SPX HPUTP Series Bedienungsanleitung

Operating Instructions for:

HPUTP150001K

HPUTP150002K

Air-Powered

HPUTP Series

Hydraulic Pump

Form No. TAP 11024

Rev. 5 March 8, 2012

Original Instructions

SPX Bolting Systems

Unit 4, Wansbeck Business Park

Rotary Parkway

Ashington

Northumberland NE63 8QW

spxboltingsystems.com

Tel: +44 (0) 1670 850580

Fax: +44 (0) 1670 850655

Form No. TAP 11024

Rev. 5 March 8, 2012

Form No. TAP 11024

Rev. 5 March 8, 2012

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HPUTPSeriesAir/HydraulicPumps........................................4

Safety Symbols and Denitions............................................5

SafetyPrecautions .....................................................5

InitialSetup...........................................................8

OperatingInstructions...................................................9

Performance Specications..............................................10

GeneralMaintenance ..................................................11

SPXBoltingSystemsFacilities...........................................13

Form No. TAP 11024

Rev. 5 March 8, 2012

HPUTP Series Air/Hydraulic Pumps

Description

Air Motor

The air/hydraulic pumps are suitable for operation

up to 1,500 bar (21,750 psi).

The pump requires 6.0-6.9 bar (90-100 psi) of

supplied air pressure. Weight can be up to 23 kg

(50 lbs).

Note: The air supply must be minimum 0.8 M3/

min. (28 CFM) standard and 1.6 M3/min. (56

CFM). Use of an air lter/lubricator is recom-

mended.

Figure 1. HPUTP Series

Description

The HPUTP series hydraulic pumps are designed to have a maximum of 1500 bar (21,750 psi)

at a ow rate of 0.72 litres/min (44 cu. in/min) or 1.14 liters/min (70 cu.in/min) depending on

model. All pumps come fully assembled, less uid, and ready for work.

Form No. TAP 11024

Rev. 5 March 8, 2012

The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death

or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor

or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

IMPORTANT: Important is used when action or lack of action can cause equipment failure, either

immediate or over a long period of time.

Safety Symbols and Denitions

WARNING:

• The following procedures must be performed by qualied, trained personnel who

are familiar with this equipment. Operators must read and understand all safety

precautions and operating instructions included with the pump. If the operator cannot

read these instructions, operating instructions and safety precautions must be read

and discussed in the operator's native language.

• These products are designed for general use in normal environments. These products

are not designed for lifting and moving people, agri-food machinery, certain types of

mobile machinery, or in special work environments such as: explosive, ammable, or

corrosive. Only the user can decide the suitability of this product in these conditions or

extreme environments. SPX Hydraulic Technologies will supply information necessary

to help make these decisions. Consult your nearest SPX Hydraulic Technologies

facility, refer to SPX Hydraulic Technologies Facilities in this document.

• Safety glasses must be worn at all time by the operator and anyone within sight of

the unit. Additional personal protection equipment may include: face shield, goggles,

gloves, apron, hard hat, safety shoes, and hearing protection.

• The owner of this tool must ensure that safety-related decals are installed, maintained,

and replaced if they become hard to read.

• Shut OFF the motor before opening any connections in the system.

• The guide cannot cover every hazard or situation so always do the job with SAFETY

FIRST.

Pump

WARNING:

• Do not exceed the hydraulic pressure rating noted on the pump nameplate or tamper

with the internal high pressure relief valve. Creating pressure beyond rated capacities

can result in personal injury.

• Retract the system before adding uid to prevent overlling the pump reservoir. An

overll can cause personal injury due to excess reservoir pressure created when

cylinders are retracted.

Safety Precautions

Form No. TAP 11024

Rev. 5 March 8, 2012

• The pump must be used in an upright position.

• Repairs to the pump unit should only be carried out by SPX Bolting Systems or an

authorized Service Agent.

• Do not connect pump to hydraulic system powered by another pump.

Hoses

WARNING:

• Before operating the pump, tighten all hose connections using the correct tools. Do

not overtighten. Connections should be only secure and leak-free. Overtightening can

cause premature thread failure or high pressure ttings to split at pressures lower

than their rated capacities.

• Should a hydraulic hose rupture, burst, or need to be disconnected, immediately shut

off the pump and shift the system pressure manual release valve twice to release

pressure. Never attempt to grasp a leaking hose under pressure with your hands. The

force of escaping hydraulic uid could cause serious injury.

• Do not subject the hose to potential hazard, such as re, sharp surfaces, heavy impact,

or extreme heat or cold. Do not allow the hose to kink, twist, curl, or bend so tightly

that the uid ow within the hose is blocked or reduced. Periodically inspect the hose

for wear, because any of these conditions can damage the hose and possibly result in

personal injury.

• Do not use the hose to move attached equipment. Stress can damage the hose and

possibly cause personal injury.

• Hose material and coupler seals must be compatible with the hydraulic uid used.

Hoses also must not come in contact with corrosive material such as creosote-

impregnated objects and some paints. Consult the manufacturer before painting a

hose. Never paint the couplers. Hose deterioration due to corrosive materials may

result in personal injury.

• Avoid straight line tubing connections in short runs. Straight line runs do not provide

for expansion and contraction due to pressure and/or temperature changes. See

diagrams in Initial Setup section of this form.

• Eliminate stress in the tube lines. Long tubing runs should be supported by brackets or

clips. Tubes through bulkheads must have bulkhead ttings. This makes easy removal

possible and helps support the tubing.

• Carefully inspect all hoses and ttings prior to use. Before each use, check entire hose

for cuts, leaks, abrasion or bulging of cover, or damage or movement of couplings. If

any of these conditions exist, replace the hose immediately. NEVER attempt to repair

the hose.

Cylinder

DANGER:

• Do not exceed rated capacities of the cylinders. Excess pressure may result in personal

injury.

• Read and understand all safety and warning decals and instructions for devices

attached.

• Inspect each cylinder and coupler before each shift or usage to prevent unsafe

Safety Precautions continued

Form No. TAP 11024

Rev. 5 March 8, 2012

conditions from developing.

• Avoid pinch points or crush points that can be created by the load or parts of the

cylinder.

• To help prevent material fatigue if the cylinder is to be used in a continuous application,

the load should not exceed 85% of the rated capacity or stroke.

IMPORTANT

• Keep the cylinder clean at all times.

• Always use protective covers on disconnected quick couplers.

• Limiting the stroke and pressure on all cylinders will prolong their life.

Safety Precautions continued

Form No. TAP 11024

Rev. 5 March 8, 2012

Initial Setup

1. Remove all packing materials from the assembled unit.

2. Inspect the unit upon arrival. The carrier, not the manufacturer, is responsible for any damage

resulting from shipment.

Filling the Pump Reservoir

Most pumps are shipped without hydraulic uid in the reservoir. Hydraulic uid may have been shipped

in a separate container, but if hydraulic uid is needed, use only approved Power Team hydraulic uid

rated at AW 46 47 cSt @ 38°C (237 SUS @ 100°F). If low temperature requirements are needed, use

hydraulic uid 5.1 cSt @ 100°C (451 cSt @ -40°C). Operating temperature ranges are from

-10°–60° C(14–140°F).

1. Clean the area around the filler cap to remove debris. Debris in the hydraulic fluid can damage the

polished surfaces and precision-fit components of this pump.

2. Remove the filler cap and insert a clean funnel with a filter.

3. Fill the reservoir with hydraulic fluid to 2.6 cm (1 in.) from the cover plate.

4. Replace the filler cap. Verify the breather-hole is open, if applicable.

5. Fully open the pressure release valve.

6. Connect air supply to pump unit.

7. Slowly open the pump unit air stop valve, starting the pump unit.

8. Allow the pump to circulate the oil, watching the oil flow through the opaque plastic oil return tube

running from the pressure release valve back to tank. Any air that is present within the pump unit

pressure chamber will be displaced and seen through this oil return tube. When most of the air

bubbles cease to emerge and the oil flows freely, stop the pump unit.

The pump unit is now ready for use.

Hydraulic Connections

1. Clean the areas around the fluid ports of the pump and cylinders.

2. Inspect all threads and fittings for signs of wear or damage, replace as needed.

3. Clean all hose ends, couplers or union ends.

4. Remove the dust cap from the hydraulic fluid outlets.

5. Connect the hose assembly to the hydraulic fluid outlet, and couple the hose to the cylinder.

CAUTION: To prevent personal injury from leaking hydraulic uid, seal all hydraulic

connections with a high-quality, non-hardening, pipe thread sealant.

IMPORTANT: Sealant tape or non hardening sealer tape can be used to seal hydraulic

connections if only one layer of tape is used. Apply tape carefully, two threads back, to

prevent it from being pinched by the coupler and broken off inside the system. Loose

pieces of sealant could travel through the system and obstruct the ow of uid or cause

jamming of precision-t parts.

Form No. TAP 11024

Rev. 5 March 8, 2012

Operating Instructions

Prior to operating pump, the following checks should be carried out;

a. Hydraulic oil level - check reservoir level, ensure tank is at least ½ full.

b. Air lubricator oil level - refill if needed.

c. Air regulator water trap - drain water as necessary.

d. Pump purging procedure has been carried out.

The pump unit should be regulated on-site to either stall at a predetermined hydraulic pressure

(associated with the particular bolt tensioner and bolt size to be tightened) or to the maximum pressure

of the tensioning tools, i.e. 1,500 bar (21,750 psi). This is achieved by carrying out the following

procedure:

1. Either loop a 3m (9.8 ft) feed hose across the pump hydraulic oil outlets or alternatively attach blank

female couplings.

WARNING: Unattached couplings, male or female, must not be pressurised under any

circumstances

2. Open the pump hydraulic oil pressure release valve.

3. Ensure that the pump start/stop valve is closed.

4. Connect the pump to the air supply

5. Turn the air pressure regulator adjustment knob anti clockwise until the air pressure gauge reads

zero pressure.

6. Open the pump start/stop valve. As the regulator has been set to read zero pressure the pump

should not start. If the pump does operate, it should be very slow.

7. Close the hydraulic oil pressure release valve. Do not overtighten, the valve seat will be damaged if

overtightened. A light nip will suffice.

8. Rotate the air pressure regulator adjusting knob slowly clockwise until the required hydraulic oil

pressure reads on the pump pressure gauge

9. Close the pump start/stop valve.

10. Slowly open the hydraulic oil pressure release valve to relieve the system pressure.

The pump is now ready for operation and will automatically stall at the pre-set pressure. When using

the pump unit the following safety rules must be adhered to.

Always wear eye protection during pump operation and during tensioning.

Although the pump may be have been pre-set to stall at a certain pressure, always monitor the

pressure gauge during pressure build up.

Always depressurize before leaving the system unattended.

Form No. TAP 11024

Rev. 5 March 8, 2012

Performance Specications

The information in the following charts can be used as a basis to determine if the system is performing

as expected during operation.

Pump RPM

dB_A at

Idle and

1500 bar

(21,750 psi)

Air Supply

Req'd bar

(psi)

Air

Consumption

cu.m/min

(CFM)

Hydraulic

Fluid Type

Hydraulic

Fluid

Capacity

L(Gal)

Air

Lubricator

Fluid

Air

Lubricator

Drip Rate

Pump

Dimensions

mm (in)

Standard N/A 85 6.0-6.0

(90-100)

0.8 (28) GB

UNIPOWER

SRC46

9.5 (2) FUCHS

SILKAIR

VG22

approx. 1

drop per

30 pump

strokes

420x420x390

(16.5x16.5x15.3)

High

Flow

N/A 85 6.0-6.0

(90-100)

1.6 (56) GB

UNIPOWER

SRC46

9.5 (2) FUCHS

SILKAIR

VG22

approx. 1

drop per

30 pump

strokes

456x530x515

(17.9x20.8x20.2)

Pump Max. Pressure

Output bar (psi) Fluid Delivery* l/min (cu. in./min.) @

0 bar (0 psi) 200 (2,900) 600 (8,702) 1,500

(21,750)

Standard 1500 (21,750) 0.72 (43.9) 0,47 (28.6) 0.39 (23.7) 0.25 (15.2)

High Flow 1500 (21,750) 1.14 (69.6) 0.96 (58.%) 0.80 (48.8) 0.50 (30.5)

* Typical delivery. Actual ow varies with eld conditions.

Table 1. Drive Unit Requirements

Table 2. Fluid Pressure Chart

Item Description

1 Stop/Start Valve

2 Lubricator Oil Level

3 6 in. Oil Pressure Gauge

4 Fluid Outlet(s)

Item Description

5 Pressure Release Valve

6 Reservoir Filler Cap

7 Fluid Reservoir

8 Water Trap

Item Description

9 Air Pressure Gauge

10 Air Filter/Regulator

11 Air Lubricator

12 Lubricator Drip Adjuster

Figure 2. Component Identication

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