Operating Manual for the Battery Powered Hydraulic Pump Kit READ THIS FIRST! customer manual TOOLING ASSISTANCE CENTER

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1 Operatng Manual for the Battery Powered Hydraulc Pump Kt Customer Manual JAN 12 SAFETY PRECAUTIONS READ THIS FIRST! customer manual 1. INTRODUCTION DESCRIPTION OPERATING PRECAUTIONS Precautons for the Rechargeable Pump Precautons for the Battery Cartrdge and Pump Precautons for the Battery Cartrdge Precautons for the Battery Cartrdge Charger OPERATION Battery Chargng Instructons Attachng the Battery Cartrdge Attachng the Hydraulc Hose Attachng the Remote Control Cord Controllng the Pump (Fgure 6) Gude to Crmpng Capacty MAINTENANCE AND INSPECTION Before Storng the Pump Daly Mantenance Sem-Annual Mantenance Ol Leaks REPAIR/REPLACEMENT TROUBLESHOOTING REVISION SUMMARY Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 10 LOC B

2 DANGER STOP SAFETY PRECAUTIONS AVOID INJURY Safeguards are desgned nto ths applcaton equpment to protect operators and mantenance personnel from most hazards durng equpment operaton. However, certan safety precautons must be taken by the operator and repar personnel to avod personal njury, as well as damage to the equpment. For best results, applcaton equpment must be operated n a dry, dust-free envronment. Do not operate equpment n a gaseous or hazardous envronment. Carefully observe the followng safety precautons before and durng operaton of the equpment: ALWAYS wear approprate ear protecton. ALWAYS wear approved eye protecton when operatng powered equpment. ALWAYS keep guard(s) n place durng normal operaton. ALWAYS nsert power plug nto a properly grounded receptacle to avod electrcal shock. ALWAYS turn off the man power swtch and dsconnect electrcal cord from the power source when performng mantenance on the equpment. NEVER wear loose clothng or jewelry that may catch n movng parts of the applcaton equpment. NEVER nsert hands nto nstalled applcaton equpment. NEVER alter, modfy, or msuse the applcaton equpment. TOOLING ASSISTANCE CENTER CALL TOLL FREE (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY) The Toolng Assstance Center offers a means of provdng techncal assstance when requred. In addton, Feld Servce Specalsts are avalable to provde assstance n the adjustment or repar of the applcaton equpment when problems arse whch your mantenance personnel are unable to correct. INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER When callng the Toolng Assstance Center regardng servce to equpment, t s suggested that a person famlar wth the devce be present wth a copy of the manual (and drawngs) to receve nstructons. Many dffcultes can be avoded n ths manner. When callng the Toolng Assstance Center, be ready wth the followng nformaton: 1. Customer name 2. Customer address 3. Person to contact (name, ttle, telephone number, and extenson) 4. Person callng 5. Equpment number (and seral number f applcable) 6. Product part number (and seral number f applcable) 7. Urgency of request 8. Nature of problem 9. Descrpton of noperatve component(s) 10. Addtonal nformaton/comments that may be helpful 2 of 10

3 1. INTRODUCTION Fgure 1 Battery Powered Pump (Fgure1) s a portable, battery-powered, hydraulc pump used to power hydraulc hand tools. The battery powered hydraulc pump kt comes complete wth a 8,200 ps hydraulc pump and controller ( ); a battery charger ( ); two nckel-cadmum battery cartrdges ( ); a 3/8 Inch female screw type coupler ( ); and a metal storage box ( ). The metal storage box s not shown n Fgure 1. When readng ths manual, pay partcular attenton to DANGER, CAUTION, statements. DANGER Denotes an mmnent hazard whch may result n moderate or severe njury. STOP CAUTION! Denotes a condton whch may result n product or equpment damage. Hghlghts specal or mportant nformaton. Dmensons n ths manual are n metrc unts [wth U.S. customary unts n brackets]. 3 of 10

4 2. DESCRIPTION Refer to Fgure 2. BATTERY POWERED PUMP Output ,200 ps Drve Unt For Sngle Actng Cylnders Rated Voltage V Usage Lght Duty Ol Delvery Pressure MPa Hgh Pressure Stage /mn. Low Pressure Stage /mn Dmensons: In. Hgh x 6 In. Wde x 10 In. Deep Weght: lbs (wth two batteres) Flow: Cu/In/Mn@300ps 18 Cu/In/Mn@8,200 ps Flud Reservor Capacty Cu/In BATTERY CARTRIDGE (Standard) Battery Type Sealed Nckel Cadmum Voltage ,4Vdc Rated Current Ah Charge Tme mnutes Dmenson In Long X 2.7 In. Wde X 5.3 In. Hgh Weght pounds HIGH OUTPUT BATTERY CARTRIDGE (Optonal) Battery Type N-mH (Nckel Metal Hydrde) Voltage ,4Vdc Rated Current Ah Charge Tme mnutes Dmensons In Long X 2.7 In. Wde X 5.3 In. Hgh Weght pounds BATTERY CHARGER Input Voltage Vac Sngle Phase Chargng Capacty VA Dmensons In Long X 4.5 In. Wde X 3.7 In. Hgh Weght pounds REPLACEMENT CONTROLLER May be ordered separately Fgure 2 4 of 10

5 3. OPERATING PRECAUTIONS 3.1. Precautons for the Rechargeable Pump 1. When connectng the coupler, be sure that no foregn objects are attached. If the coupler has become drty, clean t carefully before connectng t. Engagng the coupler when foregn objects are present wll damage the seals and lead to ol leakage from the connecton. 2. Make sure that the coupler s securely connected. If the unt s pressurzed whle the coupler s not properly connected, there wll be damage to the seals or the crmp head. 3. Although a flexble hydraulc hose s used, do not bend t whle pressure s beng appled, or subject the hose to shocks from metal objects. Ether of these wll shorten the workng lfe of the hose and may result n the hose burstng. 4. Never move the pump by pullng on the hydraulc hose or the remote control cords Precautons for the Battery Cartrdge and Pump 1. To ensure smooth operaton of the pump, always use the pump after t has been stored for at least one hour at 10 C to 25 C. If the pump s stored for an extended perod below -5 C, vscosty of the ol ncreases. 2. Allow the pump to cool 10 mnutes after each 20 mnutes of use. The pump was desgned for lght duty and cannot be used contnuously. Be sure that nether the motor or the ol become hot. 3. Check the hydraulc ol regularly. Replensh the ol when the level becomes low. Use the approprate hydraulc ol type. 4. The pump s a precson devce and should not be dropped or subjected to shocks or other abuse Precautons for the Battery Cartrdge 1. Do not short crcut the contacts or expose the cartrdge to water, ol, or solvents. 2. Do not dsassemble or attempt to repar the battery cartrdge. 3. Do not dspose of the battery cartrdge n a fre. 4. Do not drop or abuse the battery cartrdge. 5. Do not leave the cartrdge n an area where t wll be exposed to temperatures greater than 140 F (60 C) for an extended perod. 6. The battery has a lmted lfe. When the crmpng capacty becomes about one half that of the orgnal capacty, the battery should be replaced. 7. If the battery s stored wthout beng charged, natural dranage wll cause the power to be reduced. The battery should be completely re-charged every three months f not n use Precautons for the Battery Cartrdge Charger Ths unt s for chargng the battery cartrdge n the pump kt only. 1. The LED ndcator s green whle the unt s chargng the battery. The ndcator turns an orange color when the chargng s completed. 2. Allow battery cartrdges to cool completely before chargng. 3. Allow at least 15 mnutes between charges when chargng several cartrdges n successon. 4. Charge the batteres at an ambent temperature of 50 F to 95 F (10 C to 35 C). Chargng tme s approxmately 25 mnutes for battery number ; 45 mnutes for battery number Never short crcut the output termnals. 6. Do not expose the charger to water, ol, or solvents. 7. Do not dsassemble the charger, attempt to modfy t, drop t, or otherwse abuse t. 5 of 10

6 4. OPERATION 4.1. Battery Chargng Instructons 1. Insert the plug end of the charger nto a 120 Vac power source. The LED ndcator on the charger wll flash red, ndcatng that the charger s n stand by mode and s ready to charge a battery. CAUTION! DO NOT plug the charger nto a generator. Ths wll probably cause the fuse n the charger to short, and the charger wll not operate. 2. To charge a draned battery, nsert the battery nto the charger untl the LED ndcator regsters a steady green. Ths ndcates the battery s beng charged and wll be completed n approxmately 25 mnutes. The LED ndcator wll regster orange when chargng s complete. 3. Charge only approprately cooled batteres. If the ndcator regsters a steady red color when the battery s nserted, the battery s too hot to be charged and must be cooled to room temperature. Do NOT leave the battery n the charger to cool. The charger wll not recognze that the battery s already nserted and wll fal to charge the battery. 4. Consult the Toolng Assstance Center at f the LED ndcator goes out or s flashng red. 5. To recondton the battery, nsert the battery nto the charger and push the R button. The LED ndcator should flash green to ndcate that the dscharge cycle s n process. For techncal questons or dffculty n operaton, call the Toolng Assstance Center at Attachng the Battery Cartrdge 1. Pull out on the battery cartrdges whle pressng the latch. See Fgure 3. Latch Pull Out On The Battery Charger Fgure 3 To replace the two battery cartrdges push them frmly back nto place. Always nstall and use both battery cartrdges at the same tme. 2. After attachng the battery cartrdges, check to see f they are n place by pullng them, wthout pressng the latch. Two battery cartrdges must be nserted nto the cartrdge slots snce they are connected n seres to actvate a 28.8 Vdc motor. 6 of 10

7 4.3. Attachng the Hydraulc Hose Attach the male coupler of the hydraulc hose to the female coupler of the hydraulc pump as shown n Fgure 4. Male Coupler of the Hydraulc Hose No Gaps Coupler Rng Female Coupler of the Hydraulc Pump Fgure 4 2. Gently pull on the couplers to determne f they are securely connected. If the couplers are not engaged properly, the ram wll advance but wll not retract. 3. Attach the applcaton head to the opposte sde of the hose (f t's not already attached) Attachng the Remote Control Cord Attach the remote control cord to the pump. Remove the cap from the receptacle at the pump. Then nsert the plug of the control cord and tghten the rng securely. The attached cord should resemble Fgure 5. Plug of the Remote Control Cord Remote Control Cord Fgure Controllng the Pump (Fgure 6) 1. To advance the pston, press and hold the UP button. 2. To retract the pston, press and hold the DOWN button. 3. When the hydraulc power reaches 8,200 ps, the motor shuts off and compresson s complete. UP Button DOWN Button Fgure 6 7 of 10

8 4.6. Gude to Crmpng Capacty Ths gude corresponds to battery cartrdge number , only. In addton these fgures are approxmate and can vary accordng to chargng and crmpng condtons. When the crmpng cycles are reduced to approxmately 1/2 the normal cycle, ths ndcates that the battery lfe s exhausted and the battery should be replaced a wth a new one. Each battery can be charged approxmately 500 cycles. For battery cartrdge number : Cable sze = 750 MCM Average Number of Crmpng Cycles = 50 tmes 5. MAINTENANCE AND INSPECTION 5.1. Before Storng the Pump Perform the followng steps after the pston has reached t's lowest poston. 1. Remove the battery cartrdge. 2. Dsconnect the plug of the remote control cord. Be sure that the cord does not become pulled, loose, or twsted. 3. Replace the receptacle cover. 4. Dsconnect the coupler. 5. Re-attach the dust cap of the coupler to prevent dust from gettng nto the system Daly Mantenance It s recommended that the pump be nspected daly by operatng and mantenance personnel. 1. Check the hydraulc ol level and t's contamnaton vsually through the ol gage. Add hydraulc ol f approprate. 2. If contamnaton of the ol s observed, replace the hydraulc ol completely (approxmately one lter). Shell T5 Hydraulc Ol s recommended. 3. When replacng the hydraulc ol, remove the ar vent (refer to Fgure 7). Ar Vent Fgure 7 8 of 10

9 5.3. Sem-Annual Mantenance Completely replace the hydraulc ol every sx months. Shell T5 Hydraulc Ol s recommended. CAUTION! NEVER use vegetable ol or brake ol wth ths pump. If the tool s mantaned regularly and correctly, t should provde trouble-free servce. If a problem does occur, contact the Toolng Assstance Center (see the bottom front page) Ol Leaks In most cases, t s possble to repar ol leaks usng the method descrbed below. 1. Remove the coupler at the pont of the leak. 2. Carefully remove the sealng tape (PTFE tape) from the screw. 3. Wrap NEW sealng tape one and one half tmes around the screw head. 4. Begn wrappng the sealng tape 1mm to 2mm from the edge of the thread. See Fgure 8. 1 mm to 2 mm Sealng Tape Fgure 8 5. Tghten the coupler back nto poston. (The screw torque should be Nm [3-5Kgf-cm 2 ].) The pump s shpped wth Shell T5 ol n the pump. Do NOT mx the ol. Always completely replace the ol f another type of ol s used. 6. REPAIR/REPLACEMENT If there are major problems wth the battery powered pump, t should be returned to: CUSTOMER SERVICE ( ) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA For customer repar servce, call of 10

10 7. TROUBLESHOOTING 1. Replace the battery before consderng other causes. a. Power to the pump s provded by the battery. Should a problem occur, the battery should be replaced. b. Low battery power wll not allow the pump to pressurze. The battery should be charged or replaced before consderng other causes. 2. Inspect the connecton pont to be sure that no leakng exsts. The ol delvery of the pump s mnmal, so that even the slghtest ol leak wll effect performance. 3. Man causes of malfuncton are as follows: a. One of the pump's parts requres repar. b. The hydraulc ol s contamnated. Replace the ol as descrbed n Paragraph 5.2. c. The straner s clogged. d. There has been mechancal wear. Although some repars and replacements can be accomplshed on ste, t s recommended that parts be shpped back to TE Connectvty for repar/replacement. Refer to Secton 6. TROUBLESHOOTING GUIDE PROBLEM CAUSE SOLUTION Even when the on button s pressed, nothng happens. The pressure does not ncrease. (No pressure s measured at the head.) It takes a long tme for the pston to advance. The pston does not retract to ts lowest poston. Defectve electrcal supply Defectve crcut board Remote control connecton wre s dsconnected Battery falure Ol leaks from the jont Insuffcent amounts of hydraulc ol Cloggng of the straner The pump mechansm s broken Battery falure Ol s hot Ol leaks from the jont Insuffcent amounts of hydraulc ol Ar s trapped n the hose or head Pump mechansm s broken Defectve crcut board Remote control connecton wre s dsconnected Pump mechansm s broken Check the electrcal connecton. Consult Toolng Assstance for repar servce. 1. Charge or replace the battery 2. Repar the ol leak and replensh hydraulc ol. 3. Overhaul the pump and remove the blockage. 4. Consult Toolng Assstance for repar servce. 1. Charge or replace the battery. 2. Allow pump to cool. Repar leak. 3. Replensh hydraulc ol. 4. Consult Toolng Assstance for repar servce. Consult Toolng Assstance for repar servce. 8. REVISION SUMMARY Removed msused trademark for PTFE. Updated document to corporate requrements. 10 of 10