Titan WindMaster 2010 Bedienungsanleitung

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Operating Manual

TITAN®WindMaster™2010

Hydraulic Tensioning Pump

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Contents

Contents ...........................................................................................2

Signs and symbols ...........................................................................3

Before starting ..................................................................................4

Starting .............................................................................................5

Pressure adjustment.........................................................................6

Venting .............................................................................................7

Coupling of the high-pressure hoses................................................7

Safety hints.......................................................................................9

Short guidance ...............................................................................10

Maintenance...................................................................................11

Operational disturbances and their recovery..................................12

Technical data................................................................................12

Hydraulic-schematic.......................................................................15

Electric-schematic ..........................................................................16

Appendix.........................................................................................17

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Signs and symbols

Attention!

Attention: Slipping Hazard!

Attention: Overhead Hazard!

Command: High Importance!

Command: Wear protective eye wear with

side shields or safety goggles!

Command: Wear hard toe shoes!

Forbidden!

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Before starting

These operating instructions is designed to give you some information about the

handling and safe application of theTITAN®WindMaster™ Hydraulic Tensioner

Pump.

Please read these operating instructions carefully to ensure the optimum function

and a high degree of safety.

The equipment is delivered fully assembled, functionally tested, vented and filled with

hydraulic oil. To prevent the oil from spilling during transport, the filling and venting

opening (depending on the model) is sealed with a plug.

Please ensure that it is replaced by the venting screw before commissioning (see

appendix).

SAFETY HINTS: WE STRONGLY RECOMMEND THE INSTALLATION OF A

GAUGE ON THE PUMP OR ON THE CYLINDER TO AVOID DAMAGE TO THE

COMPONENTS. PROPER PRESSURE CONTROL IS CRITICAL TO THE TASK AT

HAND AND TO SAFETY IN EVERY STEP OF THE WORK (Fig. 1).

Fig. 1

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Starting

Note: The TITAN®WindMaster™ 2010 Pump produces extremely high

hydraulic pressure. Extreme care must be taken to ensure safety.

Failure to do so may result in severe injury or death.

Before starting the work, please make sure that the oil level in the pump tank is

correct. The oil gauges should be filled with oil. Filling the tank approximately 1

cm under the tank caps is allowed. In some cases it can be necessary to refill the

device with oil.

Use only hydraulic oil and never aggressive oil, because it can results in

damaging your seals.

NOTE: CHECK AND ENSURE THAT THE APPLICATION AND ITS

THREADED FASTERNERS ARE SUITABLE FOR THE MAXIMUM

OPERATING PRESSURE.

HINT: ALSO, ONLY HOSES AND CONNECTIONS WITH SUITABLE

OPERATING PRESSURE RATINGAND SAFETY FACTORS SHOULD BE

USED. CHECK ALL HOSES FOR KINKING AND IF FOUND, REPLACE

PRIOR TO PRESSURIZING. FOR BEST RESULTS AND OPTIMUM SAFETY,

USE ONLY TITAN®SUPPLIED HOSES, CONNECTIONS AND ACCESSORIES.

ATTENTION: NEVER USE THE HOSES AS A CARRING HANDLE.

The high-pressure hose must be shifted as straight-lined and directly as possible,

in each case never exceed the minimum bending radius. The hose should not be

overdriven or loaded. Sharp edged parts can damage the hose. Pay attention

particularly to the suitable threaded connections.

For tightening the threaded bolt or stud connection we recommend normal

spanners without extension, in order to avoid overloading at the threads. For the

hose connectors only use the threaded bolt or stud connections specified in our

catalogue under accessories.

Dirt particles in the hydraulic system can lead to damages at the cylinder faces

and at the valve seats, therefore replace dirty hydraulic fluid before starting.

After all components are examined for the structural integrity necessary for the

desired pressure, the device can be plugged in to the electricity supply. Turn the

main switch to the pos.1 to start the pump.

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

By operating the tracer ⇑on the hand remote control (Fig. 2) the hydraulic

pressure develops. Before starting, in each case, check the adjusted pressure

(chap. Pressure adjustment).

Fig. 2

By operating the tracer ⇓on the remote control the pressure can be reduced

again.

If you are not using the pump motor, please switch it off (Main switch on Pos.0)

In order to avoid unnecessary wear and thermal loads on the device.

Do not touch the motor and parts near the motor after using it, since the

surfaces can be hot.

Pressure adjustment

The output / consumer pressure can be determined by adjusting the low pressure

at the pressure limiting valve. This adjusts the input pressure of the pressure

converter.

Turning clockwise (+) will increase the pressure, turning counterclockwise (-) will

reduce the pressure. The pressure converter operates with a conversion ratio of

1:13. This means, for example, that 10 bar of low pressure will generate an

output pressure of 130 bar.

The electric hydraulics pumps are factory-installed and adjusted to 1000 bar

initial pressure.

CAUTION: Disconnect all hoses and tensioners PRIOR to adjusting the

pressure.

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Venting

Because air is compressible, air within the system can lead to accidents. It is

therefore essential to vent the system of air, prior to using the pump, hose and

tensioner before starting the work. To accomplish this, let the pump run at a low

pressure until the hydraulic system is fully vented.

•Screw in the pressure limiting valve by approx. one revolution from the

point at which the spring takes effect, set switch I, to motor on, and vent

the entire system at the breather screw of the tensioner or at the end of

the hose until pure oil escapes without bubbles.

•Make the desired pressure adjustment (Chap. Pressure adjustment).

Coupling of the high-pressure hoses

CAUTION: IT IS VERY IMPORTANT THAT THE TWO HALVES OF THE

COUPLING ARE ALWAYS CLEANED THROUGHLY BEFORE CONNECTING.

Dirt in the halves of the coupling also makes the complete connection more

difficult, obstructing the flow of fluid because it will be possible that the two balls

will not open fully.

NOTE: THEREFORE, PLEASE ALWAYS CHECK THAT THE COUPLING IS

FULLY ENGAGED OR, IF SCREW UNIONS ARE EMPLOYED, THAT THEY

ARE FULLY SCREWED IN.

NOTE: WE RECOMMEND THAT THE DUST CAPS SHOULD ALWAYS BE

SCREWED ON WHEN THE COUPLING IS DISCONNECTED.

WE WILL NOT ACCEPT GUARANTEE CLAIMS RESULTING FROM THE

INCORRECT USE OF OUR EQUIPMENT OR FROM THE USE OF

EQUIPMENT OR SPARE PARTS MADE BY OTHER MANUFACTURERS.

NOTE: QUALIFIED PERSONNEL MUST CONDUCT ALL REPAIRS OR

MODIFICATIONS TO THE PUMPS. INCORRECT HANDLING CAN CAUSE

THE GUARANTEE TO BE VOIDED.

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Handling instruction for the heating mechanism

Heate

Fig. 3 Switch box, heater

•Switch-on the Power supply.

•By pressing the heating-button (see Fig. 3) the pump runs one minute in a

pressure-free circulation to warm up the oil.

- After first pressuring, the heating mechanism is out of action.

•If you want to use the heating-mechanism again (after pressuring), you

must switch off/on the pump.

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Safety hints

Apart from observing the general accident prevention regulations, the following

safety instructions must be observed to prevent life-endangering conditions,

damage and an increased accident hazard.

If leaks occur when pressure is applied, the pressure must be relieved

immediately. The leak must be sealed and defective components must be

replaced.

When repairs are made use original spare parts only. The unauthorised

replacement of damaged components with non-original spare parts is not

permitted.

All components must be handled exclusively as described in the

operating instructions and the general drawing. Changes to the

functional sequence or a different application are not allowed.

It must always check if the high-pressure hoses are connected correctly.

The high-pressure hoses must be laid such that they cannot be driven

over by vehicles or unnecessarily trodden by persons. Never lay hoses over

sharp objects (danger of cutting) and do not pinch or trap them.

Before the pressure is applied, the maximum working pressure (without

consumers) must be adjusted by an authorised person at the pressure-

limiting valve (Chap. Pressure adjustment).

The unit is not fitted with a safety valve. The maximum system pressure

of 2500 bar must never be exceeded.

Repairs must only be conducted when the system is depressurised and

disconnected from the power.

Verify the oil level before each commissioning.

You must carry protection eyeglasses while working with high-pressure

hydraulic aggregates.

In the case of use of a remote control, pay attention to electromagnetic

radiations.

TITAN Technologies International, Inc.®

9001 Jameel Street, Suite 180 • Houston, TX 77040

Toll-Free: 866.345.8484 • Phone: 281.449.9994 • Fax: 281.449.9996 • Email:[email protected]

http://www.titanti.com

Short guidance

The following steps must be taken before the first start:

•Fill up hydraulic fluid (e.g. ISO VG 46) at the filler pipe if necessary until

the oil gauge is filled with oil

•Connect the plug to a power source (Consider the electrical data)

•Disconnect all hoses to the consumers

•Close the manual shut-off valve (otherwise pressure-free circulation)

•Adjust the working pressure at the pressure limiting valve

•Build up the pressure by operating the tracer ⇑

•Stop building up the pressure by releasing the tracer ⇑

•Release the pressure by opening the manual shut-off valve or by

operating the tracer ⇓

CAUTION: ALWAYS CHECK THE MAX. ADJUSTED HYDRAULIC

PRESSURE FIRST WITHOUT THE HOSES OR TOOLS CONNECTED.

THE MAX. PERMISSIBLE HYDRAULIC PRESSURE OF THE SUPPLIED

HYDRAULIC GAUGE MUST NOT BE EXCEEDED.

TURN THE REGULATING KNOB COUNTERCLOCKWISE →REDUCES THE

PRESSURE

TURN THE REGULATING KNOB CLOCKWISE →INCREASES THE

PRESSURE

Always observe the hydraulic pressure gauge when applying pressure to the

pump.

Safety requires that you read very carefully and understand fully the operation

instructions, prior to turning on and operating the pump.

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