General Troubleshooting

The following problems and solutions are intended for the benefit of knowledgeable and suitably capable technicians and maintenance personnel.
DO NOT MAKE REPAIRS WITHOUT CHECKING WITH THE MANUFACTURER. Always disconnect electrical power when making repairs.

For your safety and for proper installation of product and operation/handling of the hydraulic swaging equipment provided, refer to the manual provided with the equipment.

TROUBLESHOOTING GUIDE FOR PE400 PUMP

  • PUMP MOTOR WILL NOT RUN


      1. A.  No power reaching pump.
            Check all three phases are being supplied to starter contacts. Check fuses or circuit breaker.
      2. B.  Wrong power supplied to pump.
            Verify that power supplied to pump matches requirement.
      3. C.  Previous overload.
            Press reset button on overload relay inside control box. (CARE! Electrical Hazard)

    PUMP MOTOR WILL RUN BUT SHUTS OFF FREQUENTLY


      1. A. Wrong voltage, causing overheating.
            Check with voltmeter.
      2. B. Wrong overload relay amperage setting.
            Match overload relay amperage setting to motor FLA rating.
      3. C. Excessively long power cord.
            Shorten cord or increase wire gauge to minimize voltage drop.
      4. D. Phase imbalance, missing phase; pump sounds noisy.
            Check with voltmeter.

    PUMP MOTOR WILL RUN BUT NOTHING HAPPENS WHEN FOOT PEDALS ARE DEPRESSED


      1. A. Motor rotation is incorrect.
            Verify correct motor rotation. Swap two power phases if incorrect.
      2. B.  Control cord has broken/damaged wire or bad connection at foot pedal or control box.
      3. C.  Broken hydraulic line inside reservoir.
            Replace if necessary.
      4. D.  Broken shear pins between motor and pump drive shaft.
            Test by shutting pump down and timing how long motor spins. Normal is less than 10 seconds.
      5. E.  No or low fluid level in tank.
            Make sure fluid level is filled above sight glass in tank. (It may be necessary to prime the pump if fluid has been changed.)

    PUMP RUNS BUT PERFORMANCE IS SLOW


      1. A.  Low voltage.
            Check power source, voltage at the pump while under load; power cord connections.
      2. B.  Hydraulic leak.
            Check line inside reservoir between pump and control valve; check for any other external or internal leaks.
      3. C. Broken seal and/or spring in control valve.

    SYSTEM OPERATES BUT DOES NOT REACH 10,000 PSI


      1. A.  Check pressure gauge for damage.
            Use in-line test gauge to verify. Replace gauge if faulty.
      2. B.  Pressure switch damage.
            Replace if necessary.
      3. C.  Pressure switch set too low.
            Adjust as necessary to increase pressure.
      4. D.  Hydraulic leak.
            Check check hose inside reservoir.
      5. E.  Pump safety valve
            Make sure pump safety valve is not blowing off prematurely. Adjust as required.

    DIES STICKING


      1. A.  Use liquid soap on couplers more frequently. Do not use a petroleum-based lubricant!
            (Note: Brand new dies tend to stick more at first until they break-in.)
      2. B. System pressure too high.
            Set between 10,000 and 10,600 PSI.

    COUPLER or BUTTONHEAD DOES NOT APPEAR FULLY SWAGED


      1. A.  Low pressure.
            Verify pressure using steps outlined in "SYSTEM OPERATES BUT DOES NOT REACH 10,000 PSI".
      2. B.  Die wear
            Inspect dies for wear using a die profile gauge. Replace dies if necessary.