USER MANUAL Electric pump
Contents
1. J Vall WIRELESS REMOTE CON PROD 8 7 2 PRESSURE GAUGE READING 8 7 3 SETTING OF TORQUE VALUE BOLTLOAD csecccccccececccccsceccccuscecccccecececeuuceccccuucececsaucececsaaseseeeaees 9 8 USE OF THE Q 10 8 1 ADJUST THE TORQUE ccccccseecccceccccccccccscccceseccccaucceccauccecuscscccuucececuccecuauscecuscececuuceccuueccecucecceaeeecuausss 10 8 2 SETTING THE ROTATION OF THE WRENCH sscccccccsececccccceecceccuseeeccccuucececccauceccccuauceccecsuececceuaacececens 10 9 INSPECTION AND CALIBRATION 11 9 1 INSPECTION BEFORE EACH USE cscccccsseccccsecccccecccccucccccscscccuceececaccccususcccuucececuuceccuueseecuucseccaucceeuaeess 11 BON L uuu uuu ins aw ante 11 10 MAINTENANTCE 12 10 1 MINOR MAINTENANCE c ccseccccceccccccccccccecccccececcuseccecaeececcuccccusececcucecceaccecuecececauccecusessecaneeeeaes 12 10 2 MAINTENANCE AT HY TORC ccccccsecccccsccccccccccccccccccecccccuccccuscccccuecseceececeuscscecauccecusessecaeceeeaes 12 11 MALFUNCTIONS AND SOLUTIONS2. 10 1 Minor maintenance Hydraulic oil Change the oil completely after 40 operation hours or at least once a year Use only High grade oil ISO VG 46 or 32 Quick couplers hoses Clean dirty or rigid couplers or replace them 10 2 Maintenance at HYTORC Torque wrench Depending of the usage but at least once a year disassemble the tool completely Clean inspect change small springs and lubricate again Inspection on capacity at 100 200 300 and 700 BAR Pump unit Calibrate pump pressure gauge once a year and fill glycerine level Motor electrical and air driven The rotor axle and bearings clean and lubricate once a year Clean the control valves the pump on regular functioning determine the output capacity of the pump and measure the constant pressure Clean and replace the filters Tuning of the needed gear change points Determine the work temperature the constant pressure the volume measurement the power and air decrease etc Replace the oil 11 MALFUNCTIONS AND SOLUTIONS 11 1 Torque wrench The tool does not operate anymore gt check if all couplers both on tool as well as on pump side are tightened properly The coupling nut of the female coupler has to be tightened completely to the collar of the male coupler 11 2 Pumps pump pressure at a fixed adjustment does not repeat accurately gt pump pressure adjusting valve is dirty or damaged contact HYTORC Ne
3. Important To change the pressure screw back the wing nut to a lower than the desired pressure After this follow the description as mentioned above to adjust the pressure Right turn is higher pressure left turn is lower pression 8 USE OF THE WRENCHES 8 1 Adjust the torque Every tool comes with its own pressure torque table Search the desired torque in the right column Nm kgm or ft lbs and read the associated pressure Bar of PSI DRUK AANHAALMOMENT IN DEUK PRESSURE PRESSURE 1 09 23 219 1 200 187 28 262 1 00 231 42 98 Fig 10 torque table 8 2 Setting the rotation direction Changing the rotation direction is different for each wrench and 15 independent of the pump unit Read the manual that is delivered with the wrench 10 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI Tel 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 HYTGRC 9 INSPECTION AND CALIBRATION The electrical pomp units are equipped with termal protection The motor and oil temperature are monitored When the value for the maximum temperature is exceeded the pump shuts down and a red light appears or the green light goes out 9 1 Inspection before each use e Check the oil level in the reservoir e Check the hoses for
4. USER MANUAL Electric pump 58 lt aN OE 2 4 HYTGRC INDEX 1 WELCOME AT HYTOR C auwwwwwumunananananananananananananaanananananana 3 2 GENERAL INFORMATIOQONN umuumuuuununananananananananananana 3 SAFETY INSTRUCTIONS 3 4 CONNECTING TO THE HYDRAULIC PUMP UNIT 5 5 CONNECTING A VOLTAGE SOURCE 5 5 1 VOLTAGE AND THE TYPE OF CABLE uuu u uu uuu ua 5 5 2 ROTATION DIRECTION OF THE 400 VOLTAGE PUMPS ccsecccccseccccceccccccccccuccccccucceccecccecueceeeaes 5 6 CONNECTING THE HYDRAULIC HOSES 6 DA HOSE COUPLER u A 6 6 2 PRESSURE RELEASE OF THE HOSES BEFORE DISASSEMBLE sssccccccseecccccccececcccaccccccccacccccceeaeeececeaees 7 7 OPERATION OF THE PUMP 7 7 1 REMOTE CONTROL FUNCTIONS 2
5. uwuwuwuuuunnnn n 12 11 1 TORQUE WPEEN0 12 11 2 12 11 2 1 PVC UG PUI VIE a 13 2 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGIE 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 HYTGRC 1 WELCOME AT HYTORC Thank you for buying HYTORC equipment This user manual and safety instruction is designed to provide you with the basic knowledge required to operate and maintain your new HYTORC equipment Please read this manual carefully and follow the instructions provided If you still have any questions regarding HYTORC bolting equipment please do not hesitate and call us at 31 0 24 3660 660 or contact at info hytorc nl You also find more information on our website www hyiorc nl 2 GENERAL INFORMATION Your purchase of HYTORC equipment entitles you to the following HYTORC services Instructions to your employees within your organization by a HYTORC specialist Free annual inspection of your HYTORC equipment Free loaner equipment in case of failure under warranty your HYTORC equipment cannot be repaired within 5 workdays you get an equivalent free loaner tool 24 hour service World wide warranty When you need help abroad No problem We help you HYTORC equipment according to the newest technol
6. equipment is connected to the pump it can damage the pump unit When another brand pump unit is used no flawless operation can be guaranteed 4 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGIE 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 4 CONNECTING TO THE HYDRAULIC PUMP UNIT All HYTORC pump units are ready for use at delivery Before use always check the oil level All HYTORC pump units have to be filled with hydraulic oil type HLP 32 or equivalent If the oil is delivered separately then fill the pump before use It is possible to use a different oil with another viscosity but please consult us before using another kind of oil Filling with biodegradable oil is only allowed at the new pump types 5 CONNECTING TO A VOLTAGE SOURCE 5 1 Voltage and the type of cable sure the right line power is present 230 or 400 Volt Beware of over and undervoltage caused by using an extension cable that is to long or to thin Use the hydraulic pomp only if the green yellow grounding cables are connected lf needed use an 2 5 electrical extension cable unreel the cable wince completely 5 2 Rotation direction of the 400 Voltage pumps If the pump does not start or has problems starting most of the time the cau
7. is operated With a push on the lower button you completely shut down the pump unit Stop button Fig 4 remote control types 7 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI Tel 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 7 1 1 Wireless remote control Make contact with the pump unit by placing the little green cube with the metal strip in the remote control The metal strip faced down so it can make contact with the screws on the remote control 1 Push the start button wait till you hear a click 2 Push once on the up button The pump starts running Press up again and pressure is build 3 The pump is ready for use 4 Push the down button to shut down the pump unit Fig 5 wireless remote control 7 2 pressure gauge reading Digital pressure gauge There are pump units that have a digital pressure gauge These pressure gauges have a double read out one with small LED lights and one with a more precise digital readable display The LED light read out is not accurate Therefore we always recommend to read from the digital display LED lights Digital display HydroWer Made in Garitany Fig 6 pressure gauge 8 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen
8. not use hydraulic hoses uni swivels pump power or remote cords as means of moving the equipment Maintain your HYTORC equipment with For top performance inspect tools power pack and accessories for visual damage frequently and always prior to use Always follow instruction for proper tool and pump maintenance Refer to the Operations Maintenance Section in chapter 10 for further clarification Stay alert Watch what you are doing Use Common sense Do not use power equipment under the influence of any mood altering substances Prior to operation Ensure that all hydraulic connections are securely connected and there is no leakage Verify that the hydraulic hoses are not kinked or otherwise damaged Make sure that the square drive and its retainer are fully and securely engaged certain that all connectors elbows fitting and swivels are not bent loose damaged Prior to use Check sockets for size quality and flaws do not use if questionable Cycle tool to ensure proper function Locate a solid secure reaction point sure the reaction arm retaining clamp 1 fully engaged sure the hydraulic hoses are free of the reaction point Pressurize the system momentarily if the tool tends to ride up or to creep stop and re adjust the reaction arm to a more solid and secure position Commentary pump units are exclusive for HY TORC tools and vice versa other
9. NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 Analog pressure gauge This gauge has also two scales read One written in the other in PSI Both have the same accuracy The pressure scale in Bar Pressure scale in PSI Fig 7 analog pressure gauge 7 3 Setting of torque value boltload Take the remote control and push the button The pump unit starts working and the tool makes one stroke Repeat this twice and check if the tool works Turn the wing nut completely back left Push the remote control button and hold this Adjust the pressure by slowly screw in the black button Read the pressure on the gauge When the right pressure is reached secure the pressure by locking the wing nut Release the button and push this again to check if the right pressure is reached The HYTORC hydraulic pump unit has a working range from 20 BAR up tp 700 BAR Within this range the pressure is infinitely adjustable Fig 8 wing nut FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI Tel 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 Fig 9 Pressure release button
10. damage e Screw on the couplings well Fig 11 oil level check WARNING Loose couplings can be dangerous when these are under pressure Tightening the couplings too tight can cause damage to the thread Make sure the couplings are screwed on tight but don t screw them with a tong Check both oil levels in the pump unit reservoirs Check the power supply the right E voltage No damage to cables or hoses of the remote control Check if there is no damage to the power cables Check the hydraulic hoses for damage The pressure is 700 Bar Adjust the pump pressure to 200 Bar Check if the needle repeatedly comes back to 200 Bar Repeat this at 400 and 700 Bar gt Oil pressure gauges are filled with glycerine When the glycerine level drops there is a leak and repair is needed VV VV V gt If the gauge is filled with hydraulic oil this indicates an internal leak gt Clean wrench after every use and inspect the tool for enough lubricant 9 2 Calibration Every pump has its own calibration report which will be delivered separately with the HYTORC pump The advise is to maintain and calibrate the pump every year 11 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 HYTGRC 10 MAINTENANCE
11. derland B V 31 0 24 3660660 Pump runs and produces pressure but the tool does not turn gt check coupler connections The ring of the female coupler has to be tightened completely to the collar of the male coupler The tool turns in the wrong direction gt probably two hoses an even number hoses are connected to each other or the male and female couplers are interchanged 12 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGIE 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 HYTGRC 11 2 1 Electrical pump units Motor makes strange noise and produces no pressure gt check rotating direction Motor runs to slow or stops automatically after starting gt voltage drop in the power Usually too thin or too long extension cable is used Check pump unit with the main plug directly in the electric point Motor runs but does not switch from forward to reverse gt rupture in the remote control cable gt valve block defect Motor does not run gt no electrical power or rupture in supply cable 13 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGIE 32 0 38 705 220 www hytorc be
12. nelux be Version 2 2 sept 2013
13. ocking and after that unscrew the couplings e Type 1008 The male coupling is inserted in the female coupling After that tighten the locking ring on the female coupling For loosening the couplings first unscrew the locking ring then move the slideable part on the female coupling backwards After this the two parts can be loosened by moving them axial Type Pioneer fie jji W Mi Z 4 EE a 8 2 LYN MELEE i ttre Sy Ce reas 4 gA gt ELE AN X x LER SAN A Fig 2 coupler types 6 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGI Tel 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 6 2 Pressure release of the hoses before disassemble When the couplings are stuck after use most likely there is some residual pressure left in the hose By pushing the button on the pressure releasing valve on top of the pump unit the hose becomes pressureless and the couplings can be disconnected by hand Fig pressure release valves 7 OPERATION OF THE PUMP FUNCTIONS 7 1 Remote control functions With the upper button you turn on the pump unit Push the button again and hold it the pump builds up pressure and the tool
14. ogy A full year complete warranty Qualified work force employable for solutions at difficult challenges 3 SAFETY INSTRUCTIONS Warning Your HYTORC torque machine is a power tool and as with any other power tool certain safety precautions should be observed to avoid accidents or personal injury The following instructions will assist you Read all instructions Keep work area clean and well lit Consider work area environment Electrical Pumps should never be used in an atmosphere that can be considered potentially volatile If there is any doubt use an air pump Note Metal to metal contact can cause sparks precautions should be taken Avoid premature tool starting The Pump Remote Control is for the TOOL OPERATOR only 3 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan 65B 2630 Aartselaar BELGIE 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 HYTGRC Guard against electric shock Make sure the pump is properly grounded and the proper voltage is being used Store equipment properly After use tools and accessories should be properly stored to avoid deterioration Proper safety attire When handling hydraulic equipment use work gloves hard hats safety shoes and other applicable clothing Use safety glasses with side covers Moving equipment Do
15. se is a high resistant in the cables Use a thicker or a shorter cable Another cause is a cable cut This gives the same problems as when a thin cable is used In such case renew the cable With 400 Volt pump units it is necessary to check the rotating direction of the motor When after plugging in a red light appears you can reverse the phase in the plug by turning it 180 wit a screw driver phase reversing plug fig1 reverse of the phase rotation direction pump 5 FOR MORE INFORMATION HYTORC Nederland BV Platinawerf 8 6641 TL Beuningen NEDERLAND Tel 31 0 24 3 660 660 www hytorc nl HYTORC Benelux BVBA Ysselaarlaan65B 2630 Aartselaar BELGI 32 0 38 705 220 www hytorc benelux be Version 2 2 sept 2013 6 CONNECTING THE HYDRAULIC HOSES 6 1 Hose coupler types A safety coupling exists of a male and female coupling part There are 3 types e Type Pioneer The couplings have to be pressure free before connecting them together Slide the couplings together and screw the moveable ring of the female coupling to the male coupling Make sure the ring is fully tightened The tool will not work when the ring is not completely tight e Type 716 This is the same coupling as Type Pioneer but the male and female couplings have a toothed locking which are axial moveable Tightening is possible by sliding the couplings together For loosening first axial move the toothed l
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