Hytorc HY-Air Series User manual

Hydraulic unit
JetPro-S-Air, HY-Air, HY-Twin-Air
English translation of the original German operating
instructions
for qualified and authorized operating personnel
Status 6/2019
Always store these operating instructions together at the hydraulic unit. Ensure that the operating instructions
are available for the qualified and authorized operating personnel. Read and comply with the operating
instructions.
Non-observance can lead to injury and possibly death.

Publisher
HYTORC Technologies GmbH
Kleinbeckstr. 3–17
45549 Sprockhövel, Germany
Tel.: [phone]
Fax: [phone]
[e-mail]
www.hytorctech.com
Document no.
BA-0060-EN00
Revision no.
00
Document type
Operating instructions
Issue date
6/7/2019
Copyright
© 2019, HYTORC Technologies GmbH
All rights, including those of reprinting and reproduction of any parts of
this document and its translation, are reserved by the publisher.
No part of this document may be reproduced in any form or copied
using electronic reproduction systems without the written consent of
the publisher.
We reserve the right to make technical changes in the course of further
development.

Table of contents
Notes concerning this manual and the manufacturer ............................................6
Keep the manual available .............................................................................................6
Design features of this manual.......................................................................................6
Referenced documents...................................................................................................7
Manufacturer's address ..................................................................................................7
Person responsible for documentation...........................................................................8
Warranty and liability ......................................................................................................8
Safety........................................................................................................................9
ATEX marking.................................................................................................................9
Equipment group (1).............................................................................................9
Equipment category (2)......................................................................................10
Ignition protection type (3)..................................................................................10
Explosion group (4) ............................................................................................10
Temperature class (5) ........................................................................................10
Equipment protection level (6)............................................................................11
ATEX marking of the unit....................................................................................11
Responsibilities of the operating company...................................................................11
Persons at particular risk..............................................................................................12
Qualification of personnel.............................................................................................12
Connecting the Compressed Air Supply ............................................................12
Tool connection ..................................................................................................12
Setting pressure/torque......................................................................................13
Assessing the state of the unit ...........................................................................13
Carrying the unit .................................................................................................13
Ban of unauthorized conversions .................................................................................14
Personal protective equipment.....................................................................................14
Basic safety information................................................................................................15
Preventing serious injury or death......................................................................15
Preventing explosion hazards ............................................................................15
Preventing burns from oil and hot surfaces........................................................15
Preventing poisoning..........................................................................................15
Preventing bone fractures and crushing.............................................................16
Preventing eye damage......................................................................................16
Preventing skin irritation.....................................................................................16
Preventing material damage ..............................................................................16
Intended use.................................................................................................................17
Ambient conditions .......................................................................................................17
Design characteristics of warning information..............................................................18

Design of information about property damage .............................................................19
Warning and information signs.....................................................................................20
Description............................................................................................................. 22
Directional data.............................................................................................................23
Overview front right.......................................................................................................24
Overview front left.........................................................................................................25
Layout...........................................................................................................................25
Display and operating elements ...................................................................................26
Pressure gage....................................................................................................26
Couplings............................................................................................................26
Remote control for manual version ....................................................................27
Remote control for semi-automatic version........................................................28
Torque valve.......................................................................................................29
Maintenance unit................................................................................................30
Type plate.....................................................................................................................30
Available accessories...................................................................................................31
Workspaces and positions............................................................................................31
Purpose and function....................................................................................................32
Unpacking and checking the delivery................................................................... 33
Unpacking.....................................................................................................................33
Checking package and condition..................................................................................33
Storing the unit ...................................................................................................... 34
Moving the unit ...................................................................................................... 35
Commissioning the unit ........................................................................................ 36
Initial commissioning.....................................................................................................36
Daily commissioning.....................................................................................................38
Tool connection..................................................................................................38
Connecting the Compressed Air Supply ............................................................41
Bleeding the screw system (generator, hose, tools)..........................................41
Check oil level ....................................................................................................42
Checking functioning of the manometer.............................................................43
Performing a test run....................................................................................................43
Operating the unit.................................................................................................. 44
Changing tools..............................................................................................................44
Setting the pressure......................................................................................................48
Performing a screwing process ....................................................................................49

After use .................................................................................................................50
Decommissioning the unit.....................................................................................52
Servicing the unit ...................................................................................................53
Maintenance schedule..................................................................................................53
Changing the hydraulic oil ............................................................................................54
Filling the Maintenance Unit’s Oiler..............................................................................57
Cleaning the unit ....................................................................................................58
Remedying faults or malfunctions ........................................................................59
Table of faults ...............................................................................................................59
Disposal..................................................................................................................63
In the USA.....................................................................................................................63
In Europe ......................................................................................................................64
Technical specifications ........................................................................................65
HY-Air ...........................................................................................................................65
JetPro-S-Air ..................................................................................................................66
HY-Twin-Air...................................................................................................................66

Notes concerning this manual and the
manufacturer
6
Notes concerning this manual and the
manufacturer
These instructions help you to use the following hydraulic units safely:
JetPro-S-Air
HY-Air
HY-Air-2
HY-Air-SA
HY-Air 2-SA
HY-Twin-Air
These hydraulic units are hereinafter referred to as “unit(s)”.
Keep the manual available
These operating instructions are a part of the unit. Make sure that the
operating instructions are always accessible for the user at the site and are in
legible condition. Enclose the operating instructions when you sell the unit or
transfer it in any other way.
Design features of this manual
Various elements of these operation manual have fixed design characteristics.
These allow you to easily distinguish the following elements:
Normal text
Lists
Action steps
References to headers are set in quotation marks.
‘Labels’ of switches or other elements are set in inverted commas.
Table titles are set in bold.
Tips. Contains additional information.

Notes concerning this manual and the
manufacturer
7
Referenced documents
WARNING
Risk of injury from non-compliance with the applicable
documentation.
Prior to working with the unit, read all applicable
documents and comply with them.
These can be found in the documentation folder of the unit.
More information, instructions and details about the unit components can be
found in the documentation from the respective manufacturers. These
documents are regarded as a part of these instructions. Store these
documents together with this manual. Hand over these documents when
selling the unit or passing it on in other ways.
Referenced documents are the following document types in particular:
operating instructions
assembly instructions
maintenance or repair instructions
wiring diagrams
terminal diagrams
hydraulic diagrams
safety data sheets
drawings
spare parts lists
declarations of conformity or declarations of incorporation
ex-protection document of the operator
Observe and follow the information from the referenced documents.
These can be found in the documentation folder of the unit.
Manufacturer's address
HYTORC Technologies GmbH
Kleinbeckstr 3–17
45549 Sprockhövel
Germany
Telephone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.hytorctech.com

Notes concerning this manual and the
manufacturer
8
Person responsible for documentation
HYTORC Technologies GmbH
Michael Westermann
Kleinbeckstr 3–17
D-45549 Sprockhövel
Germany
Warranty and liability
In general our General Terms and Conditions apply. Warranty and liability
claims for personal injury or property damage are always excluded if they are
due to one or more of the following causes:
Improper use of the unit
Improper transport, installation, commissioning, operation and maintenance
of the unit
Ignoring the instructions in this manual
Ignoring the hazard notices on the unit
Unauthorized modifications of the unit
Inadequate monitoring of components which are subject to wear.
Incorrectly executed repairs
Disasters caused by outside intervention or an act of God.

Safety
9
Safety
WARNING
Severe injuries or death caused by accidents due to
disregard of the instructions in this guide.
In particular the failure to observe the instructions in the
Chapter on Safety, can lead to accidents.
Read and follow all instructions in this manual before you
begin working with or on the unit.
In addition to the notes in these operating instructions, also follow, in any
case, the statutory and other regulations, e.g.:
Accident prevention regulations
Regulations for safe and professional work
The applicable on-site regulations for explosion protection and fire protection
ATEX marking
The ATEX marking contains notes on the permissible use of the unit in
potentially explosive atmospheres. The following information is displayed:
Equipment group (1)
Equipment category (2)
Ignition protection type (3)
Explosion group according to DIN EN ISO 80079-36: 2016, DIN EN ISO
80079-37: 2016 (4)
Temperature class (5)
Equipment protection level (EPL) (6)
Equipment group (1)
Equipment that is intended for operation in a potentially explosive atmosphere
is classified into two groups. Group I includes equipment that is used in mines
susceptible to firedamp, e.g. in coal mines. The unit belongs to equipment
group II and can therefore be used in all potentially explosive areas except for
mining.

Safety
10
Equipment category (2)
Equipment category II comprises equipment that was designed in such a way
that ensures a high level of safety if the equipment is used as intended with
the prescribed parameters. Equipment of this category can be used in areas
where a potentially explosive atmosphere of gases, vapors, mists or dust/air
mixtures occurs occasionally. This is indicated with the letter G. Equipment of
category III is also included if it is likely that a potentially explosive atmosphere
will only occur rarely or for a short period of time. The unit falls under
equipment category II. Equipment of this category may only be used in zones
1 and 2 and/or zones 21 and 22.
Ignition protection type (3)
The ignition protection type represents the design principle followed in the
unit’s development with regard to explosion protection. The ignition protection
type “h” stands for “constructional safety” of non-electrical equipment.
Constructional safety means that constructional measures have been taken to
reduce hazards caused by ignitable temperatures or sparks to a very low level.
Explosion group (4)
Equipment of group II can also be classified according to the type of
potentially explosive atmosphere where the equipment may be used. The
subgroups IIA, IIB and IIC are used for this purpose. This classification is
based on the maximum experimental safe gap (MESG) and the minimum
ignition current ratio (MICR) of the gas mixture.
Temperature class (5)
Flammable gases and vapors are split into different temperature classes
according to their level of flammability (see table). The maximum surface
temperature of a piece of electrical equipment must always be below the
ignition temperature of the gas, vapor or air mixture where it is used.
Equipment that meets the requirements of a higher temperature class (e. g.
T5) is naturally also permitted for applications that require a lower temperature
class (e. g. T2 or T3).
Temperature -
class
Ignition temperature of gases
and vapors in °C
Maximum surface temperature
of equipment in °C
T1
> 450
450
T2
> 300 to 450
300
T3
> 200 to 300
200
T4
> 135 to 200
135
T5
> 100 to 135
100
T6
> 85 to 100
85