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Hytorc LIGHTNING PUMP Series Operation Manual

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LIGHTNING™ PUMP Series / Smart and Standard Models
Basic Operations Manual
333 Route 17 N.
Mahwah, NJ 07430
USA
edition 1.2
800-FOR-HYTORC
(800-367-4986)
201-512-9500
hytorc.com

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  • Page 1 LIGHTNING™ PUMP Series / Smart and Standard Models Basic Operations Manual 333 Route 17 N. 800-FOR-HYTORC hytorc.com Mahwah, NJ 07430 (800-367-4986) 201-512-9500 edition 1.2...
  • Page 3 WHERE UNMATCHED SUPPORT MEETS OPERATIONAL PEACE OF MIND Downtime due to tool maintenance can significantly impact project timelines and operational efficiency. Our HY-Care service plans directly address this issue, providing essential support when you need it most. With this program, the hassle and uncertainty of tool servicing are taken off your shoulders, allowing every bolt tightened to be a step towards a more efficient, safer, and cost-effective operation.

  • Page 4: General Power Tool Safety Warnings

    GENERAL POWER TOOL SAFETY WARNINGS WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term “power tool”...
  • Page 5 4) Power tool use and care a) Do not force the power tool. Use the correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed b) Do not use the power tool if the switch does not turn it on and off Any power tool that cannot be controlled with the switch is dangerous and must be repaired...

  • Page 7: Table Of Contents

    12. Troubleshooting NOTICE OF PROPRIETARY RIGHTS: HYTORC Division UNEX Corporation (“HYTORC”) is the owner of all content included in this document and all right, title and interest to such content shall remain with HYTORC. COPYRIGHT NOTICE: © 2024 HYTORC. Any unauthorized use or distribution of any material from this document, without HYTORC’s written permission, is strictly prohibited. TRADEMARK NOTICE: This document contains numerous registered trademarks and servicemarks of HYTORC in the U.S.

  • Page 8: Concerning This Manual And The Manufacturer

    NOTES CONCERNING THIS MANUAL AND THE MANUFACTURER...
  • Page 9 Document type Manual Issue date October, 2024 © 2024, HYTORC Technologies GmbH All rights, including those of reprinting and reproduction of any parts of this document and its translation, are reserved by the publisher. Copyright No part of this document may be reproduced in any form or copied using electronic reproduction systems without the written consent of the publisher.

  • Page 10: Position

    POSITION...
  • Page 11 2. Position Tips Contain additional information. DIRECTIONAL DATA - SMART On the front side (B), you can see the couplers. Rear: On the rear side, you can see the battery pack. Left and right: The sides of the frame are paneled. Top: The remote control holder and the sight glass for the oil level are situated on the top (A).
  • Page 12 DIRECTIONAL DATA - STANDARD Front: On the front side (B), you can see the couplers. Rear: On the rear side, you can see the battery pack. Left and right: The sides of the frame are paneled. Top: The remote control holder and the sight glass for the oil level are situated on the top (A). Bottom: The hydraulic drive is located at the bottom.
  • Page 13 The pump can be operated in two positions: Vertical position (V): In the vertical position, the pressure Horizontal position (H): In the horizontal position, the gauge or screen is vertical and/or front facing (forward). pressure gauge or screen is on the top of the pump. In this The couplers face forward in this position.

  • Page 14: Documents

    DOCUMENTS...
  • Page 15 Maintenance and repair manuals Spare parts lists Declarations of conformity or declarations of incorporation ▶ Please heed and comply with the information from the applicable documents Manufacturer’s address HYTORC Technologies GmbH Kleinbeckstr. 3–17 45549 Sprockhövel, Germany Germany Telephone: Tel.: +49 (0)2324 847 93-0 Fax: Fax: +49 (0) 2324-84793-999 Email: info@hytorctech.com...

  • Page 16: Warranty And Liability

    WARRANTY AND LIABILITY...
  • Page 17 4. Warranty and Liability Primarily, our General Terms and Conditions apply. Warranty and liability claims for personal injury or property damage are always excluded, if they are due to one or more of the following causes: Improper use of the pump Improper transport, installation, use, operation and maintenance of the pump Ignoring the instructions in this manual Ignoring the hazard notices on the pump...

  • Page 18: Safety And Compliance

    SAFETY AND COMPLIANCE...
  • Page 19 5. Safety and Compliance y Severe injuries or death caused by accidents due to disregard of the instructions in this guide. y In particular the failure to observe the instructions in the Chapter on Safety, can lead to accidents. y Read and follow all instructions in this manual before you begin working with or on the pump. WARNING Read all safety warnings, instructions, illustrations and specifications provided with this battery.

  • Page 20: Preventing Electric Shock

    Intended use The pump is used exclusively for driving hydraulic assembly tools for bolts and nuts in the commercial sector. With the torque tool, torque connections can be loosened or tightened with a predetermined torque. Intended use also includes observing and following all instructions in this manual, especially the safety instructions. Any other use is considered to be improper and will void the warranty and liability claims.
  • Page 21 Handling batteries safely Risk of serious or fatal injuries from electric shocks or fire if the battery pack is not used properly! Observe and follow the instructions in the supplied manual when using the battery pack and charger. Only use the battery pack and charger if they are in perfect working order. Do not make any changes to the battery pack or charger.
  • Page 22 Preventing burns from oil and hot surfaces During and after operation, burns on metallic surfaces or from hydraulic oil are possible. When working on or with the pump wear protective gloves against thermal risks. Preventing poisoning The pump may overheat. In this case, oil mist and oil vapors can form. Make sure there is sufficient ventilation.

  • Page 23: Qualification Of Personnel

    Preventing skin irritation Contact with hydraulic oil may cause skin irritation. Always provide a strong and tight connection between the pump and hydraulic tools. Wear nitrile gloves at work where you might come in contact with hydraulic oil. Make sure that the permissible pressure defined by the manufacturer is not exceeded. Observe the tool and hose manufacturer’s specifications.
  • Page 24 Establishing a power supply The operating personnel must have the following knowledge and experience: They have been taught and instructed for the work. They are aware that improper operation, maintenance and repairs can cause accidents. They are able to assess hazards that may arise from noise and heat. They are able to assess hazards that may arise from electrical voltage and power.

  • Page 25: Personal Protective Equipment

    Carrying the pump The following skills and experience are required for the operating personnel: – have been taught and trained for the work – can assess hazards that arise from improper carrying – know that, with a weight of 25 kg/55 lbs., the pump is only permitted to be carried with the help of a second person. Ban of unauthorized conversions Unauthorized conversions or changes on the pump may lead to serious or even lethal injuries.
  • Page 26 Design characteristics of warning information DANGER Sections with the word DANGER warn of imminent dangerous situations that lead to death or serious injury. WARNING Sections with the word WARNING warn of imminent dangerous situations that may lead to death or serious injury.

  • Page 27: Warning And Information Signs

    ATTENTION These notes warn of situations that can lead to property damage and limited functionality Warning and information signs Make sure that all warnings and signs attached to the pump are clearly visible and legible. Replace damaged or lost warnings and signs immediately. The following labels are affixed to the pump: Warning or information sign Meaning or explanation...

  • Page 28: Overview

    OVERVIEW...
  • Page 29 6. Overview Description The hydraulic pump comes with one or four pairs of couplers as tool connections. You can convert an existing pump with one tool connection to have four tool connections. For this, please contact the manufacturer. The figures and descriptions in this manual refer to a hydraulic pump with four pairs of couplers. The hydraulic pump with one tool connection differs only in the number of tool connections.
  • Page 30 OVERVIEW FRONT LEFT AND TOP - SMART NAME Oil drain Remote control in holder Connection for remote control CAN-connection for subsequent extensions Antenna Frame Protective side panel USB A port Ethernet port...
  • Page 31 OVERVIEW FRONT RIGHT AND TOP - STANDARD NAME Sight glass Oil cap with air relief valve Remote control in holder Power button Oil filter Electric motor Couplers LIGHTNING™ PUMP Series Basic Operations Manual...
  • Page 32 OVERVIEW FRONT LEFT AND TOP - STANDARD NAME Oil drain Pressure gauge Protective side panel Pressure control valve USB A port...
  • Page 33 OVERVIEW REAR LEFT AND TOP - SMART NAME Battery pack LIGHTNING S Remote cable lock Oil cooler (Side panel removed for clarity.) LIGHTNING™ PUMP Series Basic Operations Manual...
  • Page 34 OVERVIEW REAR LEFT AND TOP - STANDARD NAME Battery pack LIGHTNING S Remote cable lock Oil cooler (Side panel removed for clarity.)
  • Page 35 OVERVIEW OF THE HYDRAULIC PUMP WITH A ONE-TOOL CONNECTION NAME Advance Coupler Retract Coupler OVERVIEW OF THE HYDRAULIC PUMP WITH A FOUR-TOOL CONNECTION NAME Advance coupler ("A") – Upper Row Retract coupler ("B") – Lower Row LIGHTNING™ PUMP Series Basic Operations Manual...

  • Page 36: Battery Pack

    CHECKING LEVELS AND CHARGING THE BATTERY PACK Battery pack Checking levels and charging the battery pack NAME NAME Power Button Handle LEDs Release Lever To check the charge level of the battery press the power If you would like to charge or store the battery pack remove it button (5) on the battery pack.
  • Page 37 COUPLERS The couplers are arranged on the front side of the pump. The couplers are used to connect the tools. There are one or four pairs of couplers on the pump depending on the model. One coupler on each set is used to connect the Advance function (“A”), the other to connect the Retract function (“B”).

  • Page 38: Purpose And Function

    There is a pressure gauge in the menu for checking the Electrical voltage current pressure. The required torque is set on the display. The Output Smart model has torque and pressure for applicable HYTORC Manufacturer date tools already programmed into the pump. Operating mode...

  • Page 39: Technical Specifications

    AVIA fluid HVI 32 or other oils Depth: 662 mm (26.1 in) temperatures above 10 °C (50 °F): recommended by HYTORC. Starting at +10 °C (50 °F) Operating weight including hydraulic oil and battery pack Recommended viscosity grades: 32–46 mm²/s, below +10 °C (50 °F) One pair of couplers 37.9 kg (82.2 lbs.) / 40.6 kg (80.5 lbs.)

  • Page 40: Using The Pump

    USING THE PUMP...

  • Page 41: Initial Use

    7. Using the Pump INITIAL USE When you use the pump for the first time after delivery, you must: Fill with hydraulic oil. Check the battery pack and remote control are in working condition and not damaged. Charge battery pack. Insert the battery pack.

  • Page 42: Check Oil Level

    Filling the oil ▶ Make sure that the pump is standing on a flat surface in the vertical position. ▶ Remove the oil cap (1) from the pump filling port. ▶ The filling connection (2) below the oil cap is accessible. ▶...
  • Page 43 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. Risk of slipping due to leaked oil ▶ Take up spilled oil with a suitable binder agent. ▶...

  • Page 44: Power Button

    CAUTION Injuries caused by the ejection of the torquing tool from the torque connection. ▶ Prior to switching on the pump, place the torquing tool on the ground. ▶ Make sure that no unauthorized persons are in the work area. Power button An LED power button is located on the right-hand side of the electrical control system.
  • Page 45 CAUTION! Operating errors due to setting incorrect language. After setting the language, the language changes immediately. ▶ Do not set a language you do not understand. Setting the language When powering on for the first time, the first screen prompts you to set a language.
  • Page 46 Setting the temperature units ▶ Choose the temperature unit by pressing one of the icons: – °C (Celsius) – °F (Fahrenheit) – K (Kelvin) ▶ Then press the back button. Setting the torque unit ▶ Choose the torque unit by pressing one of the icons: –...

  • Page 47: Start Screen

    TOUCH SCREEN DISPLAY – SMART START SCREEN NAME Settings Menu Name of current menu screen Daily Use – both models For daily operation you must: Check the oil level. Check that the battery pack and remote control are in in working condition and not damaged. Charge battery pack.
  • Page 48 The pressure control valve is used for adjusting the required oil pressure. Refer to the torque tool’s manual for information about the pressure required for a given torque value. Alternatively, visit the download area on the HYTORC website. Check for correct pressure on the pressure gauge (pictured left). Pressure Regulator Press and hold the green button on the remote control to switch the motor on.

  • Page 49: Connecting Tools

    CONNECTING TOOLS Before you can connect a tool, you must remove the protective caps from the pair of couplers. The protective caps are permanently connected to the corresponding couplers. Connecting a tool with a quick connect coupler (Smart) ▶ Ensure that the hydraulic hoses are not damaged. ▶...

  • Page 50: Operation

    Air in the system error (Smart only) If the error message “Air in the system” is displayed, proceed as follows: ▶ Ensure that none of the components of the torquing system is leaking. ▶ Connect a twin-line hydraulic hose to a pair of couplers. ▶...
  • Page 51 Before and after each tool change perform a test run. This ensures that no oil leaks occur, and all components are functioning correctly. Once a test run is successful, the pump can used for tightening. Performing a test run – Smart Performing a test run –...
  • Page 52 Supervisor HYTORC service technician A logged-in supervisor is identified on the display by a turquoise-colored user icon. Basic software operation ▶ Operate the software by pressing the icons in the center (1) or at the side (3).

  • Page 53: Symbol Description

    Explanation of the Symbols Explanation of the icons (indicators) The following icons can be found on the sides of the screen. The following icons can be displayed in the top and bottom bars of the display screen. SYMBOL DESCRIPTION ICON DESCRIPTION Back to home screen.
  • Page 54 Settings menu The settings menu can be accessed by all users (does not require a login with password): Language Date and time Network Display Units Settings menu for supervisors (requires a login with password). All settings for users Advanced settings Logging in as supervisor ▶...
  • Page 55 Adjusting the display ▶ Press an icon to call up the setting. Orientation The red line indicates the top of the screen. Auto Rotation- The screen orientation automatically rotates as you shift the pump from vertical to horizontal and back. Native –...
  • Page 56 Gauge Style Circular scales are used for illustration in this manual. Select desired style and the go back to Start Screen. You can choose between two display options to indicate the pressure during measurement and tightening. “Default”: circular scale “Modern”: curved scale Advanced settings at supervisor level The advanced settings for supervisors include: User accounts...
  • Page 57 Changing the menu authorizations for user accounts ▶ Press a box to check or uncheck certain menus or pages. The menu and/or screen is only visible to users if checked. If the check mark for a menu is deleted, the screens following it will automatically be hidden, even if the check marks for those screens are still set.

  • Page 58: System Components

    The “New Password” input field is displayed. The new password can be made up of any number of characters. ▶ Enter the new password under “New Password”. The password is changed. ▶ Make a note of the new password and keep this safe from unauthorized access.

  • Page 59: System Report

    System report ▶ Press System Report icon. ▶ Connect a USB data storage device to the USB port on the left-hand side of the touchscreen case. ▶ Press the “Save” icon. ▶ The System Report is saved. This can be read by the manufacturer’s service personnel.

  • Page 60: Loading The Configuration

    Service menu Loading the configuration Configuration files contain customer-specific parameters or licenses, such as the license for a specific future software upgrade. ▶ To obtain configuration data for the pump, contact the manufacturer. ▶ Connect a USB data storage device with a saved configuration to the USB port on the left-hand side of the display.
  • Page 61 Tightening in manual mode Press “Manual” on the start screen. The “Target Torque” menu is displayed: Press the input field for the target torque. The numerical keypad is displayed: ▶ Use the CLR icon to delete any preset value. ▶ Use the numerical keypad to enter the required torque. ▶...
  • Page 62 Tool selection (manual mode) ▶ To see all tool choices, move the screen display using the arrow keys or the scroll bar until the required tool is displayed. ▶ Select the required tool. ▶ Tap a tool image once to highlight it. ▶...
  • Page 63 System measuring (manual mode) System measuring starts and checks the current status of the pump. ▶ Place the connected torque tool on the ground. ▶ Press and hold the green button on the remote control. ▶ When pressing the green button, the red one will also light up. ▶...
  • Page 64 Carrying out the tightening process (manual mode) Once the system measuring has been successfully completed, the torquing process can be started. ▶ Place the connected tool on the first bolt. ▶ Press the green button on the remote control. ▶ The menu with the scales for torque and pressure is displayed.
  • Page 65 Tightening in automatic mode ▶ Press “Automatic” on the start screen. The “Target Torque” menu is displayed: ▶ Press the input field for the target torque. The numerical keypad is displayed. ▶ Use the CLR icon to delete any preset value. ▶...
  • Page 66 ▶ Once all inputs are correct, confirm the job settings by pressing OK ▶ To change an input go back to the required menu using Documentation (only in automatic mode) This function allows you to document the torquing processes. Press the “Activate” button to display Documentation input field. ▶...
  • Page 67 System measuring (automatic mode) System measuring starts and it checks the current status of the pump. ▶ Place the connected torque tool on the ground. ▶ Press and hold the green button on the remote control. ▶ When pressing the green button, the red one will also light up. When the target pressure is reached, a buzzer sounds.
  • Page 68 Carrying out the tightening process (automatic mode) Once the system measuring has been successfully completed, the torquing process can be started. ▶ Place the connected tool on the first bolt. ▶ Press the green button on the remote control. ▶ The menu with the scales for torque and pressure is displayed. You can see the progress on the scale display.
  • Page 69 Releasing the tool during the tightening operation It may be necessary to release a tool during the tightening process (example: because it is under strain or gets stuck). ▶ Open the job menu using the menu icon. ▶ In the job menu, choose “Release Tool” ▶...
  • Page 70 Calling up an existing job ▶ Press the “Jobs” icon. The overview of saved jobs is displayed. If necessary, scroll the screen until the required job is displayed. ▶ To select the job, press that job icon once to select the job ▶...
  • Page 71 Saving the current job After a change is made, the “Save” icon is displayed in the menu. ▶ Confirm by pressing “Save” ▶ To save the current job press “Yes” in the following query. If changes are made, another job is created. Deleting a job ▶...

  • Page 72: Removing Tools

    REMOVING TOOLS Removing tools - Smart (quick connect coupler) ▶ Align the notch and turn to unlock the coupler. Detach the socket (“female”) connection (1) on the hydraulic hose of the tool from the plug (“male”) connection (A) of the pump. ▶...
  • Page 73 Removing tools – Standard (screw style coupler) ▶ Twist the screw style coupler off the socket (“female”) connection (B) until loose. ▶ Detach the plug (“male”) connection (2) from the socket (“female”) connection (B). ▶ Twist the screw style coupler off the socket (“female”) connection (1) until loose. ▶...

  • Page 74: After Use

    AFTER USE...

  • Page 75: Powering Off The Pump

    8. After Use POWERING OFF THE PUMP Daily use Long-Term ▶ Press the red button on the remote control. The motor is To take the pump out of operation for more than three months switched off and the pressure is released. proceed as follows: ▶...

  • Page 76: Changing The Hydraulic Oil

    CHANGING THE HYDRAULIC OIL...
  • Page 77 9. Changing the Hydraulic Oil Draining the hydraulic oil Proceed as follows to change the hydraulic oil: ▶ Switch the pump off. ▶ Remove the battery pack. ▶ Remove connected torquing tools from the couplers. ▶ Place the pump horizontally on a load bearing, solid, flat surface so that a container can be positioned under the oil drain plug. ▶...
  • Page 78 Replacing the oil filter ▶ Place the pump in its horizontal position. ▶ Unscrew the cap (1) from the pump housing using a size 30 wrench. The oil filter (2) is found in the cap (1). ▶ Pull the oil filter (2) out of the cap. ▶...
  • Page 79 CAUTION! The case will come apart by undoing the wrong torque connections. ▶ Only undo the nine protruding hexagon socket torques. ▶ Make sure that all countersunk screws remain securely fastened.

  • Page 80: Servicing The Pump

    SERVICING THE PUMP...

  • Page 81: Pressure Sensor

    10. Servicing the Pump SERVICING THE PRESSURE SENSOR - SMART ONLY The pressure sensor must be calibrated at least once a year. Depending on the local operating conditions, the operator can also specify shorter intervals. It is easier to access the pressure sensor by removing the side panel. To remove and install the pressure sensor (pictured right), the right-hand side panel should be removed from the pump.

  • Page 82: Maintenance Schedule

    ▶ Annually or according to the Calibrate the pressure sensor. Pressure sensor ▶ operating conditions Please contact your HYTORC partner. Every 6 years or according to ▶ operator frequency. Always Hydraulic hoses Have all hydraulic hoses replaced by qualified personnel.
  • Page 83 Firmware Update - Smart ▶ Put the file on a USB drive and plug it into the pump. ▶ Power on the pump. ▶ Follow the instructions on the pump display. The update is installed. Firmware Update - Standard ▶ Put the file on a USB drive and plug it into the pump ▶...

  • Page 84: Disposal

    DISPOSAL...
  • Page 85 11. Disposal Disposal (In the USA – Contact your local HYTORC representativle for more information and disposal locations.) Observe and follow the regulations for disposal. If in doubt, please consult your municipal or local authority. WARNING Risk of poisoning from hydraulic oil ▶...
  • Page 86 Disposal (In Europe) Observe and follow the regulations for disposal. If in doubt, please consult your municipal or local authority. Contact your local HYTORC representativle for more information and disposal locations. WARNING Risk of poisoning from hydraulic oil ▶ Hydraulic oil can contaminate ground water and soil.
  • Page 87 LIGHTNING™ PUMP Series Basic Operations Manual...

  • Page 88: Troubleshooting

    TROUBLESHOOTING...
  • Page 89 12. Troubleshooting The following errors may be indicated by the power button: INDICATOR CAUSE REMEDY ▶ Switch off the motor. The power button lights up yellow. Charge the battery pack as soon as possible. The battery pack charge level is low. The power button flashes red briefly and then ▶...

  • Page 90: Error Indicators

    The warning horn is not used to indicate an error. Error indicators FAULT POSSIBLE CAUSE REMEDY ▶ Have the electrical components checked, serviced, or replaced by qualified Electrical components are damaged. personnel. Charge the battery pack. ▶ The power supply has been Place the battery pack properly in the battery pack holder.

  • Page 91: Features And Benefits

    URGENT SOLUTIONS REQUIRE IMMEDIATE SUPPORT Every minute of downtime can mean lost productivity and revenue, which is why HYTORC’s 24/7 Customer Support is your steadfast partner against the unpredictable nature of bolting challenges. Imagine a support system where, no matter the time, a live HYTORC bolting specialist is always ready to provide swift, customized solutions that keep your operations running smoothly.

  • Page 92: Change Log

    CHANGELOG 05/2024 - First edition. 10/2024 - Compliance updates.
  • Page 94 Headquarters: Contact: Online: Follow: 333 Route 17 N., 1-800-FOR-HYTORC hytorc.com Mahwah, NJ 07430 info@hytorc.com +1-201-512-9500 102524-PR-MAN-LGHTNGPUMP 102524-PR-MAN-LGHTNGPUMP...

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