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XP-AIRMulti-PortPowerPack

OperationandMaintenanceManual

TorsionX XP-AIRMulti-PortPowerPack(Updated9/5/17) 2

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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