Instruction SheetPowaPak™ Electric Power ConsolesEA - Electrc Automatic - Fully AutomaticEU - Electric Ultra - Semi Automatic

T-ENG-4537-AA

Choose the required product series fromthe left side of the screen, then click onthe required language.The following languages are listed:

CD with Instruction Sheets in PDF-formatPlease find the CD enclosed in the back of this manual

English (GB)Français (FR)Deutsch (DE)Italiano (IT)Danish (DN)

The install program of the AcrobatReader 6.0 is included on the CD.

ENGLISH

3

Instruction Sheet PowaPakElectric Power Console

Index1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.1 Manual Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.2 Automatic Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.2.1 Load Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2.2 Create Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2.3 New Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.2.4 Edit Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.2.5 Delete Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.2.6 Information and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

1. Introduction

PowaPak Automatic and Ultra PumpsThese units have been developed for anindustrial environment for use with HydraulicTorque Wrenches, the Automatic version usingenhanced technology enabling automatictightening of nuts to a predetermined torquevalue.

Delivery InstructionsUpon delivery all components must beinspected for damage incurred during ship-ping. If damage is found, the carrier should benotified immediately. Shipping damage is notcovered by the Hydratight warranty.

CE Declaration of Conformity

Hydratight PowaPak Automatic and Ultra

Hydratight declares that these models meetthe applicable standards and directives issuedby the European Community. For details referto the separate Certification.

2. SafetyBe aware that the operator is fully responsibleduring the operation of these units. Hydratightis not responsible for damage or injury causedby the misuse of this pump. ContactHydratight immediately if a potentiallyhazardous situation arises.

Read this manual carefully and observe allsafety precautions.� Ensure that electric is switched off and

unit is disconnected from the powersource prior to any maintenance work.

� Make sure you have completed safetyinduction training specific to the worksurroundings. The operator should bethoroughly familiar with the controls andthe proper use of the Pump unit.

� Always wear eye protection andprotective gloves, as a minimum.

� Make sure of the efficiency of the siteearth connection before starting to use thePump unit.

4

ENGLISH

� Ensure that hoses and tools are connectedcorrectly, and in good condition.

� Ensure cables and hoses are not placedunder any tension, and are not formedinto any tight bends.

� Never lift or drag the pump by the hosesor cables. Use handhold or lifting pointsprovided.

� Never exceed the equipment maximumworking pressure.

� Make sure the hydraulic pressure isdissipated to zero before attempting todisconnect hoses.

� Do not apply pressure to any disconnectedhose or coupling.

� Do not try and loosen any coupling or con-nector while the equipment is pressurised.

� Never leave the Pump unit unattendedwhile pressurised.

� Do not handle pressurised hoses� Use only hoses and connectors

recommended for this equipment.� Make sure the hydraulic oil is at the

correct level to avoid malfunctioning.� Do not keep the motor loaded for long

periods of time, as excessive heat will begenerated.

� Keep all the hoses and connections cleanand free of debris.

� Make sure that the electricity supply iscorrect for the Pump unit supplied (checkdata plate on reservoir).

� Servicing of the electrical system shouldonly be carried out by a qualifiedelectrician.

� Ensure Pump unit is placed on a stableflat surface, with enough space around itto enable connections and adjustments tobe made.

� Always store Pump unit in a dry cleanhumid free environment. On reuse checkrotor runs freely, and that electricalinsulation is sound, and oil level is correct.

� Never detect possible leaks by touchingthe hoses, connections etc. High-pres-sure liquids can be injected into the skincausing serious injury.

� If the Pump unit is dropped from anyheight, have it inspected thoroughlybefore it is operated again.

ENGLISH

5

3. AssemblyThe pump unit reservoir is supplied without oil.Fill the pump through the oil filler cap (Fig. 1)using the oil recommended in section 9 to suitthe operating environment.

Fig. 1

Important – the pump contains two linkedhydraulic chambers therefore it is essential tofill the pump as below. Observe the max andmin oil levels as shown in Fig. 2.

� Fill to max level & allow settling (leveldrops as second chamber fills via porting).

� Refill to max level.� Check and refill after initial operation of

the pump i.e. manifold assembly primed.

Prior to each use ensure the oil level iscorrect, top up if necessary.

Fig. 2

Connect the hoses to the pump connectors asindicated in Fig. 3.

Fig. 3

Ensure electrical compatibility of the pumpand the power supply, check the informationon the pump data plate attached to thereservoir.

Check the cables for signs of damage beforeconnecting the pump to the power supply. If itis necessary to replace the power cable,ensure the cable is attached securely to theplug, and that the shroud is fitted correctly toprevent ingress of moisture.

The pump control panel is non-serviceable, ifdefective return the pump to Hydratight or anauthorised service centre for repair. Anyintervention will invalidate the Hydratight’swarranty and responsibility.

OILFILLERCAP

MAXIMUMLEVELOIL

MINIMUMLEVELOIL

HIGHPRESSURECONNECTOR(ADVANCE)

LOWPRESSURECONNECTOR(RETURN)

Fig. 5 Automatic/Manual Selection

Fig. 6 Automatic/Manual Display

Depressing the “START/ADVANCE” button(see Fig 7.) on the handset will advance thewrench. When the button is released thewrench will retract.

To switch off simply, press the “OFF” button(see Fig 7.) on the handset, this will initiate thefollowing actions:-

i) Retract the wrench.ii) Reduce the hydraulic system pressure.iii) Switch off the pump.

A two second delay is possible before initia-tion however it is not necessary to keep thebutton depressed.

Fig. 7 Handset Buttons

The Automatic model enables the user toswitch units of oil pressure (Bar or psi, left

HYDRATIGHT

XXX Bar 21∞ C

MANUAL MODE

XXX Bar 21∞ C

AUTO / MANUAL

MANUAL / AUTO

4. OperationDepending on the model, the pump can beoperated in the following modes:-

Ultra Model - Manual mode only. AutomaticModel - Manual or Automatic mode.

The operation of both pump models consists ofincreasing the hydraulic pressure through alow-pressure gear pump to 97 bar, thenincreasing to 700 bar utilising a high-pressurepiston pump. A pressure regulator valveenables adjustment of the oil pressure (Fig. 4).

Fig. 4 Pressure regulator

4.1 Manual Mode (Ultra & Automatic Models)In manual mode the hydraulic outlet pressureis controlled by the manual pressure regulatorvalve (Fig. 4) for both the Ultra and Automaticmodel. With the torque wrench and hosesconnected, the regulator valve can be adjust-ed until the desired pressure is indicated onthe pressure gauge or LCD (Automatic modelonly).

Upon switching on, the Automatic modeldefaults to Automatic mode so it is necessaryto change to ‘manual mode’. Pressing the“MANUAL/AUTOMATIC” button (Fig 5) on thecontrol panel will change to show “MANUALMODE” flashing on the display (Fig 6).

6

ENGLISH

MANUAL/AUTOMATICSELECTORBUTTON

PRESSURE REGULATOR VALVE

EMERGENCY STOPBUTTON

START AND ADVANCEBUTTON

OFF BUTTON

ENGLISH

7

hand) and oil temperature (°C or °F, righthand) in each screen, by pressing “�” or “�”keys (see Fig. 8). The error and maintenancemessages (described later) are also active.

Fig. 8 Unit Selection

4.2 Automatic Mode (Automatic Model Only)To use the pump in automatic mode themanual pressure regulator valve (Fig. 4) mustbe closed.

Upon switching on the pump defaults toautomatic mode and displays the defaultscreen (Fig. 9). As described previously inSect 4.1 „manual mode� pressing “�” or “�”keys will switch the units of oil pressure and oiltemperature (Fig. 9).

Fig. 9 Default Screen

For automatic operation it is necessary for thefollowing data to be entered into the pump

� Tool (wrench) reference� Required torque or tool pressure

The data is used to create a tighteningsequence consisting of a series of tooladvance and retract cycles that will terminatewhen the pre-programmed torque or pressureis achieved. The unit monitors the cycle timeto determine when the tightening sequence iscomplete. To ensure the final tightening torquehas been achieved the unit automaticallyapplies several further cycles.

The required torque or pressure controlswhen the tightening sequence is completeand the tool reference ensures the pressuredoes not exceed the maximum allowable forthat tool.

The data is entered ether manually at thecontrol panel or via PC software available

from Hydratight. The following instructions arebased on manual entry at the control panel.

Once the tightening sequence has beengenerated the pump is ready for use. Thetightening sequence can be used to tightennumerous fasteners, however if the pump isswitched off the tightening sequence data willbe lost. It is therefore advisable that the databe stored as a ‘program’ so it can be reused.The pump allows for up to 50 programs to bestored.

It is possible to run an automatic tighteningsequence by either of the following:-

� Load an existing program (see 4.2.1)� Create a tightening sequence (4.2.3)� Create a New Program (see 4.2.3)

Fig. 10 below indicates the main menu that isaccessed from default screen by pressing the“ENTER” key.

Fig. 10 Default Screen

MANUAL MODE

XXX Bar 21∞ C

MANUAL MODE

XXX PSI 70∞ F

HYDRATIGHT

XXX Bar 21∞ C

HYDRATIGHT

XXX PSI 70∞ F

HYDRATIGHT

LOADPROGRAM

LOADTOOL

NEWPROGRAM

EDITPROGRAM

DELETEPROGRAM

INFORMATIONPROGRAM

MAIN MENU

AUTO / MANUAL

Pressing the “�” or “�” keys moves betweenthe screens. Programs can be created,deleted or edited from the pumps main menusystem or via connection to PC software.

4.2.1 Load ProgramFrom the main menu locate the “LOADPROGRAM” screen by scrolling with the “�”or “�” keys then press the “ENTER” key.Select the desired program by scrolling withthe “�” or “�” keys then press the “ENTER”button again. Fig.11 gives an example ofprogram 2 being selected.

Fig. 11 Loading a Program

Once the required program has beenselected, one or numerous fasteners can betightened.

The screens shown during the tighteningsequence are indicated in Fig. 12. The initialscreen shows the program name, toolreference, torque or pressure with “START”indicating the program is now ready for use.Start the pump by pressing the “Start/AdvanceButton” on the Handset (see Fig. 7).

For safety, it is necessary to hold down the“Start/Advance” button to maintain the tighten-ing sequence. If the button is released thesequence will stop and the tool will return tothe retract position.

As indicated in Fig. 12 the program automati-cally alternates between the second and thirdscreens during the tightening operation.

When the tightening sequence is complete thefinal screen is displayed momentarilyindicating the sequence has ended and thetorque or pressure has been achieved.

8

ENGLISH

After a period of inactivity the display willreturn to the first screen of the sequence,ready for another tightening sequence.Alternatively the user can return to the initialscreen immediately by pressing the “ENTER”key.

Fig. 12 Tightening Sequence

4.2.2 Create Tightening SequenceWith reference to Fig. 13 from the main menulocate the “LOAD TOOL” screen by scrollingwith the “�” or “�” keys then press the“ENTER” key. Scroll through the availabletools using the “�” or “�” keys. Once thedesired tool is displayed, it can be selected bypressing the “ENTER” key. Next use the “�”or “�” keys, to select the required magnitude(Torque or Pressure), press “ENTER” to selectthe desired value.

If Torque is selected, use the “�” or “�” keys,to switch between the operating units of Nm orftlbs. If Pressure is selected, use the “�” or“�” keys, to switch between the operatingunits of bar or psi. Once the desired unit isdisplayed press the “ENTER” key to select it.

The final screen requires the torque orpressure value to be entered. In this screen, acursor appears under the digit that can bemodified. The “�” or “�” keys will allowincreasing or decreasing values of the digitbeing modified. The “ENTER” key willdisplace the cursor to the next digit (right) andthe “CANCEL” key will displace the cursor tothe previous digit (left).

LOADPROGRAM

SELEC. PROGRAM

Program 1

MAIN MENU

ENTER

SELEC. PROGRAM

Program 2

SELEC. PROGRAM

Program N

RSLXX. PROGRAM

xxxxNm START?

ENTER

RSLXX PROGRAM

AUTO / MANUAL

xxxxx START?

RSLXX PROGRAMxxxxx >

RSLXX PROGRAMxxxxx --->

RSLXX PROGRAMxxxxx END

TIGHTENING SEQUENCE

LEGENDFlashing Text

EnterCancelOn/Advanced (Remote)Automatic ActionsTimer

ENGLISH

9

Important Note – The pump does not allowthe input of values that exceed the pressurelimits of the selected tool.

Once the desired value has been entered, the“ENTER” key must be pressed again and thiswill advance to the tightening sequencescreen (Fig. 13).

Automatic tightening can now be carried outby pressing the “Start/Advance Button” on theHandset as described in section 4.2.1 andFig. 12.

Having created the tightening sequence if thepump is switched off all data is lost. It is there-fore recommended that the data be saved asa Program. From the tightening sequence ini-tial screen press the “�” key (Fig. 14). Thisdisplays the screen requesting confirmation tosave the data, press the “ENTER” key toaccept. The next menu screen allows entry of

Fig. 13 Creating a Tightening Sequence

the program name. On these screens the“ENTER”, “CANCEL” and the “�” or “�” keysallow entry of numbers and text2. The“ENTER” and “CANCEL” keys move thecursor to the next and previous characterrespectively while the “�” or “�” keysdecrease and increase respectively thenumber or text character being entered. Thename length is limited to a maximum of eightcharacters (all eight characters must be filledhowever blank spaces can be entered bypressing the ‘ENTER’ key). Pressing the‘ENTER’ key once the final character hasbeen entered will save the program. Refer toFig.14 for the keystroke sequence required tocarry out these actions.

2 Characters available:_0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ

LOADTOOL

SELECT TOOLRSLXX

RSLXX MAGNITUDETorque

RSLXXNm

UNIT

RSLXXXxxxxNm

RSLXXXXxxxNm

RSLXXXXXxxNm

RSLXXftlb

UNIT

RSLXXXxxxx ftlb

RSLXXXXxxx ftlb

RSLXXXXXxx ftlb

RSLXXbar

UNIT

RSLXXXxxxx bar

RSLXXXXxxx bar

RSLXXXXXxx bar

RSLXXPSI

UNIT

RSLXXXxxxx PSI

RSLXXXXxxx PSI

RSLXXXXXxx PSI

RSLXXPressure

MAGNITUDE

RSLXXxxxxx START?

RSLXXxxxxx >

RSLXXxxxxx --->

RSLXXxxxxx END

TIGHTENING SEQUENCE

LEGENDFlashing Text

EnterCancelOn/Advanced (Remote)Automatic ActionsTimer

It is important to note that the pump does notallow the creation of programs with emptynames, or identical names to those alreadystored in the memory. Should this occur amessage will be displayed followed by theoption to change the name.

This name creating sequence is also used toedit the name of an existing program asdescribed later in 4.2.4.

10

ENGLISH

4.2.3 New ProgramFrom the main menu use the “�” or “�” keysto select “NEW PROGRAM” then press“ENTER”. Fig. 15 indicates the sequence tofollow for entering the required program datai.e. Tool Ref, Torque/Pressure, Units, NumericValue, and Program name. With the exceptionthat the program name is automaticallyrequested, the sequence is identical to thosepreviously illustrated in Fig. 13 and Fig. 14.

Fig. 14 Creating a Program from a Tightening Sequence

Fig. 15 Creating a New Program

LEGENDFlashing Text

EnterCancelOn/Advanced (Remote)Automatic ActionsTimer

RSLXXxxxxx START?

RSLXXxxxxx >

RSLXXxxxxx --->

RSLXXxxxxx END

RSLXXxxxxx START?

RSLXX SAVE?xxxxx

RSLXXxxxxxxxx

RSLXXxxxxxxxx

RSLXXxxxxxxxx

HYDRATIGHTXXXBar 21∞

NAM

NA

N

TIGHTENING SEQUENCE PROGRAM’S NAME

NEWPROGRAM

SEL. TOOLRSLXX

RSLXX MAGNITUDETORQUE

RSLXXNm

UNIT

RSLXXXxxxxNm

RSLXXXXxxxNm

RSLXXXXXxxNm

RSLXXftlb

UNIT

RSLXXXxxxx ftlb

RSLXXXXxxx ftlb

RSLXXXXXxx ftlb

RSLXXbar

UNIT

RSLXXXxxxx bar

RSLXXXXxxx bar

RSLXXXXXxx bar

RSLXXPSI

UNIT

RSLXXXxxxx PSI

RSLXXXXxxx PSI

RSLXXXXXxx PSI

RSLXXPRESSURE

MAGNITUDE

RSLXXxxxxx

RSLXXxxxxx

RSLXXxxxxx

PROGRAM’S NAME

LEGENDFlashing Text

EnterCancelOn/Advanced (Remote)Automatic ActionsTimer

N

NA

NAMEXXXXXBar

HYDRATIGHT21∞

ENGLISH

11

4.2.4 Edit ProgramIt may be necessary to change some of theparameters that define a program (tool ref,torque, pressure etc) or the program name.This can be achieved from the main menu byusing the “�” or “�” keys to select “EDITPROGRAM”. Once accepted by pressing the“ENTER” button, the same sequence of stepsas previously shown in “New Program”section (4.2.3. and Fig. 14) will be displayed.

Press the “ENTER” key once the desiredprogram has been selected then continueusing the “ENTER” key until the requiredparameter (or name) to be changed isselected. Edit the values or characters aspreviously described in the ‘tighteningsequence’ section (4.2.2).

Fig. 16 indicates the sequence to follow forediting a program.

Fig. 16 Editing a Program

SELECT PROGRAM

SELECT TOOLRSLXX

RSLXX MAGNITUDETORQUE

RSLXXNm

UNIT

RSLXXXxxxxNm

RSLXXXXxxxNm

RSLXXXXXxxNm

RSLXXftlb

UNIT

RSLXXXxxxx ftlb

RSLXXXXxxx ftlb

RSLXXXXXxx ftlb

RSLXXbar

UNIT

RSLXXXxx bar

RSLXXXXx bar

RSLXXXXX bar

RSLXXPSI

UNIT

RSLXXXxxxx PSI

RSLXXXXxxx PSI

RSLXXXXXxx PSI

RSLXXPRESSURE

MAGNITUDE

RSLXXxxxxxxxx

RSLXXxxxxxxxx

RSLXXxxxxx

PROGRAM’S NAME

LEGENDFlashing Text

EnterCancelOn/Advanced (Remote)Automatic ActionsTimer

N

NA

NAMEXXXXXBar

HYDRATIGHT21∞

EDITPROGRAM

PROGxx

4.2.5 Delete ProgramShould it be necessary to delete a programfrom the pump memory follow the sequenceshown in Fig. 17. Programs that have beenprotected using the PC software will display apadlock icon at the end of the program name.It is not possible to delete protected programsat the pump control panel. Protectedprograms can only be unprotected anddeleted from PC software program.

To delete an unprotected program (withoutpadlock icon) from the pump control panelselect “DELETE PROGRAM” then press the“ENTER” key. Use the “�” or “�” keys to findthe program to be deleted.

Press “ENTER” to delete the selectedprogram. The next screen requestsconfirmation to delete the program, press the“ENTER” key to accept. The control panelreturns to the default screen.

Fig. 17 Delete Program

4.2.6 Information and Error MessagesThe final main menu is the “INFORMATION”screen, which provides the pump dataincluding the operating hours, the pumpprogram version, and the serial number (SeeFig. 18).

12

ENGLISH

Fig. 18 Information Screen

The performance of the pump is continuouslymonitored during operation such that thepump will automatically stop if problemsoccur.

The following are monitored:-� Motor Temperature� Hydraulic Oil Level� Oil Temperature� Oil Pressure� Temperature Sensor Operation� Pressure Transducer Operation� Solenoid Valve Operation

When an error is detected, the pump will stopthe current tightening sequence, retract thetool (if possible), stop the pump and displaythe error message.

For safety reasons, an error message cannotbe deleted until the error has been rectifiedand accepted by pressing the “ENTER”button. Only then can the pump be restarted.

To ensure maintenance is carried out atperiodic intervals the pump displays amaintenance warning relating to the numberof operating hours (Fig. 19). If the pumpdetects that the recommended time formaintenance inspection has been exceeded,a warning will appear when the pump isswitched on. The maintenance warning canbe accepted by pressing ‘ENTER’ tocontinue using the pump if necessaryhowever maintenance should be carried out atthe next available period.

Fig. 19 Maintenance Warning

DELETEPROGRAM

SELEC. PROGRAM

MAIN MENU

PROGXX

DELETE PROGRAM?PROGXX

HYDRATIGHTXXXBar 21∞C

INFORMATION

Hydratight v2.2

MAIN MENU

xh SN: ooxx

MAINTENANCE

HYDRATIGHT

LOAD PROGRAM

LOAD TOOL

NEWPROGRAM

EDIT PROGRAM

DELETE PROGRAM

INFORMATION

MAIN MENU

XXXBar 21•C

HYDRATIGHTV2.2

MAINTENANCEDELETE PROGRAM?

SELEC. PROGRAMPROGXX

SELECT TOOL RSLXX

RSLXX MAGNITUDE

Torque

Pressure

RSLXX UNIT Nm

RSLXX UNITXXXXxNm

ft.lb XXxft.lb

bar XXxbar

PSI XXXXxPSI

xxxxxxxxRSLXX NAMEXX

xxxxxxxxRSLXX NAMEXX

xxxxxxxxRSLXX SAVE?

xxxxxxxx START?

xxxxx >

xxxxx ENDRSLXX PROGXX

xxxxx --->RSLXX PROGXX

MANUAL MODEXXXBar 21•C

ALARMALARM'S TEXT

LEGEND

EnterCancelAccept (Remote)

Automatic Actions

Timer

Flashing Text

?

DATA FOR PROGRAM ORMANUAL INPUT MODE

TIGHTENING SEQUENCE

NAME OF THE PROGRAM

INDEPENDANT SCREENS

?

?

?

?

?

?

?

0-9

0-9

0-9

0-9

0-9A-Z

0-9A-Z

PROGXX

RSLXX UNIT

RSLXX UNIT

RSLXX UNITRSLXX UNIT

RSLXX UNIT

RSLXX UNIT

RSLXX PROGXX

RSLXX PROGXX

RSLXX MAGNITUDE

ENGLISH

13

Fig. 20 shows a diagram of the completemenu system for the pump. Refer to theLegend associated with the diagram to ensurefamiliarity regarding the effects of certainactions and error messages.

Certain activities e.g. deletion of protectedprograms, changing languages etc cannot be

done at the pump control panel and requirethe PC software program. To use thesoftware, the pump must be connected to thePC via the cable supplied. The pump must beconnected to the power supply tocommunicate with the PC software.

Fig. 20 Complete Menu System

5. Maintenance and TroubleshootingImportant – Prior to any maintenance,depressurise the hydraulic system and dis-connect the pump from the electrical supply.

For normal use Fig. 21 can be used forguidance, however in extreme working

14

ENGLISH

conditions maintenance should be carried outmore frequently.

Refer to the Chart in Fig. 22 for information. Ifthe pump requires technical service or spareparts, contact Hydratight or any of theirauthorised Service Centres.

Fig. 22 Troubleshooting

Fig. 21 Maintenance Schedule

Frequency

Prior to each use Check the oil level in the reservoir is between the maxi-mum and minimum indicators.

Set zero pressure, then incrementally adjust pressure upto 150Bar (2175psi) and check for leaks, increase to700Bar (10000psi), whilst audibly monitoring for noiseindicating possible wear or damage. If necessary contactHydratight for advice.

Check that the unit reaches the maximum pressure.

Check all power cable, hydraulic hoses and couplings fordamage. Replace as required.

It is recommended that the pump is returned to Hydratightor one of their authorised service centres for a completemaintenance check.

Monthly

After 200 hours of use

Maintenance

Problem

Motor does not start Emergency switchdepressed

Damaged wiring

Pressure retained in themanifold block

Check the switch

Check and fix the wiring

Open the regulator valvefully and start the motor,readjust the valve to thecorrect pressure

The hydraulic oil level isincorrect

Fill with oil to themaximum level, if theproblem persists checkfor leaks

Motor overheating

Oil Contaminated Empty the oil and refillwith the correct oil

Pressure increase veryslowly

Cause Solution

The adjustment isincorrect

Adjust to the correctpressure and lock off

Correct pressure notachieved

ENGLISH

15

6. Technical Specifications

Electric Input 230V 1PhFrequency 50HzMax Advance Pressure 690 Bar

(10000 psi)Max Retract Pressure 110 Bar

(1595 psi)Power 1.5kWCurrent Draw (Full Load) 10.5AR.P.M. 2800First Stage Flow 4.0 lpmSecond Stage Flow 1.11 lpmReservoir Capacity 3.7 litresUsable Oil 1.7 litresSound Level 78 dBProtection Classification IP54

Electric Input 115V 1PhFrequency 50/60 HzMax Advance Pressure 690 Bar

(10000 psi)Max Retract Pressure 110 Bar

(1595 psi)Power 1.5kWCurrent Draw (Full Load) 20.5AR.P.M. 3420First Stage Flow 4.01 lpmSecond Stage Flow 1.11 lpmReservoir Capacity 3.7 litresUsable Oil 1.7 litresSound Level 78 dBProtection Classification IP54

7. Warranty� Hydratight guarantees the PowaPak

Pump only for the purpose for which it isintended.

� The pump is guaranteed against defectsin workmanship and materials for twoyears from the date on which the productis delivered to the original purchaser.

� Hydratight reserves the right to replacepartially or completely to satisfy thewarranty.

Important Note – Changing one or morecomponents does not extend the warranty.

The warranty does not apply in the followingcases:-

� Incorrect disassembly, re-installation ofreplacement parts and assembly.

� Defects or wear due to carelessness ornegligence.

� Non adherence to recommended mainte-nance schedule.

� Modification to the operating conditions.� Incorrect storage of the pump unit as

described in section 2.� If other than original Hydratight spare

parts are used for repair.

8. Spare Parts

Refer to the “Repair Parts Sheets”, or contactHydratight for information to attain correctparts.

16

ENGLISH

9. Hydraulic FluidsThe industrial standard “ISO Viscosityclassification for liquid lubricants” is coveredby ISO3448, DIN51519. The index No.following the ISO VG prefix indicates thenominal viscosity at 40 degrees centigrade.

Guidelines for selection:-

� VG10, VG15Systems intended for short operating periodsor use in an open environment. Systems

intended for continuous operation (for use inopen environment, operation in winter).

� VG22, VG32General application (for use in openenvironment, operation in summer only).

� VG46, VG68Systems used in tropical conditions atambient temperatures up to 40°C or enclosedenvironments.

ISOVG

100

ISOVG

68

ISOVG

46ISO

VG32

ISOVG

15

ISOVG

22

ISOVG

10

-40 -30 -20 -10 0 10 20 30 40 50 100Temperature (?C)3

5

10

20

50

100

500

1000

-40 -20 0 20 40 200Temperature (?F)10060 80

Reference TemperatureISO 3448, DIN 51519

Temperature / viscosity curve

optimum range

Vis

cosi

ty(m

m2/

s)

ENGLISH

17

18

ENGLISH

Please contact Hydratight if the CD is not included,or visit www.hydratight.com for a download of the manual.

With offices in Australia, Azerbaijan, Brasil, France, Germany, Holland, Kazakhstan, Qatar, Saudi Arabia, Singapore,Trinidad, UK and USA; manufacturing facilities in four locations; and sales representation in more than 50 countries,we can justifiably claim to be a global business, offering international standards through local operations.

Providing Safe, Reliable Connections

USA - HOUSTON, TXTel: +1 713 860 4200Fax: +1 713 860 4201Email: houston@hydratight.com

USA - RED WING, MNTel: +1 651 388 8661Fax: +1 651 388 0002Email: solutions@dlricci.com

USA - DENVER, COTel: +1 303 749 6000Fax: +1 303 749 6001Email: denver@hydratight.com

BRASIL - RIO DE JANEIROTel: +55 (21) 2220 3167Fax: +55 (21) 2220 6717Email: rio@hydratight.com

BRASIL - MACAETel: +55 (22) 2763 3127Fax: +55 (22) 2763 3113Email: macae@hydratight.com

TRINIDAD - POINT LISASTel: +1 868 636 3440Fax: +1 868 679 2140Email: trinidad@hydratight.com

UK - WALSALLTel: +44 (0) 121 50 50 600Fax: +44 (0) 121 50 50 800Email : enquiry@hydratight.com

UK - MORPETHTel: +44 (0)1670 515 432Fax: +44 (0)1670 513 110Email: contact@hydratight.com

UK - ABERDEENTel: +44 (0) 1224 215 930Fax: +44 (0) 1224 215 950Email: aberdeen@hydratight.com

FRANCE - ARGENTEUILTel: +33 (0)1 34 10 57 17Fax: +33 (0)1 34 10 50 81Email: pivicat@hydratight.com

GERMANY - BURSCHEIDTel: +49 (0)2174 780061Fax: +49 (0)2174 780054Email: germany@hydratight.com

GERMANY - KERPENTel: +49 (0)2237 923010Fax: +49 (0)2237 9230199Email: germany@hydratight.com

HOLLAND - ALKMAARTel: +31 (0)72 511 8899Fax: +31 (0)72 511 8855Email: holland@hydratight.com

AZERBAIJAN - BAKUTel: +994 12 437 2694Fax: +994 12 437 2695Email: baku@hydratight.com

KAZAKHSTAN - ATYRAUTel: +7 7122 971095Fax: +7 7122 971096Email: atyrau@hydratight.com

SAUDI ARABIA - DAMMAMTel: +966 3 833 8600Fax: +966 3 833 8487Email: saudi@hydratight.com

QATAR - DOHATel: +974 460 0350Fax: +974 441 2897Email: qatar@hydratight.com

SINGAPORETel: +65 6515 4971Fax: +65 6515 4972Email: singapore@hydratight.com

AUSTRALIA - QUEENSLANDTel: +61 (0)7 3264 7719Fax: +61 (0)7 3264 7819Email: queensland@hydratight.com

AUSTRALIA - PERTHTel: +61 8 9353 1659Fax: +61 8 9353 1668Email: perth@hydratight.com

WORLDWIDE OFFICES

HT/PK/EA-EU/INS/E/08-07

Contact

www.hydratight.com