Atlas Copco D500 Instruction sheet

D500 HP Hydraulic Air Pump
Printed Matter No. 9839 2189 01 Pneumatic Pump
Publication Date 2020-09-07
Valid from Serial No. - Product Instructions
D500 HP Hydraulic Air Pump 8434220006
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and instructions may result in
electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference

2© Atlas Copco Industrial Technique AB - 9839 2189 01
Table of Contents
Product Information................................................................................................3
General Information ..........................................................................................3
Warranty ................................................................................................3
Website..................................................................................................3
ServAid ..................................................................................................3
Safety Data Sheets MSDS/SDS............................................................4
Country of Origin ...................................................................................4
Dimensional Drawings...........................................................................4
Overview...........................................................................................................4
Introduction............................................................................................4
Precautions............................................................................................4
Atlas Copco Air Driven Pump Unit.........................................................4
Technical Product Data .........................................................................4
Service Overview..............................................................................................4
Service Recommendations....................................................................4
Installation ...............................................................................................................6
Installation Instructions .....................................................................................6
Before Connecting the Air Supply .........................................................6
Pump Preparation..................................................................................8
Safety On/Off Valve...............................................................................9
Operation ...............................................................................................................10
Ergonomic Guidelines.....................................................................................10
Operating Instructions.....................................................................................10
Pump Operation ..................................................................................10
Shut down procedure ..........................................................................13
Adjustment of Pressure Release Valve (PRV) ....................................13
Service ...................................................................................................................14
Maintenance Instructions................................................................................14
Service Recommendations..................................................................14
Lubrication Instructions...................................................................................14
Hydraulic Fluid.....................................................................................14
Repair Instructions..........................................................................................15
Hydraulic Pump Seal Replacement.....................................................15
Troubleshooting....................................................................................................23
Troubleshooting ..............................................................................................23

D500 HP Hydraulic Air Pump EN Product Information
© Atlas Copco Industrial Technique AB - 9839 2189 01 3
Product Information
General Information
WARNING Risk of Property Damage or Severe Injury
Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow
all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.
►Read all Safety Information delivered together with the different parts of the system.
►Read all Product Instructions for installation, operation and maintenance of the different parts of
the system.
►Read all locally legislated safety regulations regarding the system and parts thereof.
►Save all Safety Information and instructions for future reference.
Warranty
■Product warranty will expire 12 months after the product is first taken into use, but will in any case ex-
pire at the latest 13 months after delivery.
■Normal wear and tear on parts is not included within the warranty.
■Normal wear and tear is that which requires a part change or other adjustment/overhaul during
standard tools maintenance typical for that period (expressed in time, operation hours or other-
wise).
■The product warranty relies on the correct use, maintenance, and repair of the tool and its component
parts.
■Damage to parts that occurs as a result of inadequate maintenance or performed by parties other
than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the
warranty.
■To avoid damage or destruction of tool parts, service the tool according to the recommended mainte-
nance schedules and follow the correct instructions.
■Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.
Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover
contracts. For further information contact your local Service representative.
For electrical motors:
■Warranty will only apply when the electric motor has not been opened.
Website
Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on
the Atlas Copco website.
Please visit: www.atlascopco.com.
ServAid
ServAid is a portal that is continuously updated and contains Technical Information, such as:
■Regulatory and Safety Information
■Technical Data
■Installation, Operation and Service Instructions
■Spare Parts Lists
■Accessories
■Dimensional Drawings
Please visit: https://servaid.atlascopco.com.

Product Information EN D500 HP Hydraulic Air Pump
4© Atlas Copco Industrial Technique AB - 9839 2189 01
For further Technical Information, please contact your local Atlas Copco representative.
Safety Data Sheets MSDS/SDS
The Safety Data Sheets describe the chemical products sold by Atlas Copco.
Please consult the Atlas Copco website for more information www.atlascopco.com/sds.
Country of Origin
For the Country of Origin, please refer to the information on the product label.
Dimensional Drawings
Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.
Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.
Overview
Introduction
The operating and maintenance procedures listed within this manual should be adhered to and will enable
the operator to obtain maximum efficiency and reliability from the equipment.
Precautions
Prior to connecting the hydraulic pump to any equipment, the user is to ensure that :
■The working pressure of the hydraulic pump and the equipment to be operated are compatible. i.e.
maximum working pressure of the hydraulic tensioning tools, hydraulic connections & hydraulic
hoses.
■The reservoir pump capacity is adequate to operate the equipment throughout its range.
The hydraulic oil specification used within the pump and the equipment are compatible.
Atlas Copco Air Driven Pump Unit
Atlas Copco air driven pump units operate on the simple but efficient principle of power magnification
through the use of differential areas. A relatively large air-operated piston drives the smaller piston, which
provides fluid flow at high pressures. All Atlas Copco air driven pump units are fitted into an easily trans-
portable, tubular steel frame.
The pump units are available, fitted with a large choice of pressure gauges and are supplied complete with
an air pressure regulator which can be set to stall the pump unit when it reaches the pressure required for
each particular tensioning application.
Technical Product Data
Technical Product Data can be found on either ServAid, or the Atlas Copco website.
Please visit: https://servaid.atlascopco.com or www.atlascopco.com.
Service Overview
Service Recommendations
Preventive maintenance is recommended at regular intervals. See the detailed information on preventive
maintenance. If the product is not working properly, take it out of service and inspect it.

D500 HP Hydraulic Air Pump EN Product Information
© Atlas Copco Industrial Technique AB - 9839 2189 01 5
If no detailed information about preventive maintenance is included, follow these general guide-
lines:
■Clean appropriate parts accurately
■Replace any defective or worn parts

Installation EN D500 HP Hydraulic Air Pump
6© Atlas Copco Industrial Technique AB - 9839 2189 01
Installation
Installation Instructions
Before Connecting the Air Supply
It is strongly recommended that the pump is regulated in order to stall at the required tensioning pressure.
This is achieved by adjustment of the air regulator valve.
Before connecting an air supply, it is important to check the following,
■The pressure release valve is fully open (rotated fully anti-clockwise).
■The On /Off valve is off (In the horizontal position). The On/OFF valve is by default closed until manu-
ally operated and held.
■The oil Tank has sufficient oil (Grade ISO 10, 32, 68).
■Check that the cap seal plug has been removed.
The oil tank on this pump unit is fitted with a cap seal plug to prevent oil spillage during transit. Re-
move the M6 cap screw and seal from tank cap prior to use.The oil tank on this pump unit is fitted
with a cap seal plug to prevent oil spillage during transit. Remove the M6 cap screw and seal from
tank cap prior to use.
■In the event of the pump being used at sub-zero temperatures, add deicer additives to the oil to pre-
vent the oil from freezing.
Setting pump stall pressure
1. Atlas Copco supply all pump units with the air pressure regulator set to stall the pump at its maximum
working pressure. Connect the main air supply to the pump unit. Slowly activate the safety On/Off
valve by holding the control down, the pump will begin to operate, no pressure can be generated be-
cause the pressure release valve is open, so the oil is simply circulated through the system back to
the tank.
2. Before adjusting the pressure on the air filter/regulator, it is necessary for the ‘Snap Action Lock’ to
be in the up position. By turning the adjustment knob anticlockwise on the regulator, reduce the air
pressure to zero PSI, the pump will slow down considerably and may even stop.

D500 HP Hydraulic Air Pump EN Installation
© Atlas Copco Industrial Technique AB - 9839 2189 01 7
3. Fully close the pressure release valve by rotating clockwise to stop. As this is done, a slight pressure
will be generated on the pressure gauge and the pump will finally stall.
4. Slowly increase the air supply pressure by turning the adjustment knob clockwise, the oil pressure
gauge will indicate a higher pressure as more and more air is allowed into the pump unit. Stop the air
adjustment when the oil pressure gauge indicates the desired tensioning pressure.
5. Stop the pump by releasing the On/Off valve and release the pressure by slowly opening the pres-
sure return valve, the pump gauge will fall to zero. Lock the air regulator by pushing down on to the
‘Snap Action Lock’.
Operate the pump again and allow it to stall, check the pressure and further adjust if necessary. When sat-
isfied that the pump stall pressure is correct the pump unit is now ready for the tensioning operation.

Installation EN D500 HP Hydraulic Air Pump
8© Atlas Copco Industrial Technique AB - 9839 2189 01
Pump Preparation
1. Ensure the pressure release valve is in the open position (rotate anti-clockwise to stop). The pres-
sure relief valve is fitted with a torque limiter to prevent over tightening it. Limiter will ‘Click Out’ as a
preventative measure.
2. Ensure the On/Off valve is in the off position.
3. Connect the air hose to the air inlet connector. Give the hose a sharp tug afterwards, to ensure a
solid connection.

D500 HP Hydraulic Air Pump EN Installation
© Atlas Copco Industrial Technique AB - 9839 2189 01 9
4. Connect the hydraulic link hose to the female quick connector. (Refer to the operation manual sup-
plied with your tensioners for correct hydraulic link hose configuration)
5. Ensure an adequate volume of oil is contained in the Oil Tank.
Safety On/Off Valve
The pump unit is fitted with a safety On/Off valve. The spring loaded valve defaults to off when the valve
handle is untouched. Holding the valve handle in the down position turns the pump on. Releasing the han-
dle turns the pump off.

Operation EN D500 HP Hydraulic Air Pump
10 © Atlas Copco Industrial Technique AB - 9839 2189 01
Operation
Ergonomic Guidelines
Consider your workstation as you read through this list of general ergonomic guidelines to identify areas
for improvement in posture, component placement, or work environment.
■Take frequent breaks and change work positions frequently.
■Adapt the workstation area to your needs and the work task.
■Adjust for a convenient reach range by determining where parts and tools need to be located to
avoid static load.
■Use workstation equipment such as tables and chairs appropriate for the work task.
■Avoid work positions above shoulder level or with static holding during assembly operations.
■When working above shoulder level, reduce the load on the static muscles by lowering the weight
of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce
the load on the static muscles by holding the tool close to the body.
■Take frequent breaks.
■Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.
■Adjust for a convenient field of vision that requires minimal eye and head movements.
■Use appropriate lighting for the work task.
■Select the appropriate tool for the work task.
■In noisy environments, use ear protection equipment.
■Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibra-
tion.
Operating Instructions
Pump Operation
1. Close the pressure release valve (clockwise).

D500 HP Hydraulic Air Pump EN Operation
© Atlas Copco Industrial Technique AB - 9839 2189 01 11
2. Hold down the On/Off valve. The pressure gauge will slowly indicate pressure.
WARNING It is recommended that the pressure should never exceed 90% of the Gauge’s
maximum pressure rating.

Operation EN D500 HP Hydraulic Air Pump
12 © Atlas Copco Industrial Technique AB - 9839 2189 01
3. Once the desired pressure is reached, release the On/Off valve. The valve will spring back to the Off
position. Check the pressure reading on the oil pressure gauge. (Ensure the pressure is holding
steady before approaching any pressurised bolt tensioning equipment).

D500 HP Hydraulic Air Pump EN Operation
© Atlas Copco Industrial Technique AB - 9839 2189 01 13
4. To release the hydraulic pressure slowly open the pressure release valve (anticlockwise), the pres-
sure will slowly fall.
Shut down procedure
1. Disconnect the main air supply.
2. Open the oil pressure release valve.
3. Open the On/Off valve (air will vent through the exhaust).
4. Close the On/Off valve
5. Drain water from the air filter
6. Top-up the oil tank
7. Store in pump box supplied.
Adjustment of Pressure Release Valve (PRV)
The PRV is factory set to vent air should the pump over pressurise. Adjustment is not necessary.

Service EN D500 HP Hydraulic Air Pump
14 © Atlas Copco Industrial Technique AB - 9839 2189 01
Service
Maintenance Instructions
Service Recommendations
Preventive maintenance is recommended at regular intervals. See the detailed information on preventive
maintenance. If the product is not working properly, take it out of service and inspect it.
If no detailed information about preventive maintenance is included, follow these general guide-
lines:
■Clean appropriate parts accurately
■Replace any defective or worn parts
Lubrication Instructions
Hydraulic Fluid
The performance of hydraulic equipment is heavily dependent on the quality and characteristics of the hy-
draulic fluid selected for use. The choice of the specification and viscosity of the hydraulic fluid should be
based of the conditions of use, taking into account several factors as follows:
■The range of environmental temperature.
■The range of oil viscosity defined for the equipment.
■The application (range of pressures, sources of contamination of the hydraulic fluid, the type of pump,
etc.)
■The ease of getting a proper replacement or equivalent hydraulic fluid.
Example: ISO Grade 15, 32 and 68.
For changing or refilling the oil, it is recommended to use the same oil as supplied with the pump.

D500 HP Hydraulic Air Pump EN Service
© Atlas Copco Industrial Technique AB - 9839 2189 01 15
Hydraulic Oil Selection Chart
Please use the link below to find our safe data sheets for Maximizer.
https://www.atlascopco.com/en-uk/sys/safetydatasheets
Repair Instructions
Hydraulic Pump Seal Replacement
This section states how the internal seals within the hydraulic pump are replaced. See alsoDimensional
Drawings [Page4] of hydraulic pump. If the users have any issues, please contact Atlas Copco directly for
assistance.

Service EN D500 HP Hydraulic Air Pump
16 © Atlas Copco Industrial Technique AB - 9839 2189 01
To Disassemble the Air Motor
Item No. Part No. Description
1 P10212-031 Washer-lock
2 11-5007AO00 End
3 11 -5181P000 Cylinder-air
4 11-5048A000 Piston-air
5 P11000-429 O-ring
6 P11000-252 O-ring
7 11-5047N000 Bearing assembly
8 P11000-231 O-ring
9 P11000-028 O-ring
10 11-5178A000 APA valve assembly
11 11-5057P000 Bumper
12 11-5005M000 Spring
13 11-5060A000 Pilot valve assembly
14 11-5112A000 Head
15 11-5012N000 Bumper
16 P11000-214 O-ring
17 P11000-144 O-ring
18 P10214-031 Washer-flat

D500 HP Hydraulic Air Pump EN Service
© Atlas Copco Industrial Technique AB - 9839 2189 01 17
Item No. Part No. Description
19 12-R262S000 Retaining ring
20 P11000-223 O-ring
21 P10231 Bolt-hex
22 12-R200S000 Retaining ring
23 12-31CNFH1Z Nut-hex
24 11-5172N000 Plug
25 12-25C313CPSS Set screw-hex socket
Air Motor Assembly Parts List
1. Remove the 5/16” bolts (8 off), (Item 21), that clamp the air cylinder, (Item 3), between the head,
(Item 14), and the air cylinder end, (Item 2). Remove the head by tapping on a fitting screwed into ei-
ther the “AIR IN” or the “AIR OUT” ports with a soft hammer.
When removing retaining rings care must be taken not to damage the groove in which they sit.
Damage to the groove can decrease the holding effectiveness and may allow the retaining ring
to become disengaged during operation. Careless removal of the retaining rings can damage
the groove creating “BURRS”. These “BURRS” can migrate throughout the air motor assembly
causing major damage to all internal components.
2. Remove the retaining ring, (Item 22), from the bottom of the air piston, (Item 4), and remove the hy-
draulic piston, (item 14) of the hydraulic assembly . The pilot valve assembly, (Item 13), may then be
pushed out through the bottom of the air piston.
3. Remove the retaining ring, (Item 19), from the head assembly. Remove the bearing assembly, (Item
7), by lifting or prying it out with a hammer handle or similar tool. The APA piston, (Item 10), may also
be removed at this time. The Bearing assembly has a moulded rubber seat and should be replaced if
worn or damaged. The “O” ring, (Item 20), in the bearing assembly, the “O” Ring, (Item 9), in the up-
per part of the air piston actuating valve, and the “O” rings* on the pilot valve assembly head should
be replaced as a routine matter while the pump is disassembled as they are especially important for
maximum performance.
For o rings on the pilot valve refer "Repairing the Pilot Valve Assembly".
4. The head assembly has a rubber bumper, (Item 15), inserted in the upper portion of the body. This
acts as an air seal and a cushion for the air piston actuating valve. If worn or damaged, it should be
replaced.
5. When the dry seal, (Item 5), and the “O” rings, (Item 16), are worn or damaged they need to be re-
placed. Slide the dry seal off the air piston, (Item 4). When installing the dry seal, (Item 5), and the
“O” rings, (Items 8 and 17), a small amount of silicone grease or other suitable lubricant should be
applied.
Do not remove the APA sleeve, (Item 10), from the head casting unless replacement is to be
made.

Service EN D500 HP Hydraulic Air Pump
18 © Atlas Copco Industrial Technique AB - 9839 2189 01
Repairing the Pilot Valve Assembly
Item No Part No. Description
1 12-R093S000 RETAINING RING
2 P11000-216 O- ring
3 P11000-214 O-ring
4 11-5016M000 Spring
5 11-5049A000 Valve body
6 11-5032X403 Air check assembly
7 11-5024A403 Seat
Pilot Valve Assembly Parts List
1. The pilot valve assembly, has an air check assembly (item 6), located in the lower end.
2. Remove the retaining ring(item 1), which locks the valve seat(item 7), in place and remove the valve
seat with a spanner wrench.
3. The air check assembly, and the Spring(item 4), will then drop out and may be inspected for wear or
damage.
4. Replace the springs(item 4) and worn parts as required.
5. When installing the spring, in the air check assembly, the assembly should be screwed together until
the component parts are drawn up just snuggly with no travel in the bolt assembly and then the nut
should be backed off one complete turn for proper adjustment.
6. When the assembly adjustment has been done correctly, the valve will open approximately 1/32 inch
when the bolt assembly is depressed to open the valve.

D500 HP Hydraulic Air Pump EN Service
© Atlas Copco Industrial Technique AB - 9839 2189 01 19
To Replace the Packing in the Hydraulic Cylinder
Item No. Part No. Description
1 11-5007S407 Retainer
2 11 -50 14S000 Spring
3 P110 03-11 0 O ring
4 12-0440S437 Check ball
5 11-5021S000 Seat inlet
6 11 -5034 S001 Ball guide
7 P11000-113 O ring
8 11-5028N000 Gasket
9 P1 1227-111 Back up
9 P11227-110 Back up
9 P11227-011 Back up
9 P11227-010 Back up
10 11-5051P000 Piston bumper
11 12-25 N87W F 1Z Fender washer
12 12-25F37SBC45Z Button head cap screw
13 P10212-025 Helical spring lock washer
14 11-5010S080(140:1) Hydraulic piston
14 11-5010S100(195:1) Hydraulic piston
14 11-501OS160 (280:1) Hydraulic piston
14 11-5010S250(440:1) Hydraulic piston
15 P1 1000 -1 11 O ring
15 P 11000 -1 1 0 O ring
15 P1 10 00-0 11 O ring

Service EN D500 HP Hydraulic Air Pump
20 © Atlas Copco Industrial Technique AB - 9839 2189 01
Item No. Part No. Description
15 P1 10 00-0 10 O ring
16 11-5 0 11B0 80 (140:1) Hydraulic cylinder
16 11-5 011 B1 00 (195:1) Hydraulic cylinder
16 11-5 0 11B1 60 (280:1) Hydraulic cylinder
16 11- 5011B250 (440:1) Hydraulic cylinder
17 11-5022S000 Seat outlet
18 P102 02-050 Retaining ring
19 11 -50 1 8S000 Spring guide
Hydraulic Assembly Parts List
It is not necessary to dismantle the air motor. Use the air motor and hydraulic assembly cross sections
and parts lists as reference.
1. Disconnect the air supply line, remove the muffler if necessary and loosen the set screw (Item 25) in
the air cylinder end, (Item 2).(Refer air motor assembly parts list)
2. Unscrew the air motor from the hydraulic cylinder.
3. The hydraulic piston will be removed with the air motor, permitting convenient replacement of the
packing in the hydraulic cylinder.
4. Replace the backup rings and the “O” rings.
5. Refer hydraulic assembly parts list table for the size and kind of packing required, and when installing
new packing, be sure that the backup rings are properly in place. If they are damaged or not installed
correctly, the “O”ring will malfunction, with resultant loss of pressure and packing failure. When re-
placing the air motor, install a new gasket(item 8) and see that the hydraulic piston is in proper align-
ment before screwing the air motor down into position. Tighten the air motor securely and the set
screw (Item 25 from air motor assembly parts list ), in the air cylinder end.
Models with isolator attachment or “V” ring packing in the hydraulic cylinder will require removal
of the isolator or the adapter on “V” ring packed cylinders to replace the packing.
The Hydraulic Piston
The Hydraulic Piston has a rubber bumper(Item 10), in the head. If replacement is required remove the
cap screw(item 12) and install new rubber bumper and washers(item 13 and item 11). Apply “LOCTITE”
sealant to the cap screw threads when replacing and tighten securely, but not to exceed 4 Lbs.ft (5.50
Nm) max of torque.