TorcUP EP500, EP1000 Owner's Operation And Maintenance Manual
EP500 AND EP1000
OPERATION AND MAINTENANCE
MANUAL
Torque Wrench Power Pump
MODELS EP500, EP500-230V, EP1000, EP1000-Q, EP1000-230V, EP1000-Q-230V
1025 Conroy Place, Easton PA 18040 * U.S.A.
Phone: +1 610-250-5800 * Fax:+1 610-250-2700
Toll Free: 1-888-TORCUP-1
Email: sales@torcup.com * Website: www.torcup.com
Operational and Maintenance Manual for TorcUP
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EP500 & EP1000 Torque Wrench Pump
Version 1: 2013 April
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING PUMP.
IT IS THE RESPONSIBILITY 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.
EP500 EP1000
Shown with
optional quad kit
CONTENTS
Category Page # Category Page #
Manual Index 1 Control Valves 8
General Warnings 2 Power Control Switches 8
Safe and Correct Use 3-5 Pressure Torque Setting 9
Warranty Statement 4 Completing the job 9
Working Pressure 5 Periodic Maintenance 9
Install Vent Plug 5 Oil Level 10
Adding Oil 5 Oil Intake Screen 10
General Safety 5 Oil Flushing 10
Technical Specications 6 Troubleshooting 11
Install Hydraulic Connections
Electrical 7 EP500 Parts Index 23
Connecting Tools 7 Pendant 37
Initial Startup 7
Pump Mounting 8
TorcUP Inc. is not responsible for customer modication of tools for applications on
which TorcUP Inc. was not consulted.
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 specications in this Operational Manual are based on the latest information available at the time of publica-
tion. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be respon-
sible for ensuring that a safe working environment and safe systems of work are in place before operating the equipment.
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 Ofce or Distributor.
6 EP1000 Parts Index 12
For Technical Support & Information Contact:
TorcUP Inc.
1025 Conroy Place, Easton, PA 18040 USA
Phone: +1 610-250-5800 Fax:+1 610-250-2700
email: sales@torcup.com
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY
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Do NOT exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.
Do not use damaged,
frayed or deteriorated
hydraulic hoses
and ttings.
Always wear ear protection
when operating this tool.
Keep body stance
balanced and rm.
Do not overreach
when operating this
tool.
Always wear eye
protection
when
operating or
performing
maintenance
on this tool.
Do not carry
the tool
by the hose.
The Torque Reaction Arm must be
positioned against a positive stop.
Do not use the arm as a dead
handle. Take all precautions to
make certain the operator’s hand
cannot be pinched between the
arm and a solid object.
USING THE TOOL
• Keep hands, loose clothing & long hair away from the reaction arm and working area 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 an 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 accessories that correctly t the bolt or nut and function without tilting the tool off
the axis of the bolt.
• This tool is not insulated against electric shock.
• This equipment must not be operated or serviced unless the operator read the operating instructions
and fully understands the purpose, consequences and procedure of each step.
Depending on the working environment your local health and safety regulations may require
you protective gear (i.e. Ear Protection, Safety Shoes, Hard Hat, Gloves, Coveralls, etc.) In
case external forces are exerted on the equipment, non-compliance with these regulations may
result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.
SAFE AND CORRECT USE
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Operation of the Equipment in Accordance with Specied Use
1. Inspect, maintain, operate and install the tool in accordance with all applicable standards and
regulations (local, state, country, federal, etc.)
2. Do not remove any labels. Replace any damaged labels immediately.
3. Be sure all hoses and ttings are the correct size and tightly secured.
4. Do not use damaged, frayed or deteriorated hydraulic hoses and ttings. Do not paint hoses.
5. Do not lubricate tools with ammable or volatile liquids such as kerosene, diesel or jet fuel. Use
only TorcUP recommended lubricants.
6. Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet current
safety and health standards. Use cleaning solvents in a well ventilated area.
7. Keep work area clean, uncluttered, ventilated and illuminated.
Safety Information When Using The Tool
1. When wearing gloves always be sure that the gloves will not prevent the throttle mechanism from
being released.
2. Always wear eye protection when operating or performing maintenance on this tool.
3. Always wear hearing protection when operating this tool.
4. Always use personal protective equipment appropriate to the tool used and material worked.
This may include dust mask or other breathing apparatus, safety glasses, ear plugs, gloves,
apron, safety shoes, hard hat and other equipment.
5. Keep others a safe distance from your work area, or ensure they use appropriate personal
protective equipment.
6. Be aware of buried, hidden or other hazards in your work environment. Do not contact or damage cords, conduits, pipes, or hoses that may contain electrical wires, explosive gases or harmful
liquids.
7. Keep hands, loose clothing, long hair and jewelry away from working end of tool.
8. Power tools can vibrate in use. Vibration, repetitive motions or uncomfortable positions may be
harmful to your hands and arms. Stop using any tool if discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming.
9. Keep body stand balanced and rm. Do not overreach when operating this tool. Anticipate and
be alert for sudden changes in motion, reaction torques, or forces during start up and operation.
10. DO NOT USE THIS TOOL WHEN TIRED, UNDER THE INFLUENCE OF MEDICATION,
DRUGS OR ALCOHOL.
11. Never use a damaged or malfunctioning tool or accessory.
12. Do not modify the tools, safety devices or accessories.
13. Do not use this tool for purposes other than those recommended
14. Never exceed rated pressure of tool.
SAFE AND CORRECT USE
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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 uid, 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 T
Service Center for evaluation and repair. This pump offers 13 month warranty.
RECEIVING INSTRUCTIONS
orcUP Authorized
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.
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 representative for clarication.
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 representative 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 per-
sonal injury.
CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent
damage to, or destruction of equipment, or other property.
SAFE AND CORRECT USE
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WARNING: Wear proper personal protective gear when operating hydraulic equipment.
DANGER: To avoid personal injury, keep hands and feet away from work-piece during operation.
WARNING: Do not exceed equipment ratings. Overloading causes equipment failure and possible
personal injury. The pump tools are designed for a maximum pressure of 10,000 PSI (700kg/cm
2
).
Do not connect a jack or cylinder to a pump. 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.
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.
TECHNICAL SPECIFICATIONS
WORKING PRESSURE
The pump’s maximum working pressure is 10,000 PSI
(700kg/cm
such as tools, hoses, etc. used with this pump are
rated at 10,000 PSI (700kg/cm
INSTALL VENT PLUG
Remove shipping plug from reservoir and install
vent plug supplied with pump.
ADDING OIL
Remove oil ller cap and add TorcUP hydraulic oil
into reservoir. Oil level should not exceed 1” from
the reservoir cover. Oil should be ISO 32 or 46
weight.
*As a “rule of thumb” oil should be lled about an inch below the
top of the reservoir when the unit is powered down and all
connected tools or cylinders are retracted.
2
). Make sure that all hydraulic equipment
2
) operating pressure.
EP500
EP1000
EP500
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EP1000
TECHNICAL SPECIFICATIONS
LUBRICATION
INSTALL HYDRAULIC CONNECTIONS
Use only tools, hoses and accessories rated at 10,000 PSI
(700kg/cm
to connect your coupling(s) or hose(s) to manifold. Use
1.5 wraps of Teon 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.
2
). Remove the shipping plugs from the ports
TECHNICAL SPECIFICATIONS
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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.
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 T
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.
orcUP model decal.
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 Teon 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.
STARTING THE PUMP FOR THE FIRST TIME
1. Check for any leaks, repair as needed.
2. When rst plugged in the solenoid makes 4 “clicks” relieving any pressure still in the system.
When the button to turn off the pump is pressed it goes through the same sequence for the
same reason. It is then safe to remove tool and hoses.
3. 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.
TECHNICAL SPECIFICATIONS
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PUMP MOUNTING
Refer to the chart for mounting dimensions to
secure the pump to a xed surface.
1 gal.
(4L)
A 11 15.13 17 19.6
B 0.56 1.68 2.75 4.69
C 0.56 3.57 4.37 5.03
D 1.16 1.43 1.93 2.93
E 8.19 9.75 9.75 11.75
F 1/4-2unc 1/4-2unc 1/4-2unc 1/4-2unc
(4 places) (4 places) (4 places) (4 places)
1.5 gal.
(6L)
2.5 gal.
(10L)
5 gal
(20L)
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.
2 Position
-
4 Way Solenoid
POWER CONTROL SWITCHES
Remote pendant.
Congured with motor 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/
replug the unit into power supply, then
depress the motor “ ON” to continue.
Press UP or Down
To Turn Pump Off
Press UP or Down
To Turn On Pump
OPERATION PROCEDURES
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PRESSURE TORQUE SETTING
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 builds up.
3. Turn pump on. Press and hold 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.
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 the valve upon powering off to release pressure.
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.
The electrical power cord must be disconnected from electrical outlets
before performing maintenance or repair procedures.
OPERATION PROCEDURES
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MAINTAIN OIL LEVEL
Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in
oil when all tools are retracted. Add TorcUP oil (Model # AO1 – 1 gallon) when necessary. Oil level
should be no more than 1” from top of reservoir plate – with cylinders retracted and motor off.
CLEAN OIL INTAKE SCREEN ONCE A YEAR
Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not to damage
the gasket.
Applies to 1, 1.5, 2, 2.5 gallon reservoirs:
Remove the ve allen socket head cap screws, securing the screen to the 1st stage gear pump. Care
should be taken not to remove the center plate and gears. Remove and clean with nonammable
solvent, blow dry clean. Reinstall in reverse order and torque bolts to 75 inch pounds. Keep the motor
and pump as clean as possible.
Applies to the 5 and 10 gallon reservoirs:
Unscrew screen from bottom of pump unit and clean
with nonammable solvent. Blow dry and reassemble.
Keep areas around pump unobstructed to provide good
air ow around the motor and pump. Keep the motor
and pump as clean as possible.
FLUSH THE PUMP
If you suspect your pump has been contaminated or
discover sludge or other deposits on internal
components, you should thoroughly ush the pump.
Remove the old oil from the reservoir, then thoroughly
clean the reservoir and rell with a clean, nonammable
ushing oil. Reassemble the pump and motor to the
reservoir.
Run the pump in no load condition for 1 or 2 minutes maximum. Unplug the pump and remove the
motor and pump assembly again. Now drain the ushing oil and re-clean the inside of the reservoir.
(Make sure ushing uid is also drained from pump assembly). Reassemble the pump and rell the
reservoir with TorcUP hydraulic oil and reassemble the pump.
TROUBLESHOOTING
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PROBLEM CAUSE-SOLUTION
Sporadic Tool Action: • Air in the hydraulic system. Bleed the hydraulic circuit.
• Check reservoir oil level.
Motor Will Not Start: • Be sure power cord is not damaged.
• Check for tripped circuit breaker; be sure breaker is of
adequate size.
• Have motor checked for proper operation.
• Have qualied electrician inspect for loose or faulty wiring or
switch.
.
Noisy Operation: • Air in system.
• Be sure the oil reservoir is lled to normal level.
• Check all points where air might leak into system.
• Clogged or blocked intake screen.
Pump Oil is Over Heating: • Inspect for high pressure leakage at the pump (leaking at
plug or relief valve).
• Oil level is low. Fill reservoir to normal level, or retrot the
pump with larger reservoir or heat exchanger.
Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from
side to side.
• Inspect to make sure that external adjustable relief valve is
set properly.
• Defective control valve, take to nearest TorcUP Authorized
Service Center for repair.
• Incorrect motor rotation, take to nearest TorcUP Authorized
Service Center for repair.
• Check to make sure the intake screen is not clogged. Clean
if needed.
• Check oil reservoir is low. Fill as needed.
• Oil viscosity is too high. Replace with TorcUP oil.
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