Wren KLW4000 Series Operation and Maintenance Manual

Wren
Brand
Wren
Model
KLW4000 Series
Type
Operation and Maintenance Manual
Operating manual for the KLW4000 Series pump. Please read carefully and follow instructions, warnings and cautions
before use.
Operation and
Maintenance Manual
KLW4000 Series
Electric Hydraulic Pump
Safety Guide
Your Electric Hydraulic Pump requires correct operation and regular inspection as a precaution against direct loss to
personnel and property. Should anything abnormal occur during operation, please turn the pump off, disconnect it from
power supply and consult with your Pacific / WREN agent.
2
1.
Please ensure the power switch is turned off before plugging the pump into a power supply outlet to avoid unexpected activation of the pump.
2. Check that the electric cable and the power supply are in good condition with a good earth connection to avoid possible electric shock. Use
of an earth leakage crcuit breaker is advisable.
3. Always ensure the power supply to the pump is disconnected before carrying out any maintenance and repairs to the unit.
4. Do not make alternations to the pump – if changes are necessary, please inform Pacific / WREN or their agent for assistance. Unauthorised
modifications may void warranty.
5. The maximum hydraulic output pressure of this pump is 70 Mpa (10,000 Psi) and this has been pre-set at the factory and must not be
increased under any circumstances.
6. If this pump is used for operating other equipment, make sure the maximum required operating pressure of the equipment does not exceed
70 Mpa (10,000 Psi). If this requirement is less than 70 Mpa, it may be necessary to reduce the maximum pressure setting to alleviate
equipment damage.
7. Take care not to over-fill the pump reservoir with oil to alleviate the possibility of a pressure increase in the reservoir, spillage and
environmental pollution.
8. Make sure the hose(s) and quick coupler(s) is (are) correctly connected and tightened before building up pressure to avoid hydraulic oil loss,
personal injury and/or equipment malfunction.
9. In the event or an oil leakage, turn the pump off immediately and correct the problem before attempting to operate again.
10. Hydraulic oil leakages can be extremely dangerous and can cause serious injuries which can sometimes be fatal. Always check the complete
system before operating and do not use if there is any doubt about the system’s integrity.
11. In the event of rapid pressure release, the lifting device or the load being operated may drop or spring open etc., depending on the operation
and may cause injuries.
12. Do not operate this equipment in the vicinity of extreme heat or fire.
13. If hydraulic oil comes in contact with your eyes, immediately flush for about 15 minutes with clean water and seek urgent medical attention.
Caution!
Please ensure only ISO grade 32 hydraulic oil is used.
Do not use the pressure regulator valve as a relief valve.
Used hydraulic oil should be carefully stored and / or disposed of in an environmentally acceptable manner.
3
Description
1. The KLW4000 Series electric hydraulic pumps utilise an integrated assembly; consisting of an oil pump, control valve, oil reservoir and
electric motor to provide an independent and complete hydraulic device. It has the advantages of small volume, light weight, simple robust
structure, convenient operation and high work pressure. The pump utilises high and low oil pressure and can provide a larger oil output than
conventional hand pumps. High pressure and low pressure is controlled by an unloading overflow with automatic no-load return to reduce
power consumption and oil pressure is 70 - 700 Bar (10,000 Psi max).
2. Utilises ISO grade 32 wear-resistant hydraulic oil.
3. Working environment temperature; -10 to +80
o
C.
4. Always use appropriate high pressure hoses and quick couplers.
5. This pump is designed for use with hydraulic products of equal pressure - please consult with Pacific / Wren or their agent if in doubt about
an application.
6. Please do not use the electric hydraulic pump near flames.
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Oil reservoir
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Adjustable pressure regulator
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Pressure gauge
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Protection frame
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Motor
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Radiator
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Oil level measure
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Oil port release
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Control system
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Cover plate for oil tank
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Solenoid valve
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Quick coupler
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Valve block
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Oil port
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7
8
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Parts for KLW4000 Series Pump
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Description of Parts
•
Oil reservoir; contains the oil.
•
Adjustable pressure regulator; regulates the high pressure + or – to the set up pressure to the attached equipment.
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Pressure gauge; ranges from 0-100 Mpa.
•
Protection frame; protects pump assembly and can be used for carry frame for ease of transportation.
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Motor; electric 240 v 50 Hz motor (415 v 3 phase POA).
•
Radiator; to dissipate heat ensuring longer operating time and life of the pump.
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Oil level measure; sight glass indicating the current oil level, when the level is below 1/3rd of the reservoir storage capacity, oil must be added.
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Oil port release; port on base of Tank for removal of used oil.
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Control system; Pendant or lever control (part of the integrated control system).
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Cover plate; air tight sealing for the oil reservoir.
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Solenoid valve; electrically operated with optional manual pressure release.
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Quick coupler; for ease of attachment for both tools and hoses.
•
Valve Block; integral part of the hydraulic flow configuration
•
Oil port; includes breather cap which has a pre-filter to prevent access of dirt into the tank.
Characteristics
1. The KLW4000 is a three stage pump. The pressure relief valve is assembled in the high pressure port; the flow of 0.8 L/M is under high pressure,
the flow of 1.6 L/M is under middle pressure and the flow of 7 L/M is under low pressure.
2. Maximum operating pressure: 70 Mpa.
3. Flow: three stage, can simultaneously use up to four torque wrenches.
4. Electric motor: 240 v 50 Hz.
5. Working temperature range: -10 ~ 80
o
C.
6. Reservoir dimension: 310 x 240 x 130mm.
7. Weight of pump excluding oil: 27 kg.
8. ISO grade 32 hydraulic oil.
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Warning!
Do not attempt to operate without oil.
Always keep the unit and coupling clean and free from contamination.
Never open the tank while the pump is in operation since serious injury can occur.
5
Maintenance and Inspection
Pre-oPeration checks
1. Check if all connections are clean, secure and tight.
2. Check oil / fluid levels in the reservoir.
3. Check if the gauge is in good condition.
4. Check if all hoses are safe to use.
oPeration checks
1. Operate the pump and controls to test their function and if they are in working order.
2. Monitor the pump during the test operation for the following:
- Leaks
- Abnormal noises
- Excess vibration
- Valve condition
- Pendant or lever condition
- High temperature
3. If any abnormalities occur during testing, discontinue use and contact your Pacific / WREN agent.
after oPeration checks / maintenance
1. Check if the pump is turned off and isolated.
2. Clean the pump and remove any contamination.
3. Check the fluid levels and replenish if necessary.
changing the hydraulic oil
The oil should be replaced once a year. However, if there any of the following abnormalities occur, please replace the oil immediately.
1. If oil is contaminated in any way with dust / dirt etc.
2. If an abnormal smell occurs.
3. If the oil mixes with water and the colour of the oil has changed to milkiness.
4. If the colour of the oil has changed to black - brown.
rePlacing hydraulic oil
1. Loosen the oil filter port of the oil reservoir.
2. Remove the drain plug / screw at the front of the oil reservoir to drain the oil.
3. Clean the oil filter and reservoir.
4. Install the drain plug / screw and fill the oil reservoir with new oil as per recommendation.
Warning!
If the oil comes into contact with the eyes, please wash for at least 15 minutes with clean water and seek immediate medical assistance.
If the oil comes into contact with the skin, please wash with water and soap.
Used hydraulic oil is considered industrial waste; it should be disposed of in an environmentally friendly controlled manner.
6
Operation Instructions
The KLW4000 electric hydraulic pump is designed for hydraulic torque wrench tools. The pump contains a 2-way, 4-position control valve.Port
A is a high pressure point which exports the oil at the high pressure and port B is a low pressure point which returns the oil at low pressure.
1. Please loosen the locking nut to adjust the pressure before operating.
2. Adjust and set the operating pressure as required.
3. Please connect the power and push the switch to the “on” position. The lock button will activate the motor and the tool. Keep the lock button
pushed down until the pressure is reached.
4. The tool will retract when the retract button is pressed.
6. After operating, please turn off the power. Then press the rubber button on the top of the solenoid operated direction control valve in order
to release the pressure in hoses and equipment.
Warning!
When using this pump for first time or after service, please operate several times without load. This will eliminate the air in the system.
7
MALFUNCTION REASON FOR CAUSED MALFUNCTION SOLUTION
The voltage isn’t suitable Confirm if the voltage is suitable for the pump’s need
The power is not connected Check the power
The quick coupler is not connected properly Disconnect the coupler and reconnect it correctly
Not enough oil in the oil reservoir acting tank Fill the reservoir with suitable oil
Check if the flow control valve and the single direction
valve in the system is open
Open the flow control valve to ensure the system
is connected
AFTER REINSTALLING
THE QUICK COUPLER,
THE SYSTEM HAS
NO PRESSURE
The quick coupler can’t be connected to the correct
position, which causes no pressure in the system
De install the couplers, check if the steel roll is
elastic with a rod, if it can not move please knock it
with hammer to eliminate the mist hydraulic oil
LEAKAGE IN THE
QUICK COUPLERS
The couplers are badly worn Replace the quick coupler
The relief valve is adjusted too low
Check the gauge and adjust the relief valve to the
system set pressure
Oil is mixed with water Replace the oil
Not enough oil in the reservoir Fill the reservoir with suitable oil
Air may be sucked into the system
Repeat operating the system without load several
times to eliminate the air
The throttle and hand single-direction valve haven’t
been tightened
Tighten the valve
The throttle and hand single-direction valve haven’t
been adjusted to the correct position
Adjust to the correct position
The throttle and hand single-direction valve
have broken
Replace the valve
There is foreign matter in the oil Clean the system and replace the oil
Motor or pump bearing may be damaged Please replace it
Air may be mixed into this power pack
Exhaust the air from the system by repeat operation
without load several times
Trouble shooting of the hydraulic pump
THE PUMP CAN’T
BE STARTED
THE SYSTEM HAS
NO PRESSURE
THE PRESSURE
CAN’T REACH TO THE
SET PRESSURE
THERE IS A STRONG
NOISE WHEN THE POWER
PACK IS OPERATED
8
MALFUNCTION REASON FOR CAUSED MALFUNCTION SOLUTION
WHEN USING UNDER STATIC
PRESSURE, THE PRESSURE
REDUCES SLOWLY
The o-rings or seals may be damaged Check and replace damaged o-rings or seals
Piston or spring may be broken Check and possibly replace with new parts
Leaking may be happened at brushfire position Tighten the couplers and replace the seals
Oil level may be too low Top up the oil reservoir
High-pressure system may not eliminate the oil fully Please try several times without load before using
Too low oil temperature may make the oil heavy
and difficult to pump
Control the temperature at -10 to 60
o
C
Oil temperature may be too high causing damage to
the pump
If so, the powerpack needs a major overhaul and
possible replacement
HIGH-PRESSURE FLUX
IS NOT ENOUGH
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Explosion Drawing of the Valve System
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98
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Valve block – QTY: 1
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Female coupler – QTY: 1
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Male coupler – QTY: 1
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O Ring – QTY: 2
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O Ring – QTY: 2
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Retaining ring – QTY: 2
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Retaining ring – QTY: 2
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O Ring – QTY: 2
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O Ring – QTY: 2
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Retaining ring – QTY: 2
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Reversing valve – QTY: 2
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2
3
4
5
6
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O-Ring – QTY: 1
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O-Ring – QTY: 1
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Adjusting valve – QTY: 1
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O Ring – QTY: 1
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O Ring – QTY: 1
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Retaining ring – QTY: 1
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Unilateralism valve – QTY: 1
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O Ring – QTY: 1
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O Ring – QTY: 1
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Adjusting valve – QTY: 1
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21
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Casing screw – QTY: 2
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O Ring – QTY: 1
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Screw – QTY: 4
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O Ring – QTY: 2
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O Ring – QTY: 1
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Connector – QTY: 1
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Connector – QTY: 1
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O Ring – QTY: 1
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Gauge – QTY: 1
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Solenoid valve – QTY: 1
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Explosion Drawing of the KLW4000 Series Pump Module
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Seal gasket – QTY: 1
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Bearing – QTY: 1
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Bearing pole – QTY: 1
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Pump head – QTY: 1
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Release valve – QTY: 1
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Relief Valve – QTY: 1/set
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Retaining ring – QTY: 1/set
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O Ring – QTY: 1/set
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O Ring – QTY: 1/set
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Safety valve – QTY: 1
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Unilateralism valve – QTY: 2
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Check valve – QTY: 1/set
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Retaining ring – QTY: 1/set
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O Ring – QTY: 1/set
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O Ring – QTY: 1/set
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Retaining ring – QTY: 1
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Release valve (2) – QTY: 1
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Relief Valve – QTY: 1/set
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Retaining ring – QTY: 1/set
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O Ring – QTY: 1/set
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O Ring – QTY: 1/set
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Clip – QTY: 1
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Screw – QTY: 1
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Bearing – QTY: 1
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Metal Retaining Ring – QTY: 1
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Circle – QTY: 1
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Piston 1 – QTY: 4
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Piston 2 – QTY: 2
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Piston 3 – QTY: 2
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Bearing – QTY: 1
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Pin – QTY: 1
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Plate – QTY: 1
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Screw – QTY: 1
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Connecting plate – QTY: 1
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Screw – QTY: 16
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Filter – QTY: 1
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Hydraulic Principle
12
Hydraulic Principle
SYMBOL NAME MODEL REMARK
CRUN Working capacitance 70uF 300V.AC
CST Start capacitance 300uF 150V.AC
YC Solenoid valve GZ3-1 24V.DC
VC Rectifier bridge KBL2504
Sb1 Remote switch LAS2GQH-11Z/S/FP LOCK
Sb2 Remote switch GQ16H-10/s RETRACT
TC Transformer TD-30 110V/24V
KA Relay JQX-76F-BLU-2A 24VAC
QF Breaker BS32A 15A
M1 Motor 0.9kw 115V.AC 60HZ
M2 Cooler 110V.AC 38W
100-130 V 60 hz electrical configuration table
13
100-120 V 50 hz electrical configuration table
200-240 V 50 hz electrical configuration table
200-240 V 50 hz electrical configuration table
SYMBOL NAME MODEL REMARK
CRUN Working capacitance 50uF 300V.AC
CST Start capacitance 400uF 150V.AC
YC Solenoid valve GZ3-1 24V.DC
VC Rectifier bridge KBL2504
Sb1 Remote switch LAS2GQH-11Z/S/FP LOCK
Sb2 Remote switch GQ16H-10/s RETRACT
TC Transformer TD-30 110V/24V 30W
KA Relay JQX-76F-BLU-2A 24VAC
QF Breaker BS32A 15A
M1 Motor 1.1kw 115V.AC 50HZ
M2 Cooler 110V.AC 38W
SYMBOL NAME MODEL REMARK
CRUN Working capacitance 30uF 450V.AC
CST Start capacitance 150uF 250V.AC
YC Solenoid valve GZ3-1 24V.DC
VC Rectifier bridge KBL2504
Sb1 Remote switch LAS2GQH-11Z/S/FP LOCK
Sb2 Remote switch GQ16H-10/s RETRACT
TC Transformer TD-30 220V/24V
KA Relay JQX-76F-BLU-2A 24VAC
QF Breaker BS32A 10A
M1 Motor 1kw 220V.AC 50HZ
M2 Cooler 38W 220V.AC
SYMBOL NAME MODEL REMARK
CRUN Working capacitance 150uF 300V.AC
CST Start capacitance 25uF 450V.AC
YC Solenoid valve GZ3-1 24V.DC
VC Rectifier bridge KBL2504
Sb1 Remote switch LAS2GQH-11Z/S/FP LOCK
Sb2 Remote switch GQ16H-10/s RETRACT
TC Transformer TD-30 220V/24V
KA Relay JQX-76F-BLU-2A 24VAC
QF Breaker BS32A 10A
M1 Motor 1.1kw 220V.AC 50HZ
M2 Cooler 220V.AC 38W
14
Electrical interconnected figure
200-240 V 60 hz electrical configuration table
SYMBOL NAME MODEL REMARK
CRUN Working capacitance 30uF 450V.AC
CST Start capacitance 150uF 250V.AC
YC Solenoid valve GZ3-1 24V.DC
VC Rectifier bridge KBL2504
Sb1 Remote switch LAS2GQH-11Z/S/FP LOCK
Sb2 Remote switch GQ16H-10/s RETRACT
TC Transformer TD-30 220V/24V
KA Relay JQX-76F-BLU-2A 24VAC
QF Breaker BS32A 10A
M1 Motor 0.9kw 220V.AC 60HZ
M2 Cooler 220V.AC 38W
HEAD OFFICE
24 Foundry Rd,
Seven Hills NSW 2147 Australia
l P +61 2 8825 6900
l F +61 2 8825 6999
l E sales@pacifichoists.com.au
QUEENSLAND
5/54 Nealdon Drive,
Meadowbrook QLD 4131
l P +61 7 3170 3800
l F +61 7 3170 3811
l E sales@pacifichoists.com.au
NEW ZEALAND
11 Druces Rd,
Manukau City 2104 Auckland
l P +64 9 263 5566
l F +64 9 263 5567
l E info@pacifichoists.co.nz
WESTERN AUSTRALIA
Unit 1, 31 Colin Jamieson Drive,
Welshpool WA 6106
l P +61 8 6253 1000
l F +61 8 9458 9840
l E sales@pacifichoists.com.au
Warranty
Pacific Hoists Pty Ltd warrants that all products distributed by the company are guaranteed against
any apparent fault arising from manufacturing defects caused by faulty materials and / or workmanship.
Should any part fail due to the above within 24 months after purchasing this product Pacific Hoists Pty Ltd will repair
or replace the defective part free of charge. To make a claim pursuant to this warranty, the equipment must be delivered to
Pacific Hoists Pty Ltd. Freight charges both ways are payable by the claimant and no liability is accepted for loss or damage
during transit. The claimant is required to produce the original invoice or other purchase documents as proof of purchase when
making a claim pursuant to this warranty.
The warranty does not cover the purchaser or any other person for damage, loss, normal wear or faults caused from misuse or incorrect
installation of the equipment.
To be eligible under this warranty, the equipment is required to have been installed and operated correctly by qualified personnel and has not been
subject to abuse, neglect or adjustment carried out by an unauthorized person.
This warranty may only be varied with the written approval of the Directors of Pacific Hoists Pty Ltd. In the following statement ‘Our’ means ‘Pacific
Hoists Pty Ltd’ and ‘You’ means the ‘claimant.’
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for
a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or
replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
The benefits given to the claimant in this warranty are in addition to other rights and remedies under a law in relation to the goods or services to
which this warranty applies.
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Wren KLW4000 Series Operation and Maintenance Manual

Wren
Brand
Wren
Model
KLW4000 Series
Type
Operation and Maintenance Manual
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