Product Manual

– 2 –
General Safety Information
DISCONNECT POWER AND RELEASE ALL SYSTEM PRESSURE
BEFORE SERVICING THIS EQUIPMENT.
1. Follow all local electrical and safety codes, as well as the
National Electrical Code (NEC) and the Occupational Safety
and Health Act (OSHA).
2. Never exceed the maximum operating speed or pres-
sure.
3. When using AC motors, ground the motor properly by wir-
ing with a grounded, metal-clad raceway system, using a
separate ground wire connected to bare metal of the motor
frame, or other suitable means.
4. Guard all moving parts.
5. Drain all liquids from the system before servicing.
6. Check hoses and connections for security before each use.
7. Periodically check the pump and system components.
8. Provide a means of pressure relief for pumps whose dis-
charge line can be shut off or obstructed.
9. Wear safety glasses at all times when working with pumps.
10. Keep work area clean, uncluttered and properly lighted; re-
place all unused tools and equipment.
11. Keep visitors at a safe distance from the work area.
12. Make the workshop child-proof with padlocks, master
switches, and by removing starter keys.
13. Do not operate an engine in an enclosed area.
14. Do not spill gasoline on hot engine surfaces.
15. Store gasoline only in an approved container.
16. Keep dirty and oily cleaning rags in a tightly closed metal
container.
17. Check engine oil level before operating the engine.
18. Familiarize yourself with the controls and emergency shut-
down procedures.
19. Never operate the equipment when you are fatigued.
20. All system components pressure ratings should be greater
than maximum system pressure.
21. Guard all moving parts.
22. Replace all guards when servicing is complete.
Assembly
Our hydraulic gear pumps are packaged fully assembled and
require no further assembly before installation.
MOUNTING PUMP ASSEMBLY TO FLEXIBLE COUPLING DRIVE
SYSTEMS
1. Assemble the flexible coupling half to the pump shaft.
CAUTION
Do not force coupling half onto drive shaft; it must be a slip
fit for adjustment and to avoid internal damage.
2. Tighten the setscrew and insert rubber spider in coupling
half.
3. Assemble the other coupling half loosely to the engine/mo-
tor shaft.
4. Bolt the pump loosely to the SAE type four bolt mounting
pump adapter as furnished by the equipment manufactur-
er.
5. Align the shafts to make sure they are on center with each
other.
6. Tighten the mounting bolts.
7. Mate the coupling halves together, allowing 1/16” gap be-
tween halves.
8. Check the alignment again.
IMPORTANT: THE GAP IN THE COUPLING HALVES IS TO PREVENT
END LOADING OF THE PUMP DRIVE.
9. Tighten the setscrew in the mating coupling half.
10. Remove plastic shipping plugs from the inlet and outlet
ports.
11. Squirt clean oil into pump for pre-lubrication and start-up.
12. Turn shaft coupling slowly to ensure proper shaft align-
ment and coupling installation.
13. Connect inlet and outlet lines with an SAE straight thread
fitting and tighten.
WARNING!
THREADS ARE SAE, NOT NPTF. USING INCORRECT FIT
TINGS COULD DAMAGE THE HYDRAULIC COMPONENT OR
CAUSE PERSONAL INJURY.
NOTE: Do not use teflon tape; the O-ring provides the seal and
teflon tape is not required.
14. To avoid pump cavitation, inlet hose diameter should be as
large as possible and inlet hose length should be as short as
possible.
NOTE: Cavitation is recognized by excessive noise and foaming
of hydraulic fluid.
CAUTION
Never run assembly without hydraulic oil.
15. At initial start-up, turn the drive shaft several times by hand
to prime.
16. Bleed all air from the system to prevent erratic operation.
17. After several cycles, check the reservoir oil level and refill as
necessary.
NOTE: Be sure adequate cooling for the hydraulic oil is pro-
vided. Excessive temperatures can cause damage
WARNING!
FORM 2690164 MODELS 10530-10535, 10597-10611
– 3 –
to oil and/or system components. Cooling of oil is especially
important on systems where continuous operation is re-
quired. Cooling requirements must be based on: duty cycle,
pressure/flow, ambient temperatures, oil and component
maximum temperature specifications, and reservoir capac-
ity. Systems operating at excessively high temperatures can
be hazardous and may cause property damage and/or per-
sonal injury.
NOTE: When the ambient temperature is below 32°F, allow the
pump to operate unloaded for several minutes to warm the oil
in the reservoir.
Operation
CAUTION
Never run pump without oil in the system.
1. At initial start-up, start and stop motor several times to al-
low the pump to prime before full flow begins.
2. Bleed all air from the hydraulic system to prevent erratic
system operation.
3. Recheck reservoir oil level after a few cycles of the hydraulic
system and refill if necessary.
NOTE: When the ambient temperature is below 32°F, allow the
pump to operate unloaded for several minutes to warm the oil
in the reservoir.
NOTE: Be sure adequate cooling for the hydraulic oil is pro-
vided. Excessive temperatures can cause damage to oil and/
or system components. Cooling of oil is especially important
on systems where continuous operation is required. Cooling
requirements are based upon: duty cycle, pressure/flow, ambi-
ent temperatures, oil and component maximum temperature
ratings, and reservoir surface area. Systems operating at exces-
sively high temperatures can be hazardous and may cause pre-
mature damage and/or personal injury.
Maintenance
CAUTION
Use a clean funnel fitted with a fine mesh wire screen. Do
not use a cloth strainer. Most premature pump failures can
be attributed to dirt or foreign material entering the hy-
draulic system during filling, or lack of cleaning before fill-
ing.
1. Keep reservoir filled with hydraulic fluid.
2. Make frequent inspections of hydraulic fluid and change if
contaminated.
3. Keep the unit clean of dirt and foreign materials.
4. Keep electrical connections clean and all electrical cabi-
nets closed.
CAUTION
To perform the dual function of lubrication and power
transmission, we recommend the use of a good quality
automatic transmission fluid.
Troubleshooting Chart
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
1. Check system relief valve for proper
setting with pressure gauge in outlet line
2. Let oil cool below 140°F
3. Replace worn parts or pump
4. Replace or repair cylinder
1. Check wiring
2. Reset circuit breaker
3. Use heavier gauge wire
4. Replace pump
1. Check oil level, refill
2. Add oil as needed
3. Clean suction strainer
4. Replace or repair cylinder
5. Clean reservoir breather and reinstall
1. Add oil as needed
2. Bleed air from highest fitting in system by loos-
ening fitting very slightly and operating unit
until bubbling of air stops, then tighten
3. Clean suction strainer or inlet filter
Pump does not develop full
pressure
Pump won’t start
Will not pump oil (Motor runs
but cylinder does not move,
or moves slowly)
Pump motor unit is noisy
1. System relief valve set too low, or leaking
2. Oil temp is too high
3. Pump is worn out
4. Double acting cylinder piston seals are cut or
worn out
1. Loose connection
2. Circuit breaker tripped
3. Voltage drop
4. Seized pump
1. No oil in reservoir
2. Oil level low
3. Suction strainer is clogged
4. Double acting cylinder piston seals are cut or
worn out
5. Reservoir breather is dirty or clogged
1. Low oil level
2. Air in system
3. Suction strainer or inlet filter is clogged
FORM 2690164 MODELS 10530-10535, 10597-10611
2690164 W600-900-1500 Series ENG_rev090111.indd 2-3 9/16/11 8:01 AM
– 2 –
General Safety Information
DISCONNECT POWER AND RELEASE ALL SYSTEM PRESSURE
BEFORE SERVICING THIS EQUIPMENT.
1. Follow all local electrical and safety codes, as well as the
National Electrical Code (NEC) and the Occupational Safety
and Health Act (OSHA).
2. Never exceed the maximum operating speed or pres-
sure.
3. When using AC motors, ground the motor properly by wir-
ing with a grounded, metal-clad raceway system, using a
separate ground wire connected to bare metal of the motor
frame, or other suitable means.
4. Guard all moving parts.
5. Drain all liquids from the system before servicing.
6. Check hoses and connections for security before each use.
7. Periodically check the pump and system components.
8. Provide a means of pressure relief for pumps whose dis-
charge line can be shut off or obstructed.
9. Wear safety glasses at all times when working with pumps.
10. Keep work area clean, uncluttered and properly lighted; re-
place all unused tools and equipment.
11. Keep visitors at a safe distance from the work area.
12. Make the workshop child-proof with padlocks, master
switches, and by removing starter keys.
13. Do not operate an engine in an enclosed area.
14. Do not spill gasoline on hot engine surfaces.
15. Store gasoline only in an approved container.
16. Keep dirty and oily cleaning rags in a tightly closed metal
container.
17. Check engine oil level before operating the engine.
18. Familiarize yourself with the controls and emergency shut-
down procedures.
19. Never operate the equipment when you are fatigued.
20. All system components pressure ratings should be greater
than maximum system pressure.
21. Guard all moving parts.
22. Replace all guards when servicing is complete.
Assembly
Our hydraulic gear pumps are packaged fully assembled and
require no further assembly before installation.
MOUNTING PUMP ASSEMBLY TO FLEXIBLE COUPLING DRIVE
SYSTEMS
1. Assemble the flexible coupling half to the pump shaft.
CAUTION
Do not force coupling half onto drive shaft; it must be a slip
fit for adjustment and to avoid internal damage.
2. Tighten the setscrew and insert rubber spider in coupling
half.
3. Assemble the other coupling half loosely to the engine/mo-
tor shaft.
4. Bolt the pump loosely to the SAE type four bolt mounting
pump adapter as furnished by the equipment manufactur-
er.
5. Align the shafts to make sure they are on center with each
other.
6. Tighten the mounting bolts.
7. Mate the coupling halves together, allowing 1/16” gap be-
tween halves.
8. Check the alignment again.
IMPORTANT: THE GAP IN THE COUPLING HALVES IS TO PREVENT
END LOADING OF THE PUMP DRIVE.
9. Tighten the setscrew in the mating coupling half.
10. Remove plastic shipping plugs from the inlet and outlet
ports.
11. Squirt clean oil into pump for pre-lubrication and start-up.
12. Turn shaft coupling slowly to ensure proper shaft align-
ment and coupling installation.
13. Connect inlet and outlet lines with an SAE straight thread
fitting and tighten.
WARNING!
THREADS ARE SAE, NOT NPTF. USING INCORRECT FIT
TINGS COULD DAMAGE THE HYDRAULIC COMPONENT OR
CAUSE PERSONAL INJURY.
NOTE: Do not use teflon tape; the O-ring provides the seal and
teflon tape is not required.
14. To avoid pump cavitation, inlet hose diameter should be as
large as possible and inlet hose length should be as short as
possible.
NOTE: Cavitation is recognized by excessive noise and foaming
of hydraulic fluid.
CAUTION
Never run assembly without hydraulic oil.
15. At initial start-up, turn the drive shaft several times by hand
to prime.
16. Bleed all air from the system to prevent erratic operation.
17. After several cycles, check the reservoir oil level and refill as
necessary.
NOTE: Be sure adequate cooling for the hydraulic oil is pro-
vided. Excessive temperatures can cause damage
WARNING!
FORM 2690164 MODELS 10530-10535, 10597-10611
– 3 –
to oil and/or system components. Cooling of oil is especially
important on systems where continuous operation is re-
quired. Cooling requirements must be based on: duty cycle,
pressure/flow, ambient temperatures, oil and component
maximum temperature specifications, and reservoir capac-
ity. Systems operating at excessively high temperatures can
be hazardous and may cause property damage and/or per-
sonal injury.
NOTE: When the ambient temperature is below 32°F, allow the
pump to operate unloaded for several minutes to warm the oil
in the reservoir.
Operation
CAUTION
Never run pump without oil in the system.
1. At initial start-up, start and stop motor several times to al-
low the pump to prime before full flow begins.
2. Bleed all air from the hydraulic system to prevent erratic
system operation.
3. Recheck reservoir oil level after a few cycles of the hydraulic
system and refill if necessary.
NOTE: When the ambient temperature is below 32°F, allow the
pump to operate unloaded for several minutes to warm the oil
in the reservoir.
NOTE: Be sure adequate cooling for the hydraulic oil is pro-
vided. Excessive temperatures can cause damage to oil and/
or system components. Cooling of oil is especially important
on systems where continuous operation is required. Cooling
requirements are based upon: duty cycle, pressure/flow, ambi-
ent temperatures, oil and component maximum temperature
ratings, and reservoir surface area. Systems operating at exces-
sively high temperatures can be hazardous and may cause pre-
mature damage and/or personal injury.
Maintenance
CAUTION
Use a clean funnel fitted with a fine mesh wire screen. Do
not use a cloth strainer. Most premature pump failures can
be attributed to dirt or foreign material entering the hy-
draulic system during filling, or lack of cleaning before fill-
ing.
1. Keep reservoir filled with hydraulic fluid.
2. Make frequent inspections of hydraulic fluid and change if
contaminated.
3. Keep the unit clean of dirt and foreign materials.
4. Keep electrical connections clean and all electrical cabi-
nets closed.
CAUTION
To perform the dual function of lubrication and power
transmission, we recommend the use of a good quality
automatic transmission fluid.
Troubleshooting Chart
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
1. Check system relief valve for proper
setting with pressure gauge in outlet line
2. Let oil cool below 140°F
3. Replace worn parts or pump
4. Replace or repair cylinder
1. Check wiring
2. Reset circuit breaker
3. Use heavier gauge wire
4. Replace pump
1. Check oil level, refill
2. Add oil as needed
3. Clean suction strainer
4. Replace or repair cylinder
5. Clean reservoir breather and reinstall
1. Add oil as needed
2. Bleed air from highest fitting in system by loos-
ening fitting very slightly and operating unit
until bubbling of air stops, then tighten
3. Clean suction strainer or inlet filter
Pump does not develop full
pressure
Pump won’t start
Will not pump oil (Motor runs
but cylinder does not move,
or moves slowly)
Pump motor unit is noisy
1. System relief valve set too low, or leaking
2. Oil temp is too high
3. Pump is worn out
4. Double acting cylinder piston seals are cut or
worn out
1. Loose connection
2. Circuit breaker tripped
3. Voltage drop
4. Seized pump
1. No oil in reservoir
2. Oil level low
3. Suction strainer is clogged
4. Double acting cylinder piston seals are cut or
worn out
5. Reservoir breather is dirty or clogged
1. Low oil level
2. Air in system
3. Suction strainer or inlet filter is clogged
FORM 2690164 MODELS 10530-10535, 10597-10611
2690164 W600-900-1500 Series ENG_rev090111.indd 2-3 9/16/11 8:01 AM