Boss Hydraulics PE08TW8 User manual

PE08TW8
OPERATING INSTRUCTIONS
Three Stage Torque Wrench Pump
WARNING
Read and follow all Safety Instructions, Warnings, Cautions and
Important information provided in this manual before using the
equipment. They are provided for the safety of those operating the
equipment and to prevent personal injury and/or damage to property
when using this equipment.
THIS EQUIPMENT SHOULD ONLY BE USED BY OPERATORS
WHO HAVE BEEN TRAINED IN THE SAFE USE OF HIGH
PRESSURE HYDRAULIC EQUIPMENT
www.bosshydraulics.com.au
Form: BM008

BM008-V1
2
WARNING:
• When using the electric pump,
stand clear of the hydraulic
oil outlet to prevent possible
personal injury or property
damage. The electric pump
must be kept away from any re
source.
• Before starting, the hose or
couplings should be fully
connected, to prevent the high-
pressure hydraulic oil causing
personal injury.
• The maximum working pressure
of the hydraulic electric pump
is 700 Bar. Never adjust the
pressure beyond the set
pressure.
• Before connecting the power to
the pump ensure the power is
turned o󰀨 at the main switch.
• Do not modify the electric pump;
if you require modications
please consult Boss Hydraulics
for authorised consent. Without
the written consent from Boss
Hydraulics, any modications are
not covered by warranty.
• Do not overll the hydraulic tank.
If the tank is overlled there is a
risk of overpressurisation.
• The wrench and the hydraulic
pump are connected by a
twin line hydraulic hose with a
working pressure of 700 bar.
Each hose has both male and
female connectors at both ends
to ensure proper connection
between the pump and the
wrench.
• In circumstances where ultra
high pressure is used incorrectly,
hydraulic oil may be ejected.
In this case hydraulic oil may
penetrate your hand, causing
serious injury. If so go straight to
the hospital.
• If the hydraulic oil is sprayed into
your eyes, immediately rinse with
water for about 15 minutes, and
then go to the hospital.

BM008-V1 3
1.2. The reccomended oil (ISO 46)
should be clean and without any
impurities. Always lter the oil
before adding to the hydraulic
oil tank. In normal use, hydraulic
oil should be replaced every 12
months.
1.3. Hydraulic electric pump
designed for use in the ambient
temperature: -10- 60°C.
1.4. All hoses and ttings connected
to this pump should have a
minmum working pressure of
700 Bar.
1.5. This pump is designed to be
used only with Hydraulic torque
wrenches.
1.6.Never use pump near ames.
1.7. Do not adjust the internal
pressure relief valve.
CAUTION:
• Only use the recommended
ISO46 grade oil.
• Do not use the pressure
regulator as a general
adjustment valve or relief
valve.
IMPORTANT:
1.1 PE08TW8 hydraulic wrench
pump is assembled using
a hydraulic pump, control
valve, oil tank, motor, cooler
and remote pendant. The
pump operates at high
working pressure. Using
a 3 stage pump it allows
for high and low pressure
pumps at the same time,
allowing for a larger output
of oil. High pressure and the
low pressure pump have
automatic unloading relief
valves, Externally there is an
adjustable releif valve that
can be set from 70- 700 Bar.

BM008-V1
4
WARNING ON USAGE OF
HYDRAULIC HOSE
1. Use only a high pressure hose
with a working pressure of 700
bar.
2. Minimum bending radius:
R> 120mm. If the bending radius
is too small it will seriously
damage the high pressure hose.
3. Maxiumum operating pressure of
700 Bar.
4. Do not wind or bend the hose
during operation as there will be
too much pressure in the tubing
which can damage the hose or
cause personal injury.
5. Do not drop or press heavy
objects on the hose; severe
shocks may cause damage to
the hose or personal injury.
6. Do not drag the pump by the
hose
1. MAINTENANCE CHECK
1. Check before operation
1.1.Check if all connections are
clean and secure.
1.2.Check whether the amount
of oil in reservoir are correct,
and check for any oil spills or
leakage.
1.3.Check the pressure of the control
valve.
1.4.Check all connections or
equipment for oil spills. If there is
an oil spill please nd the cause
and act appropriately.
1.5.Check if all hoses are safe to
use.
2. Check during operation
2.1.Operate the pump as normal to
check the controls and function.
2.2.Monitor the pump for
leaks, abnormal noices
and/or vibrations and
high temperatures. If any
abnormalities are discovered
during testing please contact
Boss Hydraulics.
3. Check after operation
3.1.The power to the pump must be
switched o󰀨.

BM008-V1 5
3.2.Check for leaks or other
abnormal conditions. If any
abnormality occures during
testing please contact Boss
Hydraulics.
3.3.Clean after use and remove any
contamination.
4. Check the oil levels and
replenish whenever required. If
any of the following conditions
occur, replace it immediately:
4.1.When the oil becomes
contaminated.
4.2.When the smell of the oil
changes.
4.3.When water enters the reservoir.
WARNING:
If oil splashes into your
eyes, rinse immediately with
water for at least 15 minutes. If
the oil splashes on your skin,
wash it with water and soap.
1. MAINTENANCE CHECK (CONT)
5. Replacing hydraulic oil
5.1.Loosen the oil lter port of the oil
reservoir.
5.2.Remove the drain plug/ screw
at the front of the oil reservoir to
drain the oil.
5.3.Clean the oil lter and reservoir.
5.4.Install the drain plug/ screw and
ll the oil reservoir with new
recommended oil but do not
overll above indicated line.

BM008-V1
6
2. ASSEMBLY DIAGRAM
No. Item No. Item
1 Oil tank 8 Oil unloading hole
2 Pressure setting valve 9 Electronic control system
3 Pressure gauge 10 Tank cover
4 Protection frame 11 Direction valve
5 Motor 12 Quick coupler
6 Cooler 13 valves
7 Level gauge 14 Hole for oil adding &Ventilation

BM008-V1 7
3. OPERATION INSTRUCTIONS OF THE PUMP
1. Ensure the tank is lled with
standard clean hydraulic oil. Use
only ISO 46 anti-wear hydraulic
oil. Do not ll the oil over the
warning line. Ensure ller
breather cap is replaced and
tightened.
2. Check and ensure that the
quick connectors are clean and
have no damage. Connect the
couplings from the high pressure
hose to both the pump and the
tool, ensuring that the couplings
are fully engaged.
3. Remote control handle operation
instructions:
3.1. There is one jog button to
advance and retract (cycle the
wrench) and one ON/OFF switch
on the remote control pendant.
5.2. Press the ON / OFF switch
into the ON position and the
hydraulic electric pump will start.
5.3. To advance the tool hold down
the Advance/Retract jog button
5.4. Release the button to retract the
tool.
5.5. Repeat steps 3-4 until output
torque is reached
5.6. Press the ON/OFF switch into
the OFF position to stop the
motor.
IMPORTANT:
Note that after a short period
of no use the motor will
automatically switch o󰀨. To
start press the Advance /
Retract jog button again.

BM008-V1
8
1. The PE08TW8 is a three-
stage pump, each stage will
automatically change as the
pressure increases, The rst
stage will provide maximum
ow up to a pressure of
approximately 60 bar. The
second stage will provide
less ow up to a pressure of
approximately 280 bar. The third
stage will provide the smallest
ow output until the input
pressure has been reached up
to maximum of 700 bar.
2. The pump is a radial piston
pump design with pistons in
a symmetrical arrangement,
so that the pump structure is
compact, and stable.
3. All of the control valves in the
pump are equipped with a fully
integrated cartridge valves
4. The electric pump has an
integrated circuit board. This
integrated circuit board allows
for, simple operation, and
maximum safety. Some of these
features are as follows;
4.1.The hydraulic electric pump
will turn o󰀨 after no operation
has been received after
approximately 30 secs.
1. When using the pump all hoses
and couplings must be fully
connected.
2. Never try and increase the
pressure beyond the maximum
working pressure of the pump.
3. Always disconnect the power
before working on the pump.
4. When the pump station is in
operation, the oil returned to the
tank may be pressurized; if the
tank cover is opened at this time, it
may cause unnecessary damage
and injury;
5. Never run the pump without oil
6. Always clean ttings and couplings
before connecting in the pump
circuit.
WARNING:
3. OPERATION INSTRUCTIONS OF THE PUMP (CONT)
3a. Pump Features:
4.2.Hydraulic electric pump will
automatically remove system
pressure.
4.3.Motor overload protection and
alarm circuit.

BM008-V1 9
4. HYDRAULIC SCHEMATIC DIAGRAM

BM008-V1
10
4. TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Can’t be started
Voltage is not suitable
Check whether the supply
voltage meets the pump
station requirements
Not connected to
electricity
Check the power supply,
power connection, etc., turn
on the power
No pressure
Quick couplers not well
connected Disassemble and reconnect
No oil in the tank Add oil to the tank
There is not enough oil
inside the tank Add oil to the tank
Oil leaking at
couplers
O rings & stop rings
damaged. Replace the coupler
When static
pressure is used,
the pressure
drops slowly
Seal failure, check the
seals Replace the seals

BM008-V1 11
4. TROUBLESHOOTING (CONTINUED)
PROBLEM CAUSE SOLUTION
Cannot reach set
pressure
The relief valve is too
low
Pressure gauge detection,
relief valve transferred to the
system value
Oil mixed with oil Change the hydraulic oil
Oil inside the tank is not
enough Add oil
Air in system
Air run the system
repeatedly several times,
exhaust air
Throttle, manual check
valve is not in place Adjust to the correct position
Throttle valve, manual
check valve is damaged Replace the valves
The hydraulic oil
contains impurities
Clean the pump valve blocks
and replace with clean oil.

BOSS HYDRAULICS:
Head Ofce: 19 Ricketts Road, Mt Waverley VIC 3149 I P: 1300 BOSS HYD (1300 267 749)
E: [email protected] I W: www.bosshydraulics.com.au