Symptoms Possible Cause Correction Special Notes Add fluid to reservoir when Low fluid level cylinder is fully retracted Before running power unit Reservoir Overflows insure all air bubbles have Remove reservoir & tighten or When Lowering dissipated to prevent further Loose Inlet replace inlet tube on pump aeration of fluid Consult equipment Reservoir too small for manufacturer for correct hydraulic system reservoir size Symptoms Possible Cause Correction Special Notes Dead or Low Load test battery Charge or replace battery Ground battery directly to DC Use jumper cables to jump Poor Ground motor ground only Replace valve if stem is Check for bent valve stem bent Check cross drilled holes between o-rings of valve for Replace valve if spool is not debris shifting Directional valve not (for most directional valves Ensure valve is shifting completely shifting** the spool will cover half of (use dipstick push on valve the cross drilled holes when spool to shift valve. Look valve is at its at rest or through cross drilled holes activated positions) between o-rings insuring valve is shifting) Unit Struggles to Lift Load Use dipstick on power unit Remove load holding valve. to manually shift the valve. Inspect screen & valve for This is accomplished by Debris in screen of load debris. (DO NOT REMOVE inserting the dipstick in the holding valve VALVE FOR INSPECTION IF nose of the valve and SYSTEM IS UNDER applying pressure. Replace PRESSURE) valve if it doesn't shift. If motor doesn't run at a higher RPM after bypassing Rust in Motor Bypass Start Solenoid start solenoid, remove rear cover of motor for quick inspection. Packing on piston of cylinder Have cylinder tested by Worn seals in cylinder could be bad and be wedged certified technician against bore of cylinder.
Symptoms Possible Cause Correction Special Notes Reservoir Overflows When Lowering Low fluid level Add fluid to reservoir when cylinder is fully retracted Before running power unit insure all air bubbles have dissipated to prevent further aeration of fluid Loose Inlet Remove reservoir & tighten or replace inlet tube on pump Reservoir too small for hydraulic system Consult equipment manufacturer for correct reservoir size Symptoms Possible Cause Correction Special Notes Unit Struggles to Lift Load Dead or Low Load test battery Charge or replace battery Poor Ground Ground battery directly to DC motor Use jumper cables to jump ground only Directional valve not completely shifting** Check for bent valve stem Replace valve if stem is bent Check cross drilled holes between o-rings of valve for debris Replace valve if spool is not shifting (for most directional valves the spool will cover half of the cross drilled holes when valve is at its at rest or activated positions) Ensure valve is shifting (use dipstick push on valve spool to shift valve. Look through cross drilled holes between o-rings insuring valve is shifting) Debris in screen of load holding valve Remove load holding valve. Inspect screen & valve for debris. (DO NOT REMOVE VALVE FOR INSPECTION IF SYSTEM IS UNDER PRESSURE) Use dipstick on power unit to manually shift the valve. This is accomplished by inserting the dipstick in the nose of the valve and applying pressure. Replace valve if it doesn't shift. Rust in Motor Bypass Start Solenoid If motor doesn't run at a higher RPM after bypassing start solenoid, remove rear cover of motor for quick inspection. Worn seals in cylinder Packing on piston of cylinder could be bad and be wedged against bore of cylinder. Have cylinder tested by certified technician
Power-Pack-Master-Owners-Manual-Rev-E1.docx