Durapac PAT-1114 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Air Torque Wrench Power Unit
Model –PAT-1114

Instruction Manual
PAT-1114 Power Units - V1.1 www.durapac.com Page 2 of 15
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –Air Torque Wrench Power Units are engineered to meet Industrial Standards for
Performance and Safety. The PAT Series Torque Wrench Power Units are perfectly designed for
operating the TW and LPC Series Hydraulic Torque Wrenches.
Liquid filled pressure gauge has 1% accuracy and can be recalibrated. Scale is mpa/psi
Roll cage for portability and protection
Air motor 1.1kW Ingersoll Rand®
6 metre remote pendant incorporates a motor ON/OFF button and ADVANCE/AUTO
RETRACT button
Adjustable torque control for accurate torque settings
Oil cooler keeps oil cool during heavy duty operation
Multiple tool outlets for operating one or two tools simultaneously
3 stage pump for increased speed under load
Air filter/lubricator for efficient operation
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your power unit’s suitability for a particular application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any power unit that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any power unit that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.
3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should have an understanding of this product and safe operating procedures
before attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.
DANGER:
To avoid personal injury keep hands and feet away from work area during operation

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Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin
causing serious injury. If oil is injected under the skin, see a doctor immediately
Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be blocked mechanically
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. It is your window to what is happening in the system
Always wear protective gear when operating hydraulic equipment. The operator must
take precaution against injury due to failure of the tool or work piece(s)
Do NOT hold or stand directly in line with any hydraulic connections while pressurising
Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
All personnel must be clear before lowering load or depressurising the system
Do NOT attempt to lift a load weighing more than the capacity of the cylinder
IMPORTANT:
If at any stage, the safety related decals become hard to read, these must be replaced
Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high quality hydraulic oil
CAUTION:
KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
No alteration should be made to this device
3.1 Hydraulic Power Units
Ensure that the air source is SWITCHED OFF prior to connection of hoses and other
hydraulic equipment or prior to any repairs being undertaken
Do use a gauge or other load measuring instrument to verify load

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Do NOT exceed the rated capacity of the power unit or any equipment in the system.
Burst hazard exists if connection pressure exceeds rated pressure
Regularly inspect power unit, hoses and connections before each use to prevent
unsafe conditions from developing. Do NOT use if they are damaged, altered or in
poor condition. Do NOT operate the system with bent or damaged coupler or
damaged threads
Do NOT subject the power unit and its components to shock loads
Use only Durapac approved accessories and components
Ensure that the chosen application is stable to work on and around
Do NOT connect to an application which can return more oil to the reservoir than the
power unit reservoir can hold
Do NOT connect power unit to a hydraulic system that is powered by another pump
3.2 Hydraulic Hoses & Fluid Transmission Lines
Avoid short runs of straight line tubing. Straight line runs do not provide for expansion
and contraction due to pressure and/or temperature changes
Ensure that the minimum bending radius is greater than 120 mm
Reduce stress in tube lines. Long tubing runs should be supported by brackets or clips.
Before operating the power unit, connections should be tightened securely and leak-
free. Over tightening can cause premature thread failure or high pressure fittings to
burst
Should a hydraulic hose ever rupture, burst or need to be disconnected, immediately
shut off the power unit and release all pressure. Never attempt to grasp a leaking
pressurised hose with your hands. The force of escaping hydraulic fluid can inflict
injury
Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme heat
or cold or heavy impact
Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid
flow within the hose is blocked or reduced. Periodically inspect the hose for wear
Do NOT pull, position or move setup by the hose
Hose material and coupler seals must be compatible with the hydraulic fluid used.
Hoses also must not come in contact with corrosive materials such as battery acid,
creosote-impregnated objects and wet paint. Never paint a coupler or hose
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
4.0 Installation
IMPORTANT: Always secure threaded port connections with high grade, non-hardening pipe
thread sealant. Teflon tape can be used if only one layer of tape is used and it is applied

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carefully, two threads back, to prevent the tape from being introduced into hydraulic system,
which could cause jamming of precision-fit parts
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your power unit, its limitations and how it operates before attempting to use.
Refer to the specification chart below or if in doubt, contact a Durapac representative.
4.2 Ensure that there is adequate oil in the reservoir to perform the required function.
Ideally the gauge should not read less than 1/3. If this is the case see section 6.1
Adding Hydraulic Fluid.
4.3 Hydraulic connections –check all system fittings and connections to be sure they are
tight and leak free.
The wrench and power unit are connected by a 700 bar operating pressure, twin-line
hose assembly. Each end of the hose will have one male and one female connector to
ensure proper connection between the power unit and the wrench.
Figure 1 –Hydraulic Connectors
4.4 Air connection - connect suitable air supply to air input port. Ensure that your air source
can dedicate 1,400 Lpm @ 6.2 bar to each power unit being operated.
4.5 Remove air from the system –Air can accumulate in the hydraulic system during the
initial setup or after prolonged use, causing the cylinder to respond slowly or in an
unstable manner. Should removal of air from pump be required, please follow the
steps in 6.2 –Bleeding Air from the System in the Maintenance Section.
5.0 Operation
IMPORTANT:
To reduce the risk of personal injury and/or property damage, Hydraulic connections
must be securely fastened before building pressure in the system. Release all system
pressure before loosening any hydraulic connection in the system
When only using one hydraulic torque wrench, cover the unused hydraulic coupling
1st Stage
0-70 bar
2nd Stage
70-300 bar
3rd Stage
300-700 bar
PAT-1114 700 1.1 kW Air 7 1.6 0.8 7.4 27
Model
Number
Pressure
Rating
(bar)
Motor
Flow (Lpm)
Oil
Capacity
(L)
Dry
Weight
(kg)

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with a metal dust cap or plug the unused port
Always monitor pressure, load or position using suitable equipment. Pressure may be
monitored by means of an optional manifold and gauge. Correct application position
can only be determined by the operator of the equipment
Do NOT operate a power unit that is disconnected from the application. If operated in
this condition, the hose and connections will become pressurised. This increases the
chance of a burst hazard. Damage may also occur to the pump and its components
The power unit is designed for indoor use, please protect from the rain if used outside
Durapac Air Torque Wrench Power Units have been specifically designed to integrate
seamlessly with Durapac TW and LPC-Series Torque Wrenches. There is a 2-way, 4 position
air control valve on the pump. Port A is a high pressure port - it delivers the oil at a high
pressure. Whereas Port B is a low pressure port that delivers the oil at a low pressure.
5.1 Prior to operation, loosen the high pressure valve for adjusting pressure.
Figure 2 –Adjust Pressure
5.2 Connect the air supply.
5.3 Press the motor ON/OFF button on the remote control pendant to start the power unit.
The power unit directional valve will automatically be in retract mode at this stage.
5.4 Press the ON button on the remote control pendant to advance the tool. At this stage
the high pressure adjusting valve can be increased to the operator’s predetermined
pressure setting.
When the desired pressure is reached, the motor will stop and the pressure will be
maintained. When the pressure drops, the motor will automatically restart.
5.5 If oil cooling is required, move the air exhaust valve switch to the horizontal position.
This will direct the exhaust through the oil reservoir cooler.
Figure 3 –Oil Cooling
In cold environments the air exhaust valve switch should be left in the vertical position.

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Figure 4 –Non- Cooling
5.6 When the motor is operating, press the OFF button on the remote control pendant to
stop the motor. The piston and pressure will also be stopped at the position when the
motor stopped working. When the pressure drops, the motor will not automatically
restart.
5.7 After completion, press the rubber button on top of the air control valve in order to
release the pressure in the hoses and equipment. Disassemble components as required
and replace safety caps on the couplers.
6.0 Maintenance
IMPORTANT:
Check oil level regularly
Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the pump, hose, and application. We
recommend Durapac Hydraulic Oil or equivalent
Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre
Tighten connections as needed. Use non-hardening pipe thread compound when
servicing connections
Damage to hydraulic hoses may not be detected during visual inspections. For this
reason, Durapac recommends that hydraulic hoses be replaced on a regular basis
Ensure that the air source of the pump is shut off before beginning any maintenance
or repairs
Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and
free of foreign matter. After each use, clean couplings and attach dust caps.
Maintenance is required when wear or leakage is noticed. Periodically inspect all
components to detect any problem that may require service and maintenance.
6.1 Adding Hydraulic Fluid
WARNING: Always add oil with cylinders fully retracted (or extended, if pull cylinders) or
the system will contain more oil than the reservoir can hold
WARNING: Disconnect equipment before adding oil and never over fill the reservoir

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6.1.1 Depressurise and disconnect hydraulic hose from application/cylinder.
6.1.2 Clean the area around the filler cap. Any dirt or grime in the hydraulic oil can
damage the internal workings of the power unit.
6.1.3 Remove the filler cap located on the top plate of the reservoir.
6.1.4 Use a small funnel to fill the reservoir to within 25mm (1") from the top of
the filler hole.
6.1.5 Bleed air from system if necessary.
6.1.6 Wipe up any spilled fluid and reinstall the filler cap.
6.2 Bleeding Air from the System
6.2.1 Repeat Steps 6.1.1 to 6.1.4 (above), if required.
6.2.2 Cycle the power unit (with hydraulic torque wrench attached) several times.
6.2.3 Retract the hydraulic torque wrench. Air will be released into the pump
reservoir.
6.2.4 Recheck oil level after removing air.
6.3 Changing Hydraulic Fluid
For best results, change fluid once a year or every 300 hours of use
6.3.1 Repeat Steps 6.1.1 to 6.1.3 (above).
6.3.2 Pour used fluid into a sealable container.
6.3.3 Repeat Steps 6.1.4 to 6.1.6 (above).
6.3.4 Dispose of fluid in accordance with local regulations.
6.4 Storage
6.4.1 When not in use, depressurise and disconnect the hydraulic pump from the
application.
6.4.2 Wipe clean thoroughly and store in a clean, dry environment. Avoid
temperature extremes.
6.4.3 For transportation or long storage, replace the air vent plug with shipping
plug.
6.4.4 Shield pump with a protective cover.

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7.0 Troubleshooting
Problem
Cause
Solution
Power unit cannot be started
Unsuitable air source
Ensure the air supply meets
the power unit’s
specifications
Air source is not connected
Connect air source
Power unit has no pressure
Loose couplers
Tighten couplers
Faulty couplers
Replace couplers
Oil level too low
Refer to 6.1 –Adding
Hydraulic Fluid
Faulty pressure gauge
Replace gauge
Hydraulic couplers have a
vacuum lock
Check hydraulic couplers to
hydraulic torque wrench
Inspect couplers to ensure
they are completely
coupled
Replace couplers if
damaged
Leaking couplers
O-ring is worn or missing in
the female couplers
Replace the couplers
Power unit cannot reach the
rated pressure
Pressure is adjusted too low
for the high-pressure valve
Check the gauge
Adjust to rated value
Oil is mixed with water
Refer to 6.3 –Changing
Hydraulic Fluid
Malfunctioning pressure relief
valve
Replace pressure relief
valve
Loose high-pressure valve
Tighten valve
Air in system
Refer to 6.2 –Bleeding Air
from the System
Power unit emits a loud noise
while operating
Bearings worn or broken
Replace bearing(s)
Air in system
Refer to 6.2 –Bleeding Air
from the System
High pressure flow is reduced
Piston or springs may be
broken
Replace piston assembly
Loose couplers
Tighten couplers
Oil level too low
Refer to 6.1 –Adding
Hydraulic Fluid
Oil too cold
Control the temperature to
at least -10°C
Dirt in pump or filter is
clogged
Replace filter and clean tank

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8.0 Parts Breakdowns and Lists
8.1 Dimensional Drawing
Item Description Qty Item Description Qty
1 Oil reservoir 1 9 Roll cage 1
2 Bolt 1 10 Hydraulic couplers 1
3 Air motor 1 11 Regulating valve 1
4 Oil/water seperator 1 12 Oil gauge 1
5 Air input valve 1 13 Oil drain plug 1
6 Radiator 1 14 Screw 1
7 Air valve 1 15 Metal plate 1
8 Pressure gauge 1 16 Oil filling port 1

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8.2 Power Unit
Item Description Qty Item Description Qty
1 Oil reservoir 1 8 Pneumatic control valve 1
2 Pump 1 9 Subplate 1
3 Oil return pipe 1 10 Male elbow 1
4 Petrol pipe 1 11 Nylon tube (500mm long) 1
5 Oil return pipe 1 12 Air supply bracket 1
6 Cooling pipe 1 13 Female bulkhead fitting 1
7 Oil/water separator 1 14 Reservoir gasket 1

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8.3 Explosion of the Pump
Item Description Qty
1 Seal gasket 1
2 Ball bearing 1
3 Bearing 1
4 Screw 4
5 Pump flange 1
6 Pump body 1
7 Pressure valve assy 1
7.1 Pressure valve 1
7.2 Ring 1
7.3 O-ring 1
7.4 O-ring 1
8 Pressure valve 1
9 Check valve assy 2
9.1 One-way valve 1
9.2 Ring 1
9.3 O-ring 1
9.4 O-ring 1
9.5 Ring 1
10 Pressure valve assy 1
10.1 Pressure valve 1
10.2 Ring 1
10.3 O-ring 1
10.4 O-ring 1
11 Filter plate 1
12 Screw 1
13 Pump body 1
14
Plug 10
15
Ball bearing 1
16
Circlip 1
17 Ring 1
18 Ball bearing 1
19 Low Pressure Piston 4
20 High Pressure Piston 2
21 High Pressure Piston 2
22 Pin 1
23 Bearing end plate 1
24 Elastic washer 1
25 Screw 1
26 Connector 1
27 Screw 16
28 Filter 1

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8.4 Valve System
Item Description Qty Item Description Qty Item Description Qty
1 Subplate 1 4.3 O-ring 1 8.2 O-ring 1
2 Plug 12 4.4 O-ring 1 8.3 O-ring 1
3 Directional valve assy 2 5 Pneumatic reversing valve 1 9 Regulating valve assy 1
3.1 Valve body 1 5.1 Valve body 1 9.1 Valve body 1
3.2 Ring 1 5.2 O-ring 2 9.2 O-ring 1
3.3 O-ring 1 5.3 O-ring 1 9.3 O-ring 1
3.4 O-ring 1 6 Pressure gauge 1 10 Female coupler 1
3.5 Ring 1 7 Pressure meter joint assy 1 11 Male coupler 1
3.6 Ring 1 7.1 Pressure meter joint 1 12 Plug 2
3.7 O-ring 1 7.2 Pressure meter joint 1 13 Sealing ring 1
3.8 O-ring 1 7.3 O-ring 1 14 Elastic washer 4
4 Check valve assy 1 8 Regulating valve assy 1 15 Washer 4
4.1 Check valve body 1 8.1 Valve body 1 16 Screw 4
4.2 Ring 1

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8.5 Remote Control
Item Description Part No. Qty
1 Remote case ZAW1578 1
2 Air valve ZAW1579 1
3 Button ZAW1580 1
4 Circlip ZAW1581 1
Complete Assembly ZAW1577 1
Serial, model and part numbers need to be quoted when ordering parts.

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9.0 Hydraulic Schematic