Hi-Force AHP-BTU Series Instruction Manual

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
1
OPERATING INSTRUCTION MANUAL
AHP-BTU SERIES | AIR DRIVEN HYDRAULIC PUMPS
Hi-Force AHP-BTU series Air Driven hydraulic pumps are compatible for use with Hi-Force STS, SBT and
STU bolt tensioners as well as HTN hydraulic nuts. The pump unit is easy to operate and supplied
complete with a glycerine filled vibra-gauge and quick release outlet coupling. The complete syste,
including an air inlet filler, regulator and lubricator unit is fitted in a robust stainless steel frame. The AHP-
BTU pumps operates from a standard 7 bar air supply with an operating pressure of 1500 bar. It contains
the latest product information available at the time of publication and approval. Hi-Force reserves the right
to make changes to this document at any time without notice.
This ‘Original instructions’ document assumes that the operator carrying out any operation with this
product is trained and competent to do so. This manual does not attempt to cover all details or variations
in the equipment. Nor does thismanual claim to provide for every possible contingency met in connection
with the installation, operation, or maintenance thereof. Should further information be desired, or should
a particular problem arise which is not covered in sufficient detail, the matter should be referred to
Hi-Force.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
2
Table of Contents
1.0 Inspection upon Receipt .................................................................3
2.0 Safety Precautions...........................................................................3
3.0 Declaration of Incorporation/Conformity......................................5
4.0 Component Identification................................................................6
5.0 Installation/Setup ............................................................................9
6.0 Operation........................................................................................11
7.0 Specifications.................................................................................16
8.0 Troubleshooting.............................................................................17

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
3
1.0 Inspection upon Receipt
Upon receipt of the product, visually inspect the item for any evidence of shipping damage. Please note:
the warranty does not cover shipping damage. Notify the courier immediately if shipping damage is found
and refrain from putting the product into service. The carrier is responsible for repair and replacement
costs resulting from damage that occurred in transit.
2.0 Safety Precautions
2.1 Introduction
Read and follow all the instructions and safety warnings carefully before handling, installation or
use of any hydraulic equipment. Failure to do so could lead to equipment damage, equipment
failure, personal injury or even death. Hi-Force will not be held responsible for any damage to the
equipment, injury or death resulting from the unsafe use of, lack of maintenance to, or incorrect operation
of the product. If in doubt on the correct use of any Hi-Force equipment, contact your nearest Hi-Force
office or distributor. Only qualified personnel should be allowed to operate hydraulic equipment. If an
operator has not been trained on high-pressure hydraulic equipment and its safe usage, consult your local
Hi-Force sales office or distributor who can offer training courses for operators.
2.2 Work Area Safety
•Keep work areas clean and well lit. Cluttered spaces and inadequate lighting can result in
unnecessary accidents.
•Keep bystanders clear of any hydraulic tool activity. Personnel working in close-range should be
made aware of all high-pressure work before commencing.
2.3 General Hydraulic System Safety Precautions
Failure to observe and obey the following safety precautions could
result in property damage, significant personal injury or death;
•When operating any hydraulic equipment, all operators should ensure that all necessary personal
protective equipment (PPE) is worn, as specified by their employer. Steel toe-cap safety shoes,
safety glasses/visor, ear protection, and protective gloves should be worn at all times. All relevant
risk assessments should be completed before the use of the equipment.
•Keep hydraulic equipment away from open flames and direct heat.
•NEVER use a coupler as a tool handle, especially if the system is pressurised.
•Inspect hoses regularly for damage and wear.
•NEVER use hoses that are frayed, kinked, abraded or leaking.
•NEVER handle a pressurised hydraulic hose. Hydraulic fluid escaping under pressure from a
ruptured hose can penetrate the skin and lead to a significant medical emergency, and in some
cases, death. Should this incident occur, seek out medical attention immediately.
•Seek medical attention immediately if a hydraulic injection injury (no matter how minor) occurs.
NOTE: Images contained within this document are for illustrative purposes ONLY.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
4
•The system operating pressure MUST NOT exceed the pressure rating of the lowest-rated
component in the system.
Good Practice: Use a pressure gauge to monitor the entire system.
•Only use hydraulic tools/cylinders in a complete and tested, coupled system. NEVER attempt to
use a tool/cylinder that is not correctly coupled to its operational pump.
•NEVER pressurise an unconnected male coupler/s.
•NEVER attempt to disconnect a hose from a hydraulic system until the system’s pressure has
been completely released. Doing so can result in that pressure becoming trapped within the
system and relieving trapped pressure can be dangerous.
•NEVER try to relieve trapped hydraulic pressure in the system by loosening or attempting to
remove the coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge
unexpectedly with great force. This action could result in serious personal injury or death.
•Loosening a coupler under pressure can result in the escape of hydraulic oil at high pressure,
which can penetrate the skin and cause significant injury or death.
•NEVER use a hammer and punch to unseat a coupler check valve that is under pressure. Doing
so could result in the sudden, uncontrolled release of hydraulic oil at high pressure, which could
cause significant injury or death.
•NEVER attempt to solve, or clean-up leaks in the system while the system is pressurised.
•Immediately replace any worn or damaged parts using genuine Hi-Force parts only.
•DO NOT use any hydraulic equipment if you are under the influence of alcohol, drugs or
medication. Lack of attention whilst operating high-pressure hydraulic tools can result in personal
injury or death.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•NEVER lift, carry, or move any hydraulic components by the hose or hoses connected to them.
•Avoid damaging hydraulic hoses. ALWAYS route hoses to ensure that they are free from sharp
bends and kinks. Using a sharply bent or kinked hose will result in severe back-pressure, which
can lead to hose failure.
•NEVER use a coupler/s to lift, carry or position a tool.
•Servicing of hydraulic equipment must only be undertaken by a qualified technician.
•DO NOT drop or place heavy objects on a hydraulic hose, as this may
cause internal damage, which could result in rupture of the pressurised
hose. A ruptured hose could cause significant damage to components and
possible severe injury to personal operating nearby.
•DO NOT let familiarity gained with any hydraulic tools allow you to become complacent.
Complacency with any tooling can result in a lack of discipline toward working guidelines and
safety principles.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
5
•DO NOT remove any labels from the product. Replace any damaged or unreadable labels
immediately.
•Avoid loose clothing and jewellery that could get caught in moving parts, tie back long hair.
2.4 Hydraulic Pump Specific Safety Precautions
Failure to observe and obey the following safety precautions could
result in property damage, serious personal injury or death;
•NEVER exceed the maximum rated pressure of any hydraulic equipment. Hi-Force manufactures
its AHP-BTU air driven hydraulic pumps to operate at a maximum working pressure of 1500 bar
(21,755 psi).
DO NOT connect hydraulic torque equipment with a lower pressure capacity rating to any Hi-Force
pump of this model series.
•Make sure all equipment connected to the pump is in good working condition.
•NEVER invert the unit or lay it on its side, either in use, in transport or in storage.
•DO NOT weld any items to the pump unit or modify it in any way from its delivered condition. Your
warranty may be invalidated, and it could lead to serious personal injury.
•ALWAYS ensure there is clear communication between the pump operator and the tool operator.
DO NOT operate the pump unless the tool operator indicates it is safe to do so.
Take extra care when multiple tools are being operated by a single pump. Make sure all tool
operators have given the go-ahead before operating the pump.
•NEVER attempt to connect or disconnect a tool/hose/component while the system/pump is
under pressure.
•NEVER leave a pressurised system unattended. If you must leave the area, release the pressure
and ensure the hydraulic release valve on the pump is fully open.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•ALWAYS stand the pump on a stable, level surface during operation.
•To protect your warranty, only use the hydraulic oil grade specified in Section 5.2.
3.0 Declaration of Incorporation/Conformity
Hi-Force declares that this product has been tested and complies with the standards set out in the relevant
EU directives. The EU Declaration of Incorporation/Conformity is included as Annex A to this instruction
document and is supplied with all shipments of this product.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
6
4.0 Component Identification
1
Frame
5
Air Stop/Control Valve
2
Oil Reservoir
6
High Pressure/Pressure Release Valve
3
Oil Filler Cap
7
FRL unit (See Fig 4.3)
4
Oil Pressure Gauge
1
2
3
4
5
6
7
Fig 4.1: AHP Component Identification

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
7
8
Open Female Coupler
10
Silencer
9
Air Motor
11
Pressure Relief Valve
Fig 4.2: AHP Component Identification
8
9
10
11

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
8
12
Air Supply Inlet (3/8” BSP)
17
Air Lubricator Filler Plug
13
Air Regulator Control Knob
18
Air Lubricator Reservoir
14
Air Filter Water Trap
19
Air Pressure Gauge
15
Water Trap Drain Button
20
Water Trap Drain Port
16
Air Lubricator Control Knob
12
13
14
15
20
16
17
18
19
FRL UNIT
Fig 4.3: FRL Component Identification

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
9
5.0 Installation/Setup
5.1 Before First Use / Preparation
1. Immediately after unpacking, examine the unit for signs of transit damage and if found contact the
shipping company.
2. Establish the oil level in the oil reservoir (2). Depending on the shipping method used, the
reservoir may either be supplied full or empty. If the reservoir is empty, it must be correctly filled
before use (See section 5.2). If the reservoir was supplied full of oil, no further action is required.
IMPORTANT: Running the pump without oil will result in damage.
5.2 Filling the Reservoir with Oil
IMPORTANT: The AHP- BTU air driven hydraulic pumps use ISO46 Grade Hydraulic Oil.
•Stand the Pump on a firm, level surface.
•Remove the filler cap (3) from the filler breather.
•Fill the reservoir with clean, high-quality ISO46 hydraulic oil via the opening at the top of the
reservoir.
•Replace the filler cap (3).
IMPORTANT: Only add oil to the reservoir when the attached tool is fully retracted. Failure to do so may
result in the system containing more oil than the reservoir can hold.
5.3 Hydraulic Connections
•ALWAYS use Hi-Force XHC hoses to make connections.
•Connection to the hydraulic pump must ALWAYS be made to the male coupler on the
tensioner/Hydraulic Nut.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
10
5.3.1 Connections
Connections between couplers (see fig 5.1) are made by [1] pulling back the spring collar on the female
coupler. [2] Inserting the male coupler into the female coupler and then releasing the female spring collar.
[3] Lock the connection by (1) pushing forward on the locking-collar and then (2) twisting it clockwise and
releasing. A gentle tug on the hose should be enough to make sure the hose is correctly connected.
Disconnections are the reverse of the above process.
5.3.3. Connecting a Bolt Tensioner / Hydraulic Nut to the Pump
NOTE: For full details on how to connect a bolt tensioner/ hydraulic nut to the pump, refer to the operating
manual of the tool being used.
5.4 Filling the Air Supply Lubricant Reservoir
IMPORTANT: The AHP-BTU Series Air Motors require ISO VG 32 (SAE10) Oil.
•Turn Off or Disconnect from the Air Supply.
•Remove the Air Lubricator Filler Plug (17).
•Fill the Air Lubricator Reservoir (18) with ISO VG 32 (SAE10) Oil to the fill line marked on the
reservoir.
•Replace the Air Lubricator Filler Plug (17).
5.5 Air Supply Requirements
•The air supply must be delivered via a suitably rated air hose of at least 1/2” (13mm) diameter.
•The air supply pressure must be at least 5.5 bar (80 psi), but preferably 7 bar (100 psi).
•The compressor must be able to maintain a minimum flow rate of 50 cfm (24 l/sec).
Fig 5.1: Hydraulic Connections

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
11
5.6 Airline Connection
The air supply must be connected (via a suitable fitting) to the 3/8” BSP inlet port (12) on the FRL Unit.
5.7 Air Lubricant Setting
Adjust the air lubricant control knob (16) such that 1 drop of lubricant is added to the air supply
approximately every minute. The lubricant drops can be seen through the lubricant control knob (16) on
the top of the FRL unit.
NOTE: Allowing more oil than this into the motor can lead to contamination of the exhaust flow.
5.8 Priming the Pump
The pump is self-priming and will not need to be primed before use.
6.0 Operation
Hi-Force AHP-BTU pumps are designed for use with STS, SBT & STU bolt tensioners as well as HTN
hydraulic nuts. Ensure the operator has fully read and understood this manual in conjunction with the
chosen bolt tensioner/hydraulic nut operating manual to ensure correct and safe operation of all hydraulic
equipment in the system.
Before applying pressure to the system make sure you observe the following points
•You are aware of the correct operation of the pump unit.
•You are aware of the maximum working pressure of the bolt tensioners/hydraulic nuts.
•You are aware of the maximum piston movement of the bolt tensioners/hydraulic nuts.
•You are aware of the required working pressure/s that must be applied to the bolt
tensioners/hydraulic nuts.
•You have read and fully understood the tensioning/de-tensioning procedure.
•You have performed the relevant risk assessment/s and have a method statement (safe system of
work) for all operators to follow.
•You have read and fully understood the tensioning sequence and procedure.
6.1. Preparing the Pump for Operation
1. Fit a suitable air inlet fitting to the 3/8” BSP inlet port (12) on the FRL Unit [1].
NOTE: It is recommended to use a suitable whip check safety cable to secure the air inlet hose to
the air inlet fitting.
2. Twist and turn the High-pressure hydraulic valve handle (6) anti clockwise to open the valve, then
turn the Air valve handle (5) ¼ turn clockwise to close the valve [1] [2a].

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
12
3. Turn the Air supply on from the mains.
4. Lift the air regulator control knob (13) (the control knob will click securely in position), then twist
and turn the knob clockwise until roughly 2 bar of air pressure is achieved on the air gauge (19)
[3].
5. Twist and turn the air lubricator control knob (16) until roughly 1 droplet per minute is achieved [4].
NOTE: Allowing more oil than this into the motor can lead to contamination of the exhaust flow.
6. Open the Air stop/control valve (5) [2b].
7. Close the High pressure/Pressure release valve (6) clockwise.
NOTE: close valve to finger tight only.
2a
Air Valve closed
Air Valve open
2b
Air Inlet Port
1

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
13
6.2 Setting Hydraulic Pressure on the Pump Operation
1. Twist and turn the Air Regulator control knob (13) clockwise to build hydraulic pressure on the
Hydraulic Pressure Gauge (4) [5].
2. Once the desired pressure is reached, next slowly open the high pressure/pressure release valve
(6), by twisting and turning the handle clockwise, to release the pressure and then close the valve
again (6) (anticlockwise) and check the hydraulic pressure reading on the hydraulic gauge (4). If
the Pressure reading has changed, readjust the pressure again (repeating step 1 followed by step
2 again).
If the pressure reading has dropped below the required pressure. Simply use the
air regulator control valve (13) to build the pressure back up to the desired
pressure. However, if the pressure reading has gone above the required pressure,
you MUST release the hydraulic pressure using the high pressure/pressure
release valve (6). Then reduce the air pressure using the air regulator control knob
(13). To build hydraulic pressure back up again, close the high pressure/pressure
release valve and adjust the hydraulic pressure again using the air regulator
control knob (13), until the desired hydraulic pressure (4) is achieved, (repeat this
process again, if necessary, until the desired pressure has been achieved).
3. Once the hydraulic pressure is set, open the high pressure/pressure release valve (6), close the
air stop/control valve (5) and press down on the air regulator control knob [6]
4. The pump is now ready to be connected to the Bolt tensioner/Hydraulic nut via the Female coupler
(8).
IMPORTANT: ENSURE all the above steps have been completed before connecting to the tool.
For full details on how to connect the tool to the pump please read the tools operating manual.
3
4
CLICK!

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
14
5
CLICK!
6

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
15
6.3 Disconnecting/storage of Pump Operation
1. Once the operation/use of the pump has been completed. Open the High Pressure/pressure
release valve (6), close the air stop/control valve (5), pull up the Air regulator control knob and
unwind the knob (13) until 0 bar of air pressure is reading on the air pressure gauge (19) [7].
2. Switch the air supply from the mains off.
Even with the air supply being switched off their will still be air pressure trapped
in the hose between the mains air supply and the pump.
3. Turn the Air stop/control valve into the open position [2b].
4. Twist and turn the air regulator control knob (13) to build up air pressure. Just enough to be able to
release the trapped air pressure.
NOTE: You should be able to hear the air pressure being released.
5. Once the trapped air pressure is released, switch the air stop/control valve (5) into the closed
position [2a]. then fully turn (anticlockwise) the air regulator control knob (13) and push down on
the knob, to lock it in place.
6. Air supply hose is now ready to be discounted and the pump can now be safely put away and
stored.
CLICK!
7

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
16
7.0 Specifications
Refer to the nameplate on the pump for model identification.
AHPTBTU | Air Driven Hydraulic Pumps
Model Number
Usable Oil
Capacity
[Litres]
Oil Flow
Per
Stroke
[cm³]
Outlet
Coupler
Air Consumption
Weight
(including oil)
(kg)
AHP275BTU
7.5
1.6
STFC4
28 scfm (0.79 m³/min)
32
AHP2-237BTU
7.5
6.1
STFC4
56 scfm (0.79m³/min)
24

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
17
8.0 Troubleshooting
Hi-Force AHP-BTU air driven hydraulic pumps should be serviced and repaired only by authorised Hi-
Force repair centres. The following table gives possible causes and solutions for common problems.
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Solution
1. Air motor/Pump will
not start.
a. Air supply not connected.
Connect air supply.
b. Low air pressure/volume.
check the regulated air pressure is available
via the air pressure gauge (19) mounted on
the FRL unit.
c. Air supply restricted
check the air stop/control (5) valve is in the
open position [2b].
d. Air motor is damaged, seized or
worn.
Contact your local Hi-Force office/distributor.
2. Air motor stalls or
struggles to create
pressure.
a. Low air pressure/volume.
Check air supply, including regulator setting
and the size of the connecting hoses to
ensure the correct airflow/pressure
requirements are met. (See section 5.5-5.6)
b. Inadequately lubricated air supply.
Check air lubricator levels and make sure the
oil drip rate is correct. (See section 5.7)
3. Pump struggles to
build pressure or
maintain pressure
under load.
a. Oil level too low
Check unit for visible leaks. Add oil as per
section 5.2.
b. External oil leak in the system.
Contact your local Hi-Force office/distributor.
c. insufficient air pressure causing
pump to stall
Check air supply, including regulator setting
and the size of the connecting hoses to
ensure the correct airflow/pressure
requirements are met. (See section 5.5-5.6)
d. high pressure/pressure release
valve not closed
close high pressure/pressure release valve (6)
to build up pressure.
e. tube connections loose in the
system.
check tub connections in the system and
rectify.
f1. hydraulic check valves have
developed a leak.
f2. fluid bleeding past the seals in the
hydraulic tensioners.
Contact your local Hi-Force office/distributor
4. Pump running
incorrectly
a. pump appears to be short stroking
and running too fast without
pumping correctly
usually, indicates the air check assembly is
not working as it should be. Contact your local
Hi-Force office/distributor
b. excessive amount of oil or water is
coming through the pump air
exhaust
1. the lubricating unit on the air supply is
delivering too much oil. Adjust accordingly
(see section 5.7)
2. the filtering unit in the air supply is not
functioning correctly. The bowl should be
cleaned periodically to ensure delivery of
clean air to the pump.
3. the fluid being pumped may be leaking past
the seals in the hydraulic cylinder into the air
motor. The unit will require inspection and
repair.
5. Noisy Operation
a. Air leaking into the hydraulic
system.
Visually inspect all areas where air might leak
into the hydraulic system.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
18
TROUBLE SHOOTING GUIDE CONTINUED...
Problem
Possible Cause
Solution
b. Oil level too low.
Check unit for visible leaks. Add oil as per
section 5.2.
6. Gauge displays no
pressure reading.
a. Faulty gauge.
replace gauge
b. Pump will not build pressure.
See problems 2 & 3 above.

Operating Instruction Manual:
OM-AHP-BTU-01
Serial Numbers:
FROM BQ 9522
19
Head Office:
Hi-Force Limited
Prospect Way, Daventry
Northamptonshire NN11 8PL
United Kingdom
Tel: + 44 1327 301000 | Fax: + 44 1327 706555
www.hi-force.com
Regional Offices:
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