xp-air multi-port power pack - torsionx - proven...
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XP-AIRMulti-PortPowerPack
OperationandMaintenanceManual
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SafetyGuideTousetheXP-AIRMulti-PortPowerPacksafelyyoumustfollowcorrectoperationguidelinesandinspecttheequipmentregularly.Readandfollowallinstructionsandputonproperpersonalprotectiveequipment(PPE)priortouse.UPONRECEIPTOFTHISTOOL,INSPECTTHEPACKAGEFORDAMAGE.Carefullyinspectallcomponentsfordamageincurredduringshipping.Ifanyshippingdamageisfound,notifythecarrieratonce.ShippingdamageisNOTcoveredbywarranty.Thecarrierisresponsibleforallrepairorreplacementcostsresultingfromdamageinshipment.NeitherTorsionX,noritsdistributorsareresponsiblefordamagecausedbyunsafeand/orfaultyoperations.Ifaproblemarisesduringuse,shutoffthepowerimmediatelyandconsultyourTorsionXdistributor.ALLOFOURPRODUCTSMAYHAVEUPGRADESANDMODIFICATIONSWITHOUTNOTICE.
TableofContentsWarnings ........................................................................................................................................3
XP-AIRMulti-PortPowerPack........................................................................................................4
HydraulicCouplers .........................................................................................................................4
SetUp.............................................................................................................................................5
Operation .......................................................................................................................................7
Features: ........................................................................................................................................7
Warranties .....................................................................................................................................8
TroubleShootingGuide .................................................................................................................9
Appendix ......................................................................................................................................10
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Warnings
HydraulicHose:• Inspecthoseforwearanddamagepriortoeveryuse.
• Onlyusetwinlinehighpressurehydraulichosesratedfor10,000PSIwithatleasta3:1safetyfactor.
• Themaximumoperatingpressureis10,000PSI-Donotexceed10,000PSI.• Donotletthehosekink,twist,curlorbendsotightlythatoilflowwithinthehoseis
blockedorreduced.• Theminimumbendingradius:R>5inch.• Toosmallofabendingradiuswillkinkanddestroythehighpressurehydraulic
hose.• Beforeoperatingthehydraulicpowerpack,tightenallhydraulichoseconnectionswith
thepropertools.• Donotovertighten.• Connectionsshouldbetightenedsecurelyandleak-free.• Overtighteningcancauseprematurecouplerthreadfailure.
• Shutofftheairmotorbeforebreakinganyhydraulicconnectionsinthesystem.• Shouldahydraulichoseeverrupture,burst,orneedtobedisconnected,
immediatelyshutoffthehydraulicpowerpack.• Neverattempttograspaleakingpressurizedhosewithyourhands.Theforceof
theescapinghydraulicfluidcouldcauseseriousinjury.• Donotsubjectthehosetopotentialhazardssuchas:
• Fire• Sharpsurfaces• Extremeheatorcold• Heavyimpact
• Hosematerialandcouplersealsmustbecompatiblewiththehydraulicfluid.• Keephosesawayfromcontactwithcorrosivematerialssuchascreosote-
impregnatedobjectsandsomepaintsandsolvents.• Neverpaintahydraulichose.• Neverpainthydrauliccouplers.• Hosedeteriorationduetocorrosivematerialscanresultinprematurefailureand
seriouspersonalinjury.
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XP-AIRMulti-PortPowerPack• Donotexceedthemaximumhydraulicpressureratingof10,000PSI.• Donottamperwiththeinternalhighpressurereliefvalve.
• Creatingpressurebeyondratedcapacitiescanresultinseriouspersonalinjury.• Beforereplenishingthehydraulicoil,retractthesystemtopreventoverfillingthepump
reservoir.• Overfillingcancausepersonalinjuryduetoexcessreservoirpressurecreated
whenthewrenchesareretracted.
PowerSupply:
• Disconnectthehydraulicpowerpackfromthepowersupplywhenperformingmaintenanceorrepairs.
• Ifthepowersupplyisdamagedortheexternalairfeedisdamagedinanyway,replaceimmediately.
• Airsupplypressure(100PSI)andflowrate(50CFM).
HydraulicCouplers
• Neverovertightenthehydrauliccoupler.
• Overtighteningcancauseprematurethreadfailure.
• Checkforgapsinthehydrauliccoupler.
• Gapscancauseadisruptionintheflowofhydraulicfluid.• Gapswillcausethehydraulictorquewrenchtonotoperate.
• Immediatelyreplaceanywornordamagedhydrauliccouplers.• Donotusethehosetomovetheattachedequipment.
IMPORTANTWHENONLYUSINGONEHYDRAULICTORQUEWRENCH,COVERTHEEMPTYHYDRAULICCOUPLINGSWITHDUSTCAPS.
OperationWarnings:
• Donotpermitanyonetostandinfrontofopenhydrauliccouplersduringoperation.• Neverexceedthemaximumoperatingpressureof10,000PSI.• Beforeperforminganymaintenance,shutoffpower.
Figure1
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• Donotoperatewithoutoil.• Keepthepowerpackclean.• Donotoperateinwetconditions.
SetUp
FillingtheReservoir:Attention:Thepowerpackhasbeenshippedwithoutoilinthereservoir.Onlyuseahigh-grade(Grade46orbetter),qualitynon-foaminghydraulicoil.
1. Cleantheareaaroundthefillercap.a. Anydirtorgrimeinthehydraulicoilcandamagetheinternalworkingsofthe
powerpack.2. Removethefillercap,andinsertacleanfunnel.3. Fillwithhydraulicoilto1”fromthetopofthefillerhole.4. Replacefillercap.5. Cyclethepowerpack(withhydraulictorquewrenchattached)severaltimes.6. Retractthehydraulictorquewrenchandchecktheoillevelinthepowerpackreservoir
again.a. Thiswillalsohelpeliminateairfromthesystem.
HydraulicConnections:1. Inspectallhydraulictwinlinehoses,threadsandfittingsforsignsofwearordamage
andreplaceasneeded.2. Cleanallhoseendsandhydrauliccouplers.3. Connectthetwinlinehydraulichosetothehydraulictorquewrenchandthepower
pack,makingsureallhydrauliccouplersaresnug.4. Jogthepowerpackseveraltimes.
a. Thepowerpackisnowreadytobeputintoregularoperation.
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AdjustingtheHydraulicPressure:NOTE:Foreasyadjustmentofthepressureregulatingvalvealwaysadjustthepressurebyincreasingtothedesiredpressuresetting.
1. Loosenthelocknutonthepressureregulatingvalve,andbacktheadjustingknoboutafewturns.
a. Dosobyturningtheadjustingknobinacounterclockwisedirection.(Figure2)
b. Thiswilldecreasethepressuresettingtoapressurelowerthanthedesiredpressure.
ATTENTION:THEPOWERPACKMUSTBECOMPLETELYCONNECTEDANDTHEHYDRAULICTORQUEWRENCHMUSTNOTBEONTHEAPPLICATIONWHENADJUSTINGTHEPRESSURE.
2. Connecttheairsupply3. Pressthebuttononthetopoftheremotependanttoturnthe
powerpackon.a. Thepowerpackwilldeliverhydraulicoiltothelow
pressureport(PortB).4. Pressthebuttonontopoftheremotependant“Advance”.
a. Thepowerpackwilldeliverhydraulicoiltothehighpressureport(PortA).
5. Whileholdingthebuttoninthe“Advance”position,slowlyturntheadjustingknobinaclockwisedirection.
a. Thiswillgraduallyincreasethepressuresetting.6. Whenthedesiredpressureisreached,locktheadjustingknobinpositionbytightening
thelocknut.IMPORTANT:NEVEREXCEED10,000PSI
Figure2
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Operation1. Pressthetopbuttononthependanttoadvancethehydraulictorquewrench.2. Whenyouhearanaudible“Click”fromthehydraulictorquewrench,releasethebutton.
a. Thehydraulictorquewrenchwillautomaticallyretract.3. Whenthehydraulictorquewrenchisfullyretracted,repeattheprocessuntilthe
desiredpressure/torqueratingisreached.• Todisconnecttoolsandhosesfromsystem,youmustreleasesystempressure.
a. Toreleasepressurefromsystem,pressthebuttonontopofthesolenoid.(Figure3)
Attention:Whenusingahydraulicpowerpackforthefirsttime,activatethehydraulictorquewrenchpriortoputtingtoolonanapplication;thiswillhelpremoveanyairfromthesystem.
Features:
• XP-AIRMulti-PortPowerPackisathree-stagepowerpack.Thepressurereliefvalveisassembledinthehighpressureport.
• Flowratesforthepowerpackbystageare:• 50in/mininhighpressurestage• 110in/mininmidpressurestage• 500in/mininlowpressurestage
• Maximumoperatingpressure:10,000PSI• TheXP-AIRMulti-PortPowerPackcansimultaneouslyruntwotorquewrenchesatthe
sametime.• Acceptableworkingtemperature:-20Fto120F• Overalldimensions:11.8”x14.8”x17.9”• Weight(nooil):60lbs• Hydraulicoil:ISOVG46#
Figure3
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Warranties1.TorsionXguaranteestheXP-AIRMulti-PortPowerPackqualityfor12monthsfromthedateofpurchase.2.Ifanyqualityissueduetothedefectsofthematerialsorworkmanshipisfoundwithintheguaranteeperiod,TorsionXwillrepairorreplacethedefectiveproductsatTorsionX’sdiscretion.3.Iftheequipmentisfoundtobedamagedduetonegligence,operatingthepowerpackincorrectly,tamperingwith,orattemptingtorepairthepowerpackinpartorwhole,thewarrantyisinvalidated.
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TroubleShootingGuideMalfunction Reasonformalfunction Solution
Un-suitablepowersource.Confirmthepowersupplymeetsthepump’sspecifications.Thepowerpackdoesnotstart.
Thepowerisnotconnected. Checkthepowerconnection.
Thehydrauliccouplersarenotconnectedproperly.
Tightenorre-install.
Nooilinthetank. Filloil.
Notenoughoilintank. Filloil.
Thesystemhasnohydraulicpressure.
Faultypressuregauge. Replacegauge.
Thesystemstillhasnohydraulicpressureaftercheckingtheabove.
Thehydrauliccouplersmayhaveavacuumlock.
Checkhydrauliccouplerstohydraulictorquewrench.Inspectcouplerstoensuretheyarecompletelycoupled.Occasionallycouplershavetobereplacedbecausethecheckballdoesnotstayopenduetowear.
Hydrauliccouplersareleaking.Theo-ring,iswornormissinginthefemalehydrauliccouplers.
Replacethehydrauliccouplers.
Thepressuresettingforhigh-pressurereliefvalveisadjustedtoolow.
Replacehighpressurereliefvalve.
Oilismixedwithwater. Replacetheoil.
Pressurereliefvalvebroken. Replacevalve.
Airmaybeinsystem.Repeatoperatingthesystemwithnoloadseveraltimestoeliminateair.
High-pressurereliefvalvemaybeloose. Tightenvalve.
Thedesiredhydraulicpressurecannotbereached.
Theo-ringforhigh-pressurereliefvalvemaybewornormissing.
Replaceo-rings.
Thebearing(s)maybewornorbroken. Replacebearing(s).Thereisaloudnoisewhenthepowerpackisoperated. Airmaybeinsystem.
Repeatoperatingthesystemwithnoloadseveraltimestoeliminateair.
Pistonorspringmaybebroken. Replacepistonassembly.
Hydrauliccouplersmaybeloose. Tightenhydrauliccouplers.
Oillevelmaybelow. Fillwithoil.
Oilmaybetoocold. Changehydraulicoiltoalightergrade.
High-pressureflowisreduced.
Dirtinpumporfilterisclogged. Replacefilterandcleantank.
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Appendix
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