TorcUP EP500 Owner's Operation And Maintenance Manual
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TorcUP EP500 Owner's Operation And Maintenance Manual

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EP500
OPERATION AND MAINTENANCE
MANUAL
Torque Wrench Power Pump
MODELS EP500, EP500-230V, EP1000, EP1000-Q, EP1000-230V, EP1000-Q-230V
EP1000
AND
1025 Conroy Place, Easton PA 18040 * U.S.A.
Phone: +1 610-250-5800 * Fax:+1 610-250-2700
Email: sales@torcup.com * Website: www.torcup.com
Toll Free: 1-888-TORCUP-1

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  • Page 1 EP500 EP1000 OPERATION AND MAINTENANCE MANUAL Torque Wrench Power Pump MODELS EP500, EP500-230V, EP1000, EP1000-Q, EP1000-230V, EP1000-Q-230V 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: Table Of Contents

    TorcUP Inc. was not consulted. TorcUP has taken every care 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.
  • Page 3 Avoid sharp bends and kinks that will cause severe back-up pressure in hoses an lead to premature hose failure. • Use accessories recommended by TorcUP. • Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.

  • Page 4: Safe And Correct Use

    4. Do not use damaged, frayed or deteriorated hydraulic hoses and fittings. Do not paint hoses. 5. Do not lubricate tools with flammable or volatile liquids such as kerosene, diesel or jet fuel. Use only TorcUP recommended lubricants. 6. Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet current safety and health standards.

  • Page 5: Warranty Statement

    Keep this manual for reference. WARRANTY STATEMENT TorcUP products are warranted to be free of defects in materials and workmanship under normal use for as long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty does not cover: normal wear &...

  • Page 6: Working Pressure

    INSTALL VENT PLUG Remove shipping plug from reservoir and install vent plug supplied with pump. ADDING OIL Remove oil filler cap and add TorcUP hydraulic oil into reservoir. Oil level should not exceed 1” from EP1000 EP500 the reservoir cover. Oil should be ISO 32 or 46 weight.

  • Page 7: Install Hydraulic Connections

    TECHNICAL SPECIFICATIONS LUBRICATION EP500 EP1000 INSTALL HYDRAULIC CONNECTIONS Use only tools, hoses and accessories rated at 10,000 PSI (700kg/cm ). Remove the shipping plugs from the ports to connect your coupling(s) 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.

  • Page 8: Electrical

    Check for proper electrical supply before connecting. Be sure the electrical connection is grounded. Check that your power supply agrees with the motor nameplate and/or TorcUP model decal. NOTE: MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE PRESENCE OF CONDUCTIVE LIQUIDS.

  • Page 9: Pump Mounting

    TECHNICAL SPECIFICATIONS PUMP MOUNTING Refer to the chart for mounting dimensions to secure the pump to a fixed surface. 1 gal. 1.5 gal. 2.5 gal. 5 gal (4L) (6L) (10L) (20L) 15.13 19.6 0.56 1.68 2.75 4.69 0.56 3.57 4.37 5.03 1.16 1.43...

  • Page 10: Pressure Torque Setting

    Completely change the hydraulic oil and clean 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.
  • Page 11 Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in oil when all tools are retracted. Add TorcUP oil (Model # AO1 – 1 gallon) when necessary. Oil level should be no more than 1” from top of reservoir plate – with cylinders retracted and motor off.

  • Page 12: Oil Level

    Incorrect motor rotation, take to nearest TorcUP Authorized Service Center for repair. • Check to make sure the intake screen is not clogged. Clean if needed. • Check oil reservoir is low. Fill as needed. • Oil viscosity is too high. Replace with TorcUP oil. 11/37...
  • Page 13 How to Identify Parts EP1000 Torque Wrench PARTS INDEX for Your Model. Power Pump How to Identify Parts for Your Model. MODEL NUMBER & DATE CODE LOCATION For example, the date code and serial number October 07 = Year 2007 42 = Week number in year MODEL NUMBER &...
  • Page 14 COMMON COMPONENTS Common components EP1000 Torque Wrench used in pumps Power Pump EP1000 Note: This illustration is for reference only. The appearance of your unit may differ from unit shown. NOTE: This illustration is for reference only. The appearance of your unit 13/37...
  • Page 15 Common components EP1000 Torque Wrench used in pumps Power Pump COMMON COMPONENTS EP1000 ITEM # DESCRIPTION PART # PART # QTY. ITEM # DESCRIPTION PART # PART # QTY. PUMP ASM. 1.00 HEAVY HEX JAM NUT 1/4-20 69234 69234 2.00 SEE PAGE 16 RESERVOIR SEE PAGE 23...
  • Page 16 Common components EP1000 Torque Wrench used in pumps Power Pump 230v COMMON COMPONENTS NOTE: This illustration is for reference EP1000 only. The appearance of your unit 15/37...
  • Page 17 SUB PUMP ASSEMBLY (46335) PUMP ASM. EP1000 16/37...
  • Page 18 Sub Pump Assembly EP1000 Torque Wrench Power Pump SUB PUMP ASSEMBLY (46335) PUMP ASM. (46335) PUMP ASM. EP1000 ITEM # DESCRIPTION PART # QTY. PUMP BODY G5 45750 1.00 BEARING ROLLER 5/8x13/16x5/8 WIDE 68360 1.00 THRUST BEARING 66033 1.00 THRUST WASHER 66474 2.00 ECCENTRIC SHAFT ASM 5/8"...
  • Page 19 SUB PUMP ASSEMBLY EP1000 (46336) PISTON BLK ASM. (46336) PISTON BLK ASM. ITEM # DESCRIPTION PART # QTY. GEN II PISTON BLOCK 45539 1.00 BALL 1/8" 90906 2.00 SPRING 66042 1.00 BALL STOP 68810 1.00 BALL RETAINER 66043 1.00 INTAKE SEAT 66046 1.00 GASKET 25/64X19/32...
  • Page 20 Valve Sub Assemblies VALVE SUB ASSEMBLY (46291) 3 & 4 WAY SOLENOID VALVE 115V. / 230V. EP1000 ITEM # DESCRIPTION PART # QTY. BODY-VALVE 68708 1.00 SLIDER ADV/RET ONLY 44328 1.00 BALL 3/16" 90548 4.00 SET SCREW 1/4-28 X 1/4 CUP 40254 4.00 O-RING 7/32X11/32...
  • Page 21 MANIFOLD ASSEMBLY (46292) MANIFOLD ASM. EP1000 ITEM # DESCRIPTION PART # QTY. VALVE MANIFOLD 46270 1.00 CARTRIDGE RELIEF VALVE 45423 1.00 1/16 PIPE PLUG-FLUSH 40049 3.00 PIPE PLUG 1/8" FLUSH 81093 3.00 PIPE NIPPLE 1/8 NPT 68917 1.00 PIPE COUPLING 1/8 68918 1.00 INT.RELIEF ASM HF...
  • Page 22 Bracket Sub EP1000 Torque Wrench Assemblies Power Pump BRACKET SUB ASSEMBLY (46281) BRACKET SUB ASM. 115V. (46281) BRACKET SUB ASM. 115V. EP1000 ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY. MOUNTING BRACKET G3/G5 46233 1.00 RING TERMINAL 1/4" 69917 1.00 PLUG AND CORD ASSY...
  • Page 23 Bracket Sub EP1000 Torque Wrench Assemblies Power Pump BRACKET SUB ASSEMBLY (46289) BRACKET SUB ASM. 230V. EP1000 ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY. MOUNTING BRACKET 46233 1.00 RING TERMINAL 1/4" 69917 1.00 POWER CORD 14-3 IEC 69604R 72.00 SHCS #10-32X1/4"...
  • Page 24 RESERVOIR EP1000 (46109P) 1.0 GALLON RESERVOIR (45996P) 1.5 GALLON RESERVOIR (DS1328025) 1.5 GALLON RESERVIOR (46213P) 2.5 GALLON RESERVOIR (45996P) 1.5 GALLON RESERVIOR (46213P) 2.5 GALLON RESERVIOR 1.5 GALLON RESERVOIR NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY. THE APPEARANCE OF YOUR UNIT MAY DIFFER FROM UNIT SHOWN.
  • Page 25 NOTE: This illustration is for reference COMMON COMPONENTS only. The appearance of your unit EP500 24/37...
  • Page 26 COMMON COMPONENTS EP500 25/37...
  • Page 27 Common components EP500 Torque Wrench used in pumps Power Pump COMMON COMPONENTS EP500 ITEM # DESCRIPTION 115 V. 230 V. QTY. ITEM # DESCRIPTION 115 V. 230 V. QTY. PUMP ASSEMBLY 1.00 BHCS 10-24 x 3/8 LG 69236 69236 4.00...
  • Page 28 PUMP ASSEMBLY EP500 (46541) PUMP ASM. (46541) PUMP ASM. ITEM # DESCRIPTION PART # QTY. GEAR SECTION ASSEMBLY SEE PAGE 31 PUMP VALVE SECTION ASSEMBLY SEE PAGE 34 SHCS 5/16-24 X 1" LG 84188 4.00 PISTON BLOCK TUBE G3 45537 1.00...
  • Page 29 GEAR SECTION ASSEMBLY (45535) GEAR SECTION ASM. EP500 (45535 GEAR SECTION ASM.) 28/37...
  • Page 30 Assembly Power Pump (45535) GEAR SECTION ASM. GEAR SECTION ASSEMBLY EP500 (45535 GEAR SECTION ASM.) ITEM # DESCRIPTION PART # QTY. G3 PUMP BODY 2 PISTON 45419 1.00 TUBE-GUIDE .11 68894 2.00 SHCS 1/4-28 X 1 1/2 89148 2.00 SET SCREW #10-24 X 1/4 CUP 44596 2.00...
  • Page 31 SUB COMPONENT ASSEMBLIES EP500 (45533) PISTON BLK ASM. ITEM # DESCRITPION PART # QTY. GEN II PISTON BLOCK 45539 1.00 BALL 1/8" 90906 2.00 SPRING 66042 1.00 BALL STOP 68810 1.00 BALL RETAINER 66043 1.00 INTAKE SEAT 66046 1.00 GASKET 29/64 X 5/8 1.00...
  • Page 32 PUMP VALVE ASSEMBLY (46025) PUMP VALVE SECT ASM. EP500 (46025) PUMP VALVE SECT ASM. ITEM # DESCRIPTION PART # QTY. PB VALVE BODY SECT. 43269 1.00 BALL 5/16" 91701 1.00 SPRING 68225 1.00 GASKET 25/64X19/32 1.00 SCREW, BALL STOP 68226 1.00...
  • Page 33 Valve Sub Assemblies EP500 Torque Wrench Power Pump VALVE SUB ASSEMBLIES (46291) 3 & 4 WAY SOLENOID VALVE 115V. / 230V. EP500 (46291) 3 & 4 WAY SOLENOID VALVE 115V./230V. ITEM # DESCRIPTION PART # QTY. BODY-VALVE 68708 1.00 SLIDER ADV/RET ONLY 44328 1.00...
  • Page 34 EP500 Torque Wrench Manifold Assembly Power Pump COMMON COMPONENTS EP500 (46292) MANIFOLD ASM. (46292) MANIFOLD ASM. ITEM # DESCRIPTION PART # QTY. VALVE MANIFOLD 46270 1.00 CARTRIDGE RELIEF VALVE 45423 1.00 1/16 PIPE PLUG-FLUSH 40049 3.00 PIPE PLUG 1/8" FLUSH 81093 3.00...
  • Page 35 Bracket Sub Assemblies EP500 Series Electric Power Pump BRACKET SUB ASSEMBLIES EP500 (46483 BRACKET SUB ASM. 115V. (46483) BRACKET SUB ASM. 115V. ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY. MOUNTING BRACKET 46233 1.00 RING TERMINAL 1/4"...
  • Page 36 Bracket Sub Assemblies EP500 Series Electric Power Pump BRACKET SUB ASSEMBLIES EP500 (46484) BRACKET SUB ASM. 230V (46484) BRACKET SUB ASM. 230V. ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY. MOUNTING BRACKET 46233 1.00 RING TERMINAL 1/4"...

  • Page 37: Pendant

    EP-500 and EP-1000 Pendant www.torcup.com EP500 & EP1000 PENDANT EMPTY BRWN-BLK GRN/YLW-GRN BLUE-WHT ITEM # DESCRIPTION PART # PENDANT BODY 69083 1.00 2 SWITCH JUNCTION BOX 689151 1.00 ITEM # PART# DESCRIPTION QUANTITY TOGGLE SWITCH 69487 2.00 01 – 69083...
  • 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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