TorcUP EP1000 Owner'S Operation And Maintenance Manual Download

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OPERATION AND MAINTENANCE

MANUAL

Torque Wrench Power Pump

MODELS EP500, EP500-230V, EP1000, EP1000-Q, EP1000-230V, EP1000-Q-230V

EP500

AND

EP1000

1025 Conroy Place, Easton PA 18040 * U.S.A.

Phone: +1 610-250-5800 * Fax:+1 610-250-2700

Toll Free: 1-888-TORCUP-1

Email: [email protected] * Website: www.torcup.com

Summary of Contents for EP1000

Page 1: ...h Power Pump MODELS EP500 EP500 230V EP1000 EP1000 Q EP1000 230V EP1000 Q 230V EP500 AND EP1000 1025 Conroy Place Easton PA 18040 U S A Phone 1 610 250 5800 Fax 1 610 250 2700 Toll Free 1 888 TORCUP 1 Email sales torcup com Website www torcup com ...

Page 2: ... in preparing this Operational Manual that is intended as a technical guideline only TorcUP accepts no liability in relation to any use or reliance made of any information in this Operational Manual All information illustrations and specifications in this Operational Manual are based on the latest information available at the time of publica tion The right is reserved to make changes at any time w...

Page 3: ...ies recommended by TorcUP Use only impact sockets and accessories Do not use hand chrome sockets or accessories Use only sockets and accessories that correctly fit the bolt or nut and function without tilting the tool off the axis of the bolt This tool is not insulated against electric shock This equipment must not be operated or serviced unless the operator read the operating instructions and ful...

Page 4: ... personal protective equipment appropriate to the tool used and material worked This may include dust mask or other breathing apparatus safety glasses ear plugs gloves apron safety shoes hard hat and other equipment 5 Keep others a safe distance from your work area or ensure they use appropriate personal protective equipment 6 Be aware of buried hidden or other hazards in your work environment Do ...

Page 5: ...f damage is found notify carrier at once Shipping damage will not be covered by warranty The carrier is responsible for all loss associated with shipping damage SAFETY Make sure to read the instructions warnings and precautions carefully Follow any recommended safety precautions to avoid personal injury or damage to the unit TorcUP cannot be responsible for any damage or injury from unsafe use lac...

Page 6: ...impact may cause internal damage to hose wire strands Applying pressure to a damaged hose may cause it to rupture IMPORTANT Do not lift hydraulic equipment by the hose or swivel couplers Use the carrying handle or other means of safe transport CAUTION Keep hydraulic equipment away from flames and heat Excessive heat will soften seals resulting in fluid leaks Heat also weakens hose materials For op...

Page 7: ... or hose s to manifold Use 1 5 wraps of Teflon tape or suitable thread sealant on all threads leaving the first complete thread free of tape to ensure no foreign matter enters the hydraulic circuit When making connections with quick disconnect couplings make sure the couplings are fully engaged Threaded connec tions such as fittings gauges etc must be securely tightened and leak free EP500 EP1000 ...

Page 8: ... extension cord as the pump s motor must be grounded CONNECTING HYDRAULIC TOOLS Use only tools hoses and accessories rated at 10 000 PSI 700kg cm 2 When making connections with quick disconnect couplings make sure the couplings are fully engaged Threaded connections such as fittings gauges etc must be securely tightened and leak free Use 1 5 wraps of Teflon tape or suitable thread sealant on all t...

Page 9: ...n 4 Way Solenoid Valve for Hydraulic Torque Wrenches To Advance depress the Advance Switch To Retract release advance switch to Retract Tool 2 Position 4 Way Solenoid POWER CONTROL SWITCHES Remote pendant Configured with motor control pendant Press UP or Down To Turn Pump Off Press UP or Down To Turn On Pump NOTE In the event multiple buttons are depressed for longer than 5 seconds the unit is pro...

Page 10: ...ean the intake screen and magnet located in the reservoir twice a year If equipped change the external oil filter twice a year Use TorcUP oil only Model AO1 1 gallon Change the oil more frequently when used in extremely dusty areas or when the oil has been overheated Using oil other than TorcUP Brand may void the pump s warranty The following conditions require more frequent oil changes Rigorous d...

Page 11: ...clean as possible Applies to the 5 and 10 gallon reservoirs Unscrew screen from bottom of pump unit and clean with nonflammable solvent Blow dry and reassemble Keep areas around pump unobstructed to provide good air flow around the motor and pump Keep the motor and pump as clean as possible FLUSH THE PUMP If you suspect your pump has been contaminated or discover sludge or other deposits on intern...

Page 12: ...take screen Pump Oil is Over Heating Inspect for high pressure leakage at the pump leaking at plug or relief valve Oil level is low Fill reservoir to normal level or retrofit the pump with larger reservoir or heat exchanger Pump Runs But Will Not Pump Oil Pump is not primed Run pump a few minutes tipping from side to side Inspect to make sure that external adjustable relief valve is set properly D...

Page 13: ...ate code and serial number J October 07 Year 2007 42 Week number in year J 07 42 A B C D E F G H I J K L 1 2 3 4 5 6 7 8 9 10 11 12 How to Identify Parts for Your Model EP1000 Torque Wrench Power Pump MODEL NUMBER DATE CODE LOCATION MODEL DECAL PLACEMENT DATE CODE COVER PLATE STAMPING LOCATION 12 37 ...

Page 14: ...ts used in pumps EP1000 Torque Wrench Power Pump NOTE This illustration is for reference only The appearance of your unit Note This illustration is for reference only The appearance of your unit may differ from unit shown EP1000 13 37 ...

Page 15: ...TH DIN CONNECTOR 46294 46324 1 00 12 BLANK DECAL 3 X 4 87305 87305 1 00 52 SIGHT GAUGE 46009 46009 1 00 13 MANIFOLD ASM 1 00 57 1 4 IN NIPPLE 4100067 4100067 1 00 14 VALVE GASKET 69242 69242 1 00 58 1 4 NIPPLE CT210 CT210 1 00 15 SHCS 3 8 16 X 2 3 4 99921 99921 3 00 59 1 4 SELF LOCKING COUPLER 45765 45765 1 00 16 ADAPTER ASSY 68963 68963 1 00 62 GAUGE SHROUD ASSEMBLY 46474 46474 1 00 17 HEX PIPE P...

Page 16: ...COMMON COMPONENTS Common components used in pumps EP1000 Torque Wrench Power Pump 230v NOTE This illustration is for reference only The appearance of your unit 16 EP1000 15 37 ...

Page 17: ...SUB PUMP ASSEMBLY 46335 PUMP ASM EP1000 16 37 ...

Page 18: ...0 20 OUTLET TUBE PISTON BLOCK 45815 1 00 21 BALL 5 16 91701 3 00 22 UNLOADING SPRING 43671 1 00 23 ADJUSTING SCREW G5 45903 1 00 24 O RING 5 8X3 4 URETH 1 00 25 PIPE PLUG FLUSH 1 16 W COATING 40049 7 00 26 WEAR PLATE G5 45909 1 00 27 BOTTOM PLATE 9 32 G5 45900 1 00 28 GEAR PUMP 0 281 45824 2 00 29 SHAFT IDLER 68850 1 00 30 SCREEN 1 00 31 TUBE GUIDE 11 68894 2 00 32 SHCS 1 4 28 X 1 3 4 68255 5 00 3...

Page 19: ...RETAINING RING EXTERNAL 1 1 8 45931 1 00 05 THRUST WASHER 68026 2 00 ITEM DESCRIPTION PART QTY 01 GEN II PISTON BLOCK 45539 1 00 02 BALL 1 8 90906 2 00 03 SPRING 66042 1 00 04 BALL STOP 68810 1 00 05 BALL RETAINER 66043 1 00 06 INTAKE SEAT 66046 1 00 07 GASKET 25 64X19 32 1 00 08 PLUG PISTON BLOCK 68825 1 00 09 GASKET 29 64 X 5 8 1 00 10 ADAPTOR 255 DIA 68909 1 00 11 SPRING PISTON 68340 1 00 12 PI...

Page 20: ...7 BACK UP WASHER 3 00 08 SHEAR SEAL 68383 3 00 09 SPRING 68384 3 00 10 O RING 2 5 8 X 2 3 4 1 00 11 BEARING ROLLER 5 16x1 2x5 16 WIDE 68385 4 00 12 PIN BEARING 68390 2 00 13 PIPE PLUG FLUSH 1 16 W COATING 40049 1 00 14 SHCS 10 32 X 1 LG PLATED 68264 2 00 15 VALVE TOP PLATE MACHINED 46272 1 00 17 O RING 3 16X5 16 1 00 19 VALVE PLUG 2 POSITION SLIDER 46271 1 00 26 O RING SAE PORT 10 2 00 27 SPRING 6...

Page 21: ... 3 00 04 PIPE PLUG 1 8 FLUSH 81093 3 00 05 PIPE NIPPLE 1 8 NPT 68917 1 00 06 PIPE COUPLING 1 8 68918 1 00 07 INT RELIEF ASM HF 68999 1 00 68999 INT RELIEF ASM ITEM DESCRIPTION PART QTY 01 CARTRIDGE 66096 1 00 02 CONE REL VLVE 66086 1 00 03 POPPET RELIEF SPRING 44641 1 00 04 RELIEF VALVE ADJUSTING SCREW 66083 1 00 05 HEX NUT 7 16 20 68920 1 00 21 EP1000 20 37 ...

Page 22: ... 1 00 18 PART S DS1042900 1 00 05 BRIDGE RECTIFIER 25A 68623 1 00 1 00 06 SHCS 10 32 X 1 2 66805 1 00 20 MOLDED DIN CONNECTOR W CORD 46327 1 00 07 FITTING CORD L TIGHT 68375 1 00 21 PUSH THRU BUSHING 46420 1 00 08 LOCKNUT 1 2 INCH 85510 1 00 1 00 09 MACHINE SCREW W LOCK WASH 46248 5 00 1 00 10 HOLE PLUG 7 8 69652 2 00 24 FUSE HOLDER 30 AMP 46481 1 00 11 HHCS 1 4 20 X 75 PLT 65891 2 00 25 FUSE 25 A...

Page 23: ...0 18 PART S DS1042900 1 00 05 BRIDGE RECTIFIER 25A 68623 1 00 1 00 06 SHCS 10 32 X 1 2 66805 1 00 20 MOLDED DIN CONNECTOR W CORD 46327 1 00 07 FITTING CORD L TIGHT 68375 1 00 21 PUSH THRU BUSHING 46420 1 00 08 LOCKNUT 1 2 INCH 85510 1 00 1 00 09 MACHINE SCREW W LOCK WASH 46248 5 00 1 00 10 HOLE PLUG 7 8 69652 2 00 24 FUSE HOLDER 30 AMP 46481 1 00 11 HHCS 1 4 20 X 75 PLT 65891 2 00 25 FUSE 25 AMP 4...

Page 24: ...0 85469 1 00 05 BREATHER VENT 3 8 NPT 68000 1 00 46348 1 00 06 1 4 SOC PIPE PLUG 93950 1 00 93950 1 00 07 SAE 12 HEX PLUG WITH PORT N A 0 00 46118 1 00 08 HHCS 1 4 20 x 3 4 LG PLATED 65891 9 00 65891 14 00 09 SEALING WASHER 65892 9 00 65892 14 00 52 SIGHT GAUGE 46009 1 00 46009 1 00 73 COVER PLATE 46350 1 00 45928 1 00 46213P 2 5 GALLON RESERVIOR 73 2 5 GALLON QTY 46213P 1 00 85469 1 00 46348 1 00...

Page 25: ...NOTE This illustration is for reference only The appearance of your unit COMMON COMPONENTS EP500 24 37 ...

Page 26: ...COMMON COMPONENTS EP500 25 37 ...

Page 27: ... GAUGE 46009 46009 1 00 12 BLANK DECAL 3 X 4 87305 87305 1 00 13 MANIFOLD ASM 1 00 14 VALVE GASKET 69242 69242 1 00 15 SHCS 3 8 16 X 2 3 4 99921 99921 3 00 57 1 4 IN NIPPLE 4100067 4100067 1 00 16 ADAPTER ASSY 68963 68963 1 00 58 1 4 NIPPLE CT210 CT210 1 00 17 HEX PIPE PLUG 3 8 COATING 46513 46513 1 00 59 1 4 SELF LOCKING COUPLER 45765 45765 1 00 19 VALVE ASM 2P 4W 1 00 62 GAUGE SHROUD ASM 46474 4...

Page 28: ... DESCRIPTION PART QTY 01 GEAR SECTION ASSEMBLY SEE PAGE 31 1 00 02 PUMP VALVE SECTION ASSEMBLY SEE PAGE 34 1 00 03 SHCS 5 16 24 X 1 LG 84188 4 00 04 PISTON BLOCK TUBE G3 45537 1 00 PUMP ASSEMBLY 46541 PUMP ASM EP500 27 37 ...

Page 29: ... 45535 GEAR SECTION ASM GEAR SECTION ASSEMBLY 45535 GEAR SECTION ASM EP500 28 37 ...

Page 30: ... 2 WIDE 68891 1 00 16 O RING 1 4X3 8 1 00 17 GEAR PUMP 375 68896 2 00 18 BALL 1 8 90906 2 00 19 BEARING ROLLER 1 2x11 16x1 2 WIDE 69330 3 00 20 BOTTOM PLATE 3 8 GEARS G3 45536 1 00 21 POW R BUDDY WEAR PLATE 43279 1 00 22 POW R BUDDY ECCENCTRIC RING 43275 1 00 23 THRUST WASHER 3 4 ID 43349 4 00 24 THRUST BRG 3 4 ID 43348 2 00 25 POW R BUDDY IDLER SHAFT 43276 1 00 26 RING RETAINING 68892 1 00 27 WAS...

Page 31: ... TUBE 45426 1 00 45538 PISTON BLK ASM 13 ITEM DESCRIPTION PART QTY 01 PISTON BLOCK 45539 1 00 02 BALL 1 8 90906 2 00 03 SPRING 66042 1 00 04 BALL STOP 68810 1 00 05 BALL RETAINER 66043 1 00 06 INTAKE SEAT 66046 1 00 07 GASKET 29 64 X 5 8 1 00 08 PLUG PISTON BLOCK 68825 1 00 09 GASKET 25 64X19 32 1 00 10 ADAPTER 290 PISTON 68820 1 00 11 SPRING PISTON 68340 1 00 12 PISTON 0 290 DIA 45425 1 00 13 MAL...

Page 32: ... 1 00 0 0 2 2 1 X 8 3 G N I R O 1 1 12 ADJUSTING SCREW 43274 2 00 13 1 16 SOC PIPE PLUG 97641 2 00 0 0 1 6 1 5 X 6 1 3 G N I R O 2 2 23 BACKUP WASHER 56080087 1 00 24 POW R BUD DUMP PLUG 43283 1 00 25 1 4 SOC PIPE PLUG 93950 1 00 0 0 1 F E I L E R T X E T A E S 7 2 0 0 1 F E I L E R T X E E N O C 8 2 29 SPRING RELIEF VALVE 1 00 30 ROLL PIN 1 8X15 16 81332 1 00 31 PLUG SAE 4 68258 1 00 REBUILD KIT ...

Page 33: ... SHEAR SEAL 68383 3 00 09 SPRING 68384 3 00 10 O RING 2 5 8 X 2 3 4 1 00 11 BEARING ROLLER 5 16x1 2x5 16 WIDE 68385 4 00 12 PIN BEARING 68390 2 00 13 PIPE PLUG FLUSH 1 16 W COATING 40049 1 00 14 SHCS 10 32 X 1 LG PLATED 68264 2 00 15 VALVE TOP PLATE MACHINED 46272 1 00 17 O RING 3 16X5 16 1 00 19 VALVE PLUG 2 POSITION SLIDER 46271 1 00 26 O RING SAE PORT 10 2 00 27 SPRING 68711 1 00 29 SPACER VALV...

Page 34: ...0 04 PIPE PLUG 1 8 FLUSH 81093 3 00 05 PIPE NIPPLE 1 8 NPT 68917 1 00 06 PIPE COUPLING 1 8 68918 1 00 07 INT RELIEF ASM HF 68999 1 00 68999 INT RELIEF ASM ITEM DESCRIPTION PART QTY 01 CARTRIDGE 66096 1 00 02 CONE REL VLVE 66086 1 00 03 POPPET RELIEF SPRING 44641 1 00 04 RELIEF VALVE ADJUSTING SCREW 66083 1 00 05 HEX NUT 7 16 20 68920 1 00 36 36 COMMON COMPONENTS EP500 46292 MANIFOLD ASM 33 37 ...

Page 35: ... SHCS 10 32 X 1 2 66805 1 00 1 00 07 FITTING CORD L TIGHT 68375 1 00 20 MOLDED DIN CONNECTOR W CORD 46327 1 00 08 LOCKNUT 1 2 INCH 85510 1 00 21 PUSH THRU BUSHING 46420 1 00 09 MACHINE SCREW W LOCK WASH 46248 5 00 1 00 10 HOLE PLUG 7 8 69652 2 00 1 00 11 HHCS 1 4 20 X 75 PLT 65891 2 00 24 FUSE HOLDER 30 AMP 46481 1 00 12 HEX NUT 1 4 20 PLATD 93849 2 00 25 FUSE 25 AMP 46482 1 00 13 WIRE 14 BLACK 68...

Page 36: ...R 25A 68623 1 00 1 00 06 SHCS 10 32 X 1 2 66805 1 00 20 MOLDED DIN CONNECTOR W CORD 46327 1 00 07 FITTING CORD L TIGHT 68375 1 00 21 PUSH THRU BUSHING 46420 1 00 08 LOCKNUT 1 2 INCH 85510 1 00 1 00 09 MACHINE SCREW W LOCK WAS 46248 5 00 1 00 10 HOLE PLUG 7 8 69652 2 00 24 FUSE HOLDER 30 AMP 46481 1 00 11 HHCS 1 4 20 X 75 PLT 65891 2 00 25 FUSE 25 AMP 46482 1 00 12 HEX NUT 1 4 20 PLATD 93849 2 00 2...

Page 37: ... Cord Fitting 1 05 DS1309052 Pendant Wire 1 EP 500 and EP 1000 Pendant www torcup com BRWN BLK GRN YLW GRN BLUE WHT EMPTY 4 39 EP500 EP1000 PENDANT ITEM DESCRIPTION PART QTY 1 PENDANT BODY 69083 1 00 2 2 SWITCH JUNCTION BOX 689151 1 00 3 TOGGLE SWITCH 69487 2 00 4 CORD FITTING 68375 1 00 5 PENDANT WIRE DS1309052 1 00 36 37 ...

Page 38: ...SAVE THESE INSTRUCTIONS DO NOT DESTROY NOTES 1025 Conroy Place Easton PA 18040 U S A Phone 1 610 250 5800 Fax 1 610 250 2700 Toll Free 1 888 TORCUP 1 Email sales torcup com Website www torcup com 37 37 ...

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