TorcUP EP1000 Operating & Maintenance Instructions

WARNING

IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATION.

IT IS THE RESPONSIBLITIY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS MANUAL INTO

THE HANDS OF THE OPERATOR.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

The use of other than genuine TorcUP replacement parts may result in safety hazards, decreased tool

performance, and increased maintenance, and may invalidate all warranties.

Repairs should be made only by authorized personnel. Consult your nearest TorcUP Authorized

Service Center. Refer all communications to the nearest TorcUP Office or Distributor.

WARNING

For Technical Support and Information Contact:

TorcUP, Inc.

1025 Conroy Place, Easton, PA 18040

Toll Free: (888) TORCUP-1 Fax: [phone]

E-mail: [e-mail]

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY

• Keep hands, loose clothing and long hair
away from the reaction arm and working area
during operation. Do not attempt to support the
tool with your hands during operation.

• This tool will exert a strong reaction force.
Use proper mechanical support and correct
reaction arm positioning to control these
forces. Do not position the reaction arm so that
it tilts the tool off the axis of the bolt and never
use the swivel inlets as a reaction stop.

Avoid sharp bends and kinks that will cause
severe back-up pressure in hoses and lead to
premature hose failure.

• Use accessories recommended by TorcUP.

• Use only impact sockets and accessories. Do

not use hand (chrome) sockets or accessories.

• Use only sockets and accesssories that
correctly fit the bolt or nut and function without
tilting the tool off the axis of the bolt.

• This tool is not designed for working in
explosive atmospheres

Always wear eye protection when operating

Always wear eye protection when operating

or performing maintenance on this tool.

or performing maintenance on this tool.

Always wear ear protection

when operating this tool.

Keep body stance balanced and firm. Do

not overreach when operating this tool.

!

the hose.

Do not use damaged, frayed or

deteriorated hydraulic hoses and

fittings.

The Torque Reaction Arm must be

positioned against a positive stop. Do not

precautions to make certain the operator’s

hand cannot be pinched between the Arm

use the Arm as a dead handle. Take all

and a solid object.

Operate at 10,000 psig (681bar)

maximum pressure.

10,000 psig

10,000 psig

(681 bar)

Always turn off the pump and

disconnect the power before

installing, removing, or adjusting

any accessory on this tool, or

before performing any maintenance

(681 bar)

on this tool.

ON

ON

OFF

OFF

POWER

POWER

Do not carry the tool by

NOTICE

SAVE THESE INSTRUCTIONS. DO NOT DESTROY.

-

••• 1 •••

EP500 & EP1000
TORQUE PUMPS

Rev. - A

Date - 0709

CO NTENTS

Receiving Instructions and Warranty Statement .........................................................................................................1

Safe and Correct Use ............................................................................................................................................... 2-3

Technical Specifications ...............................................................................................................................................4

Working Pressure .........................................................................................................................................................4

Install Vent Plug ............................................................................................................................................................4

Adding Oil .....................................................................................................................................................................4

Install Hydraulic Connections .......................................................................................................................................5

Electrical .......................................................................................................................................................................5

Connecting Hydraulic Tools...................................... ....................................................................................................5

Starting the Pump for the First Time ............................................................................................................................5

Pump Mounting ............................................................................................................................................................6

Control Valves ...............................................................................................................................................................6

Power Control Switches ...............................................................................................................................................6

Pressure Torque Setting ...............................................................................................................................................7

After Completing the Job .............................................................................................................................................7

Periodic Maintenance ...................................................................................................................................................7

Maintain Oil Level .........................................................................................................................................................8

Clean Oil Intake Screen ................................................................................................................................................8

Flushing the Pump .......................................................................................................................................................8

Problem / Cause - Solutions ........................................................................................................................................9

- Note -

TorcUP has taken every care in preparing this Operational Manual that is intended as a technical guideline only.
TorcUP accepts no liability in relation to any use or reliance made of any information in this Operational Manual.

All information, illustrations and specications in this Operational Manual are based on the latest information

available at the time of publication. The right is reserved to make changes at any time without notice.
Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe
systems of work are in place before operating the equipment.

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EP Torque Pumps

••• 2 •••

EP500

EP1000

IMPORTANT - READ CAREFULLY

This manual contains important information for the correct installation, operation and maintenance of this
equipment. All persons involved in the installation, operation and maintenance of this equipment must be
thoroughly familiar with the contents of this manual. To safeguard against the possibility of personal injury or
property damage, follow the recommendations and instructions of this manual. Keep this manual for reference.

WARRANTY STATEMENT

TorcUP products are warranted to be free of defects in materials and workmanship under normal use for
as long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty does
not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper fluid, or use in a
manner for which they are not intended. If the customer believes a product is defective, the product must be
delivered, or shipped freight prepaid, to the nearest TorcUP Authorized Service Center for evaluation and
repair.

1.0 RECEIVING INSTRUCTIONS

Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify carrier at
once. Shipping damage will not be covered by warranty. The carrier is responsible for all loss associated with
shipping damage.

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••• 3 •••

2.0 SAFETY

Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautions
to avoid personal injury or damage to the unit. TorcUP cannot be responsible for any damage or injury from unsafe
use, lack of maintenance or incorrect operation. In the event any questions or concerns arise, contact TorcUP or a

local Distributor for clarication.

The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make
sure that all hydraulic equipment such as rams, hoses, etc. used with this
pump are rated at 10,000 PSI (700kg/cm2) operating pressure.

If you have never been trained on high-pressure hydraulic safety, consult
your distributor or service center for a free TorcUP Hydraulic Safety Course.

Failure to comply with the following cautions and warnings could cause equipment damage, property damage or
personal injury.

DANGER is only used when your action or lack of action may cause serious injury or even death.

WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury.

CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage
to, or destruction of equipment, or other property.

WARNING: Wear proper personal protective gear when operating hydraulic equipment.

DANGER: To avoid personal injury, keep hands and feet away from cylinder and work-piece during operation.

WARNING: Do not exceed equipment ratings. Overloading causes equipment failure and possible personal injury.

The wrenches are designed for a maximum pressure of 10,000 PSI (700kg/cm2). Never set the relief valve to a higher
pressure than the maximum rated pressure of the pump. Higher settings may result in equipment damage and/or
personal injury.

WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in
the system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is
happening in the system.

CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leading
to premature hose failure.
Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.

IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying handle or other means
of safe transport.

CAUTION: Keep hydraulic equipment away from ames and heat. Excessive heat will soften seals, resulting in uid

leaks. Heat also weakens hose materials. For optimum performance do not expose equipment to temperatures of
65° C (170° F) or higher. Protect hoses and cylinders from weld spatter.

DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious
injury. If oil is injected under the skin, see a doctor immediately.

DANGER: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the
cylinder becomes severely overloaded, components can fail catastrophically causing severe personal injury or death.

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••• 4 •••

3.0 TECHNICAL SPECIFICATIONS

EP500 Electric Torque Wrench

Voltage 115V 230V

Operating Pressure 10,000 PSI (700kg/cm2)

Electrical Power Source 20 Amps 115V Grounded 50/60 Hz 10 Amps 220V Grounded 50/60 Hz

Motor Rating 1.125 Hp Single Phase

Flow Rate 554 cu. in./ min. @ 1,100 psi, 46 cu. in / min. @ 10,000 psi

Maximum Operating

Temperature

18 Amps @ 10,000 psi (700kg/cm2)

170F - (65C)

1.125 Hp Single Phase

10 Amps @ 10,000 psi (700kg/cm2)

EP1000 Electric Torque Wrench

Voltage 115V 230V

Operating Pressure 10,000 PSI (700kg/cm2)

Electrical Power Source 20 Amps 115V Grounded 50/60 Hz 10 Amps 220V Grounded 50/60 Hz

Motor Rating 1.5 Hp Single Phase

Flow Rate 575 cu. in./ min. @ 1,100 psi, 55 cu. in / min. @ 10,000 psi

Maximum Operating

Temperature

18 Amps @ 10,000 psi (700kg/cm2)

170F - (65C)

1.5 Hp Single Phase

10 Amps @ 10,000 psi (700kg/cm2)

4.0 WORKING PRESSURE

The pump’s maximum working pressure is 10,000 PSI (700kg/cm2). Make sure that all hydraulic equipment such as
rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2) operating pressure.

4.1 INSTALL VENT PLUG

Remove SHIPPING PLUG (A) and install VENT PLUG (B) into cover plate.

4.2 ADDING OIL

Remove OIL FILLER CAP (C) and add TorcUP Hydraulic Oil into reservoir. Oil level should not exceed 1” from the
reservoir cover.

*As a “rule of thumb” oil should be visual in site window when

the unit is powered down and all connected tools or cylinders
are retracted.

B

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A

C

N O T E :
V e n t P l u g / O i l F i l l L o c a t i o n i s a p p l i c a b l e t o t h e
1 . 5 , 2 . 5 , 5 & 1 0 g a l l o n r e s e r v o i r s .

O n e g a l l o n m o d e l s u t i l i z e t h e d r a i n p l u g f o r
r e m o v i n g a n d a d d i n g o i l . V e n t p l u g a r e p r e - i n s t a l l e d
u n d e r t h e s h r o u d .

••• 5 •••

“

4.3 INSTALL HYDRAULIC CONNECTIONS

Use only cylinders, tools, hoses and accessories rated at 10,000 PSI
(700kg/cm2). Remove the shipping plugs from the ports to connect your

coupling(s) or hose(s) to manifold. Use 1.5 wraps of Teon tape (or suitable
thread sealant) on all threads, leaving the rst complete thread free of tape to

ensure no foreign matter enters the hydraulic circuit.

When making connections with quick disconnect couplings, make sure the

couplings are fully engaged. Threaded connections such as ttings, gauges,

etc. must be securely tightened and leak free.

WARNING: Loose or improperly threaded ttings can be potentially

dangerous if pressurized; however, severe over tightening can cause premature
thread failure. Fittings need to be tightened secure & leak free. Never hold or
stand directly in line with any hydraulic connections while pressurizing. Never
grab, touch or in any way come in contact with a hydraulic pressure leak.
Escaping oil can penetrate the skin and a serious injury can result.

CAUTION: Do not subject the hose to potential hazards such as sharp surfaces, extreme heat or heavy impact. Do
not allow the hose to kink or twist. Inspect each hose for wear before it is used.

B”

“A”

4.4 ELECTRICAL

Check for proper electrical supply before connecting. Be sure the electrical connection is grounded. Check that your
power supply agrees with the motor nameplate and/or TorcUP model decal.

NOTE: MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE PRESENCE OF
CONDUCTIVE LIQUIDS.

1. Do not use a power or extension cord that is damaged or has exposed wires.

2. All single phase motors come equipped with a three prong grounding type plug to t the

proper grounded type electrical outlet. Do not use a two prong ungrounded extension cord
as the pump’s motor must be grounded.

4.5 CONNECTING HYDRAULIC TOOLS

Use only tools, hoses and accessories rated at 10,000 PSI (700kg/cm2). When making connections with quick

disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as ttings, gauges,
etc. must be securely tightened and leak free. Use 1.5 wraps of Teon tape (or suitable thread sealant) on all threads,
leaving the rst complete thread free of tape to ensure no foreign matter enters the hydraulic circuit.

4.6 STARTING THE PUMP FOR THE FIRST TIME

1. Locate the power switch on shroud and select to the “ON” position. Check for any leaks, repair as needed.

2. Shift pendant to the advance position to advance tool and release to retract tool. Look for movement in tool,
check for any leaks, repair as needed.

CAUTION: Never operate the pump without tool movement for more than 1 minute. Leaving the valve in the advance
or retract position without the tool’s piston rod moving will overheat the oil.

CAUTION: Never disconnect or connect any hydraulic hoses or ttings without rst unloading the tool, then unplug

the electrical cord of the pump. Open manual relief valve to assure that the system has been depressurized. View
the gauge reading and double check the gauge to assure pressure has been released.

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••• 6 •••

4.7 PUMP MOUNTING

Refer to the chart for mounting dimensions to secure the pump to a xed surface.

1 gal. (4L) 1.5 gal.(6L) 2.5 gal.(10L) 5 gal. (20L)

A

B

C

D

E

F

11 15.13 17 19.6

0.56 1.68 2.75 4.69

0.56 3.57 4.37 5.03

1.16 1.43 1.93 2.93

8.19 8.75 9.75 11.75

1/4-20unc

(4 places)

1/4-20unc

(4 places)

1/4-20unc

(4 places)

1/4-20unc

(4 places)

A

B

D

F

E

C

5.0 CONTROL VALVES

2-Postion – 4 Way Solenoid Valve for Hydraulic Torque Wrenches.

• To Advance......depress the Advance Switch

• To Retract.........release advance switch to Retract Tool.

5.1 POWER CONTROL SWITCHES

Remote pendant.

Congured with motor control pendant:

ADVANCE = Press and hold switch to turn motor on.
Energizes ADV. Coil.

ON = Press switch to turn motor on.
OFF = Press switch to turn motor off.

2 Position - 4 Way Solenoid

Motor/Valve Control Pendant

NOTE: In the event multiple buttons are depressed for longer than 5 seconds, the unit is programmed to shut
down. To restart, you will need to depress the motor “ON” to continue, or unplug / re-plug the unit into power
supply, then depress the motor “ON” to continue.

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••• 7 •••

5.2 PRESSURE TORQUE SETTING

WARNING: Make these adjustments BEFORE putting torque wrench on nut or bolt head. The pump pressure

setting may be above the pressure needed to provide the required torque for your application.
Exceeding required torque will cause equipment damage and may lead to serious personal injury.

1. See torque wrench instructions for amount of pressure required
to produce desired torque.

2. Loosen lock nut and back out relief valve to prevent unintended
pressure build up.

3. Turn pump on. Press and the “ADVANCE” switch, and read
pressure gauge.

4. While holding the switch, turn relief valve in (clockwise)
to increase pressure or out (counter-clockwise)
to decrease maximum pressure. Repeat until
correct pressure is obtained.

5. Tighten lock nut on the relief valve to maintain setting.

6. Run pump several times to test this setting before
setting tool on the nut.

Adjusting Knob

Lock Nut

Valve Assembly

5.3 AFTER COMPLETING THE JOB

Before disconnecting hoses, ttings, etc., rst be sure the tool is unloaded and retracted, then unplug the power

cord. The pump is designed to cycle valve upon power down “off.”

6.0 PERIODIC MAINTENANCE

Completely change the hydraulic oil and clean the intake screen and magnet (located in the reservoir) twice a year.
If equipped, change the external oil lter twice a year (Use TorcUP oil only, Model # AO1, 1 gallon). Change the
oil more frequently when used in extremely dusty areas or when the oil has been overheated. Using oil other than
TorcUP Brand may void the pump’s warranty.

The following conditions require more frequent oil changes.

• Rigorous duty, where oil temperature may reach 150˚ F.

• High humidity environment and extreme changes in temperature that can result in condensation inside the

reservoir.

• Dirty or dusty environments that may contaminate the oil.

• Frequent connection and disconnection of hydraulic hoses and components.

WARNING: The electrical power cord must be disconnected from electrical outlets before performing maintenance
or repair procedures.

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