Operating Instructions: HTL-PHP Air Torque Pump
Operating Instructions: HTL-PHP Air Torque Pump
HTL-PHP
Air Torque Pump
CONTENTS
Contents 2
Safety 2-3
Warranty 3
Connecting the system 3
Air Connections 4
General Information 4-5
Setting the torque and pressure 5-6
Tightening and loosening procedures 6-8
Operation 8
Maintenance 8-9
Troubleshooting guide 9
Testing 10
Declaration 11
Spare Parts 12-31
Contact Us 32
SAFETY
Tips
• Always wear the appropriate safety equipment when operating this equipment; such as
safety goggles or safety glasses and protective gloves.
• Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow
within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with
your hands.
Warnings
Any residual risks are identified within this manual with the equipment marked where
appropriate. Ensure these warnings are maintained.
2
The following label (s) are displayed on the machine for your safety, please observe all
warnings.
This warning indicates that there is a potential crush hazard and to keep
away from moving parts.
WARRANTY
HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year
from the date of shipment. The guarantee does not include the ordinary wear of both metal and
non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage
incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd.
Please note that if the equipment is disassembled or serviced by anyone other than an
authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void.
In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer
which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty
equipment, whichever is deemed most appropriate.
The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose
assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line
must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct
interconnection between the pump and wrench. Ensure the connectors are fully engaged and
screwed snugly together.
NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high
pressure on the retract side and your wrench is not able to work properly. To avoid tool
malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any
moment.
3
Connect the twin-line hose to the swivel as shown:
A
R
AIR CONNECTIONS
Ensure that you have sufficient air flow minimum flow rate 45 CFM (1275L/min) at 7 Bar
maximum pressure to operate the pneumatic pump. If in doubt, compare the pump
manufacturer’s recommended air flow rating prior to pressurising pump. Improper air flow may
damage the pump motor. For best results use air hoses equal to or larger than ¾” internal
diameter.
Use of a F.R.L. (Filter Regulator Lubricator) is essential (pictured below). Fill with oil and adjust
the air admission with the adjustment knob.
GENERAL INFORMATION
All HTL Power Packs operate at a pressure range from 500 to 10,000psi and are fully
adjustable. They have been engineered and designed for portability and high flow for increased
speed. Before using your HTL Power Pack, check the following points:
4
Working pressure
The pump’s maximum working pressure is 10,000psi / 700 Bar. Make sure all hydraulic
equipment and accessories are rated for 10,000psi / 700 Bar operating pressure.
Prior to use
Check hydraulic oil (use grade 46) level to prevent possible pump burnout. Open the filler plug
located on the reservoir plate. Look at oil fill level on the oil sight gauge. The oil level should be
approximately 2” from the top of the reservoir plate with motor off. Add oil as necessary. Do not
mix different grades of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure
before operating.
The use of a pressure gauge is required for normal pump operation. Mounted on the manifold,
the gauge permits the operator to monitor the load on the wrench. + / -3% calibrated gauges are
available for most applications.
Once the system is fully connected and correct power supply available, it is time to adjust the
pump pressure to the level needed on your job.
When tightening, use the manufacturer’s specifications to determine the torque value which you
will ultimately require.
Torque sequence may vary between workpieces, even within individual plants, depending upon
the gasket material, etc.
Next, use the pressure-torque conversion chart that is provided for the individual tool, similar to
the one below.
5
Assume you are going to use a HTL-W2 tool to torque a 1 ¼” bolt to 835lb.ft
1. First check the serial no. on the tool corresponds to the torque chart.
2. On the left hand side of the chart is the torque values. Find 835lb.ft on column.
3. Then move across the chart until you come to a diagonal line.
4. At this point, move down to the bottom of the chart. The corresponding pressure value can be
found.
5. For example the pressure is 5,300psi on a tool to produce 835lb.ft
6. Now set pressure on pump as follows in next section.
1. Loosen the knurled locking ring below the T handle on the pump’s external pressure
regulator. Then turn the T handle as shown overleaf, counter clockwise until it turns
freely and easily.
2. Turn the pump on. Using the pump’s remote control pendant, push down the advance
switch (or button on air pumps) and hold it.
3. While holding the pump in the advance mode, slowly turn the T handle clockwise and
observe the pump pressure gauge rise.
4. When your gauge reaches 4,000psi, stop turning the T handle and let the gauge settle
out.
5. If the pressure continues to rise (above 4,000psi), release the advance button and back
off your pressure slightly - by turning CCW on the T handle.
6. Then re-depress the advance switch on your remote and slowly bring pressure up to
4,000psi again.
7. When the pressure is correct, turn the pump off and tighten the knurled lock nut
provided under the T handle. This sets pump pressure, which determines torque tool
output.
8. Once your target pressure is set and locked, cycle the pump once more to ensure that
your pressure setting did not change as you turned down the knurled knob.
1. Once you have set the required hydraulic pressure on the pump, cycle the tool three or
four times to ensure that the tool is operating correctly and the ratcheting mechanism is
6
working.
2. Place the ratchet link or impact socket and tool, onto the nut that is to be tightened.
3. Make sure that the reaction point of the tool is squarely against the point of reaction
(usually the adjacent nut).
4. Make sure that the hose connections are clear of any obstructions.
5. Ensure that the person using the equipment has no body parts in the way of the tool.
Appropriate PPE should be worn at all times.
6. Once everything is safe and ready to go, apply momentary pressure to the tool,
checking that it is reacting against the desired point of reaction correctly. If it doesn’t
look right, stop and readjust the positioning.
7. Now that you’re ready to tighten the nut, press the advance button on the hand control.
The rear of the tool / reaction arm, will move against the reaction point, then the ratchet
link will turn the nut until the tool has reached the end of its stroke. The pressure will
build up to the set pressure.
8. Release the button and the piston will retract, you will hear the ratchet click. This is
ready to advance again.
10. Follow this sequence again and again until the ratchet link/tool cannot turn any further.
Always give it a couple of extra advances to ensure that it is not turning.
NOTE: The reading of full preset pressure after the cylinder has advanced does not indicate that
the nut is tightened. It only shows that the cylinder is at full stroke and can’t turn the link
anymore. You must continue to cycle the tool until it stops turning.
Loosening
NOTE: As you don’t know how tight the nut is that you are going to loosen and it may well have
been in place a long time, it will probably take a lot more torque to loosen the nut than it did to
tighten it originally.
1. Connect all the equipment together as previously done, ensuring that you have the
correct sized ratchet link for the nut.
2. Next, set the pump pressure to 10,000psi (maximum pressure of tool) to make sure you
can get maximum torque for the tool.
3. As with the tightening procedure, make sure that when you fit the link/tool on the nut in
the loosening direction, it must react squarely against the reaction point.
4. Apply pressure and check that the tool is reacting correctly. Also take precautions as
7
previous (hoses and fittings clear of obstructions and personnel safety).
5. Now, advance tool and build pressure up. The nut should start to loosen slowly.
However, sometimes it takes a few applications of pressure before the nut starts to turn.
6. As with tightening, once the cylinder has reached the end of its stroke, release button
and tool with reset. Continue to press advance button on and off until the nut is
loosened.
OPERATION
Before starting your pump, connect your hydraulic hoses to both the pump and the torque
wrench.
On air pumps, press advance button briefly, the air motor will start and the torque wrench will be
in retract position. To advance torque wrench, keep the advance button pressed. To retract the
wrench, release the advance button. To stop the pump, press the other button on the hand
control.
MAINTENANCE
HTL Hydraulic Power Packs are precision-built units and, as such, do require a certain amount
of care and maintenance.
• Hydraulic Oil - Oil should be completely changed after every 40 hours of operation, or
at least twice a year. Always make sure the reservoir is filled with fluid. If additional oil is
required, use only high grade hydraulic oil grade 46. The oil should never get to a milky
colour state.
• Quick-Disconnects - Fittings should be checked periodically for leaks. Dirt or foreign
materials should be kept away from fittings. Clean before use.
• Hydraulic Gauge - Some gauges are liquid filled. Should this liquid level drop, it
indicates external leakage, and replacement is necessary. Should the gauge fill with
hydraulic oil, it indicates internal failure and it should be discarded. HTL recommends
that gauges are calibrated every 12 months.
• Filter on Pump - The filter should be replaced twice a year in normal use and more
often if the pump is used daily or in a dirty, harsh environment.
• Lubricator Oil Level - Check regularly and top up with HTL Pro-Air oil.
• Remote Control - The airline to the remote control unit should be checked for
obstructions or kinks in the line periodically. If there is a bend or break in the line, it must
be replaced. exist.
• Air Valve - This valve should be checked twice a year.
• Pumping Unit - The pump should be overhauled every year. This can be done by your
local distributor.
8
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE SOLUTION
Internal leak in oil line from Open reservoir, inspect oil line while
external relief valve to pump trying to build pressure if leaking tighten
body. fittings or replace.
9
TESTING
Test 1
Attach hoses to pump and tool in the normal manner. Press the advance button and hold it
down. If the pump pressure builds and the hoses flex but the tool still refuses to cycle, the
problem is most likely a loose or defective coupling connection. To find out where the bad
coupling is, remove the tool from the hoses and marry the loose ends together and cycle the
pump. If the gauge pressure reads no more than 500 psi, then the defective connection is on the
tool. A significantly greater pressure indicates that the problem is in either the pump or a hose
fitting.
Test 2
Remove screws from pump motor to reservoir, slide pump motor to the back while keeping
pistons into oil. Turn pump on. If no oil is coming out from the solenoid tube, change the
solenoid. Tighten the regulating valve to maximum, push on the advance button and while
holding down, look if any oil is coming out from the regulating tube. If oil is coming out, change
the regulating valve.
Test 3
Remove tool from hoses. Cycle pump. If pump fails to build pressure, the problem is with the
pump. If it does build pressure, the problem is with hydraulic blow-by in the tool.
Test 4
Connect the tool, pump and hoses together as normal. Cycle the pump several times. Cycle the
system once more and observe the sequence of operation. As you depress the advance button,
the tool drive should turn about 24 degrees. At this point, release the advance button. You
should see no further movement and after a moment you will hear another click. This is how the
tools are designed to operate. If you observe any other sequence of operation, the system is out
of order. Take immediate corrective action. For reference, tools and pumps are designed from
the factory plumbed as follows. This ensures that the tool, pump and ONE hose cannot possibly
be connected up incorrectly.
NOTE: Connecting two or any even number of hoses together creates one hose which is
plumbed backwards. Male to Female and Female to Male. This will cause the system to operate
backwards per Test #4 above. If your hose isn’t long enough, connect 3 hoses together, move
your pump or call HTL for a longer hose assembly.
10
DECLARATION
11
OPERATING INSTRUCTIONS
HTL-EHP110V
Electric 110v Torque Pump
CONTENTS
Contents 2
Safety 2-3
Warranty 3
Connecting the system 3-4
Electrical Connections 4
General Information 4-5
Setting the torque and pressure 5-7
Tightening and loosening procedures 7-8
Operation 8-9
Maintenance 9
Testing 9-10
Troubleshooting guide 10-12
Declaration 13
Spare Parts 14-27
Contact Us 28
SAFETY
Tips
• Always wear the appropriate safety equipment when operating this equipment; such as
safety goggles or safety glasses and protective gloves.
• Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow
within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with
your hands.
Warnings
Any residual risks are identified within this manual with the equipment marked where
appropriate. Ensure these warnings are maintained.
2
The following label (s) are displayed on the machine for your safety, please observe all
warnings.
• You can be injured if you do not obey the safety instructions as
indicated on warning stickers.
• Observe all safety instructions and warnings attached to the machine
• Ensure that safety instructions and warnings attached to the machine
are always complete and perfectly legible.
• Keep warnings and instruction labels clean.
• Replace unreadable or missing labels with new ones before operating
the machine. Make sure replacement parts include warning or
instruction labels where necessary.
This warning indicates that there is a potential crush hazard and to keep
away from moving parts.
WARRANTY
HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year
from the date of shipment. The guarantee does not include the ordinary wear of both metal and
non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage
incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd.
Please note that if the equipment is disassembled or serviced by anyone other than an
authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void.
In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer
which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty
equipment, whichever is deemed most appropriate.
The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose
assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line
must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct
interconnection between the pump and wrench. Ensure the connectors are fully engaged and
screwed snugly together.
NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high
pressure on the retract side and your wrench is not able to work properly. To avoid tool
malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any
moment.
3
A
R
Ensure connectors are fully engaged and screwed closely and completely together.
ELECTRIC CONNECTIONS
Ensure correct power availability to prevent motor failure or dangerous electrical overloading.
Electrical supply:
Minimize the length of extension cords and be sure they are of adequate wire size, with ground
connections.
WARNING: Electric motors may spark. Do not operate in an explosive atmosphere or in the
presence of conductive liquids. If using in a hazardous or explosive atmosphere ensure pump is
ATEX approved or approved to the relevant zone.
GENERAL INFORMATION
All HTL Power Packs operate at a pressure range from 500 to 10,000psi and are fully
adjustable. They have been engineered and designed for portability and high flow for increased
speed. Before using your HTL Power Pack, check the following points:
Working pressure
The pump’s maximum working pressure is 10,000psi / 700 Bar. Make sure all hydraulic
equipment and accessories are rated for 10,000psi / 700 Bar operating pressure.
Hydraulic connection
Never disconnect or connect hydraulic hoses or fittings without first retracting the wrench.
Unplug the electrical cord of the pump, and open all hydraulic controls several times to ensure
that the system has been depressurised. If the system includes a gauge, double check the
gauge to ensure pressure has been released. When making a connection with quick disconnect
couplings, make sure the couplings are fully engaged and threaded connections such a fittings,
4
gauges etc, are clean, securely tightened and leak free.
Electrical power
3. Do not use a power or extension cord that is damaged or has exposed wiring. All single
phase motors come equipped with a three prong grounding type plus to fit the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as
the pump’s motor must be grounded.
Prior to use
Check hydraulic oil (use grade 46) level to prevent possible pump burnout. Open the filler plug
located on the reservoir plate. Look at oil fill level on the oil sight gauge. The oil level should be
approximately 2” from the top of the reservoir plate with motor off. Add oil as necessary. Do not
mix different grades of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure
before operating.
The use of a pressure gauge is required for normal pump operation. Mounted on the manifold,
the gauge permits the operator to monitor the load on the wrench. + / -3% calibrated gauges are
available for most applications.
Once the system is fully connected and correct power supply available, it is time to adjust the
pump pressure to the level needed on your job.
5
When tightening, use the manufacturer’s specifications to determine the torque value which you
will ultimately require.
Torque sequence may vary between workpieces, even within individual plants, depending upon
the gasket material, etc.
Next, use the pressure-torque conversion chart that is provided for the individual tool, similar to
the one below.
Assume you are going to use a HTL-W2 tool to torque a 1 ¼” bolt to 835lb.ft
• First check the serial no. on the tool corresponds to the torque chart.
• On the left hand side of the chart is the torque values. Find 835lb.ft on column.
• Then move across the chart until you come to a diagonal line.
• At this point, move down to the bottom of the chart. The corresponding pressure value
can be found.
• For example the pressure is 5,300psi on a tool to produce 835lb.ft
• Now set pressure on pump as follows in next section.
1. Loosen the knurled locking ring below the T handle on the pump’s external pressure
regulator. Then turn the T handle as shown overleaf, counter clockwise until it turns
freely and easily.
2. Turn the pump on. Using the pump’s remote control pendant, push down the advance
switch and hold it.
6
3. While holding the pump in the advance mode, slowly turn the T handle clockwise and
observe the pump pressure gauge rise.
4. When your gauge reaches 4,000psi, stop turning the T handle and let the gauge settle
out.
5. If the pressure continues to rise (above 4,000psi), release the advance button and back
off your pressure slightly - by turning CCW on the T handle.
6.
6. Then re-depress the advance switch on your remote and slowly bring pressure up to
4,000psi again.
7. When the pressure is correct, turn the pump off and tighten the knurled lock nut
provided under the T handle. This sets pump pressure, which determines torque tool
output.
8. Once your target pressure is set and locked, cycle the pump once more to ensure that
your pressure setting did not change as you turned down the knurled knob.
1. Once you have set the required hydraulic pressure on the pump, cycle the tool three or
four times to ensure that the tool is operating correctly and the ratcheting mechanism is
working.
2. Place the ratchet link or impact socket and tool, onto the nut that is to be tightened.
3. Make sure that the reaction point of the tool is squarely against the point of reaction
(usually the adjacent nut).
4. Make sure that the hose connections are clear of any obstructions.
5. Ensure that the person using the equipment has no body parts in the way of the tool.
Appropriate PPE should be worn at all times.
6. Once everything is safe and ready to go, apply momentary pressure to the tool,
checking that it is reacting against the desired point of reaction correctly. If it doesn’t
look right, stop and readjust the positioning.
7. Now that you’re ready to tighten the nut, press the advance button on the hand control.
The rear of the tool / reaction arm, will move against the reaction point, then the ratchet
link will turn the nut until the tool has reached the end of its stroke. The pressure will
build up to the set pressure.
7
8. Release the button and the piston will retract, you will hear the ratchet click. This is
ready to advance again.
10. Follow this sequence again and again until the ratchet link/tool cannot turn any further.
Always give it a couple of extra advances to ensure that it is not turning.
NOTE: The reading of full preset pressure after the cylinder has advanced does not indicate that
the nut is tightened. It only shows that the cylinder is at full stroke and can’t turn the link
anymore. You must continue to cycle the tool until it stops turning.
Loosening
NOTE: As you don’t know how tight the nut is that you are going to loosen and it may well have
been in place a long time, it will probably take a lot more torque to loosen the nut than it did to
tighten it originally.
1. Connect all the equipment together as previously done, ensuring that you have the
correct sized ratchet link for the nut.
2. Next, set the pump pressure to 10,000psi (maximum pressure of tool) to make sure you
can get maximum torque for the tool.
3. As with the tightening procedure, make sure that when you fit the link/tool on the nut in
the loosening direction, it must react squarely against the reaction point.
4. Apply pressure and check that the tool is reacting correctly. Also take precautions as
previous (hoses and fittings clear of obstructions and personnel safety).
5. Now, advance tool and build pressure up. The nut should start to loosen slowly.
However, sometimes it takes a few applications of pressure before the nut starts to turn.
6. As with tightening, once the cylinder has reached the end of its stroke, release button
and tool with reset. Continue to press advance button on and off until the nut is
loosened.
OPERATION
Before starting your pump, connect your hydraulic hoses to both the pump and the torque
wrench.
On electric pumps, press and momentarily hold the green button on the hand control, this will
start the electric motor and put the torque wrench in retract position. To advance and retract the
torque wrench, press the yellow button on and off. To stop the pump, press the red button.
The pump is fitted with a timer; If left running for longer than 60 seconds without activation of the
8
advance button the power will be cut. This is to prevent the motor overheating and aid energy
efficiency. Re-start using the green button.
MAINTENANCE
HTL Hydraulic Power Packs are precision-built units and, as such, do require a certain amount
of care and maintenance.
• Hydraulic Oil - Oil should be completely changed after every 40 hours of operation, or
at least twice a year. Always make sure the reservoir is filled with fluid. If additional oil is
required, use only high grade hydraulic oil grade 46. The oil should never get to a milky
colour state.
• Quick-Disconnects - Fittings should be checked periodically for leaks. Dirt or foreign
materials should be kept away from fittings. Clean before use.
• Hydraulic Gauge - Some gauges are liquid filled. Should this liquid level drop, it
indicates external leakage, and replacement is necessary. Should the gauge fill with
hydraulic oil, it indicates internal failure and it should be discarded. HTL recommends
that gauges are calibrated every 12 months.
• Filter on Pump - The filter should be replaced twice a year in normal use and more
often if the pump is used daily or in a dirty, harsh environment.
• Remote Control - The spring loaded buttons on the remote handle should be checked
in the event of operating difficulties. The switch buttons should be checked periodically if
any indications of problems exist.
• Armature - (Electric Motor) Checked yearly.
• Pumping Unit - The pump should be overhauled every year.
TESTING
Test 1
Attach hoses to pump and tool in the normal manner. Press the advance button and hold it
down. If the pump pressure builds and the hoses flex but the tool still refuses to cycle, the
problem is most likely a loose or defective coupling connection. To find out where the bad
coupling is, remove the tool from the hoses and marry the loose ends together and cycle the
pump. If the gauge pressure reads no more than 500 psi, then the defective connection is on the
tool. A significantly greater pressure indicates that the problem is in either the pump or a hose
fitting.
Test 2
Remove screws from pump motor to reservoir, slide pump motor to the back while keeping
pistons into oil. Turn pump on. If no oil is coming out from the solenoid tube, change the
solenoid. Tighten the regulating valve to maximum, push on the advance button and while
holding down, look if any oil is coming out from the regulating tube. If oil is coming out, change
the regulating valve.
Test 3
Remove tool from hoses. Cycle pump. If pump fails to build pressure, the problem is with the
9
pump. If it does build pressure, the problem is with hydraulic blow-by in the tool.
Test 4
Connect the tool, pump and hoses together as normal. Cycle the pump several times. Cycle the
system once more and observe the sequence of operation. As you depress the advance button,
the tool drive should turn about 24 degrees. At this point, release the advance button. You
should see no further movement and after a moment you will hear another click. This is how the
tools are designed to operate. If you observe any other sequence of operation, the system is out
of order. Take immediate corrective action. For reference, tools and pumps are designed from
the factory plumbed as follows. This ensures that the tool, pump and ONE hose cannot possibly
be connected up incorrectly.
NOTE: Connecting two or any even number of hoses together creates one hose which is
plumbed backwards. Male to Female and Female to Male. This will cause the system to operate
backwards per Test #4 above. If your hose isn’t long enough, connect 3 hoses together, move
your pump or call HTL for a longer hose assembly.
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE SOLUTION
10
SYMPTOM PROBABLE CAUSE SOLUTION
Internal leak in oil line from Open reservoir, inspect oil line while
external relief valve to pump trying to build pressure if leaking tighten
body. fittings or replace.
11
SYMPTOM PROBABLE CAUSE SOLUTION
12
DECLARATION
13
OPERATING INSTRUCTIONS
HTL-EHP230V
Electric 230v Torque Pump
CONTENTS
Contents 2
Safety 2-3
Warranty 3
Connecting the system 3-4
Electrical Connections 4
General Information 4-5
Setting the torque and pressure 5-7
Tightening and loosening procedures 7-8
Operation 8-9
Maintenance 9
Testing 9-10
Troubleshooting guide 10-12
Declaration 13
Spare Parts 14-27
Contact Us 28
SAFETY
Tips
• Always wear the appropriate safety equipment when operating this equipment; such as
safety goggles or safety glasses and protective gloves.
• Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow
within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with
your hands.
Warnings
Any residual risks are identified within this manual with the equipment marked where
appropriate. Ensure these warnings are maintained.
2
The following label (s) are displayed on the machine for your safety, please observe all
warnings.
• You can be injured if you do not obey the safety instructions as
indicated on warning stickers.
• Observe all safety instructions and warnings attached to the machine
• Ensure that safety instructions and warnings attached to the machine
are always complete and perfectly legible.
• Keep warnings and instruction labels clean.
• Replace unreadable or missing labels with new ones before operating
the machine. Make sure replacement parts include warning or
instruction labels where necessary.
This warning indicates that there is a potential crush hazard and to keep
away from moving parts.
WARRANTY
HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year
from the date of shipment. The guarantee does not include the ordinary wear of both metal and
non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage
incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd.
Please note that if the equipment is disassembled or serviced by anyone other than an
authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void.
In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer
which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty
equipment, whichever is deemed most appropriate.
The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose
assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line
must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct
interconnection between the pump and wrench. Ensure the connectors are fully engaged and
screwed snugly together.
NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high
pressure on the retract side and your wrench is not able to work properly. To avoid tool
malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any
moment.
3
A
R
Ensure connectors are fully engaged and screwed closely and completely together.
ELECTRIC CONNECTIONS
Ensure correct power availability to prevent motor failure or dangerous electrical overloading.
Electrical supply:
Minimize the length of extension cords and be sure they are of adequate wire size, with ground
connections.
WARNING: Electric motors may spark. Do not operate in an explosive atmosphere or in the
presence of conductive liquids. If using in a hazardous or explosive atmosphere ensure pump is
ATEX approved or approved to the relevant zone.
GENERAL INFORMATION
All HTL Power Packs operate at a pressure range from 500 to 10,000psi and are fully
adjustable. They have been engineered and designed for portability and high flow for increased
speed. Before using your HTL Power Pack, check the following points:
Working pressure
The pump’s maximum working pressure is 10,000psi / 700 Bar. Make sure all hydraulic
equipment and accessories are rated for 10,000psi / 700 Bar operating pressure.
Hydraulic connection
Never disconnect or connect hydraulic hoses or fittings without first retracting the wrench.
Unplug the electrical cord of the pump, and open all hydraulic controls several times to ensure
that the system has been depressurised. If the system includes a gauge, double check the
gauge to ensure pressure has been released. When making a connection with quick disconnect
couplings, make sure the couplings are fully engaged and threaded connections such a fittings,
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gauges etc, are clean, securely tightened and leak free.
Electrical power
3. Do not use a power or extension cord that is damaged or has exposed wiring. All single
phase motors come equipped with a three prong grounding type plus to fit the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as
the pump’s motor must be grounded.
Prior to use
Check hydraulic oil (use grade 46) level to prevent possible pump burnout. Open the filler plug
located on the reservoir plate. Look at oil fill level on the oil sight gauge. The oil level should be
approximately 2” from the top of the reservoir plate with motor off. Add oil as necessary. Do not
mix different grades of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure
before operating.
The use of a pressure gauge is required for normal pump operation. Mounted on the manifold,
the gauge permits the operator to monitor the load on the wrench. + / -3% calibrated gauges are
available for most applications.
Once the system is fully connected and correct power supply available, it is time to adjust the
pump pressure to the level needed on your job.
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When tightening, use the manufacturer’s specifications to determine the torque value which you
will ultimately require.
Torque sequence may vary between workpieces, even within individual plants, depending upon
the gasket material, etc.
Next, use the pressure-torque conversion chart that is provided for the individual tool, similar to
the one below.
Assume you are going to use a HTL-W2 tool to torque a 1 ¼” bolt to 835lb.ft
• First check the serial no. on the tool corresponds to the torque chart.
• On the left hand side of the chart is the torque values. Find 835lb.ft on column.
• Then move across the chart until you come to a diagonal line.
• At this point, move down to the bottom of the chart. The corresponding pressure value
can be found.
• For example the pressure is 5,300psi on a tool to produce 835lb.ft
• Now set pressure on pump as follows in next section.
1. Loosen the knurled locking ring below the T handle on the pump’s external pressure
regulator. Then turn the T handle as shown overleaf, counter clockwise until it turns
freely and easily.
2. Turn the pump on. Using the pump’s remote control pendant, push down the advance
switch and hold it.
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3. While holding the pump in the advance mode, slowly turn the T handle clockwise and
observe the pump pressure gauge rise.
4. When your gauge reaches 4,000psi, stop turning the T handle and let the gauge settle
out.
5. If the pressure continues to rise (above 4,000psi), release the advance button and back
off your pressure slightly - by turning CCW on the T handle.
6.
6. Then re-depress the advance switch on your remote and slowly bring pressure up to
4,000psi again.
7. When the pressure is correct, turn the pump off and tighten the knurled lock nut
provided under the T handle. This sets pump pressure, which determines torque tool
output.
8. Once your target pressure is set and locked, cycle the pump once more to ensure that
your pressure setting did not change as you turned down the knurled knob.
1. Once you have set the required hydraulic pressure on the pump, cycle the tool three or
four times to ensure that the tool is operating correctly and the ratcheting mechanism is
working.
2. Place the ratchet link or impact socket and tool, onto the nut that is to be tightened.
3. Make sure that the reaction point of the tool is squarely against the point of reaction
(usually the adjacent nut).
4. Make sure that the hose connections are clear of any obstructions.
5. Ensure that the person using the equipment has no body parts in the way of the tool.
Appropriate PPE should be worn at all times.
6. Once everything is safe and ready to go, apply momentary pressure to the tool,
checking that it is reacting against the desired point of reaction correctly. If it doesn’t
look right, stop and readjust the positioning.
7. Now that you’re ready to tighten the nut, press the advance button on the hand control.
The rear of the tool / reaction arm, will move against the reaction point, then the ratchet
link will turn the nut until the tool has reached the end of its stroke. The pressure will
build up to the set pressure.
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8. Release the button and the piston will retract, you will hear the ratchet click. This is
ready to advance again.
10. Follow this sequence again and again until the ratchet link/tool cannot turn any further.
Always give it a couple of extra advances to ensure that it is not turning.
NOTE: The reading of full preset pressure after the cylinder has advanced does not indicate that
the nut is tightened. It only shows that the cylinder is at full stroke and can’t turn the link
anymore. You must continue to cycle the tool until it stops turning.
Loosening
NOTE: As you don’t know how tight the nut is that you are going to loosen and it may well have
been in place a long time, it will probably take a lot more torque to loosen the nut than it did to
tighten it originally.
1. Connect all the equipment together as previously done, ensuring that you have the
correct sized ratchet link for the nut.
2. Next, set the pump pressure to 10,000psi (maximum pressure of tool) to make sure you
can get maximum torque for the tool.
3. As with the tightening procedure, make sure that when you fit the link/tool on the nut in
the loosening direction, it must react squarely against the reaction point.
4. Apply pressure and check that the tool is reacting correctly. Also take precautions as
previous (hoses and fittings clear of obstructions and personnel safety).
5. Now, advance tool and build pressure up. The nut should start to loosen slowly.
However, sometimes it takes a few applications of pressure before the nut starts to turn.
6. As with tightening, once the cylinder has reached the end of its stroke, release button
and tool with reset. Continue to press advance button on and off until the nut is
loosened.
OPERATION
Before starting your pump, connect your hydraulic hoses to both the pump and the torque
wrench.
On electric pumps, press and momentarily hold the green button on the hand control, this will
start the electric motor and put the torque wrench in retract position. To advance and retract the
torque wrench, press the yellow button on and off. To stop the pump, press the red button.
The pump is fitted with a timer; If left running for longer than 60 seconds without activation of the
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advance button the power will be cut. This is to prevent the motor overheating and aid energy
efficiency. Re-start using the green button.
MAINTENANCE
HTL Hydraulic Power Packs are precision-built units and, as such, do require a certain amount
of care and maintenance.
• Hydraulic Oil - Oil should be completely changed after every 40 hours of operation, or
at least twice a year. Always make sure the reservoir is filled with fluid. If additional oil is
required, use only high grade hydraulic oil grade 46. The oil should never get to a milky
colour state.
• Quick-Disconnects - Fittings should be checked periodically for leaks. Dirt or foreign
materials should be kept away from fittings. Clean before use.
• Hydraulic Gauge - Some gauges are liquid filled. Should this liquid level drop, it
indicates external leakage, and replacement is necessary. Should the gauge fill with
hydraulic oil, it indicates internal failure and it should be discarded. HTL recommends
that gauges are calibrated every 12 months.
• Filter on Pump - The filter should be replaced twice a year in normal use and more
often if the pump is used daily or in a dirty, harsh environment.
• Remote Control - The spring loaded buttons on the remote handle should be checked
in the event of operating difficulties. The switch buttons should be checked periodically if
any indications of problems exist.
• Armature - (Electric Motor) Checked yearly.
• Pumping Unit - The pump should be overhauled every year.
TESTING
Test 1
Attach hoses to pump and tool in the normal manner. Press the advance button and hold it
down. If the pump pressure builds and the hoses flex but the tool still refuses to cycle, the
problem is most likely a loose or defective coupling connection. To find out where the bad
coupling is, remove the tool from the hoses and marry the loose ends together and cycle the
pump. If the gauge pressure reads no more than 500 psi, then the defective connection is on the
tool. A significantly greater pressure indicates that the problem is in either the pump or a hose
fitting.
Test 2
Remove screws from pump motor to reservoir, slide pump motor to the back while keeping
pistons into oil. Turn pump on. If no oil is coming out from the solenoid tube, change the
solenoid. Tighten the regulating valve to maximum, push on the advance button and while
holding down, look if any oil is coming out from the regulating tube. If oil is coming out, change
the regulating valve.
Test 3
Remove tool from hoses. Cycle pump. If pump fails to build pressure, the problem is with the
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pump. If it does build pressure, the problem is with hydraulic blow-by in the tool.
Test 4
Connect the tool, pump and hoses together as normal. Cycle the pump several times. Cycle the
system once more and observe the sequence of operation. As you depress the advance button,
the tool drive should turn about 24 degrees. At this point, release the advance button. You
should see no further movement and after a moment you will hear another click. This is how the
tools are designed to operate. If you observe any other sequence of operation, the system is out
of order. Take immediate corrective action. For reference, tools and pumps are designed from
the factory plumbed as follows. This ensures that the tool, pump and ONE hose cannot possibly
be connected up incorrectly.
NOTE: Connecting two or any even number of hoses together creates one hose which is
plumbed backwards. Male to Female and Female to Male. This will cause the system to operate
backwards per Test #4 above. If your hose isn’t long enough, connect 3 hoses together, move
your pump or call HTL for a longer hose assembly.
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE SOLUTION
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SYMPTOM PROBABLE CAUSE SOLUTION
Internal leak in oil line from Open reservoir, inspect oil line while
external relief valve to pump trying to build pressure if leaking tighten
body. fittings or replace.
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SYMPTOM PROBABLE CAUSE SOLUTION
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DECLARATION
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CONTACT US
HTL Group Corporate Headquarters
45 Colbourne Avenue
Nelson Park Industrial Estate
Cramlington
Northumberland
UK
NE23 1WD
Phone: +31 (0) 88 028 4800 Phone: +61 (0) 89 249 3980
Email: info@htl-europe.com Email: info@htl-australasia.com
www.htlgroup.com
Rev.1118-2
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