Petroleum Co., Ltd. KS 302
Parr, Inc. Hydroil AW 46
Pennzoil Co. AW Hyd. Oil 46
Shell Oil Co. Telius 46
Siegel Oil Co. Titan AW Hyd. Oil #21
Southwestern Petroleum Co. Swapco AW Hyd. Oil 704-10
Standard Oil Co. (Ohio) (Boron Oil Company) Industron 48
Texaco, Inc. Rando Oil HD 46
Tosco Corp. Western Region Azalea AW 46
Tech Lube Corp. TH10
Ultrachem, Inc. Chemlube 217

MODELS C, D, E, F, & G
AIR HYDRAULIC PUMP
Max. Pressure: See Pump Data Plate
Workstation Sound Pressure Level: 83 dB(A) at Rated Capacity
Definition: An air hydraulic pump delivers hydraulic fluid under pressure through the use of compressed air
as a power source.
SAFETY EXPLANATIONS
Two safety symbols are used to identify any action or lack of action that can cause personal injury. Your
reading and understanding of these safety symbols is very important.
DANGER - Danger is used only when your action or lack of action will cause serious human injury or
death.
WARNING - Warning is used to describe any action or lack of action where a serious injury can occur.
IMPORTANT - Important is used when action or lack of action can cause equipment failure, either immediate
or over a long period of time.
WARNING: It is the operator's responsibility to read and understand the following
safety statements,
• Only qualified operators should install, operate, adjust, maintain, clean, repair, or
transport this machinery.
• These components are designed for general use in normal environments. These
components are not specifically designed for lifting and moving people, agri-food
machinery, certain types of mobile machinery or special work environments such as:
explosive, flammable or corrosive. Only the user can decide the suitability of this
machinery in these conditions or extreme environments. Power Team will supply
information necessary to help make these decisions.
These instructions are intended for end-user application needs. Most problems with new equipment are caused by
improper operation or installation. Detailed service repair instructions or parts lists can be obtained from your nearest
Power Team facility (see listing).
Form No. 105001
52431
58356
203641-OTC
203641-PF
PA4 SERIES
PA6 SERIES
PA50 SERIES
PA60
PA64
Operating Instructions for:
Sheet No. 1 of 5
Rev. 3 Date: 30 April 2003
®

Operating Instructions, Form No. 105001, Back sheet 1 of 5
SAFETY PRECAUTIONS
WARNING
General Operation
•All WARNING statements must be carefully observed to help prevent personal injury.
•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 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 be altered or kink, twist, curl, crush, cut, or bend so tightly that the fluid
flow 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 hose and possibly cause 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. Hose deterioration due to corrosive materials can result in
personal injury. Never paint the couplers.
•Inspect machine for wear, damage, and correct function before each use. Do not use machinery that is
not in proper working order, but repair or replace it as necessary.
•Replace worn or damaged safety decals.
•Modification of a product requires written Power Team authorization.
•Use only components with the same pressure rating when assembling a system or machine.
Pump
•Do not exceed the hydraulic pressure rating noted on the pump data plate or tamper with the internal high
pressure relief valve. Creating pressure beyond the rated pressure can result in personal injury.
•Before replenishing the fluid 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.
Air Supply
•Shut off and disconnect the air supply when the pump is not in use or before breaking any connections in
the system.
PREPARATION & SET-UP
Air Supply Hook-Up
Remove the thread protector from the air inlet of the pump. Select and install the threaded fittings which are
compatible with your air supply fittings. The air supply should be 20 CFM (.57 M3/min.) and 100 PSI (7 BAR) at the
pump to obtain the rated hydraulic pressure. Air pressure should be regulated to a maximum of 140 PSI (9 BAR).
Secure your pump fitting to the air supply. See illustrations on following pages.
WARNING: If improperly used, pressurized equipment can be potentially hazardous. Therefore:
•Hydraulic connections must be securely fastened before building pressure in the system.
•Release all system pressure before loosening any hydraulic connection in the system.
Venting The Reservoir
To improve hydraulic fluid delivery and increase useable hydraulic fluid capacity,
remove shipping plug and install filler/vent cap before using the pump.
Next
Page

Operating Instructions Form No. 105001
Hydraulic Connections
Clean all the areas around the fluid ports of the pump and cylinder. Inspect all threads and fittings for signs of wear or
damage and replace as needed. Clean all hose ends, couplers and union ends. Remove the thread protectors from
the hydraulic fluid outlets. Connect the hose assembly to the hydraulic fluid outlet and couple the hose to the cylinder.
See illustrations below.
IMPORTANT: Seal all external pipe connections with a high-grade, nonhardening thread sealant. Teflon tape
may also be used to seal hydraulic connections, provided 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 fluid or cause jamming of
precision-fit parts.
For Hand/Foot Operated Pumps:
For Manual Valve Operated Pumps:
This pump is equipped with a two position, 3-way/4-way control valve for operating single- or double-acting hydraulic
cylinders and requires attaching the hoses in the following manner:
When using a single-acting cylinder, attach one end of a hose to port "A" of valve and the end of the hose to the
advance port "C" of the cylinder. Then install a pipe plug in valve port "B." If the hoses are frequently connected and
disconnected, quick couplers should be used to prevent wear and tear on the fittings.
When using a double-acting cylinder, attach one hose to port "A" of valve and the other end of the hose to the
advance port "C" of cylinder. Attach the second hose to valve port "B" and the other end of the hose to return port "D"
of cylinder.
Inline Air
Pressure Gauge
Air
Supply
Air Supply
Inline Hydraulic
High Pressure Gauge
Hydraulic
High Pressure
Gauge
Inline
Air Pressure
Gauge
Tee Adapter
Tee
Adapter
Union Adapter
(swivel connector)
Air
Hose
Hydraulic
Hose(s)
Hydraulic
Hose
Hydraulic Hose
Coupler
Coupler
Fitting
Air Hose
Coupler
Lubricator
Lubricator
Filter
Filter
Single-
Acting
Cylinder
Single-
Acting
Cylinder
Double-
Acting
Cylinder
Pipe
Plug
Sheet No. 2 of 5
Rev. 3 Date: 30 April 2003
Next
Page

Operating Instructions, Form No. 105001, Back sheet 2 of 5
For Remote Controlled Pumps:
For Tandem Pumps:
With Remote Valve -
With Pump Mounted Valve -
1. Connect the pump to a remote 3-
way/4-way valve.
2. Connect the fluid line from the fluid
pressure port on the manifold to the
pump pressure port on the valve.
3. Connect the fluid line from the fluid
return port on the manifold to the
pump return port on the valve.
4. Connect the cylinder(s) to the valve.
IMPORTANT: On all single pressure
line applications, plug one port on
the valve.
1. Connect the ports of the pump valve to
cylinder(s). When port "A" is pressurized,
port "B" becomes the return. When port "B" is
pressurized, port "A" becomes the return.
2. Place the valve into the "A" or "B" position in
order to pressurize the cylinder(s) or start the
pump.
Remote
Hand Control
Tee Adapter
Filter
Air
Hose
Hydraulic
Hose
Coupler Coupler
Union Adapter
(swivel connector)
To Hydraulic
Hose
And Cylinder
Inline Hydraulic
High Pressure Gauge
Filler/Vent
Cap
Tee
Adapter
Lubricator
Three-strand
Air Hose
Single-acting
Cylinder
Air
Filter
Male
Fitting
Inline Air
Pressure
Gauge
Air
Hose
Air Filter
Position A
Position A
Hold
Hold
Position B
Position B
Port B
Port A
Ports
Port B
Plugged
Pressure
Return
PA60
Pump
PA64
Pump
Valve and Manifold
Ports are 3/8" NPTF
Air Inlet
Port-1/4" NPTF
Air Inlet
Port-1/4" NPTF
Air Lubricator
Air
Pressure
Regulator
Oil Fill
and
Vent
Port
Position A - Pressure to
cylinder port A, cylinder
port B to tank.
Hold - Neutral, all ports
blocked.
Postion B - Pressure to
cylinder port B, cylinder
port A to tank.
B
A
B
A

Operating Instructions Form No. 105001
OPERATION
PICTOGRAM DEFINITIONS
Activating the pump with the pedal end marked with this pictogram,
the flow of fluid is directed out of the reservoir.
Activating the pump with the pedal end marked with this pictogram,
the flow of fluid is directed backto the reservoir.
Priming The Pump Unit
Under certain circumstances it may be necessary to prime the pump unit. To accomplish this, perform the following
procedure:
For Hand/Foot Operated Pumps:
1. Press the release end of the pedal while holding down the air intake
valve with a flathead screwdriver. The air intake valve is located directly
under the pedal in the area marked . The valve is depressed
simultaneously with the area of the pedal during priming.
2. Allow the pump to cycle approximately 15 seconds.
3. Remove the screwdriver, and press the end of the pedal once
more.
4. If the cylinder extends or pressure builds, the pump has been
successfully primed. If the pump does not respond, repeat the procedure,
jogging the air intake valve while holding the pedal in the position.
For Manual Valve Operated Pumps:
Disconnect the hose end at the advance port of the cylinder. Direct the hose
end into a suitable container or back into the pump reservoir. Shift the valve
to the ADVANCE position and depress the end of the foot pedal inscribed
with . Allow the pump to cycle until fluid begins to flow freely into the
container or reservoir. Reconnect the hose end to the cylinder advance port.
Shift the valve to the ADVANCE position and reactivate the pump. If the
cylinder extends or builds pressure, the pump has been successfully primed.
If not, refer to the Trouble-shooting Guide of these instructions.
For Remote Controlled Pumps:
Depress the AND buttons on the remote hand control simultaneously and allow the pump to cycle for
approximately fifteen seconds. Release both buttons and then depress the button once more. If the cylinder
extends or pressure builds, the pump has been successfully primed. If the pump does not respond repeat the
procedure. If pump still does not respond, tip pump upside down and repeat procedure.
For Tandem Pumps:
1. Connect the fluid line to the pressure port and keep the return port plugged. Place the other end of the fluid line in
the pump filler hole.
NOTE: If the fluid lines are connected to a remote valve, shift the valve into the
center position and plug both cylinder ports on the valve. This lets fluid circulate
through the valve and back to the pump reservoir; thereby allowing the pump to prime.
2. Attach air line with shut-off valve to the pump.
3. Open the air valve. Pump will begin to reciprocate, and fluid will advance
through the hose or fluid 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.
Air
Intake
Valve
Filler/
Vent
Cap
ADVANCE
(Pressure
to Port A)
RETRACT
(Pressure
to Port B)
Oil
Filler/
Vent
Cap
Sheet No. 3 of 5
Rev. 3 Date: 30 April 2003
Next
Page

Operating Instructions, Form No. 105001, Back sheet 3 of 5
Pump Operation
For Hand/Foot Operated Pumps:
1. To extend the cylinder, depress the pedal on the end marked .
2. To hold the cylinder in position, release the end of foot pedal marked with to deactivate the pump.
3. To retract the cylinder, depress the pedal on the end marked .
For Remote Controlled Pumps:
1. To extend the cylinder, depress the button on the remote hand control marked .
2. To hold the cylinder in position, release the button.
3. To retract the cylinder, depress the button on the remote hand control marked .
For Manual Valve Operated Pumps:
1. To extend the cylinder, shift the valve handle to the advance position and depress the end of the foot pedal
inscribed with to activate the pump.
2. To hold the cylinder in position, release the end of foot pedal inscribed with to deactivate the pump.
3. To retract the cylinder, shift the valve handle to the retract position and depress the end of the foot pedal inscribed
with to activate the pump.
For Pumps With Air Regulators:
1. Open the air shut-off valve (if so equipped) or connect the air quick coupler (if so equipped).
NOTE: under certain circumstances the pump may need to be primed before operation. Refer to the
method described in the section entitled "Priming the Pump Unit."
2. Slowly turn the air regulator control on unit clockwise to increase pressure, counterclockwise to decrease pressure.
As air is admitted to the pump unit, it will begin to deliver fluid to the system. Continue to slowly turn the air
regulator control clockwise until gauge reads the maximum hydraulic pressure rating as stated on the pumps data
plate. A maximum hydraulic pressure reading should be obtained if air pressure is approximately 100 PSI (7 BAR).
3. Cycle the system several times by manually shifting the 3-way/4-way valve (if so equipped) or the remote valve (if
so equipped). Set the air regulator to obtain the desired hydraulic pressure. When decreasing pressure, shift the
valve after each adjustment before measuring actual hydraulic pressure.
4. Shut off and disconnect air supply to the pump and shift pump valve (if so equipped) or remote valve (if so
equipped) two times to release all system pressure. Check fluid level with hydraulic system retracted. The pump is
now ready for operation.
NOTE: •The hydraulic pressure is increased or decreased by adjusting the air inlet pressure at the
regulator.
•On two stage pumps, the air pressure regulator that is mounted on the pump controls only the output
from the high pressure stage. The output of the low pressure stage of the pump is determined by the air line
pressure coming from the remote regulator. A remote regulator is required to control the air pressure from the air
line. The independent functioning of the low and high pressure stages of this pump can best be described as
follows. At the minimum air line pressure of 40 PSI (3 BAR), the low pressure stage of the pump will deliver 480
PSI (33 BAR) hydraulic pressure (with the pump regulator turned counterclockwise to prevent air pressure from
activating the high pressure stage of the pump.) At the minimum air line pressure of 40 PSI (3 BAR) the high
pressure stage of the pump will deliver 4,000 PSI (275 BAR) hydraulic pressure (with the pump regulator turned
clockwise to allow air pressure to reach the high pressure stage.) Always remember that the pump regulator must
be turned fully counterclockwise when the pump is used to produce 1,200 PSI (83 BAR) or less.

Operating Instructions Form No. 105001
PREVENTIVE MAINTENANCE
IMPORTANT: • Any repair or servicing that requires dismantling the pump must be performed in a dirt-free
environment by a qualified technician.
• Dispose of machine and fluids properly.
Lubrication
For Hand/Foot, Manual Valve, and Remote Control Operated Pumps:
If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends installing an
automatic air line oiler in the air inlet line as close to the pumping unit as possible. Set the unit to feed approximately
one drop of oil per minute into the system. Use SAE grade oil, 5W to 30W.
For Tandem Pumps:
These models have an integral air pressure regulator, air filter and lubricator. Set the lubricator to feed one drop of oil
per minute to the system. Use SAE grade oil, 5W to 30W. For servicing the air regulator, lubricator and filter system,
see the operating and service instructions provided.
Bleeding Air From The System
During the first moments of operation or after prolonged use, a significant amount of air may accumulate within the
hydraulic system. This entrapped air may 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 the cylinder) free of any load. The
cylinder must be at lower level than the pump to allow air to be released through the pump reservoir.
Inspecting The Hydraulic Fluid Level
Check the fluid level in the reservoir after every 10 hours of use. Drain and replenish the reservoir with Power Team
hydraulic fluid after every 300 hours of use approximately.
For pumps with a 105 cubic inch (1.7 l) reservoir capacity:
The fluid level should be 1/2 inch (12.7 mm) from the filler/vent cap with all cylinders retracted.
For pumps with a 2 gallon (7.6 l) reservoir capacity:
The fluid level should be 1-3/4 inch (44.5 mm) from the filler/vent cap with all cylinders retracted.
Draining And Flushing The Reservoir
IMPORTANT: Wipe the pump exterior completely clean before attempting this procedure!
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 and refill half full with clean hydraulic fluid. Rinse the filter clean.
3. Place the pump assembly back onto the reservoir, and secure with two of the machine screws assembled in
opposite corners of the housing.
4. Run the unit for several minutes. Use the same method described in the section titled "Priming the Pump Unit."
5. Drain and clean the reservoir once more.
6. Refill the reservoir with Power Team hydraulic fluid and replace the pump assembly (with gasket) on the reservoir
and install the screws. Torque the screws as follows: For 105 cubic inch (1.7 l) reservoirs, torque to 25 to 30 inch
pounds (2.8 to 3.4 N•m); for 2 gallon (7.6 l) reservoirs, torque to 35 to 45 inch pounds (4.0 to 5.0 N•m)
IMPORTANT: Drain and clean the other hydraulic system components (hoses, cylinders, etc.) before
reconnecting them to the pump. This will prevent contaminated fluid from entering the pump again.
Sheet No. 4 of 5
Rev. 3 Date: 30 April 2003
Next
Page

Operating Instructions, Form No. 105001, Back sheet 4 of 5
Refilling The Reservoir
If additional fluid must be added to the reservoir, use only Power Team hydraulic fluid (215 SSU @ 100° F [38° C]).
Clean the entire area around the filler plug before adding fluid to the reservoir. Remove the filler plug, and insert a
clean funnel with filter. The cylinder must be fully retracted and the air supply disconnected when adding the fluid to
the reservoir.
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.
A routine should be established to keep the pump as free from dirt as possible. All unused couplers must be sealed
with thread protectors. All hose connections must be free of grit and grime. Any equipment hooked up to the pump
should also be kept clean. Use only Power Team hydraulic fluid in this unit and change as recommended (every 300
hours).
ACCESSORIES
Gauges and accessories may not be included with the pump. However, a hydraulic gauge is strongly recommended
whenever the pump is used!
WARNING: • The gauge must be of the proper rating for the pressure used!
• Use only Power Team approved accessories, hydraulic fluid, and repair parts!
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 clamp the hose to the male fitting.
Installing An In-line Hydraulic Pressure Gauge
1. Remove the thread protector from the hydraulic outlet port and inspect the threads and fittings for signs of wear.
2. Install a tee adapter, with gauge, between the hose coupling and the pump hydraulic outlet port.
3. Tighten all connections securely! DO NOT OVERTIGHTEN HOSE CONNECTIONS.
Fire-Resistant Hydraulic Fluid
Flame Out 220™ fire-resistant hydraulic fluid is compatible with all Power Team hydraulic equipment. The use of this
fluid does not require the changing of seals in any Power Team pump or cylinder and is available through your local
Power Team distributor.

Operating Instructions Form No. 105001
OPERATOR TROUBLESHOOTING GUIDE
If this guide does not resolve your pump problem,
contact an authorized hydraulic service center or a company headquarters listed on back sheet 5 of 5.
Pump will continue to run slowly
even after desired pressure is
reached.
Excess oil spray from muffler.
1. Output pressure equal to or
higher than relief valve setting.
2. Defective 3-way/4-way valve or
other components leaking.
1. Air lubricator is set too rich (if so
equipped).
1. Normal operation.
2. Repair or replace.
1. Set at one drop per minute.
Pump reciprocates but no fluid
delivery (cylinder will not extend)
Low fluid delivery (cylinder
extends slowly)
Pump will not build to maximum
pressure (no visible leakage)
Pump builds pressure but will not
hold system pressure
1. Low fluid level.
2. Pump not primed.
3. Fluid intake filter contaminated.
1. Inadequate air supply
a. Check air input supply.
b. Contamination, check air side
of pump (plugged air inlet
screen).
2. Hydraulic failure
a. Check the fluid inlet filter for
contamination.
b. Air in hydraulic system.
1. Check the air supply.
2. Pressure regulator improperly
adjusted (if so equipped).
1. Check the hydraulic connections
and other system components
for leakage, including 3 way/4
way valve (if so equipped).
1. Add fluid as instructed in
Preventive Maintenance section.
2. Prime pump as instructed in
Operation section.
3. Remove reservoir and clean
intake filter and reinstall.
1. a. Should be 20 CFM
(.57 M3/min.) minimum.
b. Clean and reassemble.
2. a. Remove reservoir and clean
intake filter and reinstall.
b. Bleed the system as
described in the Preventive
Maintenance section.
1. 100 PSI (7 BAR) is required to
obtain maximum pressure.
2. Adjust according to instructions
in Operation section.
1. Refit or repair as needed.
PROBLEM CAUSE SOLUTION
Sheet No. 5 of 5
Rev. 3 Date: 30 April 2003

Operating Instructions, Form No. 105001, Back sheet 5 of 5
POWER TEAM FACILITIES
A
USTRALIA
28 Clayton Road
Clayton North
Victoria
A
ustralia
Tel: [phone]
F
AX: 61 (3) 95628080
E
-mail:
[email protected]
EUROPE
Klarenanstelerweg 5 D
6468 EP Kerkrade
N
etherlands
Tel: [phone]
F
AX: 31 (45) 5678878
E
-mail: [email protected]
FAR
EAST
19 Joo Koon Road
Singapore 628978
Singapore
Tel: [phone]
FAX: [phone]
E-mail:
[email protected]
JAPAN
2-5-53 Minowacho
Kohoku-Ku, Yokohama,
Kanagawen 223-0051
Japan
Tel: [phone]
FAX: [phone]
KOREA
So-Anyang P.O. Box 50
Kyounggi-Do
Korea 430-600
Tel: [phone]
FAX: [phone]
E-mail: [email protected]
UNITED
STATES
SPX Corporation-Fluid Powe
r
5885 11th Street
Rockford, IL 61109-3699
USA
Telephone: [phone]
FAX: [phone]
Cust. Service/Order Entry
Tel: [phone]
FAX: [phone]
E-mail:
[e-mail]
Technical Services
Tel: [phone]
FAX: [phone]
For more information, Internet address: http://www.powerteam.com (or) http://www.hytec.com
CERTIFIED
MEXICO
Gustavo Baz 15
Col. Echegaray C.P. 53310
Naucalpan, Edo. de Mexico
Tel: [phone]
FAX: [phone]
E-mail: [email protected]
Mexico
®

Klarenanstelerweg 5 D
6468 EP Kerkrade
Netherlands
Telephone: [phone]
Fax: [phone]
EC Declaration of Incorporation
as defined by
European Communities Directive 89/392/EEC, Annex II(B)
MANUFACTURER’S NAME:
MANUFACTURER’S ADDRESS: 5885 11th Street Telephone: [phone]
Rockford, Illinois 61109 Fax: [phone]
USA
TYPE OF EQUIPMENT: RECIPROCATING AIR PISTON HYDRAULIC PUMP.
ORDER NUMBER OR PART NUMBER: PA4 Series, PA6 Series, PA50 Series, PA60, PA64, 52431,
58356, 203641-OTC, 203641-PF.
APPLICATION OF EC COUNCIL DIRECTIVE(S): 89/392/EEC as amended by 91/368/EEC, 93/44/EEC,
and 93/68/EEC.
STANDARD(S) TO WHICH CONFORMITY IS DECLARED: EN292-1, and EN292-2.
I, the undersigned, hereby declare that the equipment specified above conforms to the above
European Communities Directive(s) and Standard(s). This product is not to be put into
service until the machine has been declared in conformity with the provisions of the
European Communities Directive(s).
PLACE: Owatonna, Minnesota USA ________________________________________
(Signature)
DATE: 1 JAN 1995 Michael S. O’Brien
(date / month / year) Director Quality / Technical Services
Appendix to 105001
®
®

PA6M-WCI
PA6M-1
PA6M-1-CAR
PA6M-1-STEL
PA6M-2
PA6N
PA6-SS
PA6V
MODEL F
AIR HYDRAULIC PUMP
This section covers these following pumps:
1
234
6
7
8
9
10
11
12 13
4
6
7
Two gallon reservoir.
Form No. 101652
PA6 Series
Parts List for:
Tech. Services: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
SPX Corporation-Fluid Power
5885 11th Street
Rockford, IL 61109-3699 USA
Phone: [phone]
Fax: [phone]
Internet Address:
http://www.powerteam.com
IMT200
PA6
PA6-AMH
PA6-AW
PA6-AERO
PA6-AUTO
PA6-BEST
PA6-CB
PA6-CMS
PA6-HUNT
PA6-HUTH
PA6-HYDRA
PA6-KJ
PA6-LUAM
PA6-LUKAS
PA6-NT
PA6-PFAFF
PA6-PRO
PA6-SEAL
PA6-TAL
PA6-2
PA6-2-CM
PA6-2E
PA6-2N
PA6-2V
PA6-2-FS-LR
PA6A
PA6AM
PA6AUTO ROBOT
PA6E
PA6FACOM
PA6M
PA6M-CAR
PA6M-CHIEF
PA6M-DE-STA-CO
PA6M-DK
PA6M-PF
PA6M-PFAFF
PA6M-PL
PA6M-ROM
1U-7545
203641-PF
58430
70130-Y12
(PA6M-DES-50)
910301
910303
Litho in USA
Sheet No. 1 of 6
Rev. 35 Date: 29 Mar. 2001
- More models are listed in Parts List 101950.-
Note: These views may not be exact
representations of your pump due to
the variation of pumps listed, but all
parts have been accounted for and are
in this parts list.
To Parts
List