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- Page 1 AP1000 OPERATION AND MAINTENANCE MANUAL Air Power Pack MODELS AP1000, AP1000-Q 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...
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Page 2: Table Of Contents
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. All information, illustrations and specifications in this Operational Manual are based on the latest information avail- able at the time of publication. -
Page 3: Failure To Observe The Following Warnings Could Result In Injury
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 damage, frayed or deteriorated air 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 cur- rently safety and health standards. - Page 5 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 &...
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Page 6: Technical Specifications
Litre Model Style Function lbs. Number Motor/ 4 HP @ 100 psi/ 700 cu. in./min. @1,100 psi Auto Advance/ AP1000 Torque 63.75 28,92 Solenoid 60cfm 55 cu.in./min.@10,000 psi Retract Retract Control WORKING PRESSURE The pump’s maximum working pressure is 10,000 PSI (700kg/cm ). -
Page 7: Install Vent Plug
Remove SHIPPING PLUG (A) and install VENT PLUG (B) into cover plate. ADDING OIL Remove OIL FILLER CAP (C) and add TorcUP Inc. hydraulic oil into reservoir. Oil level should not exceed 1” from the reservoir cover. *As a “rule of thumb” oil should be filled about an inch below the top of the reservoir when the unit is powered down and all connected tools or cylinders are retracted. -
Page 8: Air Control Buttons
TECHNICAL SPECIFICATIONS AIR CONTROL BUTTONS ADVANCE RETRACT RUN = Press and hold button to activate STOP air solenoid and turn on. STOP = Release run button and press this button to turn off motor. Make these adjustments BEFORE putting torque wrench on nut or bolt head. -
Page 9: Air Motor And Filter Lubricator
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 10: Periodic Maintenance
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: Trouble Shooting
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. • Supplying air line too small • Not enough air pressure... -
Page 12: Ap1000 Parts Index
PARTS INDENTIFCATION This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Pump Sub Assemblies and Sub-Components Valve Sub Assemblies Pages 17-18 Page 19-21 Pendants Manifold Page 23 Sub-Assembly Page 22 Common Components Page 13-15 Reservoir Page 24... - Page 13 PARTS INDENTIFCATION 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 A B C D E F G H I 1 2 3 4 5 6 7 8 9 11 12 DATE CODE COVER PLATE...
- Page 14 COMMON COMPONENTS Note: This illustration is for reference only. The appearance of your unit may differ from unit shown.
- Page 15 COMMON COMPONENTS Balloon # Item Description Quantity 18131 HYDRAULIC OIL 1 QT. HYD OIL-1 GAL. 46335SS PUMP ASM. G5 2 STAGE 45996P RESERVOIR 1.5 GAL. BLACK RESERVOIR GASKET 46348 BREATHER VENT 3/8 NPT 46697 1/2 FLUSH PLUG W/SEALANT 46118 SAE #12 HEX PLUG WITH PORT 65891 1/4-20 X .75 HHCS ZINC 65892...
- Page 16 COMMON COMPONENTS Balloon # Item Description Quantity 97084 SHCS 3/8-16 X 3/4 LG 86447B AIR MOTOR 6AM PAINTED BLACK 46279 FHCS 1/4-28 x 0.50 LONG 46392 MOTOR STANDOFF 86243 ELBOW MALE 1/2 NPT PIPE DS2284900SS AIR CONTROL VALVE ASSEMBLY 45970 MALE HEX NIPPLE 1/4 - 1/8 44245 SHUTTLE VALVE...
- Page 17 PUMP ASSEMBLY (46335SS) PUMP ASM.
- Page 18 PUMP ASSEMBLY (46335SS) PUMP ASM. ITEM # DESCRIPTION PART # QTY PUMP BODY 45750 BEARING ROLLER 5/8x13/16x5/8 WIDE 68360 THRUST BEARING 66033 THRUST WASHER 66474 ECCENTRIC SHAFT ASM 5/8" 45820SS THRUST BEARING 66106 THRUST WASHER 66108 ECCENTRIC SHAFT ADAPTER 45908 O-RING 1 3/4 X 1 7/8 5602031 RETAINING RING...
- Page 19 PUMP SUB ASSEMBLY PART# 43766SS (UNLOADING PISTON ASM.)PUMP ASM. ITEM # DESCRITPION PART # QTY. UNLOAD PISTON 43765 1.00 O RING 1/4X3/8 1.00 5602009 BACK-UP WASHER TEF 43768 1.00 DOWEL PIN 1/8X3/4 LG 43686 1.00 PART# 46336SS (PISTON BLK ASM) PART# 46336SS (PISTON BLK ASM.
- Page 20 VALVE ASSEMBLY PART#46297SS (AIR SOLENOID 4W/2P) PART# 46297SS (AIR SOLENOID 4W/2P) HYDRAULIC SCHEMATIC TORQUE TO 50 IN*LBS. 4 PLACES TORQUE TO 50 IN*LBS. TORQUE TO 75 IN*LBS. 4 PLACES TORQUE TO 150 IN*LBS. TORQUE TO 25 IN*LBS. ITEM# DESCRIPTION PART # QTY BODY-VALVE 68708 SLIDER ADV/RET ONLY...
- Page 21 VALVE SUB ASSEMBLY PART# 68963SS (VALVE ADPT) ITEM# DESCRIPTION PART# QTY. VALVE ADP 88073 B-U RING 65881 O-RING 3/8X1/2 5602012 PART# 41954SS (AIR CYL ASSM ) ITEM # DESCRIPTION PART # QTY BODY AIR CYL 42744 O-RING 1/8 X 1/4 5602006 O RING 1/4X3/8 5602010...
- Page 22 VALVE SUB ASSEMBLY PART# 46544SS (AIR CONTROL VALVE ASSM.) TORQUE NOTES: APPLY TEFLON TAPE & TORQUE TO 20-25 FT*LBS TORQUE TO 20-25 FT*LBS APPLY TEFLON TAPE & TORQUE TO 80-100 IN*LBS TORQUE TO 45-55 IN*LBS Balloon # Item Description Quantity 45969 AIR CONTROL VALVE 1/2 PORTS 6011456 FITTING SWIVEL ELBOW 1/2 NPT 42381 SWIVEL ADP 1/8...
- Page 23 MANIFOLD ASSEMBLY PART# 46292SS 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 PIPE NIPPLE 1/8 NPT 68917 1.00 PIPE COUPLING 1/8 68918 1.00 INT.RELIEF ASM HF...
- Page 24 PENDANT ASSEMBLY PART# 68799SS (PENDANT ASSM.) ITEM# DESCRIPTION PART # QTY PENDANT BODY 41968 AIR PEND. BLOCK MOD. 68796 CARTRIDGE-AIR 41963 SWIVEL ADP 1/8 42381 BALL 5/32 6069613 RETAINING-RING 68808 CARTRIDGE CAP 41970...
- Page 25 Reservoirs AP-1000 Torque Wrench Power Pump RESERVOIR (45996P) 1.5 GALLON RESERVIOR (46213P) 2.5 GALLON RESERVIOR PART# 45996P 1.5 GALLON RESERVOIR PART# 46213P 2.5 GALLON RESERVOIR 1 hp 1,1 Kw AP-1000 46052 1.5 GALLON RESERVOIR NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY. THE APPEARANCE OF YOUR UNIT MAY DIFFER FROM UNIT SHOWN.
- Page 26 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...
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