Form No. E09005 Rev. B. 09.17.2015 INSTRUCTION MANUAL TWP SERIES HYDRAULIC TORQUE WRENCH PUMP 01 SAFETY INSTRUCTIONS Carefully inspect all components for shipping damage. If shipping damage is found, notify the carrier at once. The carrier is responsible for any damage resulting from shipment. To avoid personal injury or property damage, please read, understand, and follow all safety instructions. EAGLE PRO is not responsible for injury or damage resulting from unsafe and/or incorrect product use or system operation, or lack of proper maintenance. DANGER! Is used only when your action or lack of action may cause serious injury or death. WARNING! Is used when a potential danger exists that requires correct action to avoid personal injury. IMPORTANT! Is used when action of lack of action can cause equipment failure. WARNING! One person should operate both the hydraulic pump and the hydraulic torque wrench, unless there is clear and unobstructed communication between the two operators. Do not place hands near action or reaction points. IMPORTANT! To avoid personal injury or property damage, please read, understand, and follow all safety instructions. Always keep work area clean and free of clutter. When not in use, tools should be properly stored to avoid damage . Operator must wear proper safety attire when working with hydraulic equipment. Work gloves, safety glasses, hard hats, approved safety shoes, and hearing protection and/or other required clothing should be worn while operating this equipment. DANGER! The hydraulic equipment user must be a qualified operator with correct training and work experience with hydraulic equipment. Lack of knowledge in any of these areas can lead to equipment damage or personal injury. Carefully inspect hydraulic pump before using . If any damage is found, discontinue use and contact your closest authorized EAGLE PRO Service Center. To avoid personal injury, do not modify or weld hydraulic equipment without approval of EAGLE PRO INDUSTRIAL TOOLS, INC. All EAGLE PRO torque wrenches are designed for a maximum of 10,000 PSI/700 bar. Do not connect torque wrenches to a pump with a higher pressure rating or equipment damage may occur. EAGLE PRO INDUSTRIAL TOOLS, INC. 2 FORM NO. E09005 REV. A. Use high quality impact sockets that are in good condition with the hydraulic torque wrench. Ensure they are the correct size and engage the hex portion of the bolt/nut correctly. Unseen flaws or damage to the impact sockets could cause failures during use. Remain clear of impact sockets during application. Do not hammer on hydraulic torque wrench, pump or socket to enhance performance. If the bolt/nut will not rotate, select a larger torque wrench for the application. Do not pick up the torque wrench by the hydraulic hose or swivel. Do not pick up the hydraulic pump by the power cord, pendant control cord, or hydraulic hose. Electrical pumps should never be used in a potentially explosive environment. Ensure that the pump is properly grounded to guard against electrical shock. Do not use kinked or damaged hydraulic hoses. Carefully inspect the hydraulic couplers on pump, hoses, and torque wrenches before using. Never connect tools with damaged couplers or damaged port threads. The damaged coupler(s) or damaged port threads may cause equipment failure and possible personal injury. Install couplers in a clean environment. Always prevent dirt or other debris from entering into the cylinder. Dirt or debris will damage the tool and result in equipment failure and possible personal injury. Before removing or tightening hose(s) or coupler(s), always release hydraulic pressure in system . Never handle pressurized hoses; escaping oil under high pressure can penetrate the skin, causing serious injury. Seek medical aid immediately if injured. When the pump is not in use, release the valve, remove the hoses and use the dust cap to recover the port. Do not drop anything on hydraulic hoses. Fully retract the hydraulic torque wrench before adding fluid to the torque wrench pump. Failure to do so will result in excess reservoir pressure and could cause personal injury. Do not use equipment in temperatures of 150°F (65°C) or higher. Overheating will soften seals and weakens hose materials, resulting in oil leaks or other equipment failure. For hydraulic technical help or repair service, please contact the closet authorized EAGLE PRO Service Center. EAGLE PRO INDUSTRIAL TOOLS, INC. has no obligations under any warranty with respect to products that have been repaired by unauthorized personnel, modified, or damaged through misuse, abuse, accident, neglect, or mishandling. DANGER! REACTION POINT SAFETY Adjust reaction arm in the same direction as the square drive when possible. Avoid excessive play. Do not hold torque wrench during operation. If the torque wrench must be held or steadied during operation, use alternative means of securing tool to the application. Always ensure that all body parts and clothing are clear of the reaction arm and reaction surface during use. EAGLE PRO INDUSTRIAL TOOLS, INC. 3 FORM NO. E09005 REV. A. 02 INITIAL SETUP INSTRUCTIONS Visually inspect the pump for any shipping damage. If any damage is found, notify the carrier immediately. Carrier is responsible for any damage that occurs during shipment. Remove the pump from the shipping carton and fill the reservoir with the provided hydraulic fluid. First, remove the reservoir plug, see FIG A. Rotate the plug (black knurled knob) counter clockwise to loosen. Fill reservoir with supplied fluid and tighten by rotating fill knob clockwise. Fill plug needs only to be hand tight. Prior to any use, loosen the brass reservoir vent plug. Ensure this plug is tightened once work is completed, or fluid may leak from this opening. Vent Plug Fill Plug FIG A 2.1 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous overloading. Use the recommended amperage listed on the motor nameplate. Do not use the electric pump if the ground is not connected on the power plug. Always minimize the length of extension cords and be sure they are of adequate wire size, with proper ground connections. See FIG B. below for potential impact of using longer extension cords. EAGLE PRO always recommends a #10 gauge extension cord with a length of no more than 25 feet. Cord Length, Feet 10 20 30 40 50 100 1.3HP 15A 115V MOTOR (% drop from 120V in pare nthe se s) Extension Cord Wire Gauge #14 GAUGE #12 GAUGE #10 GAUGE 0.9V (0.8%) 0.6V (0.5%) 0.4V (0.3%) 1.8V (1.5%) 1.1V (0.9%) 0.7V (0.6%) 2.7V (2.3%) 1.7V (1.4%) 1.1V (0.9%) 3.6V (3.0%) 2.3V (1.9%) 1.4V (1.2%) 4.6V (3.8%) 2.9V (2.4%) 1.8V (1.5%) 9.1V (7.6%) 5.7V (4.8%) 3.6V (3.0%) FIG B WARNING! Do not operate in a potentially explosive environment, as electric motors may produce sparks. EAGLE PRO INDUSTRIAL TOOLS, INC. 4 FORM NO. E09005 REV. A. 2.2 HYDRAULIC CONNECTIONS The EAGLE PRO TWP Series torque wrench pump is equipped with an electronic solenoid pressure relief valve. Before disassembling hydraulic torque wrench system for storage, transport or maintenance, always release system pressure. Once work is completed, push the button on top of the solenoid valve. See FIG C. Before disassembling hydraulic torque system, double check pressure gauge located on pump to ensure system pressure has been released. Once system pressure has been released, it is safe to disassemble hydraulic torque system. The pumps maximum working pressure is 10,000 PSI (700 bar) . Ensure that all hydraulic equipment used with this tool are rated for 10,000 PSI (700 bar) working pressure. FIG C WARNING! Improperly connected hydraulic couplers can be dangerous if pressurized. Do not grab, touch or come in contact with a pressurized hydraulic fluid leak. Escaping fluid can penetrate the skin and cause severe injury. 03 OPERATION INSTRUCTIONS 3.1 ASSEMBLING THE SYSTEM The EAGLE PRO TWP Series torque wrench pump is connected to various EAGLE PRO torque wrench heads with a dual, high strength thermo-plastic hydraulic hose assembly complete with hydraulic couplers and protective dust covers. Attach the hose assembly to the pump valve (top male and female outlets) by pushing the male coupler fully into the female coupler. (See FIG D and FIG E). Male Coupler Female Coupler FIG D EAGLE PRO INDUSTRIAL TOOLS, INC. FIG E 5 FORM NO. E09005 REV. A. While pushing the male coupler into the female coupler, rotate the locking collar on the female coupler so that it screws onto the male collar. Ensure that the locking collar is firmly attached to the male coupler, when properly tightened, the locking teeth on the collar will engage to prevent the coupler from coming loose. The locking collar should only be hand tightened. See FIG F below. Properly seated male and female couplers FIG F IMPORTANT! Ensure hydraulic connectors are fully engaged. Connectors not properly seated can leak and cause system malfunctions. EAGLE PRO INDUSTRIAL TOOLS, INC. 6 FORM NO. E09005 REV. A. 3.2 ATTACHING PUMP TO TORQUE WRENCH HEADS See the operators manual for your specific EAGLE PRO hydraulic torque wrench for detailed instructions on assembling and setting up an EAGLE PRO hydraulic torque wrench. Attach the dual, thermo-plastic hose to the torque wrench head. Ensure that both the male and female couplers are properly seated. See FIG I. Properly seated male and female couplers on Torque wrench head FIG I 3.3 SETTING SYSTEM PRESSURE/REQUIRED TORQUE Once the torque wrench pump and torque wrench are properly assembled and connected, and the hydraulic pump has a proper power supply, the pressure on the pump must be set. The amount of pressure the pump provides ultimately dictates the amount of torque the torque wrench can produce. Torque sequence may vary from location to location and it may even vary within a single location. There are many variables that must be understood to achieve proper torque. Always abide by local procedures, regulations and ASME PCC-1-2013 standards. Each EAGLE PRO torque wrench is supplied with a pressure-torque conversion chart. See FIG J for an example of the ESW torque wrench pressure-torque conversion chart. EAGLE PRO INDUSTRIAL TOOLS, INC. 7 FORM NO. E09005 REV. A. ESW SERIES TORQUE WRENCHES MODEL ESW‐1 ESW‐3 ESW‐5 ESW‐8 ESW‐10 ESW‐20 PSI FT. LBS FT. LBS FT. LBS FT. LBS FT. LBS FT. LBS 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 5200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 9200 9400 9600 9800 10000 134 161 188 215 242 268 295 322 349 376 403 430 457 483 510 537 564 591 618 645 672 698 725 752 779 806 833 860 887 914 940 967 994 1021 1048 1075 1102 1129 1155 1182 1209 1236 1263 1290 1317 1344 328 394 459 525 590 656 721 787 852 918 984 1049 1115 1180 1246 1311 1377 1443 1508 1574 1639 1705 1770 1836 1901 1967 2033 2098 2164 2229 2295 2360 2426 2491 2557 2623 2688 2754 2819 2885 2950 3016 3082 3147 3213 3278 547 656 766 875 985 1094 1203 1313 1422 1532 1641 1750 1860 1969 2079 2188 2297 2407 2516 2626 2735 2844 2954 3063 3173 3282 3391 3501 3610 3720 3829 3938 4048 4157 4267 4376 4485 4595 4704 4814 4923 5032 5142 5251 5361 5470 783 940 1096 1253 1409 1566 1723 1879 2036 2193 2349 2506 2662 2819 2976 3132 3289 3446 3602 3759 3915 4072 4229 4385 4542 4699 4855 5012 5168 5325 5482 5638 5795 5951 6108 6265 6421 6578 6735 6891 7048 7204 7361 7518 7674 7831 1127 1352 1578 1803 2029 2254 2480 2705 2931 3156 3381 3607 3832 4058 4283 4509 4734 4959 5185 5410 5636 5861 6087 6312 6538 6763 6988 7214 7439 7665 7890 8116 8341 8567 8792 9017 9243 9468 9694 9919 10145 10370 10595 10821 11046 11272 1937 2324 2712 3099 3487 3874 4261 4649 5036 5424 5811 6198 6586 6973 7361 7748 8135 8523 8910 9298 9685 10072 10460 10847 11235 11622 12009 12397 12784 13172 13559 13946 14334 14721 15109 15496 15883 16271 16658 17046 17433 17820 18208 18595 18983 19370 FIG J EAGLE PRO INDUSTRIAL TOOLS, INC. 8 FORM NO. E09005 REV. A. Below is an example of how to properly use the ESW Torque Wrench pressure-torque chart.. EXAMPLE Application requires use of an ESW-3 EAGLE PRO hydraulic torque wrench to tighten a 1-1/2” bolt to 2100 Lb. Ft. STEP 1. Locate the correct model of the torque wrench along the top of the pressure-torque chart STEP 2. Read straight down the column until you find the closest figure to 2100. In this application it would be 2164. 2164 is about 3% over the required torque value for this application. STEP 3. From the figure of 2164, read all the way over to the left hand column of the chart, this will tell you what pressure the pump must product to reach this torque value. In this case, to reach 2164 lb. ft. of torque with the ESW-3 torque wrench, the torque wrench pump must product 6600 PSI. As 2164 lb. ft. of torque is within the +/-3% accuracy range of the ESW-3 torque wrench, you could leave the pressure at 6600 PSI. For higher precision, you should reduce the 6600 PSI by 3% to 6402 PSI. 3.4 SETTING PUMP PRESSURE Now that pump pressure has been determined, follow the procedure below to set the pump pressure. STEP 1. Loosen the lock ring on the “T” handle of the external pressure valve. Turn the “T” handle counter clockwise until it moves easily. STEP 2. Turn the pump on. Using the pendant control, push down on the ADVANCE button and hold it. T‐Handle STEP 3. While continuing to hold the ADVANCE button down, slowly turn the “T” handle clockwise and watch the pressure rise on the pump pressure gauge. STEP 4. When the gauge reaches the required pressure (see example above to determine required pressure) stop turning the “T” handle and allow the pressure to stabilize. STEP 5. If the pressure continues to rise above required pressure, release the ADVANCE button and turn the “T” handle counter clockwise, this will reduce system pressure. Press the ADVANCE button again and slowly bring the pressure up to the required pressure. STEP 6. Once the pressure is correct, turn the pump off. Tighten the lock ring on the “T” handle against the valve body. This will lock the “T” handle in place and prevent pressure changes. This sets the pump pressure which ultimately determines the torque output of the torque wrench. Cycle the pump one final time to ensure that the pressure is properly set. IMPORTANT! Do not adjust the pump pressure while the torque wrench is operating. Adjust the regulator so that the pressure is increasing, not decreasing. If you have to lower pump pressure, start the pressure setting procedure from the beginning. EAGLE PRO INDUSTRIAL TOOLS, INC. 9 FORM NO. E09005 REV. A. 3.5 PUMP OPERATION —TIGHTENING See the operators manual for your specific EAGLE PRO hydraulic torque wrench for detailed instructions on assembling and setting up an EAGLE PRO hydraulic torque wrench. With the EAGLE PRO torque wrench properly assembled and properly positioned on the work piece, follow the procedure below. STEP 1. Push down on the ADVANCE button of the pump pendant control. This will push the rear of the tool backwards until the reaction arm comes into contact with the chosen reaction point. ENSURE ALL BODY PARTS AND CLOTHING ARE FREE OF THIS AREA . STEP 2. Hold down the ADVANCE button on the pendant control as the torque wrench continues to operate. You will hear an audible CLICK once the torque wrench has reached its full extension. If you continue to hold down the ADVANCE button at this point, the pump will continue to build pressure to the preset pressure that was set earlier. This does not indicate that the proper torque has been applied to the bolt/nut. It only indicates that the cylinder is extended and is unable to rotate further until the torque wrench resets. STEP 3. Release the ADVANCE button after hearing the audible CLICK. This will reset the torque wrench. Once the torque wrench is reset, you will hear another audible CLICK. Each time the torque wrench is advanced and reset in this manner is considered a CYCLE. In order to obtain the proper amount of torque on the fastener, several CYCLES may need to be made until the tool stalls at the pre-set pressure/ torque. Always cycle the torque wrench one final time to make sure the stall point has been reached. LOCK– ON Should the torque wrench lock-on during operation, push down on the ADVANCE button to build pressure. Continue to hold the ADVANCE button down and push the drive release lever down. Release the ADVANCE button while continuing to hold the drive release lever down. This will allow the torque wrench to be removed. 3.6 PUMP OPERATION —LOOSENING Following the procedure in section 3.4 set the pump pressure to 9,000 PSI . Do not try to loosen bolt/nut with pump set at full 10,000 PSI. Change the torque wrench to the loosening mode and properly position on work piece. Press and hold the ADVANCE button on the pendant control. Pump pressure will decrease as the bolt/nut is loosened. Once the cylinder is fully extended you will hear an audible CLICK. Release the ADVANCE button and the torque wrench will reset. Once the torque wrench is reset, you will hear an audible CLICK. Continue to CYCLE the torque wrench until you can remove the fastener by hand. IMPORTANT! If the fastener does not loosen with the above procedure, you must select a larger torque wrench to remove the fastener. EAGLE PRO INDUSTRIAL TOOLS, INC. 10 FORM NO. E09005 REV. A. 04 MAINTENANCE IMPORTANT! In order to ensure proper operation of the electric pump, completely drain and clean the pump reservoir every 250 hours, or more frequently if used in dirty environments. In general hydraulic fluid should be a light yellow and transparent liquid. If hydraulic fluid appears dark or cloudy replace the fluid. 4.1 CHANGING THE HYDRAULIC FLUID Follow the steps below to change the hydraulic fluid. STEP 1. Ensure pump is unplugged from power source and system pressure has been released. STEP 2. Unscrew and remove the reservoir oil fill plug. STEP 3. Loosen reservoir drain plug using a 6mm hex wrench. See FIG K Drain oil into approved container and dispose of properly according to local regulations. STEP 5. Loosen the (4) 5mm hex socket bolts holding the roll cage to the pump reservoir. Remove pump from roll cage STEP 4. Unscrew and remove the (6 ) 5mm hex socket bolts holding the reservoir to the top plate of the hydraulic pump. STEP 5. Lift the top plate off of the pump reservoir, being careful not to damage the pump body and set aside. Reservoir Oil Drain Plug STEP 6. Clean the pump reservoir with a mild cleaning agent and wipe dry. Ensure that any small pieces of paper towel or rag are removed from the reservoir. FIG K STEP 7. Unscrew the oil filter by hand from the pump body and clean using a mild cleaning agent and a soft brush. Flush the filter with clean hydraulic fluid to ensure any cleaning agents and/or small particles have been removed from the filter. If the oil filter is damaged contact the nearest authorized Eagle Pro service center to order a replacement. STEP 8. Screw oil filter back onto pump body, be sure to only hand tighten oil filter. Over tightening may damage the pump body. STEP 9. Reassemble pump and reservoir and place back into roll cage, and secure assembled pump to roll cage. STEP 10. Once pump is completely assembled, add new, clean ISO #32 hydraulic fluid, see Section 02 Initial Setup Instruction's on how to add hydraulic fluid. EAGLE PRO INDUSTRIAL TOOLS, INC. 11 FORM NO. E09005 REV. A. 05 Torque Wrench Pump Troubleshooting Solution 1. Inspect the power ‐ ensure you are using proper gauge extension cord 1. Fault Condition Pump will not start 2. Turn on the Power Switch 2. Power Switch Not Turned On 1. Add hydraulic fluid Pump will not 1. Low hydraulic fluid level 2. Inspect all connections, check couplers and replace any damaged items deliver hydraulic 2. Leaking connection oil, or delivers less 3. Dirt/debris in pump, filter clogged 3. Change hydraulic fluid than rated flow 4. Relief valve set too low 4. Contact your local Authorized Eagle Pro Service Center rates, or delivers 5. Directional valve failure 5. Contact your local Authorized Eagle Pro Service Center 6. Power supply voltage too low erratically. 6. Inspect the power ‐ ensure you are using proper gauge extension cord Pump builds full 1. Load greater than torque wrench capacity at full pressure 1. Replace torque wrench with larger capacity unit. pressure, torque 2. Couplers not correctly assembled 2. Inspect all connections, check couplers and replace any damaged items 1. Replace the coupler(s) Coupler leaking 1. Coupler failure System pressure 1. High pressure valve set too low 1. Contact your local Authorized Eagle Pro Service Center does not reach 2. High pressure valve failure 2. Contact your local Authorized Eagle Pro Service Center rated pressure 3. Directional valve failure 3. Contact your local Authorized Eagle Pro Service Center Torque wrench cylinder will not 1. Hydraulic connections are not connected properly 1. Inspect all connections, check couplers and replace any damaged items retract Torque wrench 1. Inspect all connections, check couplers and replace any damaged items 1. Hydraulic connections are not connected properly safety valve releasing oil 2. Coupler failure 2 Replace coupler(s) Motor shuts off 1. Motor temperature is too high 1. Allow motor to cool to normal operating temperature 1. Once hydraulic fluid reaches 86°F, system will turn on automatically Oil cooling system 1. Oil temperature has not reached 86°F 2. Contact your local Authorized Eagle Pro Service Center not cooling 2. Temperature sensor failure 3. Contact your local Authorized Eagle Pro Service Center hydraulic fluid 3. Dirt/debris in cooling system 1. Check all electrical connections and ensure you are using proper gauge 1. Incorrect electrical connections extension cord Motor runs hot 2. Stop using pump and allow motor to cool to normal operating temperature 2. Pump running too long 3. Working environment is too hot for pump 3. Do not use pump in extremely hot environments Problem Possible Cause EAGLE PRO INDUSTRIAL TOOLS, INC. 12 FORM NO. E09005 REV. A. TWP-2AF TORQUE WRENCH PUMP EAGLE PRO INDUSTRIAL TOOLS, INC. 13 FORM NO. E09005 REV. A. EAGLE PRO INDUSTRIAL TOOLS, INC. 14 FORM NO. E09005 REV. A. EAGLE PRO INDUSTRIAL TOOLS, INC. 15 FORM NO. E09005 REV. A. EAGLE PRO INDUSTRIAL TOOLS, INC. 16 FORM NO. E09005 REV. A. EAGLE PRO INDUSTRIAL TOOLS, INC. 17 FORM NO. E09005 REV. A.