# Operating Hydraulic Pump

## Setting Working Pressure on the Pump

To set the pressure on the pump, follow this procedure:

1. Loosen the knurled locking ring below the "T" handle on the pump's external pressure regulator. Then turn the "T" handle counter clockwise (CCW) 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.

   Always adjust the regulator in order to increase the pressure up - Never down. Never adjust the regulation with the tool on the application

4. When your gauge reaches 4,000 PSI stop turning the "T" handle and let the gauge settle out.

5. If the pressure continues to rise (above 4,000), release the advance button and back off your pressure slightly-by turning CCW on the "T" handle. Then re-depress the advance switch on you remote and slowly bring pressure up to 4,000 again.

6. 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.

7. 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.

## Applying Torque to Wrench

Having set your target pressure, cycle the tool three or four times to full pressure. Cycling the tool ensures that the system is operating properly and removes trapped air, if any.

Verify that any impact sockets used are rated to accept the full torque output of the tool they are to be used with. Ensure the correct size impact socket for the nut A/F has been selected, placed on the square drive and secure with a locking pin and ring.

Place the tool and the socket on the nut, making sure that the socket has fully engaged the nut, check that the drive retainer is engaged.

Make sure the reaction arm is firmly abutted against a stationary object (i.e. an adjacent nut, flange, equipment housing etc.). When positioning the wrench, make sure that the hose connections are well clear of any obstructions and that all body parts are safely out of harm's way. Then apply momentary pressure to the system to ensure proper tool placement. If it doesn't look or act right, stop and re-adjust the reaction arm.

Read Safety Instructions supplied with the torque wrench for further guidance on tool usage

1. By pushing down on the remote control button in the advance position, the rear of the tool will be pushed back until its reaction arm will contact its reaction point.

2. Continue to hold down the button as the socket turns until you hear an audible "click" which will signify the hydraulic cylinder inside the tool is fully extended and will not turn the advance further.

3. Continuing to hold down the remote control button will result in a rapid build up of pressure to the point of where the gauge reads what was preset prior to applying the wrench.

The reading of full preset pressure after the cylinder is extended DOES NOT INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the socket or the ratchet link further until the tool automatically resets itself.

Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the operator will hear an audible "click" indicating he can again push the remote control button and the socket will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the tool "stalls" at the pre-set Torque/PSI with an accuracy of +/-3%. Repeatability is +/- 1%.

Always attempt one final cycle to ensure the "stall" point has been reached.

Should the tool "lock-on" after the final cycle, push down on the remote control button once more (to build pressure) and, while maintaining this pressure, pull back on the external disengagement lever (RT) or reaction Pawl (RTX). Releasing the remote control while continuing to hold back on the pawl lever/reaction pawl will allow the tool to be removed easily.

## Loosening Procedures

First, set the pump to 9,000 PSI (Do not try directly at 10.000 PSI). Change the drive and the reaction arm to the loosening mode (Left = Loose), assuring the reaction arm abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear an audible "click". Release the remote control button, and the cylinder automatically retracts, at this time you will again hear the audible "click". Repeat this process until the fastener can be removed by hand. First, set the pump to 9,000 PSI (Do not try directly at 10.000 PSI). Change the drive and the reaction arm to the loosening mode (Left = Loose), assuring the reaction arm abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear an audible "click". Release the remote control button, and the cylinder automatically retracts, at this time you will again hear the audible "click". Repeat this process until the fastener can be removed by hand.

NOTE : If the bolt does not loosen with the above procedure, it is an indication that you need a larger tool to loosen the bolt.

## Setting Torque

All Atlas Copco power packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed. Before using your Atlas Copco power pack, check the following points.

- Is the reservoir filled with oil?

- Where is the closest electrical outlet at the job site?

- Is there enough air pressure (60 to 100 PSI) and Air flow at the job site? (Air units only)

- Is the gauge mounted and rated for 10,000 PSI/700 bar?

## Working Pressure

The pump's maximum working pressure is 10,000 PSI / 700bar. Make sure all hydraulic equipment and accessories are rated for 10,000 PSI / 700bar operating pressure. Hydraulic pumps are available with higher pressure outputs, if not using an Atlas Copco power pack verify maximum operating pressure of the unit being used and ensure the system maximum operating pressure (10,000 PSI / 700 bar) is not exceeded.

## Hydraulic Connections

Never disconnect or connect hydraulic hoses or fittings without first unloading the wrench. Unplug the electrical cord of the pump, and open all hydraulic controls several times to assure that the system has been depressurized. If the system includes a gauge, double check the gauge to assure pressure has been released. When making a connection with quick disconnect couplings, make sure the couplings are fully engaged threaded connections such a fittings, gauges etc. must be clean and securely tightened and leak free.

CAUTION - Loose or improperly threaded couplers can be potentially dangerous if pressurized, however, severe over tightening can cause premature thread failure. Fittings need to be only tightened secure and leak free. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury. Do not subject the hose and potential hazard such as sharp surfaces, extreme heat or heavy impact. Do not allow the hose to kink and twist. Inspect the hose for wear before it is used.

## Electrical Power

1. Check the proper electrical supply before connecting.

2. This motor may spark. Do not operate in an explosive atmosphere or in pressure of conductive liquids.

   - 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.

3. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical overloading.

## Prior to Use

Check hydraulic oil (Use Atlas Copco maximiser range 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. Class1 certified calibrated gauges are available for most applications