TWP-2AF Torque Wrench Pump Manual REV B.

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Transcript of TWP-2AF Torque Wrench Pump Manual REV B.

  • Form No. E09005

    Rev. B. 09.17.2015

    INSTRUCTION MANUAL

    TWP SERIES HYDRAULIC TORQUE WRENCH PUMP

  • EAGLEPROINDUSTRIALTOOLS,INC. 2 FORMNO.E09005REV.A.

    Carefully inspect all components for shipping damage. If shipping damage is found, notify the carrier at once. The carrier is responsible for any damage resulting from shipment.

    To avoid personal injury or property damage, please read, understand, and follow all safety instructions.

    EAGLE PRO is not responsible for injury or damage resulting from unsafe and/or incorrect product use or system operation, or lack of proper maintenance.

    WARNING! One person should operate both the hydraulic pump and the hydraulic torque wrench, unless there is clear and unobstructed communication between the two operators. Do not place hands near action or reaction points.

    DANGER! Is used only when your action or lack of action may cause serious injury or death.

    WARNING! Is used when a potential danger exists that requires correct action to avoid personal injury.

    IMPORTANT! Is used when action of lack of action can cause equipment failure.

    DANGER! The hydraulic equipment user must be a qualified operator with correct training and work experience with

    hydraulic equipment. Lack of knowledge in any of these areas can lead to equipment damage or personal injury.

    Carefully inspect hydraulic pump before using . If any damage is found, discontinue use and contact your closest authorized EAGLE PRO Service Center.

    To avoid personal injury, do not modify or weld hydraulic equipment without approval of EAGLE PRO INDUSTRIAL TOOLS, INC.

    All EAGLE PRO torque wrenches are designed for a maximum of 10,000 PSI/700 bar. Do not connect torque wrenches to a pump with a higher pressure rating or equipment damage may occur.

    IMPORTANT! To avoid personal injury or property damage, please read, understand, and follow all safety instructions. Always keep work area clean and free of clutter. When not in use, tools should be properly stored to avoid damage . Operator must wear proper safety attire when working with hydraulic equipment. Work gloves, safety

    glasses, hard hats, approved safety shoes, and hearing protection and/or other required clothing should be worn while operating this equipment.

    01 SAFETY INSTRUCTIONS

  • EAGLEPROINDUSTRIALTOOLS,INC. 3 FORMNO.E09005REV.A.

    Use high quality impact sockets that are in good condition with the hydraulic torque wrench. Ensure they are the correct size and engage the hex portion of the bolt/nut correctly. Unseen flaws or damage to the impact sockets could cause failures during use. Remain clear of impact sockets during application.

    Do not hammer on hydraulic torque wrench, pump or socket to enhance performance. If the bolt/nut will not rotate, select a larger torque wrench for the application.

    Do not pick up the torque wrench by the hydraulic hose or swivel. Do not pick up the hydraulic pump by the power cord, pendant control cord, or hydraulic hose. Electrical pumps should never be used in a potentially explosive environment. Ensure that the pump is properly grounded to guard against electrical shock. Do not use kinked or damaged hydraulic hoses. Carefully inspect the hydraulic couplers on pump, hoses, and torque wrenches before using. Never

    connect tools with damaged couplers or damaged port threads. The damaged coupler(s) or damaged port threads may cause equipment failure and possible personal injury.

    Install couplers in a clean environment. Always prevent dirt or other debris from entering into the cylinder. Dirt or debris will damage the tool and result in equipment failure and possible personal injury.

    Before removing or tightening hose(s) or coupler(s), always release hydraulic pressure in system . Never handle pressurized hoses; escaping oil under high pressure can penetrate the skin, causing serious

    injury. Seek medical aid immediately if injured.

    When the pump is not in use, release the valve, remove the hoses and use the dust cap to recover the port. Do not drop anything on hydraulic hoses. Fully retract the hydraulic torque wrench before adding fluid to the torque wrench pump. Failure to do so

    will result in excess reservoir pressure and could cause personal injury.

    Do not use equipment in temperatures of 150F (65C) or higher. Overheating will soften seals and weakens hose materials, resulting in oil leaks or other equipment failure.

    For hydraulic technical help or repair service, please contact the closet authorized EAGLE PRO Service Center. EAGLE PRO INDUSTRIAL TOOLS, INC. has no obligations under any warranty with respect to products that have been repaired by unauthorized personnel, modified, or damaged through misuse, abuse, accident, neglect, or mishandling.

    DANGER! REACTION POINT SAFETY

    Adjust reaction arm in the same direction as the square drive when possible. Avoid excessive play. Do not hold torque wrench during operation. If the torque wrench must be held or steadied during

    operation, use alternative means of securing tool to the application.

    Always ensure that all body parts and clothing are clear of the reaction arm and reaction surface during use.

  • EAGLEPROINDUSTRIALTOOLS,INC. 4 FORMNO.E09005REV.A.

    02 INITIAL SETUP INSTRUCTIONS

    Visually inspect the pump for any shipping damage. If any damage is found, notify the carrier immediately. Carrier is responsible for any damage that occurs during shipment.

    Remove the pump from the shipping carton and fill the reservoir with the provided hydraulic fluid. First, remove the reservoir plug, see FIG A. Rotate the plug (black knurled knob) counter clockwise to loosen. Fill reservoir with supplied fluid and tighten by rotating fill knob clockwise. Fill plug needs only to be hand tight. Prior to any use, loosen the brass reservoir vent plug. Ensure this plug is tightened once work is completed, or fluid may leak from this opening.

    2.1 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous overloading. Use the recommended amperage listed on the motor nameplate. Do not use the electric pump if the ground is not connected on the power plug.

    Always minimize the length of extension cords and be sure they are of adequate wire size, with proper ground connections. See FIG B. below for potential impact of using longer extension cords. EAGLE PRO always recommends a #10 gauge extension cord with a length of no more than 25 feet.

    WARNING! Do not operate in a potentially explosive environment, as electric motors may produce sparks.

    FIG B

    FillPlug

    VentPlug

    FIG A

    #14 GAUGE #12 GAUGE #10 GAUGE10 0.9V (0.8%) 0.6V (0.5%) 0.4V (0.3%)20 1.8V (1.5%) 1.1V (0.9%) 0.7V (0.6%)30 2.7V (2.3%) 1.7V (1.4%) 1.1V (0.9%)40 3.6V (3.0%) 2.3V (1.9%) 1.4V (1.2%)50 4.6V (3.8%) 2.9V (2.4%) 1.8V (1.5%)

    100 9.1V (7.6%) 5.7V (4.8%) 3.6V (3.0%)

    Cord Length,

    FeetExtension Cord Wire Gauge

    1.3HP 15A 115V MOTOR (% drop from 120V in parentheses)

  • EAGLEPROINDUSTRIALTOOLS,INC. 5 FORMNO.E09005REV.A.

    2.2 HYDRAULIC CONNECTIONS The EAGLE PRO TWP Series torque wrench pump is equipped with an electronic solenoid pressure relief valve. Before disassembling hydraulic torque wrench system for storage, transport or maintenance, always release system pressure. Once work is completed, push the button on top of the solenoid valve. See FIG C. Before disassembling hydraulic torque system, double check pressure gauge located on pump to ensure system pressure has been released. Once system pressure has been released, it is safe to disassemble hydraulic torque system.

    The pumps maximum working pressure is 10,000 PSI (700 bar) . Ensure that all hydraulic equipment used with this tool are rated for 10,000 PSI (700 bar) working pressure.

    FIG C WARNING! Improperly connected hydraulic couplers can be dangerous if pressurized. Do not grab, touch or come in contact with a pressurized hydraulic fluid leak. Escaping fluid can penetrate the skin and cause severe injury.

    03 OPERATION INSTRUCTIONS

    3.1 ASSEMBLING THE SYSTEM The EAGLE PRO TWP Series torque wrench pump is connected to various EAGLE PRO torque wrench heads with a dual, high strength thermo-plastic hydraulic hose assembly complete with hydraulic couplers and protective dust covers.

    Attach the hose assembly to the pump valve (top male and female outlets) by pushing the male coupler fully into the female coupler. (See FIG D and FIG E).

    FemaleCoupler

    FIG D FIG E

    MaleCoupler

  • EAGLEPROINDUSTRIALTOOLS,INC. 6 FORMNO.E09005REV.A.

    While pushing the male coupler into the female coupler, rotate the locking collar on the female coupler so that it screws onto the male collar. Ensure that the locking collar is firmly attached to the male coupler, when properly tightened, the locking teeth on the collar will engage to prevent the coupler from coming loose. The locking collar should only be hand tightened. See FIG F below.

    FIG F

    Properlyseatedmaleandfemalecouplers

    IMPORTANT! Ensure hydraulic connectors are fully engaged. Connectors not properly seated can leak and cause system malfunctions.

  • EAGLEPROINDUSTRIALTOOLS,INC. 7 FORMNO.E09005REV.A.

    3.2 ATTACHING PUMP TO TORQUE WRENCH HEADS See the operators manual for your specific EAGLE PRO hydraulic torque wrench for detailed instructions on assembling and setting up an EAGLE PRO hydraulic torque wrench.

    Attach the dual, thermo-plastic hose to the torque wrench head. Ensure that both the male and female couplers are properly seated. See FIG I.

    FIG I

    Properlyseatedmaleandfemalecouplers

    onTorquewrenchhead

    3.3 SETTING SYSTEM PRESSURE/REQUIRED TORQUE

    Once the torque wrench pump and torque wrench are properly assembled and connected, and the hydraulic pump has a proper power supply, the pressure on the pump must be set. The amount of pressure the pump provides ultimately dictates the amount of torque the torque wrench can produce.

    Torque sequence may vary from location to location and it may even vary within a single location. There are many variables that must be understood to achieve proper torque. Always abide by local procedures, regulations and ASME PCC-1-2013 standards.

    Each EAGLE PRO torque wrench is supplied with a pressure-torque conversion chart. See FIG J for an example of the ESW torque wrench pressure-torque conversion chart.

  • EAGLEPROINDUSTRIALTOOLS,INC. 8 FORMNO.E09005REV.A.

    751876747831

    657867356891704872047361

    563857955951610862656421

    469948555012516853255482

    375939154072422943854542

    281929763132328934463602

    187920362193234925062662

    5200

    ESW8FT.LBS78394010961253140915661723

    400042004400460048005000

    280030003200340036003800

    640052006000580056005400

    1000098009600940092009000

    160018002000220024002600

    760074007200700068006600

    880086008400820080007800

    1782018208185951898319370

    MODELPSI100012001400

    154961588316271166581704617433

    131721355913946143341472115109

    108471123511622120091239712784

    85238910929896851007210460

    619865866973736177488135

    387442614649503654245811

    1037010595108211104611272

    19372324271230993487

    9017924394689694991910145

    766578908116834185678792

    631265386763698872147439

    495951855410563658616087

    360738324058428345094734

    225424802705293131563381

    547 11271352157818032029

    12031094985875766656

    186017501641153214221313

    251624072297218820791969

    317330632954284427352626

    382937203610350133913282

    448543764267415740483938

    514250324923481447044595

    314732133278 5470

    53615251

    275428192885295030163082

    236024262491255726232688

    196720332098216422292295

    157416391705177018361901

    118012461311137714431508

    91898410491115

    394459525590656721

    120912361263129013171344

    104810751102112911551182

    8879149409679941021

    725752779806833860

    564591618645672698

    403430457483510537

    242268295322349376

    ESW20ESWSERIESTORQUEWRENCHES

    FT.LBS FT.LBS FT.LBS FT.LBS FT.LBS

    215

    ESW1 ESW3 ESW5 ESW10134161188

    328

    787852

    FIG J

  • EAGLEPROINDUSTRIALTOOLS,INC. 9 FORMNO.E09005REV.A.

    Below is an example of how to properly use the ESW Torque Wrench pressure-torque chart..

    EXAMPLE

    Application requires use of an ESW-3 EAGLE PRO hydraulic torque wrench to tighten a 1-1/2 bolt to 2100 Lb. Ft.

    STEP 1. Locate the correct model of the torque wrench along the top of the pressure-torque chart

    STEP 2. Read straight down the column until you find the closest figure to 2100. In this application it would be 2164. 2164 is about 3% over the required torque value for this application.

    STEP 3. From the figure of 2164, read all the way over to the left hand column of the chart, this will tell you what pressure the pump must product to reach this torque value. In this case, to reach 2164 lb. ft. of torque with the ESW-3 torque wrench, the torque wrench pump must product 6600 PSI.

    As 2164 lb. ft. of torque is within the +/-3% accuracy range of the ESW-3 torque wrench, you could leave the pressure at 6600 PSI. For higher precision, you should reduce the 6600 PSI by 3% to 6402 PSI.

    3.4 SETTING PUMP PRESSURE Now that pump pressure has been determined, follow the procedure below to set the pump pressure.

    STEP 1. Loosen the lock ring on the T handle of the external pressure valve. Turn the T handle counter clockwise until it moves easily.

    STEP 2. Turn the pump on. Using the pendant control, push down on the ADVANCE button and hold it.

    STEP 3. While continuing to hold the ADVANCE button down, slowly turn the T handle clockwise and watch the pressure rise on the pump pressure gauge.

    STEP 4. When the gauge reaches the required pressure (see example above to determine required pressure) stop turning the T handle and allow the pressure to stabilize.

    STEP 5. If the pressure continues to rise above required pressure, release the ADVANCE button and turn the T handle counter clockwise, this will reduce system pressure. Press the ADVANCE button again and slowly bring the pres-sure up to the required pressure.

    STEP 6. Once the pressure is correct, turn the pump off. Tighten the lock ring on the T handle against the valve body. This will lock the T handle in place and prevent pressure changes. This sets the pump pressure which ultimately determines the torque output of the torque wrench. Cycle the pump one final time to ensure that the pressure is properly set.

    IMPORTANT! Do not adjust the pump pressure while the torque wrench is operating. Adjust the regulator so that the pressure is increasing, not decreasing. If you have to lower pump pressure, start the pressure setting procedure from the beginning.

    THandle

  • EAGLEPROINDUSTRIALTOOLS,INC. 10 FORMNO.E09005REV.A.

    3.5 PUMP OPERATION TIGHTENING See the operators manual for your specific EAGLE PRO hydraulic torque wrench for detailed instructions on assembling and setting up an EAGLE PRO hydraulic torque wrench.

    With the EAGLE PRO torque wrench properly assembled and properly positioned on the work piece, follow the procedure below.

    STEP 1. Push down on the ADVANCE button of the pump pendant control. This will push the rear of the tool backwards until the reaction arm comes into contact with the chosen reaction point. ENSURE ALL BODY PARTS AND CLOTHING ARE FREE OF THIS AREA .

    STEP 2. Hold down the ADVANCE button on the pendant control as the torque wrench continues to operate. You will hear an audible CLICK once the torque wrench has reached its full extension.

    If you continue to hold down the ADVANCE button at this point, the pump will continue to build pressure to the preset pressure that was set earlier. This does not indicate that the proper torque has been applied to the bolt/nut. It only indicates that the cylinder is extended and is unable to rotate further until the torque wrench resets.

    STEP 3. Release the ADVANCE button after hearing the audible CLICK. This will reset the torque wrench. Once the torque wrench is reset, you will hear another audible CLICK. Each time the torque wrench is advanced and reset in this manner is considered a CYCLE. In order to obtain the proper amount of torque on the fastener, several CYCLES may need to be made until the tool stalls at the pre-set pressure/torque. Always cycle the torque wrench one final time to make sure the stall point has been reached.

    LOCK ON

    Should the torque wrench lock-on during operation, push down on the ADVANCE button to build pressure. Continue to hold the ADVANCE button down and push the drive release lever down. Release the ADVANCE button while continuing to hold the drive release lever down. This will allow the torque wrench to be removed.

    3.6 PUMP OPERATION LOOSENING Following the procedure in section 3.4 set the pump pressure to 9,000 PSI . Do not try to loosen bolt/nut with pump set at full 10,000 PSI. Change the torque wrench to the loosening mode and properly position on work piece.

    Press and hold the ADVANCE button on the pendant control. Pump pressure will decrease as the bolt/nut is loosened. Once the cylinder is fully extended you will hear an audible CLICK. Release the ADVANCE button and the torque wrench will reset. Once the torque wrench is reset, you will hear an audible CLICK. Continue to CYCLE the torque wrench until you can remove the fastener by hand.

    IMPORTANT! If the fastener does not loosen with the above procedure, you must select a larger torque wrench to remove the fastener.

  • EAGLEPROINDUSTRIALTOOLS,INC. 11 FORMNO.E09005REV.A.

    04 MAINTENANCE

    4.1 CHANGING THE HYDRAULIC FLUID

    IMPORTANT! In order to ensure proper operation of the electric pump, completely drain and clean the pump reservoir every 250 hours, or more frequently if used in dirty environments. In general hydraulic fluid should be a light yellow and transparent liquid. If hydraulic fluid appears dark or cloudy replace the fluid.

    Follow the steps below to change the hydraulic fluid.

    STEP 1. Ensure pump is unplugged from power source and system pressure has been released.

    STEP 2. Unscrew and remove the reservoir oil fill plug.

    STEP 3. Loosen reservoir drain plug using a 6mm hex wrench. See FIG K

    Drain oil into approved container and dispose of properly according to local regulations.

    STEP 5. Loosen the (4) 5mm hex socket bolts holding the roll cage to

    the pump reservoir. Remove pump from roll cage

    STEP 4. Unscrew and remove the (6 ) 5mm hex socket bolts holding

    the reservoir to the top plate of the hydraulic pump.

    STEP 5. Lift the top plate off of the pump reservoir, being careful not

    to damage the pump body and set aside.

    STEP 6. Clean the pump reservoir with a mild cleaning agent and

    wipe dry. Ensure that any small pieces of paper towel or rag

    are removed from the reservoir.

    STEP 7. Unscrew the oil filter by hand from the pump body and clean

    using a mild cleaning agent and a soft brush. Flush the filter with clean hydraulic fluid to ensure any

    cleaning agents and/or small particles have been removed from the filter. If the oil filter is damaged

    contact the nearest authorized Eagle Pro service center to order a replacement.

    STEP 8. Screw oil filter back onto pump body, be sure to only hand tighten oil filter. Over tightening may

    damage the pump body.

    STEP 9. Reassemble pump and reservoir and place back into roll cage, and secure assembled pump to roll

    cage.

    STEP 10. Once pump is completely assembled, add new, clean ISO #32 hydraulic fluid, see Section 02

    Initial Setup Instruction's on how to add hydraulic fluid.

    FIG K

    ReservoirOilDrainPlug

  • EAGLEPROINDUSTRIALTOOLS,INC. 12 FORMNO.E09005REV.A.

    05 Torque Wrench Pump Troubleshooting Problem PossibleCause

    1.FaultCondition2.PowerSwitchNotTurnedOn1.Lowhydraulicfluidlevel2.Leakingconnection3.Dirt/debrisinpump,filterclogged4.Reliefvalvesettoolow5.Directionalvalvefailure6.Powersupplyvoltagetoolow1.Loadgreaterthantorquewrenchcapacityatfullpressure2.Couplersnotcorrectlyassembled

    Couplerleaking 1.Couplerfailure1.Highpressurevalvesettoolow2.Highpressurevalvefailure3.Directionalvalvefailure

    1.Hydraulicconnectionsarenotconnectedproperly2.Couplerfailure

    Motorshutsoff 1.Motortemperatureistoohigh1.Oiltemperaturehasnotreached86F2.Temperaturesensorfailure3.Dirt/debrisincoolingsystem

    2.Pumprunningtoolong3.Workingenvironmentistoohotforpump

    1.Incorrectelectricalconnections

    2.ContactyourlocalAuthorizedEagleProServiceCenter3.ContactyourlocalAuthorizedEagleProServiceCenter

    2.Stopusingpumpandallowmotortocooltonormaloperatingtemperature3.Donotusepumpinextremelyhotenvironments

    1.Checkallelectricalconnectionsandensureyouareusingpropergaugeextensioncord

    2.ContactyourlocalAuthorizedEagleProServiceCenter3.ContactyourlocalAuthorizedEagleProServiceCenter

    1.Inspectallconnections,checkcouplersandreplaceanydamageditems2Replacecoupler(s)1.Allowmotortocooltonormaloperatingtemperature1.Oncehydraulicfluidreaches86F,systemwillturnonautomatically

    5.ContactyourlocalAuthorizedEagleProServiceCenter6.Inspectthepowerensureyouareusingpropergaugeextensioncord1.Replacetorquewrenchwithlargercapacityunit.2.Inspectallconnections,checkcouplersandreplaceanydamageditems1.Replacethecoupler(s)1.ContactyourlocalAuthorizedEagleProServiceCenter

    Torquewrenchsafetyvalvereleasingoil

    Oilcoolingsystemnotcooling

    hydraulicfluid

    Motorrunshot

    Solution1.Inspectthepowerensureyouareusingpropergaugeextensioncord2.TurnonthePowerSwitch1.Addhydraulicfluid2.Inspectallconnections,checkcouplersandreplaceanydamageditems3.Changehydraulicfluid4.ContactyourlocalAuthorizedEagleProServiceCenter

    PumpwillnotstartPumpwillnot

    deliverhydraulicoil,ordeliverslessthanratedflowrates,ordelivers

    erratically.Pumpbuildsfullpressure,torque

    SystempressuredoesnotreachratedpressureTorquewrenchcylinderwillnot

    retract1.Hydraulicconnectionsarenotconnectedproperly 1.Inspectallconnections,checkcouplersandreplaceanydamageditems

  • EAGLEPROINDUSTRIALTOOLS,INC. 13 FORMNO.E09005REV.A.

    TWP-2AF TORQUE WRENCH PUMP

  • EAGLEPROINDUSTRIALTOOLS,INC. 14 FORMNO.E09005REV.A.

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