Graco CED2 User Manual

Operation, Repair, Parts

Renegade TSP

3A6884B

Torque Series Pump

Renegade TSP is a hydraulic power pack for use with bolt torquing wrenches only. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

Models: 17U632, 17U633, 17U634, 17U635

10,000 psi (68.9 MPa, 700 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual and on the unit before using the equipment. Be familiar with the controls and the proper usage of the equipment. Save these instructions.

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pendant Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fill Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Prime TSP Power Pack Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connect Hose and Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hose Prime Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Main Menu Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Change Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Select Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Secondary Menu (Stored Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Recycling and Disposal at End of Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2-Way, Poppet Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Pressure Set Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure Relief Valve Replacement (1,500 and 12,000 PSI) . . . . . . . . . . . . . . 33

4-Way Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Transducer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Pendant Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Wiring Diagram - 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wiring Diagram - 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Renegade TSP Torque Series Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Manifold Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Motor Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Control Box Parts - 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Control Box Parts - 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Radio Frequency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2 3A6884B

Models

Model

No. Name Voltage Pendant

17U632

17U633

17U634

17U635

Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump

120V

230V

Corded 10,000 psi (68.9 MPa, 700 bar)

Wireless 10,000 psi (68.9 MPa, 700 bar)

Corded 10,000 psi (68.9 MPa, 700 bar)

Wireless 10,000 psi (68.9 MPa, 700 bar)

Maximum Working Pressure

psi (MPa, bar)

3A6884B 3

Warnings

WARNING

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

GROUNDING

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with an appropriate grounding electrical inlet. This product must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and regulations.

• Improper installation of the grounding electrical inlet is able to result in a risk of electric

shock.

• When repair or replacement of the electrical inlet is required, do not connect the grounding

wire to either flat blade terminal.

• The wire with insulation having an outer surface that is green with or without yellow stripes

is the grounding wire.

• Check with a qualified electrician or serviceman when the grounding instructions are not

completely understood, or when in doubt as to whether the product is properly grounded.

• Do not modify the electrical inlet. Only connect the product to an extension cord having the

same configuration as the electrical inlet.

• This product is for use on a nominal 120V or 230V circuit and has a grounding electrical

inlet as illustrated in the figure below.

• Do not use a 3-to-2 adapter with this product.

• Extension Cords:

• Use only a 3-wire extension cord that has a grounding plug and a grounding receptacle that

mates with the electrical inlet on the product.

• Make sure your extension cord is not damaged. Use 12 AWG (2.5 mm

the current that the product draws.

) minimum to carry

• An undersized cord results in a drop in line voltage and loss of power and overheating.

4 3A6884B

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure leaks are able to inject oil into the body and cause serious bodily injury that can result in amputation. In the event that injection occurs, get immediate surgical treatment.

• Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin,

causing serious injury.

• Do not stop or deflect leaks with your hand, body, glove or rag.

• Do not leave the unit energized or under pressure while unattended. When the unit is not

in use, turn off the unit and follow the Pressure Relief Procedure.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

•

This system is capable of producing 10,000 psi (68.9 MPa, 700 bar). Use Graco replacement parts or accessories that are rated at a minimum of 10,000 psi (68.9 MPa, 700 bar).

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the

controls.

FIRE AND EXPLOSION HAZARD

Flammable fumes in work area can ignite or explode. To help prevent fire and explosion:

• This equipment generates sparks. Do not use in explosive atmospheres or hazardous

(classified) locations.

• Use only in well-ventilated areas.

• Do not plug or unplug power cords, or turn power or light switches on or off, when

flammable fumes are present.

• Keep work area free of debris, including solvent, rags, and gasoline.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate near children. Keep children away from equipment at all times.

• Do not overreach or stand on an unstable support. Keep effective footing and balance at

all times.

• Stay alert and watch what you are doing.

• Do not leave the unit energized or under pressure while unattended. When the unit is not

in use, turn off the unit and follow the Pressure Relief Procedure.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Avoid damaging hydraulic hoses. Avoid sharp bends and kinks when routing hydraulic

hoses. Do not kink or over-bend the hose. Using a bent or kinked hose will cause severe back-pressure. Sharp bends or kinks will cause internal damage to the hose leading to premature hose failure.

• Do not drop heavy objects on hydraulic hoses. A sharp impact may result in internal

damage to the hose. Applying pressure to a damaged hose may cause it to rupture.

• Do not expose the hose to temperatures or to pressures in excess of those specified by

the hose manufacturer.

• Do not use the hose as a strength member to pull or lift the equipment.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals

and create safety hazards.

• The system operating pressure must not exceed the pressure rating of the lowest rated

piece in the system.

•

Make sure all equipment is rated and approved for the environment in which you are using it.

3A6884B 5

Warnings

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect extension cord before servicing equipment.

• Connect only to grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on electrical inlet and extension cords.

• Store indoors.

LIFTING HAZARD

This equipment is heavy. To avoid injury, lift using:

• Two persons, or

• A hoist attach to the Lift Point.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure

and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eye wear and hearing protection.

6 3A6884B

Component Identification

Pendant

Oil Fill Cap (Breather)

Oil Level Sight

Electrical Inlet

15/20A Switch (120V only)

Pressure Relief Button

Pressure Setting Valve

Hose Connection – Advance

Hose Connection – Return

Pendant Connector

3A6884B 7

Manual Advance Switch

On/Off Switch

Display

Display Button

Wireless Remote Signal Indicator

Pendant Advance Switch

Pressure Gauge Port

Pump Stop Switch

Lift Point

Pump Rod Puller

Component Identification

Controls and Indicators

Item Description

On/Off Switch Turns TSP power pack on or off. 15A/20A Switch

(120V only)

Pressure Setting Valve Controls pressure at the tool. Turn clockwise to increase pressure. Pressure Relief Button Relieves pressure in the system (pressure goes to zero). Manual Advance Switch

or Pendant Advance Switch

Display Shows pressure and other control information. Display Button Cycles Display through display information. Pendant Pump Stop

Switch

Sets TSP power pack to either 15A or 20A. Select setting based on your circuit rating. Select 20A when a 20A circuit is available. Using the 20A setting provides the maximum performance. Select 15A when a 15A circuit is available.

Activates pump to advance the tool when pressed.

Stops pump early if pump stop is needed.

8 3A6884B

Grounding

The equipment must be grounded to reduce the risk of electric shock. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Grounding

Power Requirements

100-120 VAC, 50/60 Hz, 15A/20A, single phase.

220-240 VAC, 50/60 Hz, 10A, single phase.

Extension Cords

Use a 3-wire extension cord with an undamaged ground contact.

Use a 3-wire, 12 AWG (2.5 mm extension cord. Longer cords and higher gauge cords reduce performance.

The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and regulations.

Do not modify plug! If it will not fit in outlet, have grounded outlet installed by a qualified electrician. Do not use an adapter.

) minimum

3A6884B 9

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this

symbol.

To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure before cleaning, checking, or servicing the equipment.

NOTE: The TSP power pack is designed to automatically relieve pressure when the pump motor stops.

1. Verify displayed pressure goes to zero when motor stops.

2. If pressure is not zero, then press Pressure Relief Button.

3. Verify pressure has dropped to zero.

4. If you suspect that pressure has not been fully relieved, rotate the Pressure Setting Valve counterclockwise until rotation stops.

10 3A6884B

Setup

FULL

Setup

Pendant Setup

Corded Pendant

Attach Corded Pendant by lining up the tab on the plug with the socket located on the power pack control. Insert the plug and turn clockwise until you hear the lock click. The Corded Pendant must be selected to be the active control, see Select Control Device page 17.

Wireless Pendant

The Wireless Pendant must be selected to be the active control. See Select Control

Device page 17.

Fill Oil Tank

Unit is shipped without hydraulic oil. Before the first use, fill tank with hydraulic oil, see

Recommended Oil Temperature Ranges for Various Hydraulic Oil Weights

1. Remove Oil Fill Cap.

2. Add hydraulic oil until oil is visible at the top of the Sight Glass.

3. Replace Oil Fill Cap.

page 52.

3A6884B 11

Setup

Modes

The TSP power pack has three modes: prime, calibration, and operation.

The prime mode removes air from the pump.

The calibration mode calibrates the pressure sensor. See Calibration Procedure page 28.

The operation mode is the normal mode in which the TSP power pack is ready to torque bolts.

Prime TSP Power Pack Procedure

Priming is required after initial oil fill or pump replacement. Unit may also require priming when displayed control pressure reading fluctuates continuously.

1. Disconnect hoses, if attached.

2. Plug in TSP power pack.

3. Turn ON/OFF switch to ON position.

4. Turn Pressure Setting Valve counterclockwise until rotation stops. This is the zero pressure setting.

5. Cycle through primary menu by short pressing the control Display Button until PRIME appears on Display.

High-pressure leaks are able to inject oil into the body and cause serious bodily injury. Do not stop leaks with hand or rag.

6. Press the Advance Switch on selected control device to start prime mode. 90 will appear on the Display and will count down in seconds as the prime procedure automatically occurs.

NOTE: Press Display Button or Pump Stop Switch any time while in prime mode to cancel the procedure.

NOTE: TSP power pack will automatically return to operation mode when prime procedure is complete.

7. To ensure the TSP power pack is primed, set pressure to 8000 psi and press the Advance Switch on selected control device. The Display pressure reading should be steady at 8000 +/- 50 psi. If pressure fluctuations are 100 psi or greater, the Prime TSP Power Pack Procedure should be repeated.

8. Inspect for leaks. If leaking occurs, tighten all fittings and repeat the Prime TSP Power Pack Procedure.

9. Check hydraulic fluid level.

12 3A6884B

Setup

Connect Hose and Tool

The TSP power pack uses flush-face quick-release couplings that are durable and easy to clean. To connect hose and tool, follow the steps below.

1. Wipe the mating surfaces of the couplings on the TSP power pack and the hoses with a clean rag before making connection.

2. Connect the hoses from the TSP power pack to the hydraulic tool.

NOTE: When making connections, do not over stretch the hoses or bend hoses at a sharp angle.

Hose Prime Procedure

Prime and flush the hoses each time a hose is replaced or when swapping tools. Continuous use of a hose and tool combination should not require a prime and flush procedure unless the hoses lose oil.

1. Turn ON/OFF switch to OFF position.

2. Connect hoses to the manifold on the TSP power pack.

3. Connect hoses together at tool end of the hose.

4. Turn ON/OFF switch to ON position.

5. Set pressure control to minimum pressure.

6. Run the TSP power pack for 30 seconds to purge the air from the hoses.

7. Check hydraulic oil level. Fluid level should be at the top of the oil level sight glass. Add oil as needed.

3A6884B 13

Operation

FIRE AND EXPLOSION WARNING

To avoid serious injury, do not use in explosive atmospheres or hazardous (classified) locations.

High pressure leaks are able to inject oil into the body and cause serious bodily injury. Before each use, inspect hydraulic lines, fittings, and hoses for breaks, cracks, worn spots, bulges, kinks and any other damage. Replace damaged lines, fittings, or hoses immediately. Never attempt to repair the damaged parts.

1. Determine desired torque for your application (nut or bolt specifications based on the specific project recommendations or standards required).

2. Determine desired pump pressure by referencing wrench specifications for torque and pressure.

3. Connect hoses and wrench to TSP power pack. Only use hoses and wrenches rated at a minimum of 10,000 psi (68.9 MPa, 700 bar).

4. Plug extension cord into TSP power pack.

AMPUTATION OR CRUSH HAZARD

Unexpected pump activation can cause serious injury. Ensure hands are clear of wrench crush points when activating TSP power pack.

5. Turn ON/OFF switch to ON position.

High-pressure leaks are able to inject oil into the body and cause serious bodily injury. Do not stop leaks with hand or rag.

6. Activate TSP power pack with the selected control device; see Select Control Device page 17. While holding Advance Switch, adjust Pressure Setting Valve until desired pump pressure is shown on Display or gauge.

NOTE: Inspect for leaks. If leaking occurs, tighten all fittings and repeat the Prime TSP Power Pack Procedure page 12.

7. Attach wrench to nut or bolt per wrench manufacturer’s specifications.

8. Activate TSP power pack by pressing and holding Advance Switch until end of wrench stroke. End of stroke is indicated either by the wrench, the pack pressure rising rapidly, the nut stopping, or some combination of these factors.

9. Release Advance Switch and wrench will automatically return.

10. Repeat steps 8 and 9 until job is complete.

14 3A6884B

Operation

Shut Down

1. Turn ON/OFF switch to OFF position. Unplug the TSP power pack.

2. Disconnect hoses from TSP power pack.

Cleaning

Proper care and maintenance is recommended for best experience with the TSP power pack. For proper maintenance activity and intervals, see Maintenance page

19.

To clean, wipe TSP power pack and hoses with a rag to remove any accumulated oil and dirt after every use.

Wash TSP power pack with mild soap and water as needed. High pressure washing is not recommended.

3A6884B 15

Display

Main Menu Operation

1. Turn power ON. Display will show

 as unit powers on.

2. Once powered on, Display will show PRESSURE (in PSI, bar, or MPa - as selected). Refer to Change Display Units page 17.

3. Short press Display Button and SET

HOURS will scroll past on screen.

NOTE: SET HOURS is a resettable hour

meter that may be used to monitor oil change intervals.

4. Short press Display Button and LIFETIME HOURS will scroll past on screen.

NOTE: LIFETIME HOURS displays a lifetime hour meter and cannot be reset.

5. Short press Display Button and name of the selected control device will scroll past on screen. If no control device is selected, SELECT CONTROL DEVICE will scroll past on screen.

a. Press and hold Display Button to

select control device. Refer to Select Control Device page 17.

6. Short press Display Button and PRIME will scroll past on screen.

a. Press and hold Display Button to

reset hours to 0.

16 3A6884B

a. Press and Hold Display Button to

enter prime mode. Refer to Prime TSP Power Pack Procedure page

12.

7. Short press Display Button to return to PRESSURE screen.

Display

Change Display Units

NOTE: To change display units you must be

in the pressure screen with the pressure display at zero.

1. Press and hold the Display Button for 5 seconds to change pressure units (psi, bar, MPa) to desired units. Selection of bar or MPa changes gallons to liters x 10.

Select Control Device

1. Short press Display Button three times to move to SELECT CONTROL DEVICE mode.

2. Press the Advance Switch on desired control device to select it. Options available are:

a. Manual Advance Switch.

b. Corded Pendant.

c. Wireless Pendant.

NOTE: The TSP power pack may be paired with only one control at any time. Any previously selected devices will be ignored when a new device is selected.

3A6884B 17

+ 39 hidden pages