Instruction Manual PL19-6000EN ATP III Electric/Hydraulic Pump For additional product information visit our website at http://www.apextoolgroup.com
PL19-6000EN Specifications Pump Model Motor Motor Voltage Motor RPM 1,750 Maximum Current Draw 5526244 (ATP III) 1.7 hp (1,25 kw) Electric Motor 115 VAC, Single Phase, 50/60 Hz 20 Amps 100 psi (7 bar) = 700 in 3 /min (11,5 l/min) 700 psi (50 bar) = 535 in 3 /min (8,8 l/min) 5,000 psi (350 bar) = 76 in 3 /min (1,2 l/min) 10,000 psi (700 bar) = 60 in 3 /min (1,0 l/min) Relief Valve Adjusment Range 1,400-10,000 psi (70-700 bar) Sound Level Reservoir Capacity Weight (with oil) ATP III Electric/Hydraulic Pump Specifications Output Flow Rate * 85-90 dba 2 gallons (8 liters) 70 lbs. (31.8 kg) * Note: Output flow rate shown is at 60 Hz. Flow rate will be approximately 5/6 of shown values at 50 Hz. Figure 1 Page 2
System Configuration PL19-6000EN Carefully plan your system by selecting components designed to perform the intended operation and which will adequately perform with existing equipment. Always check the product limitations regarding pressure ranges, load capacities and set-up requirements. The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. Read all CAUTIONS, WARNINGS, and INSTRUCTIONS included with or attached to each product. Follow all safety precautions to avoid personal injury or property damage during system operation. IMPORTANT RECEIVING INSTRUCTIONS: Visually inspect all components for shipping damage. If any shipping damage is found, notify the carrier at once. Shipping damage is NOT covered under the Apex Tool Group warranty. The carrier is responsible for all repair or replacement cost resulting from damage during shipment. Figure 2 Page 3
PL19-6000EN Description Language Version: This Parts Manual is the Original Instructions intended for all persons who will use or repair these tools. Noise and Vibration: The ATP III Pump operates at 85-90 dba. General Description: An electric powered hydraulic pump mounted in a wheeled roll cage, with an integrated handle, to facilitate safely and easily moving the pump from one job location to another. Intended Use: This pump is designed to work as an integrated tube pulling system in conjunction with the Airetool ATP III gripper type pullers. The Airetool HDQ III gripper type pullers, RAV III and HDP III spear type tube pullers can also be used with this pump. Use only for the designated purpose. Do not use in any improper manner that can cause equipment damage and operator injury. Copyright protection: Apex Tool Group, LLC reserves the right to modify, supplement or improve this document or the product without prior notice. This document may not be reproduced in any way, shape or form, in full or parts thereof, or copied to another natural or machine readable language or to a data carrier, whether electronic, mechanical, optical or otherwise without the express permission of Apex Tool Group, LLC. Page 4
Safety First PL19-6000EN Safety Precautions: Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Apex Tool Group cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Apex Tool Group when in doubt as to the safety precautions and operations of this equipment. Failure to comply with the following cautions and warnings could cause equipment damage and/or personal injury. A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of, equipment or other property. A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury. A DANGER is only used when your action, or lack of action, may cause serious personal injury or even death. WARNING: Wear proper personal protective gear when operating hydraulic equipment. WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. Install pressure gauges in the system to monitor operating pressure. Avoid damaging the hydraulic hoses. Avoid sharp bends and kinks when routing the hydraulic hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends or kinks will internally damage the hose leading to premature failure. cage to safely move the pump. Keep hydraulic equipment away from flames and heat. Excessive heat will soften packing and seals, resulting in fluid leaks. Heat also weakens hose materials and packing. For optimum performance do not expose equipment to temperatures of 150 F (65 C) or higher. Protect hoses and cylinders from weld spatter. Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. IMPORTANT: Hydraulic equipment must only be serviced by a qualified hydraulic technician. To protect your warranty, use only manufactured recommended oil. Immediately replace worn or damaged parts with genuine manufacturer s parts. Standard grade parts will break causing property damage and/or personal injury. Manufacturer s parts are designed to fit properly and withstand high loads. Do not use electric pumps in an explosive environment. Adhere to al local and national electrical codes. A qualified electrician must do installation and modification on this equipment. These pumps have internal factory adjusted relief valves, which must not be repaired or adjusted except by a factory authorized service location. To prevent damage to the pump s electric motor, check specifications. An incorrect power source will cause damage to the motor. DO NOT drop heavy objects on the hoses. A sharp impact may cause internal damage to the hose wire strands. Applying pressure to a damaged hose may cause it to rupture. IMPORTANT: Do not lift hydraulic equipment by the hoses or swivel couplers. Use the integrated handle and wheeled Page 5
PL19-6000EN Installation: Position the pump to ensure that air flow around the motor and pump is not obstructed. Keep the motor clean to ensure maximum cooling during operation. Fluid Level: Check the oil level of the pump prior to start-up. If necessary add oil by removing the SAE #10 plug from the cover plate, Figure 3. Figure 3: Oil Fill Plug The reservoir is full when the oil level reaches the top of the sight glass, Figure 4. Figure 4: Oil Full Level SAE #10 Plug Reservoir Full Level Connect power to the unit and wait until OK is displayed on the LCD before pressing any button on the shroud or pendent (if equipped). NOTE: During the boot sequence, the micro processor identifies any button operation as a potential malfunction and prevents the motor from starting. You can reset by disconnecting the power for 10 seconds. Start the motor and operate the tube puller by pressing and releasing the ON/OFF button. The LCD will show the pressure in the retract circuit (B-port bypass), approximately 2500-2800 psi (173-193 bar). As the motor starts, the valve shifts automatically, retracting the tube puller. Verify the tube puller is positioned to avoid personal injury or equipment damage before starting motor. Shut off the motor by pressing the ON/OFF button. If no buttons are pressed within a continuous 20 second period, the pump s built in timer will automatically shut the motor off. NOTE: When the motor is turned off, as the motor stops turning, the valves will automatically cycle to release all pressure in both the advance and retract hoses. NOTE: Units equipped with heat exchangers allow the timer to automatically shut off the pump. During any idle period, the pump is circulating 90% of its oil flow through the heat exchanger to reduce oil temperature. Setting Pump Pressure: This pump model provides the operator with two methods of limiting the Advance (A port) pressure to the tube puller: User Adjustable Relief Valve and Auto Cycle. Figure 5: Relief Valve Control Handle Locking Nut IMPORTANT: Add oil only when all system components are fully retracted, or the system will contain more oil than the reservoir can hold. Operation: Check the oil level of the pump and add oil if necessary, as shown in Figures 3 and 4. Page 6
PL19-6000EN User Adjustable Relief Valve: Limits the pressure by opening the relief valve to redirect the pump s oil flow to the reservoir at the desired pressure value. Pressure will remain in the Advance circuit (A port) while the Pendant Up button is pressed. To adjust the pressure valve, Figure 5: 1. Verify Auto Mode is Off or Set Pres value is a minimum 100 psi (7 bar) higher than the desired relief valve setting. 2. Loosen the relief valve locking nut and turn the relief valve control handle counter-clockwise until there is a light drag when turning, this will decrease the pressure value. 3. Start the pump to allow the oil to warm above 32 F (0 C). 4. Press and hold the pendant Up button to build pressure in the advance circuit. Turn relief valve control handle clockwise to increase pressure to desired value. NOTE: To get an accurate setting, decrease the pressure to a point below the final setting and then slowly increase the pressure until it reaches the final setting. 5. Tighten the relief valve locking nut at the desired pressure value. 6. Release the pendant Up button to allow the system pressure to return to the B-port by-pass setting. 7. Recheck the final pressure setting by shifting the valve and pressurizing the system. Auto Cycle: Limits the pressure by automatically changing the tube pulling operation from Advance to Retract at the desired pressure value. When the Retract pressure reaches a factory-preset value of approximately 2,000 psi (138 bar), the pump automatically changes tube pulling operation from Retract back to Advance. The pump microprocessor does this by shifting the electric control valve to redirect the pump s oil flow between ports. This automatic cycling will continue while the pendant Up button is pressed. To activate Auto Cycle and adjust the pressure value: 1. Activate Auto Cycle by displaying the Automode menu and toggling the setting to On using the shroud arrow buttons. Save by pressing the Menu button once. 2. Set the desired Advance pressure by displaying the Set Pres menu and adjusting the value by using the shroud arrow buttons. Save and return to the OK display by pressing and holding the Menu button for 2 seconds. 3. Turn on the pump by pressing the pendant On/Off button. 4. Press and hold the pendant Up button to Auto Cycle the tube puller. 5. If the tube puller does not Auto Cycle or does so erratically, increase the User Adjustable Relief Valve setting to a minimum value of 100 psi (7 bar) higher than the desired Auto Cycle value. NOTE: Maximum Retract pressure (B port), also known as B port by-pass, is factory set at approximately 2,500-2,800 psi (173-193 bar) and cannot be adjusted. LCD Function: Figure 6: LCD Screen Number Display Text Display Besides the Pendant, which is used to switch the motor on/off and operate the valves, the Control Board with its four-button switches is the main interface between the operator and the pump. With the use of these four-button switches all functions and settings that are described in the following can be activated. Make sure that all the plastic overlay, that protects the LCD screen and the button switches, is not broken or otherwise damaged. Never punch the button switches with a sharp or pointed instrument, user fingertips only. Clean the overlay regularly with a damp cloth; never use an aggressive or abrasive detergent. Page 7
PL19-6000EN A. Boot Sequence: Firmware 5.5 and earlier: When the pump is connected to electrical power the LCD screen will show: FIRMWARE x.x for 2 seconds. Firmware 5.6 and later: When the pump is connected to electrical power the LCD screen will show: FIRMWARE x.x for 1 second, then Model xx for 0.5 seconds, and then MOTOR UN/1P/3P for 0.5 seconds. This is setup information about your pump that may be needed for service. The boot sequence is finished successfully when the text display on the LCD screen shows OK (sequence takes approximately 2 seconds). The micro-controller will automatically recognize the optional pressure transducer built into the pump. The reading after the boot process is OK in the text display and the current pump pressure on the numeric display. B. LCD Operational Buttons: The control board is equipped with four button switches, from left to right; On/Off, Menu, Down Arrow, Up Arrow, see Figure 7. The On/Off button toggles the motor OFF. The Figure 7: Operational Buttons On/Off Menu Down Arrow Up Arrow motor OFF function is available on this button even if the pump is NOT in the local mode but is operated by using the pendant control. The Menu button enables the operator to step from normal operational mode into menus. With repeated pressing the operator steps through the various menus. Pressing the Menu button also saves any changes made. To return to the normal operational mode, press and hold the Menu button for two seconds or don t push any button for 60 seconds. The Down Arrow and Up Arrow buttons serve two purposes. When the display shows one of the menus, the Down Arrow and Up Arrow buttons are used to step through the menu s options. When the pump is placed in Local Mode the UP Arrow button switches the B and A electric solenoids (the pendant is non-operational in local mode). C. Menus Available: The software provides the operator with the following Menus: Automode: Set tube puller Auto Cycle mode ON or OFF. With Automode OFF, the menu Set Pres (Firmware 5.5 and earlier) or HI PRESS (Firmware 5.6 and later) will not be available and the Set Pres or HI PRESS pressure value has no effect on the pump. Set Pres or HI PRESS: (Only available with Automode ON) Set the Advance port pressure value the tub puller will Auto Cycle at. Changes in increments of 50 psi (3.5 bar), maximum pressure value is 10,000 psi (700 bar). NOTE: Firmware 5.5 and earlier - the hidden calibration menu for the digital gauge is accessed from this menu. Units: Set the pressure units to PSI / BAR / MPa, with psi being the default setting. NOTE: Firmware 5.6 and later - the hidden calibration menu for the digital gauge is accessed from this menu. Motor: Display the motor hour meter and on/off cycle counter (can not be reset). Low Volt: Display the low voltage hour-meter (can not be reset). Advance: Display the Advance solenoid hour meter and on/off cycle counter (can not be reset). Retract: Display the Retract solenoid hour meter and on/off cycle counter (can not be reset). Local: Set the pump local mode on/off Language: Set the language of the display to English / Spanish / French / Italian / German / Portuguese, with English being the default setting. Diagnose: Display to show input signals from the pendant control and other electrical accessories. Fault Conditions: Any fault will shut down and prevent the pump from starting: A. Clearing a Fault Condition from the LCD: After the fault causing the problem has been corrected, clear the fault message from the LCD by disconnecting electrical power from the pump, wait until all characters clear the LCD (approximately 10 seconds), then reconnect the electrical power. Page 8
PL19-6000EN B. Power Failure: Display: POWER OFF Figure 8: Power Off D. Motor Overload: Display: MTR OVLD Figure 10: Motor Overload The Power Off fault is displayed when the main power supply drops to 65% or less of nominal voltage. The pump will automatically shut off the valves and the motor, and display Power Off on the LCD. NOTE: Power Off is also displayed for several seconds after the unit is disconnected from the electrical supply. C. Button Fault: Display: Button Fault Figure 9: Button Fault The Motor Overload fault is displayed when the electric current drawn by the motor exceeds the pre-set limit of the internal circuit breaker. The internal circuit breaker will automatically reset once the condition has been corrected; however, the operator must clear the fault and then press the motor on/off button to restart the motor. E. Oil Temperature (requires optional float/temperature switch) Display: OIL TEMP Figure 11: Oil Temperature The Button Fault is displayed when the micro processor detects any button press during the boot sequence or if the shroud on/off button is held in for more than 3 seconds. The Oil Temperature fault is displayed when the temperature of the oil inside the reservoir exceeds 175 F (80 C). Page 9
PL19-6000EN F. Oil Level (requires optional float/temperature switch) Display: OIL LEVEL Figure 12: Oil Level Warning Conditions: All warnings notify the operator of an abnormal operating condition, however, allow pump to continue operating. Warnings will automatically clear once the issue has been resolved. A. Low Voltage: Display: LOW VOLT Low Voltage Figure 13: Low Voltage The Oil Level fault is displayed when the oil level inside the reservoir drops below 1.3 (34mm) from bottom. A Low Voltage condition is defined as an operating condition when the main power supply is at or below 80% of nominal voltage. While running the pump under this condition, the Low Voltage signal will flash on the LCD and the Low Voltage hours will be counted and stored on the control board. Normal pump operation is still provided. For optimized pump performance it is recommended NOT to run the pump at a Low Voltage condition. Page 10
PL19-6000EN LCD Menus: A. Normal Operation Menu: Figure 14: Normal Operation Menu C. Set Press or High Press Menu (only available with Automode ON): Figure 16: Set Press or HI PRESS Menu The Normal Operation LCD screen indicates that the control board has booted successfully (OK); the pressure reading is 0 psi. The operator can now enter into the menus by pressing the Menu button. B. Auto Mode Menu: Figure 15: Auto Mode Menu This screen allows the operator to set the Advance port pressure value the tube puller will Auto Cycle at. Changes in increments of 50 psi (3.5 bar) by pressing either the Down or Up Arrow button or keep either button pressed for speed setting. Maximum pressure value is 10,000 psi (700 bar). Save the setting and step forward by pressing the Menu button. NOTE: Firmware 5.5 and earlier: The hidden calibration menu for the digital gauge is accessed from this menu. D. Units Menu: Figure 17: Units Menu This screen allows the operator to toggle the tube puller Auto Cycle mode ON or OFF. With Automode OFF, the menu Set Pres (Firmware 5.5 and earlier) or HI PRESS (Firmware 5.6 and later) will not be available and the Set Press / HI PRESS pressure value has no effect on the pump. Switch it ON or OFF by pressing either the Down or Up Arrow buttons. NOTE: Firmware 5.6 and later - Setting the value to ON also changes the Normal Operations menu text message from OK to AUTO. Save the setting and step forward by pressing the Menu button. This screen allows the operator to set the unit of pressure-measurement by pressing either the Down or Up Arrow button. The options available are PSI, BAR, Mpa with PSI being the default. Save the setting and step forward by pressing the Menu button. NOTE: Firmware 5.6 and later: The hidden calibration menu for the digital gauge is accessed from this menu. Page 11
PL19-6000EN E. Motor Menu: Figure 18: Motor Menu of hours the pump has been operated in low-voltage condition. Step forward by pressing the Menu button. G. Advance Menu: This screen allows the operator to read the number of Figure 20: Advance Menu This screen allows the operator to read the number of hours (ON / OFF cycles) the motor has been operated. Toggle between hours and cycles by pushing either the Down or Up Arrow buttons. Step forward by pressing the Menu button. General note for all hour and cycle displays: Hours Displayed up to 9999.9 the display will show decimal hours between 10,000-99,999 whole hours will be displayed (decimal. is not displayed) over 99,999 hours the meter starts over at 0.0 reading decimal hours. Cycles Displayed over 99,999 cycles the meter starts over at 0 F. Low Volt Menu: This screen allows the operator to read the number Figure 19: Low Volt Menu hours (On / Off cycles) the Advance solenoid has been operated. Toggle between hours and cycles by pushing either the Down or Up Arrow buttons. Step forward by pressing the Menu button. H. Retract Menu: This screen allows the operator to read the number of Figure 21: Retract Menu hours (On / Off cycles) the Retract solenoid has been operated. Toggle between hours and cycles by pushing either the Down or Up Arrow buttons. Step forward by pressing the Menu button. Page 12
PL19-6000EN I. Local Menu: Figure 22: Local Menu K. Diagnose Menu: Figure 24: Diagnose Menu This screen allows the operator to toggle the LOCAL mode ON or OFF, default is OFF. With LOCAL mode ON, the shroud buttons replace the pendant control buttons as the method to operate the pump. NOTE: The word LOCAL replaces OK on the Normal Operations display and the pendant control buttons become deactivated. LOCAL mode will provide operation of the pump if the pendant control or pendant control cable is damaged. Toggle LOCAL mode ON or OFF by pressing the Down or Up Arrow buttons. Save the setting and step forward by pressing the Menu button. J. Language Menu: not used Fan Pendant Down Arrow button Pendant Up Arrow button Pendant ON / OFF button This screen allows the operator to trouble shoot several pendant problems by displaying if the microprocessor has received a signal from the pendant control button. No signal indicates the problem is most likely with the pendant keypad or pendant cord. Use LOCAL mode to operate the pump until the problem can be corrected. Figure 25: Diagnose Menu Figure 23: Language Menu ON / OFF (Motor) button pushed Up Arrow (Advance) button pushed With a language shown on the text display the operator can change the display language by pressing the Down or Up Arrow buttons. Save the setting and step forward by pressing the Menu button. Page 13
PL19-6000EN LCD Hidden Menus: (available when the pressure transducer is installed) A. Calibration Menu: Figure 26: Calibration Menu This screen allows the operator to adjust the pressure value shown on the LCD to match a master gauge. To access this menu: Firmware 5.5 and earlier: Set AUTOMODE to ON and go to the Set Pres menu. Firmware 5.6 and later: Go to the UNITS menu Then press and hold the ON / OFF button for 7 seconds, ENTRY CODE will appear. Then press and hold both the Down Arrow and Up Arrow buttons for 7 seconds. Refer to Table A for Pump Calibration sequence. Page 14
PL19-6000EN Step Operator Action LCD Reading Comments 1 Connect master gauge to port A (Advance port) - Also connect hand pump if applicable, see comments Note: There are two methods of producing the needed pressure in steps 11 and 15, using the pumps "motor" or separate "hand pump". Connect a hand pump only if it will be used to create pressure in steps 11 and 15, and verify the pump's user adjustable relief valve is set higher than maximum pressure used in step 15. 2 Connect electrical power to pump FIRMWARE x.x, then "OK" 0 psi Boot-sequence 3 Firmware 5.5 and earlier: In the OK mode, press the If Automode is OFF, press one of the Arrow buttons AUTOMODE ON Menu button once and set Automode ON once to select ON 3.1 Firmware 5.5 and earlier: At main screen, press the Menu button once to display screen "SET PRES", SET PRES xxxx psi xxxx psi is the current pressure value of SET PRES skip step 4 4 Firmware 5.6 and later: At main screen, press the Menu button once to display screen "UNITS", skip steps 3 and 3.1 UNITS psi psi is the current unit of pressure measurement 5 Press and hold the ON / OFF button for 7 seconds ENTRY CODE Step into the hidden calibration mode 6 7.a 7.b 8 9 Press and hold the Up Arrow and Down Arrow buttons together for 7 seconds "Motor" method - Open the pump's user adjustable relief valve and verify both pump LCD and master gauge read zero. "Hand Pump" method - Open the hand pump's user control valve and verify both pump LCD and master gauge read zero. Press the Menu button to accept the pressure value into temporary memory Press one Arrow button to change from "NO" to "YES" CAL PT A CAP PT A CAP PT A SAVE A SAVE A 10 Press the Menu button once CAL PT B 2000 psi (138 bar) 11.a 11.b 12 13 "Motor" method - Press and release the shroud's ON / Off motor button to switch the pump motor on. Reading the master gauge, apply a pressure of 2,000 CAL PT B psi (138 bar) by closing the pump's user adjustable relief valve. "Hand Pump" method - Close the hand pump's control valve. Reading the master gauge, apply a pressure of 2,000 psi (138 bar) Press the Menu button to accept the pressure value into temporary memory Press one Arrow button to change from "NO" to "YES" CAL PT B SAVE B SAVE B 14 Press the Menu button once CAL PT C 8000 psi (548 bar) 15 16 17 Reading the master gauge, apply a pressure of 8,000 psi (548 bar) Press the Menu button to accept the pressure value into temporary memory Press one Arrow button to change from "NO" to "YES" CAL PT C SAVE C SAVE C 18 Press the Menu button once USE DFLT off Start of calibration process. The advance-solenoid 0 psi (0 bar) will be powered up to access the pressure transducer through valve-port A. 0 psi (0 bar) Calibrate the zero-offset, point "A" 0 psi (0 bar) Calibrate the zero-offset, point "A" no Confirm the pressure data should be stored to yes memory Calibrating gain is done with two points, starting with point "B" CAL PT B can be set at any pressure value greater than zero. First obtain the pressure value on the 2000 psi (138 bar) master gauge (ie 2250 psi) (155 bar) then use the arrow buttons to match the LCD value to the master gauge. CAL PT B can be set ay any pressure value greater than zero. First obtain the pressure value on the 2000 psi (138 bar) master gauge (ie 2250 psi) (155 bar) then use the arrow buttons to match the LCD value to the master gauge. no Confirm the pressure data should be stored to yes memory Calibrating gain is done with two points, finishing with point "C" CAL PT C can be set at any pressure value greater than CAL PT B. First obtain the pressure value on the 8000 psi (548 bar) master gauge (ie 7500 psi) (515 bar) then use the arrow buttons to match the LCD value to the master gauge. no Confirm the pressure data should be stored to yes memory Re-confirm calibration data. Leave "off" to proceed with new calibratin data. Only set to "on" to change calibration data back to factory default settings. Press Arrow button to change. 19 Press the Menu button once CAL PT A 0 psi (0 bar) Save calibration data to permanent memory. 20 Press and hold the Menu button for 3 seconds to step out of the calibration mode. OK Table A - Pump Calibration 0 psi (0 bar) Calibration complete Page 15
PL19-6000EN Maintenance: Frequently inspect all system components for leaks or damage. Electrical components (example; power cord) may only be repaired or replaced by a qualified electrician, adhering to all applicable local and national codes. Check Oil Level: Check the oil level of the pump prior to start-up, and add oil, if necessary, by removing the oil fill plug. Always be sure the cylinders are fully retracted before adding oil to the reservoir. Figure 27: Oil Fill Plug Figure 28: Oil Full Level Oil Fill Plug Reservoir Full Level NOTE: This procedure requires that you remove the pump from the reservoir. Work on a clean bench and dispose of used oil according to local codes. 1. Unscrew the 13 bolts holding the cover plate to the reservoir and lift the pump unit out of the reservoir. Be careful not to damage the filter screen. 2. Pour all oil out of the reservoir. 3. Thoroughly clean the reservoir and magnet with a suitable cleaning agent. 4. Remove the pick-up filter screen for cleaning. CAUTION: Do not pull on the screen or the bottom of the intake to avoid possible damage. Clean the screen with solvent and a soft brush. Reinstall the filter screen. 5. Reassemble the pump and reservoir, installing a new reservoir gasket. 6. Fill the reservoir with clean manufacturer recommended hydraulic oil. The reservoir is full when the oil level is in the middle of the sight gauge, see Figure 28. Troubleshooting Guide (see Table B): Only qualified factory technicians should service the pump or system components. A system failure may or may not be the result of a pump malfunction. To determine the cause of the problem, the complete system must be included in any diagnostic procedure. The information contained in Table B is intended for use as an aid in determining if a problem exists. For repair service, contact your Apex Tool Group representative. Change Oil and Clean Reservoir: The ATP III pump oil is a crisp blue color. Frequently check the oil condition for contamination by comparing the reservoir oil to new unused oil. As a general rule, completely drain an clean the reservoir every 250 hours of use, or more frequently if used in dirty environments Page 16
PL19-6000EN Table B - Trouble Shooting Guide Problem Possible Cause Pump will not start No power or wrong voltage Pendant does not function Pump in LOCAL mode Pendant damaged Motor stalls under load Low voltage Electric valve will not operate No power or wrong voltage Valve out of adjustment Solenoid cable disconnected or damaged Pump fails to build pressure Low oil level External system leak Internal leak in pump Internal leak in valve Internal leak in system component Relief valve set too low Pump builds less than full pressure Low oil level External system leak Internal leak in pump Internal leak in valve Internal leak in system component Relief valve set too low Pump builds full pressure but does not move cylinder Quick coupler not connected properly Defective quick connector on pump or hand piece Defective directional valve Cylinder drifts back on its own External system leak Internal leak in system component Cylinder will not return Valve malfunction Return flow or coupler restricted Leaky seal(s) in hand piece Couplings assembled backwards Tube puller does not Auto Cycle or Auto Cycles Auto Cycle mode set to OFF erratically Relief valve setting at or below "SET PRES" or "HI PRESS" value SET PRES value below 2,900 psi (200 bar) - Firmware 5.5 and earlier HI PRESS value below 1,400 psi (96 bar) - Firmware 5.6 and later Tube puller will not retract Retract flow restricted or blocked Valve malfunction Pump runs hot Advance or retract flol restricted High ambient temperature Page 17
PL19-6000EN Electric/Hydraulic Pump Assembly Figure 29 1 2 Page 18
Electric/Hydraulic Pump Assembly PL19-6000EN Figure 29 Ref Number # X EN Description 1 2902536 1 EDHP III Electric/Hydraulic Pump Assembly (Factory repair only) 2 ------ Serviceable Electrical Components 2994951 1 HDP 31 20 Receptacle 8567132 1 A 100 82 Reverse Switch 2983261 2 ATS 8835 Cable Clamp 2991255 1 ATP 9046 Cord Plug 2990688 1 A 100 95 Plug 2902574 1 PATP3 9 Plate 2902575 1 PATP3 4 BL Blank Box 8011043 4 4-20 x 3/8 Screw 2990308 1 A 100 66 Strain Relief 8010464 1 30 071 Wire Nut 8566942 1 AART 2 Receptacle 0981264PT 1 DAS2 Blank Box 2902576 1 ATP3 2 Switch 3 ------ Pump Mobility Parts mounted to Roll Cage (not shown) 2902841 1 ATP3 14 Axle 2902842 8 ATP3 15 U-Bolt 2902843 16 ATP3 16 Cap 2902844 2 ATP3 17 Caster 2902845 1 ATP3 18 Caster Bracket 2902846 2 ATP3 19 Wheel (#) Quantity (X) Recommended Spare Parts Page 19
POWER TOOLS SALES & SERVICE CENTERS Please note that all locations may not service all products. Contact the nearest Apex Tool Group Sales & Service Center for the appropriate facility to handle your service requirements. NORTH AMERICA SOUTH AMERICA Detroit, Michigan Apex Tool Group 2630 Superior Court Auburn Hills, MI 48236 Phone: +1 (248) 393-5640 Fax: +1 (248) 391-6295 Lexington, South Carolina Apex Tool Group 670 Industrial Drive Lexington, SC 29072 Phone: +1 (800) 845-5629 Phone: +1 (919) 387-0099 Fax: +1 (803) 358-7681 Louisville, Kentucky Apex Tool Group 1000 Glengarry Drive Suite 150 Fairdale, KY 40118 apexpowertools.com/service Canada Apex Tool Canada, Ltd. 7631 Bath Road Mississauga, Ontario L4T 3T1 Canada Phone: (866) 691-6212 Fax: (905) 673-4400 Mexico Apex Tool Group Manufacturing México S. de R.L. de C.V. Vialidad El Pueblito #103 Parque Industrial Querétaro Querétaro, QRO 76220 Mexico Phone: +52 (442) 211 3800 Fax: +52 (800) 685 5560 Brazil Apex Tool Group Ind. Com. Ferram, Ltda. Av. Liberdade, 4055 Zona Industrial Iporanga Sorocaba, São Paulo CEP# 18087-170 Brazil Phone: +55 15 3238 3820 Fax: +55 15 3238 3938 EUROPE MIDDLE EAST AFRICA England Apex Tool Group GmbH & Co. OHG C/O Spline Gauges Piccadilly, Tamworth Staffordshire B78 2ER United Kingdom Phone: +44 1827 8727 71 Fax: +44 1827 8741 28 France Apex Tool Group S.A.S. 25 rue Maurice Chevalier B.P. 28 77831 Ozoir-La-Ferrière Cedex, France Phone: +33 1 64 43 22 00 Fax: +33 1 64 43 17 17 Germany Apex Tool Group GmbH & Co. OHG Industriestraße 1 73463 Westhausen Germany Phone: +49 (0) 73 63 81 0 Fax: +49 (0) 73 63 81 222 Hungary Apex Tool Group Hungária Kft. Platánfa u. 2 9027 Györ Hungary Phone: +36 96 66 1383 Fax: +36 96 66 1135 ASIA PACIFIC Australia Apex Tool Group 519 Nurigong Street, Albury NSW 2640 Australia Phone: +61 2 6058 0300 Japan Apex Tool Group Japan Korin-Kaikan 5F, 3-6-23 Shibakoen, Minato-Ku, Tokyo 105-0011, JAPAN Phone: +81-3-6450-1840 Fax: +81-3-6450-1841 China Apex Power Tool Trading (Shanghai) Co., Ltd Building A8, No. 38 Dongsheng Road Pudong, Shanghai China 201201 Phone: +86 21 60880320 Fax: +86 21 60880298 Korea Apex Tool Group Korea #1503, Hibrand Living Bldg., 215 Yangjae-dong, Seocho-gu, Seoul 137-924, Korea Phone: +82-2-2155-0250 Fax: +82-2-2155-0252 India Apex Power Tools India Private Limited Gala No. 1, Plot No. 5 S. No. 234, 235 & 245 Indialand Global Industrial Park Taluka-Mulsi, Phase I Hinjawadi, Pune 411057 Maharashtra, India Phone: +91 020 66761111 Apex Tool Group, LLC 1000 Lufkin Road Apex, NC 27539 Phone: +1 (919) 387-0099 Fax: +1 (919) 387-2614 www.apexpowertools.com PL19-6000EN 0515 2015 Apex Tool Group, LLC Printed in USA