IBT IBT-115 User manual

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IBT-115 Single-Port Power Pack
Operation And Maintenance Manual
Welcome to the world of IBT Hydraulic Tools. This handbook contains instructions, warnings
and a trouble shooting guide. Please read and follow the instructions carefully.

Industrial Bolting Technologies IBT-115 Single-Port Power Pack 2
Safety Guide
To use the IBT-115 Single-Port Power Pack safely you must follow correct operation guidelines
and inspect the equipment regularly. Read and follow all instructions and don proper personal
protective equipment (PPE) prior to use.
UPON RECEIPT OF THIS TOOL, INSPECT THE PACKAGE FOR DAMAGE.
Carefully inspect all components for damage incurred during shipping. If any shipping damage is
found, notify the carrier at once. Shipping damage is NOT covered by warranty. The carrier is
responsible for all repair or replacement costs resulting from damage incurred during shipping.
Neither IBT nor its distributors are responsible for damage caused by unsafe and/or faulty
operations. If a problem arises during use, shut off the power immediately and consult your IBT
distributor.
ALL OF OUR PRODUCTS MAY HAVE UPGRADES AND CHANGES WITHOUT NOTICE.
Table of Contents
Warnings ......................................................................................................................................... 3
Operation Warnings........................................................................................................................ 5
Overview ......................................................................................................................................... 5
Features .......................................................................................................................................... 5
Dimensions and Parts Overview ..................................................................................................... 6
Filling the Reservoir ........................................................................................................................ 7
Operational Readiness.................................................................................................................... 7
Pressure Regulating Valve operation.............................................................................................. 7
Pressure adjustment....................................................................................................................... 8
Releasing the system ...................................................................................................................... 8
Warranties ...................................................................................................................................... 9
Appendix ……………………………………………………………………………………………………………………..………...10

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Warnings
Hydraulic Hose:
•Inspect high pressure hoses and couplings before use to
prevent injury.
•Replace hoses when signs of damage are present.
•Do not let the hose kink, twist, curl or bend so tightly that oil
flow within the hose is blocked or reduced.
•The minimum bending radius: R>5 inch.
•Too small of a bending radius will kink and destroy the high pressure hydraulic
hose.
•Before operating the hydraulic power pack, tighten all hydraulic
hose connections with the proper tools.
•Do not overtighten.
•Connections should be tightened securely and leak-free.
•Over tightening can cause premature thread failure.
•Shut off the electric motor before breaking any hydraulic
connections in the system.
•Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately
shut off the hydraulic power pack.
•Never attempt to grasp a leaking pressurized hose with your hands.
•The force of the escaping hydraulic fluid could cause serious injury.
•Do not subject the hose to potential hazards such as:
•fire
•sharp surfaces
•extreme heat or cold
•heavy impact
•Hose material and coupler seals must be compatible with the hydraulic fluid.
•Keep hoses away from contact with corrosive materials such as creosote-impregnated
objects and some paints.
•Consult the manufacturer before painting a hose.
•Never paint hydraulic couplers.
•Hose deterioration due to corrosive materials can result in serious personal
injury.

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IBT-115 Single-Port Power Pack:
•This hydraulic electric pump has a maximum operating pressure of 21,750 PSI/1500 Bar.
•Pressures in excess of 21,750 PSI/1500 Bar can damage the pump.
•Do not tamper with the internal high pressure relief valve.
•Creating pressure beyond rated capacities can result in serious personal injury.
•Before replenishing the hydraulic oil, retract the system to prevent overfilling the pump
reservoir.
•Overfilling can cause personal injury due to excess reservoir pressure created
when the tensioners are retracted.
•Shut off power before servicing equipment.
•Ensure pump is properly grounded to avoid electric shock.
•Do not modify this pump.
•Any modification will result in a voided warranty and may result in personal
injury.
•Fill the hydraulic fluid reservoir to the recommended level. Do not overfill.
•Oil temperature exceeding 140 F can cause the pump to fail.
•Keep the hydraulic pump clean.
•Dirt in the oil can lead to pump failure.
•Change oil and filter assembly annually.
Power Supply:
•Disconnect the hydraulic power pack from the power supply when performing
maintenance or repairs.
•If the power supply is damaged or the inner wiring is exposed in any way, replace
immediately.
•If the power cord is damaged or wiring is exposed, replace or repair immediately.
•Check the total amperage draw for the electrical circuit you will be using.
•Low amperage can trip electric breakers and cause the power pack to heat
excessively.
•If using an extension cord to power the hydraulic pump, make sure it is 12 gauge or
better.
Use a stable electric source. If power supply is unsteady, it may affect the performance and
damage the hydraulic power pack..

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Operation Warnings
•Do not permit anyone to stand in front of open hydraulic couplers during operation.
•Never exceed the maximum operating pressure of 21,750 PSI/1500 Bar.
•Before performing any maintenance, shut off power.
•Do not operate without oil.
•Keep the power pack clean.
•Do not operate in wet conditions.
Overview
This hydraulic pump is single acting with a working pressure of 21,750 PSI/1500 Bar.
Hydraulic fluid should be non-foaming grade 32 in the winter and non-foaming grade 46 in the
summer.
Do not use in a flammable atmosphere.
Features
•Pump Type: radial piston
•Maximum operating pressure: 21,750 PSI/1500 Bar
•Flow: 9.50 gallon/minute
•Motor: 110v 50Hz 1Kw
•Reservoir capacity: 2.64 gallon
•Reservoir Size: 11.4” x 9.4” x 6.3”
•Weight: 61lbs.
•Hydraulic Oil: Winter - ISO VG 32, Summer - ISO VG 46

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Dimensions and Parts Overview
Number Description
1 Motor 1KW 110V
2 Gauge 30,000 PSI
3 Valve Block
4 Quick Connector
5 Oil Standard
6 Drain Port Plug G1/4”
22 Reservoir
23 Power Switch
24 Pressure Regulating Valve (relief valve)
26 Ventilation Oiler
Parts Overview
1. Motor: Voltage 110v, 50Hz
2. Maximum working pressure: 21,750
PSI/1500 Bar
3. Oil port size: 1/4” BSP
4. Quick connector BSP 1/4“
5. Hydraulic oil: Winter - ISO VG 32#
Summer - ISO VG 46#.
6. Drain plug 1/4” NPT
22. Reservoir must have sufficient hydraulic
oil to ensure that the pump does not over
heat, do not overfill.
23. Power switch: to provide electricity to
the system power
24. Pressure regulating adjustment valve
(relief valve) limits the maximum working
pressure.
26. Ventilation lubricator (oiling cover): with
exhaust air function.

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Filling the Reservoir
Attention: The power pack has been shipped without oil in the reservoir. Only use a high-
grade, quality non-foaming hydraulic oil.
•Clean the area around the filler cap.
•Any dirt or grime in the hydraulic oil can damage the internal workings of the
power pack.
•Remove the filler cap, and insert a clean funnel.
•Fill with hydraulic oil to 1” from the top of the filler hole.
•Winter - ISO VG 32# Summer - ISO VG 46#
•Replace filler cap.
•Cycle the power pack several times.
•Retract the tensiorer and check the oil level in the power pack reservoir again.
•This will also help eliminate air from the system.
Operational Readiness
Prior to use:
•Check power supply.
•System rated for 21,750 PSI/1500 Bar.
•Before use, check to make sure all tools have a high pressure rating.
Pressure Regulating Valve operation
•Tighten the Pressure Regulating Valve.
oThis will cause pressure to rise when you press the remote control button.
•Pressure will hold when you turn off the unit power.
•When job is complete, open the Pressure Regulating Valve to release system pressure.

Industrial Bolting Technologies IBT-115 Single-Port Power Pack 8
Pressure adjustment
NOTE: For easy adjustment of the pressure regulating valve always adjust
the pressure by increasing up to the desired pressure setting.
1. Loosen the locknut on the pressure regulating valve, and back the
adjusting knob out a few turns.
a. Do so by turning the adjusting knob in a counterclockwise
direction.
b. This will decrease the pressure setting to a pressure lower
than the desired pressure.
2. Connect the electric power supply and flip the on/off
switch to “On”
a. This switch is located on the back of the
electrical control box.
3. Press the rocker switch on the top position to
“Advance”.
4. While holding remote rocker in the “Advance” position,
slowly turn the adjusting knob in a clockwise direction.
a. This will gradually increase the pressure setting.
5. When the pump reaches the desired pressure, lock the adjusting knob in position by
tightening the locknut.
6. Vibration can cause the Pressure Regulating Valve to loosen and cause inaccurate
pressures if locking nut is not tight.
Attention: The power pack must not be connected to the hydraulic when adjusting the
pressure. Remove any hydraulic hoses (if connected).
Releasing the system
1. Turn off the unit power.
2. Slowly open the Pressure Regulating Valve to release pressure.
3. Verify the unit pressure reads Zero (0).
4. Remove high pressure hydraulic hoses.
5. Replace plastic cover on fitting.

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Warranties
IBT guarantees the IBT-115 Single-Port Power Pack for 12 months from the date of purchase.
If any quality issue due to the defects of the materials or workmanship is found within the
guarantee period, IBT will repair or replace the defective products at IBT’s discretion.
If the equipment is found to be damaged due to negligence, operating the power pack
incorrectly, tampering with, or attempting to repair the power pack in part or whole, the
warranty is invalidated.

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Appendix
IBT-115 Single-Port Power Pack Trouble Shooting