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Always store these maintenance and repair instructions together with the hydraulic unit. Ensure that the maintenance and repair instructions are available to the qualified and authorized personnel at the TORC LLC branch. Read and observe the maintenance and repair instructions.
Table of contents Notes concerning this manual and the manufacturer ..........5 Referenced documents....................5 Design features of this manual ..................6 Manufacturer's address ....................6 Safety ........................7 Responsibilities of the operating company ..............7 Persons at particular risk ....................7 Ambient conditions ......................
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Malfunctions ......................20 Checks and repairs on electrical components............23 Preparing checks and repairs on electrical components ..........23 Moving the unit into the repair position for the electric control ......24 Carrying out checks and repairs on electrical components .......... 25 Checking the circuit board ..................
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Checking the torque valve mechanically ............84 Replacing the torque valve ................. 86 Completing repair work ..................87 Mounting the unit on the oil tank ................... 87 Cleaning unit ......................90 Carry out a test run ....................91 Disposal ......................... 92 In Europe ........................
Notes concerning this manual and the manufacturer Notes concerning this manual and the manufacturer The HYFLOW 230-2 hydraulic unit is referred to as the “unit” in the following. Referenced documents WARNING Risk of injury through failure to observe the referenced documents.
References to headers are set in quotation marks. ‘Labels’ of switches or other elements are set in inverted commas. Table titles are set in bold. Tips. Contains additional information. Manufacturer's address TORC LLC 218 Island Road N.J. 07430 Mahwah Phone: 1 888-444-TORC (8672) Email: info@torc.com Web: www.torc.com...
The responsibility lies with the head of the TORC LLC branch. The head of the TORC LLC branch has to ensure that the maintenance and repair work is only carried out by qualified and authorized personnel.
Safety Qualification of personnel These maintenance and repair instructions are intended for the qualified and authorized personnel from the TORC LLC branch. Carrying out electrical work The following knowledge and experience are required for the qualified personnel: trained for the task ...
Safety Carrying out mechanical and hydraulic tasks The following knowledge and experience are required for the qualified personnel: trained for the task aware that improper maintenance and repairs can cause accidents knows the recognized safety rules and applies them ...
Safety Basic safety information Preventing serious injury or death Using untested replacement parts poses a risk of serious or lethal injuries as these parts may fail. Only use the original spare parts specified in the spare parts list which is available as a separate document.
Safety Preventing poisoning The unit may overheat. This may lead to the formation of oil mist and oil vapor. Ensure sufficient ventilation. Wear respiratory protection in poorly ventilated rooms and if oil mist and oil vapors are present. ...
Safety Preventing skin irritation Contact with hydraulic oil during maintenance and repair work on hydraulic components may lead to skin irritation. Always create a permanent, tight connection between the unit and the hydraulic tool. Wear nitrile gloves when carrying out maintenance and repair work on hydraulic components.
Safety Explanation of symbols Hazard from electric shock Slipping hazard from leaked media Burning hazard, scalding hazard Design of information about property damage ATTENTION! These notes warn of situations that can lead to property damage and limited functionality. Warning and information signs ...
Carrying and setting down Carrying and setting down Only carry the unit by its carrying handle. Place the unit on a dry, level, solid and strong surface. Secure the unit and the associated tools against falling.
Required tools Required tools The following tools and equipment are required for maintenance and repair of the unit: one set of box and open-end wrenches one set of hexagon socket wrenches one set of crosshead screwdrivers one set of slotted screwdrivers ...
Maintenance schedule Maintenance schedule Interval Component Action Before each operation Pressure gage Check whether the display of the pressure gage reacts after switching on the unit. Have the defective pressure gage replaced by qualified personnel, see page 19. Hydraulic hoses ...
Carrying out maintenance tasks Carrying out maintenance tasks Changing the hydraulic oil WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
Carrying out maintenance tasks Replacing hydraulic hoses WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil. ...
Carrying out maintenance tasks Replacing the pressure gage To replace the pressure gage, proceed as follows: Switch off the unit. To depressurize the unit, press the stop button on the remote control several times. Disconnect the mains plug. ...
Malfunctions Malfunctions Malfunction Possible cause Corrective action The pump is not Electrical components Check the electrical working. are damaged. components, see page 25. Replace damaged electrical components or have these replaced by the manufacturer. The power supply is ...
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Malfunctions Malfunction Possible cause Corrective action The pipe work is Check the pipe work, see leaking. page 80. Replace the leaking pipe work, see page 83 The pressure is only The low pressure cut off Check the low pressure cut 70 bar.
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Malfunctions Malfunction Possible cause Corrective action The max. pressure of The torque valve is Check the torque valve 700 bar was not defective. mechanically, see page 84. reached even though Replace the defective there are no leaks. torque valve, see page 86. One or more pump ...
Checks and repairs on electrical components Checks and repairs on electrical components Preparing checks and repairs on electrical components WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. ...
Checks and repairs on electrical components Moving the unit into the repair position for the electric control WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. ...
Checks and repairs on electrical components Carrying out checks and repairs on electrical components Checking the circuit board WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. ...
Checks and repairs on electrical components Replacing the circuit board WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. Have work on electrical equipment carried out only by specialist personnel who are qualified for these tasks.
Checks and repairs on electrical components Checking the energy supply WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. Have work on electrical equipment carried out only by specialist personnel who are qualified for these tasks.
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Checks and repairs on electrical components Alternatively, you can check the power cord of the power supply for broken wires with a continuity tester. To check the power cord of the power supply with a continuity tester, proceed as follows: ...
Checks and repairs on electrical components If the result of the continuity test shows a defective line, replace the power cord, see page 29. Mount the cover of the electric control. Replacing the power cord WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment.
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Checks and repairs on electrical components Flip the orange actuating lever of the power cord on the PE terminal (PE) upwards. Remove the green-yellow wire of the power cord from the PE terminal. Remove the cable feedthrough (A) of the power cord on the housing. ...
Checks and repairs on electrical components Fix the brown cable and the blue cable to the circuit board. Clip the green-yellow wire of the power cord into the PE terminal. Flip the orange actuating lever on the PE terminal downwards. ...
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Checks and repairs on electrical components Connect the mains plug to a grounded mains socket with a voltage of 230 V and a frequency of 50/60 Hz. To check the input line, connect a multimeter to the (ON) connection and the (COM) connection.
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Checks and repairs on electrical components If no voltage is present, the circuit board is defective. Replace the defective circuit board, see page 26. If voltage is present, the circuit board is fine. In this case, check the wiring of the remote control, as follows: ...
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Checks and repairs on electrical components Replace the defective remote control, see page 35. Connect the multimeter to the wire of the (OFF) connection and the wire of the (COM) connection. Press the OFF button (A) on the remote control. ...
Checks and repairs on electrical components Replacing the remote control WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. Have work on electrical equipment carried out only by specialist personnel who are qualified for these tasks.
Checks and repairs on electrical components Disconnect the cable feedthrough (A) of the remote control cable. Remove the hose clamp of the remote control cable on the oil tank. Remove the defective remote control. Install a functioning remote control. ...
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Checks and repairs on electrical components Excessive motor temperature can be identified by the following signs: The motor temperature fuse automatically switches off the motor. The capacitor (A) does not switch off. The LED (B) on the circuit board goes out. Excessive motor temperature can have the following causes: ...
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Checks and repairs on electrical components To check the capacitor, proceed as follows: Let the motor cool down to a temperature of about 25 °C/77 °F. Check the temperature with a contactless thermometer. Move the unit into the repair position for the electric control, see from page 24.
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Checks and repairs on electrical components Measure the current at 0 bar. The regular current is 10.2 A ± 0.5 A at a pressure of 0 bar. After approx. one second, the current has to decrease by about 2 A. If the current does not decrease, the capacitor is defective.
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Checks and repairs on electrical components To check the main motor winding, proceed as follows: Disconnect the black wire from the connecting terminal (C) and the red wire from the connecting terminal (E). Connect a multimeter to the black and the red cable. ...
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Checks and repairs on electrical components To check the shunt motor winding, proceed as follows: Disconnect the blue wire from the connecting terminal (D) and the white wire from the connecting terminal (F). Connect a multimeter to the blue and the white cable. ...
Checks and repairs on electrical components Replacing the capacitor To replace the capacitor, proceed as follows: Move the unit into the repair position for the electric control, see from page 24. Disconnect the black cables from the connections (X1). ...
Checks and repairs on electrical components Checking the solenoid valve electrically WARNING Risk of injury from electric shock caused by inexpert work on the electrical equipment. Disconnect the mains plug from the socket. Have work on electrical equipment carried out only by specialist personnel who are qualified for these tasks.
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Checks and repairs on electrical components Measure the voltage of the fuse. Replace the fuse if it is defective. Press the Off button (A) on the remote control. If the relay (B) clicks audibly, the relay is switching. If the relay (B) does not click audibly, the relay is defective.
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Checks and repairs on electrical components Move the unit into the repair position for the upper structures, see from page 51. Release the screw which holds down the solenoid valve connector (C). Remove the solenoid valve connector from the solenoid valve (D). ...
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Checks and repairs on electrical components Connect a multimeter to the two contacts (F) of the solenoid valve. Measure the electrical resistance of the coil. The resistance has to be 1100 Ω ± 10 %. If the resistance is outside this range, the solenoid valve is defective. ...
Checks and repairs on electrical components Replacing the solenoid valve To replace the solenoid valve, proceed as follows: Move the unit into the repair position for the upper structures, see from page 51. Release the screw which holds down the solenoid valve connector (A). ...
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Checks and repairs on electrical components Remove the solenoid valve from the valve block. For the new solenoid valve, ensure that the 4 O-rings (D) are in the corresponding boreholes and that they are undamaged. Connect the new solenoid valve and the valve block with the M5 hexagon socket screws using a 4 mm hexagon socket wrench.
Checks and repairs on hydraulic components Checks and repairs on hydraulic components Preparing checks and repairs on hydraulic components Proceed as follows to prepare checks and repairs on the unit: Ensure that the couplings on the unit are secured with the appropriate protective caps and the protective plugs.
Checks and repairs on hydraulic components Removing the carrying handle To remove the carrying handle, proceed as follows: Place the unit on a solid surface. Release the screw connections (A) with two combination wrenches WAF 10. Remove the screws, the nuts and the tooth lock washer and keep them in safe place.
Checks and repairs on hydraulic components Moving the unit into the repair position for the upper structures Proceed as follows to bring the unit into the repair position for the upper structures: Place the unit on a solid surface. ...
Checks and repairs on hydraulic components Moving the unit into the repair position for the lower structures WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents.
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Checks and repairs on hydraulic components Remove the screws, the nuts and the tooth lock washer and keep them in safe place. Hold the unit by the couplings and on the underside of the electric control.
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Checks and repairs on hydraulic components ATTENTION! Risk of damaging the cover with the structures through the jaws of the vise. Use protective jaws for the vise. Lift the cover with the structures from the oil tank. Chuck the unit in a vise with the help of a second person. ...
Checks and repairs on hydraulic components Carrying out checks and repairs on hydraulic components Checking the torque valve hydraulically CAUTION Health hazard from contact with hydraulic oil. Wear nitrile gloves and chemical-resistant protective goggles during work that may include contact with hydraulic oil.
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
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Checks and repairs on hydraulic components Check whether oil is dripping from the tank pipe/borehole 5 (E). If oil is dripping from the tank pipe/borehole 5, the torque valve is defective. If the torque valve is defective, replace it, see page 86.
Checks and repairs on hydraulic components Checking the solenoid valve hydraulically CAUTION Health hazard from contact with hydraulic oil. Wear nitrile gloves and chemical-resistant protective goggles during work that may include contact with hydraulic oil. To check the solenoid valve electrically, proceed as follows: ...
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
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Checks and repairs on hydraulic components Check whether oil is dripping from the tank pipe/borehole 7 (E). If oil is dripping from the tank pipe/borehole 7, the solenoid valve is defective. If the solenoid valve is defective, replace it, see page 47.
Checks and repairs on hydraulic components Checking the pump flange WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
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Checks and repairs on hydraulic components Check whether oil is dripping from the pump flange (E). If oil is dripping from the pump flange, the O-ring of the pump flange is defective. If the O-ring of the pump flange is defective, send the unit back to the manufacturer for repair.
Checks and repairs on hydraulic components Checking and cleaning the screen filter WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
Checks and repairs on hydraulic components Checking the maximum pressure valve To check the maximum pressure valve, proceed as follows: Move the unit into the repair position for the upper structures, see from page 51. Remove the carrying handle, see from page 50. ...
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
Checks and repairs on hydraulic components Check whether oil is dripping from the maximum pressure valve (E). If oil drips from the maximum pressure valve, it is defective. If the maximum pressure valve is defective, replace it, see page 67. Replacing the maximum pressure valve WARNING Slipping hazard from leaked oil.
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Checks and repairs on hydraulic components To replace the maximum pressure valve, proceed as follows: Move the unit into the repair position for the lower structures, see from page 52. Unscrew the maximum pressure valve (A) from the pump flange (B) with a combination wrench WAF 14.
Checks and repairs on hydraulic components Checking and replacing the pump element To check the pump element, proceed as follows: Move the unit into the repair position for the lower structures, see from page 52. Release the screw connections (A) of the pump element with a 5 mm hexagon socket wrench.
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Checks and repairs on hydraulic components Place the pump element with the rear side facing upwards on a stable surface, ensuring that the piston (B) does not slide from the housing (C). Press the ball (D) into the pump element with a sharp tool, e. g. long nose pliers.
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Checks and repairs on hydraulic components Check whether the ball is being pushed out again by the spring behind it. If the ball is not being pushed out again, the spring is defective. If the spring is defective, replace the pump element. ...
Checks and repairs on hydraulic components Checking the low-pressure cut off valve WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
Checks and repairs on hydraulic components Check whether any oil is emitted from the tank pipe (F) at a pressure of less than 50 bar. If oil is emitted from the tank pipe, the low-pressure cut off valve is defective. ...
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Checks and repairs on hydraulic components To replace the low-pressure cut off valve, proceed as follows: Move the unit into the repair position for the lower structures, see from page 52. Unscrew the low-pressure cut off valve (A) from the pump flange (B) with a combination wrench WAF 17.
Checks and repairs on hydraulic components Checking the back pressure valve WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
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Checks and repairs on hydraulic components Check whether oil is emitted from the back pressure valve (E). If oil is emitted from the back pressure valve, it is defective. If the back pressure valve is defective, replace it, see page 79.
Checks and repairs on hydraulic components Replacing the back pressure valve To replace the back pressure valve, proceed as follows: Move the unit into the repair position for the lower structures, see from page 52. Unscrew the back pressure valve (A) from the valve block (B) with a combination wrench WAF 14.
Checks and repairs on hydraulic components Checking the pipe work WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
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Checks and repairs on hydraulic components Lift the cover (B) at the front by approx. 15 cm (6"), as otherwise oil could be ejected through the ball bearing. Support the cover with a rectangular piece of wood (C). ...
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Checks and repairs on hydraulic components Check whether oil is dripping from the pipe work (E). If oil drips from the pipe work, it is defective. If the pipe work is defective, replace it, see from page 83.
Checks and repairs on hydraulic components Replacing the pipe work To replace the pipe work, proceed as follows: Move the unit into the repair position for the lower structures, see from page 52. Unscrew the pipe work (A) from the valve block (B) with an open-end wrench WAF 19.
Checks and repairs on mechanical components Checks and repairs on mechanical components Preparing checks and repairs on mechanical components Proceed as follows to prepare mechanical checks and repairs on the unit: Ensure that the couplings on the unit are secured with the appropriate protective caps and the protective plugs.
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Checks and repairs on mechanical components To check the torque valve mechanically, proceed as follows: Move the unit into the repair position for the upper structures, see from page 51. Turn the cross-shaped knob (C) counter-clockwise to gain access to the wing nut (B).
Checks and repairs on mechanical components Replacing the torque valve CAUTION Risk of burns from hot components. The wing nut can reach a temperature of about 60 °C during operation. Wear protective gloves to prevent burns when releasing the wing nut. To replace the torque valve, proceed as follows: ...
Completing repair work Completing repair work Mounting the unit on the oil tank WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil.
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Completing repair work Ensure that the seal (F) at the top of the oil tank is installed and undamaged. Place the unit (D) onto the oil tank (E).
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Completing repair work Use the screws M6 × 20 for fixing the unit to the oil tank. Place the screws (A) into the boreholes from the top. Secure the power cord to the oil tank with a hose clamp. ...
Cleaning unit Cleaning unit WARNING Slipping hazard from leaked oil. Bruising and bone fractures possible. Clean up any leaked oil with a cloth or suitable binding agents. Wear safety shoes with non-slip soles. CAUTION Health hazard from contact with hydraulic oil. ...
Carry out a test run Carry out a test run After each maintenance or repair measure, carry out a test run according to the operating instructions for the unit.
Disposal Disposal In Europe Observe and follow the regulations for disposal. If in doubt, please consult your municipal or local authority. WARNING Risk of poisoning from hydraulic oil Hydraulic oil can contaminate ground water and soil. Always dispose of hydraulic oil in an environmentally friendly manner using a specialist firm.
Disposal In the USA Observe and follow the regulations for disposal. If in doubt, please consult your municipal or local authority. WARNING Risk of poisoning from hydraulic oil Hydraulic oil can contaminate ground water and soil. Always dispose of hydraulic oil in an environmentally friendly manner using a specialist firm.
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