Atlas Copco D500 Merkblatt

D500 HP Hydraulic Air Pump

Printed Matter No. 9839 2189 01 Pneumatic Pump

Publication Date 2020-09-07

Valid from Serial No. - Product Instructions

D500 HP Hydraulic Air Pump 8434220006

WARNING

Read all safety warnings and instructions

Failure to follow the safety warnings and instructions may result in

electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference

2© Atlas Copco Industrial Technique AB - 9839 2189 01

Table of Contents

Product Information................................................................................................3

General Information ..........................................................................................3

Warranty ................................................................................................3

Website..................................................................................................3

ServAid ..................................................................................................3

Safety Data Sheets MSDS/SDS............................................................4

Country of Origin ...................................................................................4

Dimensional Drawings...........................................................................4

Overview...........................................................................................................4

Introduction............................................................................................4

Precautions............................................................................................4

Atlas Copco Air Driven Pump Unit.........................................................4

Technical Product Data .........................................................................4

Service Overview..............................................................................................4

Service Recommendations....................................................................4

Installation ...............................................................................................................6

Installation Instructions .....................................................................................6

Before Connecting the Air Supply .........................................................6

Pump Preparation..................................................................................8

Safety On/Off Valve...............................................................................9

Operation ...............................................................................................................10

Ergonomic Guidelines.....................................................................................10

Operating Instructions.....................................................................................10

Pump Operation ..................................................................................10

Shut down procedure ..........................................................................13

Adjustment of Pressure Release Valve (PRV) ....................................13

Service ...................................................................................................................14

Maintenance Instructions................................................................................14

Service Recommendations..................................................................14

Lubrication Instructions...................................................................................14

Hydraulic Fluid.....................................................................................14

Repair Instructions..........................................................................................15

Hydraulic Pump Seal Replacement.....................................................15

Troubleshooting....................................................................................................23

Troubleshooting ..............................................................................................23

D500 HP Hydraulic Air Pump EN Product Information

Product Information

General Information

WARNING Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow

all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

►Read all Safety Information delivered together with the different parts of the system.

►Read all Product Instructions for installation, operation and maintenance of the different parts of

the system.

►Read all locally legislated safety regulations regarding the system and parts thereof.

►Save all Safety Information and instructions for future reference.

Warranty

■Product warranty will expire 12 months after the product is first taken into use, but will in any case ex-

pire at the latest 13 months after delivery.

■Normal wear and tear on parts is not included within the warranty.

■Normal wear and tear is that which requires a part change or other adjustment/overhaul during

standard tools maintenance typical for that period (expressed in time, operation hours or other-

wise).

■The product warranty relies on the correct use, maintenance, and repair of the tool and its component

parts.

■Damage to parts that occurs as a result of inadequate maintenance or performed by parties other

than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the

warranty.

■To avoid damage or destruction of tool parts, service the tool according to the recommended mainte-

nance schedules and follow the correct instructions.

■Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover

contracts. For further information contact your local Service representative.

For electrical motors:

■Warranty will only apply when the electric motor has not been opened.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on

the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

■Regulatory and Safety Information

■Technical Data

■Installation, Operation and Service Instructions

■Spare Parts Lists

■Accessories

■Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

Product Information EN D500 HP Hydraulic Air Pump

4© Atlas Copco Industrial Technique AB - 9839 2189 01

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

Introduction

The operating and maintenance procedures listed within this manual should be adhered to and will enable

the operator to obtain maximum efficiency and reliability from the equipment.

Precautions

Prior to connecting the hydraulic pump to any equipment, the user is to ensure that :

■The working pressure of the hydraulic pump and the equipment to be operated are compatible. i.e.

maximum working pressure of the hydraulic tensioning tools, hydraulic connections & hydraulic

hoses.

■The reservoir pump capacity is adequate to operate the equipment throughout its range.

The hydraulic oil specification used within the pump and the equipment are compatible.

Atlas Copco Air Driven Pump Unit

Atlas Copco air driven pump units operate on the simple but efficient principle of power magnification

through the use of differential areas. A relatively large air-operated piston drives the smaller piston, which

provides fluid flow at high pressures. All Atlas Copco air driven pump units are fitted into an easily trans-

portable, tubular steel frame.

The pump units are available, fitted with a large choice of pressure gauges and are supplied complete with

an air pressure regulator which can be set to stall the pump unit when it reaches the pressure required for

each particular tensioning application.

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Service Overview

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive

maintenance. If the product is not working properly, take it out of service and inspect it.

D500 HP Hydraulic Air Pump EN Product Information

If no detailed information about preventive maintenance is included, follow these general guide-

lines:

■Clean appropriate parts accurately

■Replace any defective or worn parts

Installation EN D500 HP Hydraulic Air Pump

6© Atlas Copco Industrial Technique AB - 9839 2189 01

Installation

Installation Instructions

Before Connecting the Air Supply

It is strongly recommended that the pump is regulated in order to stall at the required tensioning pressure.

This is achieved by adjustment of the air regulator valve.

Before connecting an air supply, it is important to check the following,

■The pressure release valve is fully open (rotated fully anti-clockwise).

■The On /Off valve is off (In the horizontal position). The On/OFF valve is by default closed until manu-

ally operated and held.

■The oil Tank has sufficient oil (Grade ISO 10, 32, 68).

■Check that the cap seal plug has been removed.

The oil tank on this pump unit is fitted with a cap seal plug to prevent oil spillage during transit. Re-

move the M6 cap screw and seal from tank cap prior to use.The oil tank on this pump unit is fitted

with a cap seal plug to prevent oil spillage during transit. Remove the M6 cap screw and seal from

tank cap prior to use.

■In the event of the pump being used at sub-zero temperatures, add deicer additives to the oil to pre-

vent the oil from freezing.

Setting pump stall pressure

1. Atlas Copco supply all pump units with the air pressure regulator set to stall the pump at its maximum

working pressure. Connect the main air supply to the pump unit. Slowly activate the safety On/Off

valve by holding the control down, the pump will begin to operate, no pressure can be generated be-

cause the pressure release valve is open, so the oil is simply circulated through the system back to

the tank.

2. Before adjusting the pressure on the air filter/regulator, it is necessary for the ‘Snap Action Lock’ to

be in the up position. By turning the adjustment knob anticlockwise on the regulator, reduce the air

pressure to zero PSI, the pump will slow down considerably and may even stop.

D500 HP Hydraulic Air Pump EN Installation

3. Fully close the pressure release valve by rotating clockwise to stop. As this is done, a slight pressure

will be generated on the pressure gauge and the pump will finally stall.

4. Slowly increase the air supply pressure by turning the adjustment knob clockwise, the oil pressure

gauge will indicate a higher pressure as more and more air is allowed into the pump unit. Stop the air

adjustment when the oil pressure gauge indicates the desired tensioning pressure.

5. Stop the pump by releasing the On/Off valve and release the pressure by slowly opening the pres-

sure return valve, the pump gauge will fall to zero. Lock the air regulator by pushing down on to the

‘Snap Action Lock’.

Operate the pump again and allow it to stall, check the pressure and further adjust if necessary. When sat-

isfied that the pump stall pressure is correct the pump unit is now ready for the tensioning operation.

Installation EN D500 HP Hydraulic Air Pump

8© Atlas Copco Industrial Technique AB - 9839 2189 01

Pump Preparation

1. Ensure the pressure release valve is in the open position (rotate anti-clockwise to stop). The pres-

sure relief valve is fitted with a torque limiter to prevent over tightening it. Limiter will ‘Click Out’ as a

preventative measure.

2. Ensure the On/Off valve is in the off position.

3. Connect the air hose to the air inlet connector. Give the hose a sharp tug afterwards, to ensure a

solid connection.

D500 HP Hydraulic Air Pump EN Installation

4. Connect the hydraulic link hose to the female quick connector. (Refer to the operation manual sup-

plied with your tensioners for correct hydraulic link hose configuration)

5. Ensure an adequate volume of oil is contained in the Oil Tank.

Safety On/Off Valve

The pump unit is fitted with a safety On/Off valve. The spring loaded valve defaults to off when the valve

handle is untouched. Holding the valve handle in the down position turns the pump on. Releasing the han-

dle turns the pump off.

Operation EN D500 HP Hydraulic Air Pump

10 © Atlas Copco Industrial Technique AB - 9839 2189 01

Operation

Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas

for improvement in posture, component placement, or work environment.

■Take frequent breaks and change work positions frequently.

■Adapt the workstation area to your needs and the work task.

■Adjust for a convenient reach range by determining where parts and tools need to be located to

avoid static load.

■Use workstation equipment such as tables and chairs appropriate for the work task.

■Avoid work positions above shoulder level or with static holding during assembly operations.

■When working above shoulder level, reduce the load on the static muscles by lowering the weight

of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce

the load on the static muscles by holding the tool close to the body.

■Take frequent breaks.

■Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

■Adjust for a convenient field of vision that requires minimal eye and head movements.

■Use appropriate lighting for the work task.

■Select the appropriate tool for the work task.

■In noisy environments, use ear protection equipment.

■Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibra-

tion.

Operating Instructions

Pump Operation

1. Close the pressure release valve (clockwise).

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