TorcUP EP500 Installation guide

OPERATION AND MAINTENANCE
MANUAL
Torque Wrench Power Pump
MODELS EP500, EP500-230V, EP1000, EP1000-Q, EP1000-230V, EP1000-Q-230V
EP500 AND EP1000
1025 Conroy Place, Easton PA 18040 * U.S.A.
Phone: [phone] * Fax:[phone]
Toll Free: 1-888-TORCUP-1
Email: [email protected] * Website: www.torcup.com

Operational and Maintenance Manual for TorcUP
EP500 & EP1000 Torque Wrench Pump
TorcUP Inc. is not responsible for customer modication of tools for applications on
which TorcUP Inc. was not consulted.
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING PUMP.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS
MANUAL INTO THE HANDS OF THE OPERATOR.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
The use of other than genuine TorcUP replacement parts may result in safety
hazards, decreased tool performance, and increased maintenance, and may
invalidate all warranties. Repairs should be made only by authorized
personnel. Consult your nearest TorcUP Authorized Service Center.
Refer All Communications to the Nearest TorcUP Ofce or Distributor.
For Technical Support & Information Contact:
TorcUP Inc.
1025 Conroy Place, Easton, PA 18040 USA
Phone: [phone] Fax:[phone]
email: [email protected]
CONTENTS
TorcUP has taken every care in preparing this Operational Manual that is intended as a technical guideline only. TorcUP
accepts no liability in relation to any use or reliance made of any information in this Operational Manual. All information,
illustrations and specications in this Operational Manual are based on the latest information available at the time of publica-
tion. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be respon-
sible for ensuring that a safe working environment and safe systems of work are in place before operating the equipment.
Version 1: 2013 April
Category Page # Category Page #
Manual Index 1 Control Valves 8
General Warnings 2 Power Control Switches 8
Safe and Correct Use 3-5 Pressure Torque Setting 9
Warranty Statement 4 Completing the job 9
Working Pressure 5 Periodic Maintenance 9
Install Vent Plug 5 Oil Level 10
Adding Oil 5 Oil Intake Screen 10
General Safety 5 Oil Flushing 10
Technical Specications 6 Troubleshooting 11
Install Hydraulic Connections 6 EP1000 Parts Index 12
Electrical 7 EP500 Parts Index 23
Connecting Tools 7 Pendant 37
Initial Startup 7
Pump Mounting 8
EP500 EP1000
Shown with
optional quad kit
1/37

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY
Do NOT exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.
Always wear eye
protection
when
operating or
performing
maintenance
on this tool.
Always wear ear protection
when operating this tool. Do not carry
the tool
by the hose.
Keep body stance
balanced and rm.
Do not overreach
when operating this
tool.
USING THE TOOL
• Keep hands, loose clothing & long hair away from the reaction arm and working area during operation.
• This tool will exert a strong reaction force. Use proper mechanical support and correct reaction arm
positioning to control these forces. Do not position the reaction arm so that it tilts the tool off the axis of
the bolt and never use the swivel inlets as a reaction stop.
• Avoid sharp bends and kinks that will cause severe back-up pressure in hoses an lead to premature
hose failure.
• Use accessories recommended by TorcUP.
• Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.
• Use only sockets and accessories that correctly t the bolt or nut and function without tilting the tool off
the axis of the bolt.
• This tool is not insulated against electric shock.
• This equipment must not be operated or serviced unless the operator read the operating instructions
and fully understands the purpose, consequences and procedure of each step.
Depending on the working environment your local health and safety regulations may require
you protective gear (i.e. Ear Protection, Safety Shoes, Hard Hat, Gloves, Coveralls, etc.) In
case external forces are exerted on the equipment, non-compliance with these regulations may
result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.
The Torque Reaction Arm must be
positioned against a positive stop.
Do not use the arm as a dead
handle. Take all precautions to
make certain the operator’s hand
cannot be pinched between the
arm and a solid object.
Do not use damaged,
frayed or deteriorated
hydraulic hoses
and ttings.
2/37

SAFE AND CORRECT USE
Operation of the Equipment in Accordance with Specied Use
1. Inspect, maintain, operate and install the tool in accordance with all applicable standards and
regulations (local, state, country, federal, etc.)
2. Do not remove any labels. Replace any damaged labels immediately.
3. Be sure all hoses and ttings are the correct size and tightly secured.
4. Do not use damaged, frayed or deteriorated hydraulic hoses and ttings. Do not paint hoses.
5. Do not lubricate tools with ammable or volatile liquids such as kerosene, diesel or jet fuel. Use
only TorcUP recommended lubricants.
6. Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet current
safety and health standards. Use cleaning solvents in a well ventilated area.
7. Keep work area clean, uncluttered, ventilated and illuminated.
Safety Information When Using The Tool
1. When wearing gloves always be sure that the gloves will not prevent the throttle mechanism from
being released.
2. Always wear eye protection when operating or performing maintenance on this tool.
3. Always wear hearing protection when operating this tool.
4. Always use personal protective equipment appropriate to the tool used and material worked.
This may include dust mask or other breathing apparatus, safety glasses, ear plugs, gloves,
apron, safety shoes, hard hat and other equipment.
5. Keep others a safe distance from your work area, or ensure they use appropriate personal
protective equipment.
6. Be aware of buried, hidden or other hazards in your work environment. Do not contact or dam-
age cords, conduits, pipes, or hoses that may contain electrical wires, explosive gases or harmful
liquids.
7. Keep hands, loose clothing, long hair and jewelry away from working end of tool.
8. Power tools can vibrate in use. Vibration, repetitive motions or uncomfortable positions may be
harmful to your hands and arms. Stop using any tool if discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming.
9. Keep body stand balanced and rm. Do not overreach when operating this tool. Anticipate and
be alert for sudden changes in motion, reaction torques, or forces during start up and operation.
10. DO NOT USE THIS TOOL WHEN TIRED, UNDER THE INFLUENCE OF MEDICATION,
DRUGS OR ALCOHOL.
11. Never use a damaged or malfunctioning tool or accessory.
12. Do not modify the tools, safety devices or accessories.
13. Do not use this tool for purposes other than those recommended
14. Never exceed rated pressure of tool.
3/37

SAFE AND CORRECT USE
IMPORTANT - READ CAREFULLY
This manual contains important information for the correct installation, operation and maintenance of
this equipment. All persons involved in the installation, operation and maintenance of this equipment
must be thoroughly familiar with the contents of this manual. To safeguard against the possibility
of personal injury or property damage, follow the recommendations and instructions of this manual.
Keep this manual for reference.
WARRANTY STATEMENT
TorcUP products are warranted to be free of defects in materials and workmanship under normal use
for as long as the original purchaser owns them, subject to the guidelines and limitations listed. This
warranty does not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, im-
proper uid, or use in a manner for which they are not intended. If the customer believes a product is
defective, the product must be delivered, or shipped freight prepaid, to the nearest TorcUP Authorized
Service Center for evaluation and repair. This pump offers 13 month warranty.
RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify
carrier at once. Shipping damage will not be covered by warranty. The carrier is responsible for all
loss associated with shipping damage.
SAFETY
Make sure to read the instructions, warnings and precautions carefully. Follow any recommended
safety precautions to avoid personal injury or damage to the unit. TorcUP cannot be responsible for
any damage or injury from unsafe use, lack of maintenance or incorrect operation. In the event any
questions or concerns arise, contact TorcUP or a local representative for clarication.
The pump’s maximum working pressure is 10,000 PSI(700kg/cm2). Make sure that all hydraulic
equipment such as rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2)
operating pressure.
If you have never been trained on high-pressure hydraulic safety, consult your representative for a
free TorcUP Hydraulic Safety Course.
Failure to comply with the following cautions and warnings could cause equipment damage, property
damage or personal injury.
DANGER is only used when your action or lack of action may cause serious injury or even death.
WARNING indicates a potential danger that requires correct procedures or practices to avoid per-
sonal injury.
CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent
damage to, or destruction of equipment, or other property.
4/37

WARNING: Wear proper personal protective gear when operating hydraulic equipment.
DANGER: To avoid personal injury, keep hands and feet away from work-piece during operation.
WARNING: Do not exceed equipment ratings. Overloading causes equipment failure and possible
personal injury. The pump tools are designed for a maximum pressure of 10,000 PSI (700kg/cm2).
Do not connect a jack or cylinder to a pump. Never set the relief valve to a higher pressure than the
maximum rated pressure of the pump. Higher settings may result in equipment damage and/or per-
sonal injury.
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.
CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic
hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will inter-
nally damage the hose, leading to premature hose failure. Do not drop heavy objects on hose. A sharp
impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may
cause it to rupture.
IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying handle
or other means of safe transport.
CAUTION: Keep hydraulic equipment away from ames and heat. Excessive heat will soften seals,
resulting in uid leaks. Heat also weakens hose materials. For optimum performance do not expose
equipment to temperatures of 65° C (170° F) or higher. Protect hoses and cylinders from weld spatter.
SAFE AND CORRECT USE
TECHNICAL SPECIFICATIONS
WORKING PRESSURE
The pump’s maximum working pressure is 10,000 PSI
(700kg/cm2). Make sure that all hydraulic equipment
such as tools, hoses, etc. used with this pump are
rated at 10,000 PSI (700kg/cm2) operating pressure.
INSTALL VENT PLUG
Remove shipping plug from reservoir and install
vent plug supplied with pump.
ADDING OIL
Remove oil ller cap and add TorcUP hydraulic oil
into reservoir. Oil level should not exceed 1” from
the reservoir cover. Oil should be ISO 32 or 46
weight.
*As a “rule of thumb” oil should be lled about an inch below the
top of the reservoir when the unit is powered down and all
connected tools or cylinders are retracted.
EP500 EP1000
5/37

LUBRICATION
TECHNICAL SPECIFICATIONS
INSTALL HYDRAULIC CONNECTIONS
Use only tools, hoses and accessories rated at 10,000 PSI
(700kg/cm2). Remove the shipping plugs from the ports
to connect your coupling(s) or hose(s) to manifold. Use
1.5 wraps of Teon tape (or suitable thread sealant) on all
threads, leaving the rst complete thread free of tape to
ensure no foreign matter enters the hydraulic circuit.
When making connections with quick disconnect couplings,
make sure the couplings are fully engaged. Threaded connec-
tions such as ttings, gauges, etc. must be securely tightened
and leak free.
EP500
EP1000
6/37

TECHNICAL SPECIFICATIONS
Loose or improperly threaded ttings can be potentially dangerous if pressurized;
however, severe over tightening can cause premature thread failure. Fittings need
to be tightened secure & leak free. Never hold or stand directly in line with any
hydraulic connections while pressurizing. Never grab, touch or in any way come in
contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and a
serious injury can result.
CAUTION: Do not subject the hose to potential hazards such as sharp surfaces, extreme heat or
heavy impact. Do not allow the hose to kink or twist. Inspect each hose for wear before it is used.
ELECTRICAL
Check for proper electrical supply before connecting. Be sure the electrical connection is grounded.
Check that your power supply agrees with the motor nameplate and/or TorcUP model decal.
NOTE: MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE
PRESENCE OF CONDUCTIVE LIQUIDS.
1. Do not use a power or extension cord that is damaged or has exposed wires.
2. All single phase motors come equipped with a three prong grounding type plug to t the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the
pump’s motor must be grounded.
CONNECTING HYDRAULIC TOOLS
Use only tools, hoses and accessories rated at 10,000 PSI (700kg/cm2). When making connections
with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections
such as ttings, gauges, etc. must be securely tightened and leak free. Use 1.5 wraps of Teon tape (or
suitable thread sealant) on all threads, leaving the rst complete thread free of tape to ensure no foreign
matter enters the hydraulic circuit.
STARTING THE PUMP FOR THE FIRST TIME
1. Check for any leaks, repair as needed.
2. When rst plugged in the solenoid makes 4 “clicks” relieving any pressure still in the system.
When the button to turn off the pump is pressed it goes through the same sequence for the
same reason. It is then safe to remove tool and hoses.
3. Shift pendant to the advance position to advance tool and release to retract tool. Look for
movement in tool, check for any leaks, repair as needed.
CAUTION: Never operate the pump without tool movement for more than 1 minute. Leaving the valve
in the advance or retract position without the tool’s piston rod moving will overheat the oil.
CAUTION: Never disconnect or connect any hydraulic hoses or ttings without rst unloading the tool,
then unplug the electrical cord of the pump. Open manual relief valve to assure that the system has
been depressurized.
7/37

TECHNICAL SPECIFICATIONS
PUMP MOUNTING
Refer to the chart for mounting dimensions to
secure the pump to a xed surface.
1 gal.
(4L)
1.5 gal.
(6L)
2.5 gal.
(10L)
5 gal
(20L)
A 11 15.13 17 19.6
B 0.56 1.68 2.75 4.69
C 0.56 3.57 4.37 5.03
D 1.16 1.43 1.93 2.93
E 8.19 9.75 9.75 11.75
F 1/4-2unc 1/4-2unc 1/4-2unc 1/4-2unc
(4 places) (4 places) (4 places) (4 places)
CONTROL VALVES
2-Postion – 4 Way Solenoid Valve for
Hydraulic Torque Wrenches.
To Advance......depress the Advance Switch
To Retract.........release advance switch to Retract Tool.
2 Position
-
4 Way Solenoid
POWER CONTROL SWITCHES
Remote pendant.
Congured with motor control pendant:
Press UP or Down
To Turn Pump Off
Press UP or Down
To Turn On Pump
NOTE: In the event multiple buttons are
depressed for longer than 5 seconds,
the unit is programmed to shut down.
To restart, you will need to depress
the motor “ ON” to continue, or unplug/
replug the unit into power supply, then
depress the motor “ ON” to continue.
8/37

OPERATION PROCEDURES
PRESSURE TORQUE SETTING
1. See torque wrench instructions for amount of pressure required
to produce desired torque.
2. Loosen lock nut and back out relief valve to prevent unintended
pressure builds up.
3. Turn pump on. Press and hold the “ADVANCE” switch, and read
pressure gauge.
4. While holding the switch, turn relief valve in (clockwise)
to increase pressure or out (counter-clockwise)
to decrease maximum pressure. Repeat until
correct pressure is obtained.
5. Tighten lock nut on the relief valve to maintain setting.
6. Run pump several times to test this setting before
setting tool on the nut.
AFTER COMPLETING THE JOB
Before disconnecting hoses, ttings, etc., rst be sure the tool is unloaded and retracted, then unplug
the power cord. The pump is designed to cycle the valve upon powering off to release pressure.
PERIODIC MAINTENANCE
Completely change the hydraulic oil and clean the intake screen and magnet (located in the reservoir)
twice a year. If equipped, change the external oil lter twice a year (Use TorcUP oil only, Model # AO1,
1 gallon). Change the oil more frequently when used in extremely dusty areas or when the oil has been
overheated. Using oil other than TorcUP Brand may void the pump’s warranty.
The following conditions require more frequent oil changes.
•Rigorous duty, where oil temperature may reach 150˚ F.
•High humidity environment and extreme changes in temperature that can result in condensation
inside the reservoir.
•Dirty or dusty environments that may contaminate the oil.
•Frequent connection and disconnection of hydraulic hoses and components.
Make these adjustments BEFORE putting torque wrench on nut or bolt
head. The pump pressure setting may be above the pressure needed
to provide the required torque for your application.
Exceeding required torque will cause equipment damage and may lead
to serious personal injury.
The electrical power cord must be disconnected from electrical outlets
before performing maintenance or repair procedures.
9/37

MAINTAIN OIL LEVEL
Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in
oil when all tools are retracted. Add TorcUP oil (Model # AO1 – 1 gallon) when necessary. Oil level
should be no more than 1” from top of reservoir plate – with cylinders retracted and motor off.
CLEAN OIL INTAKE SCREEN ONCE A YEAR
Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not to damage
the gasket.
Applies to 1, 1.5, 2, 2.5 gallon reservoirs:
Remove the ve allen socket head cap screws, securing the screen to the 1st stage gear pump. Care
should be taken not to remove the center plate and gears. Remove and clean with nonammable
solvent, blow dry clean. Reinstall in reverse order and torque bolts to 75 inch pounds. Keep the motor
and pump as clean as possible.
Applies to the 5 and 10 gallon reservoirs:
Unscrew screen from bottom of pump unit and clean
with nonammable solvent. Blow dry and reassemble.
Keep areas around pump unobstructed to provide good
air ow around the motor and pump. Keep the motor
and pump as clean as possible.
FLUSH THE PUMP
If you suspect your pump has been contaminated or
discover sludge or other deposits on internal
components, you should thoroughly ush the pump.
Remove the old oil from the reservoir, then thoroughly
clean the reservoir and rell with a clean, nonammable
ushing oil. Reassemble the pump and motor to the
reservoir.
Run the pump in no load condition for 1 or 2 minutes maximum. Unplug the pump and remove the
motor and pump assembly again. Now drain the ushing oil and re-clean the inside of the reservoir.
(Make sure ushing uid is also drained from pump assembly). Reassemble the pump and rell the
reservoir with TorcUP hydraulic oil and reassemble the pump.
OPERATION PROCEDURES
10/37

TROUBLESHOOTING
PROBLEM CAUSE-SOLUTION
Sporadic Tool Action: • Air in the hydraulic system. Bleed the hydraulic circuit.
• Check reservoir oil level.
Motor Will Not Start: • Be sure power cord is not damaged.
• Check for tripped circuit breaker; be sure breaker is of
adequate size.
• Have motor checked for proper operation.
• Have qualied electrician inspect for loose or faulty wiring or
switch.
.
Noisy Operation: • Air in system.
• Be sure the oil reservoir is lled to normal level.
• Check all points where air might leak into system.
• Clogged or blocked intake screen.
Pump Oil is Over Heating: • Inspect for high pressure leakage at the pump (leaking at
plug or relief valve).
• Oil level is low. Fill reservoir to normal level, or retrot the
pump with larger reservoir or heat exchanger.
Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from
side to side.
• Inspect to make sure that external adjustable relief valve is
set properly.
• Defective control valve, take to nearest TorcUP Authorized
Service Center for repair.
• Incorrect motor rotation, take to nearest TorcUP Authorized
Service Center for repair.
• Check to make sure the intake screen is not clogged. Clean
if needed.
• Check oil reservoir is low. Fill as needed.
• Oil viscosity is too high. Replace with TorcUP oil.
11/37

PARTS INDEX
How to Identify Parts for Your Model.
MODEL NUMBER & DATE CODE LOCATION
For example, the date code and serial number
J = October
07 = Year 2007
42 = Week number in year
J 07 42
A B C D E F G H I J K L
1 2 3 4 5 6 7 8 9 10 11 12
How to Identify Parts
for Your Model.
EP1000 Torque Wrench
Power Pump
MODEL NUMBER & DATE CODE LOCATION
MODEL DECAL
PLACEMENT
DATE CODE COVER PLATE
STAMPING LOCATION
12/37

COMMON COMPONENTS
Common components
used in pumps
EP1000 Torque Wrench
Power Pump
NOTE: This illustration is for reference
only. The appearance of your unit
Note: This illustration is for reference only. The appearance of your unit may differ from unit shown.
EP1000
13/37

COMMON COMPONENTS
EP1000
Common components
used in pumps
EP1000 Torque Wrench
Power Pump
NOTES : REBUILD KIT ( * = COMPONENTS) -- PART # 54488
ITEM # DESCRIPTION PART # PART # QTY. ITEM # DESCRIPTION PART # PART # QTY.
02 PUMP ASM. 1.00 29 HEAVY HEX JAM NUT 1/4-20 69234 69234 2.00
03 RESERVOIR 1.00 30 BHCS 10-24 x 3/8 LG 69236 69236 4.00
04 RESERVOIR GASKET 1.00 30 BHCS 10-24 x 3/8 LG 69236 69236 4.00
05 BREATHER VENT 3/8" NPT 46348 46348 1.00 35 DECAL 5.71" x 1.15" 46355 46355 2.00
06 PIPE PLUG 1/4" W/ COATING 46510 46510 1.00 37 QUICK DISCON. FLAG BLUE 44491 44491 2.00
07 SAE #12 HEX PLUG WITH PT 46118 46118 1.00 42 HOLE PLUG 1/4" 46405 46405 4.00
08 HHCS 1/4-20 X .75 PLT 65891 65891 14.00 43 SPACER 1" 69353 69759 2.00
09 SEALING WASHER 65892 65892 14.00 44 HHCS 1/4-20 X 1.50 84417 87260 2.00
10 G5 RESERVOIR DECAL 46052 46052 2.00 45 WASHER 1/4" SS 88429 88429 2.00
11 LABEL SAFE USE ELEC 68068 68068 1.00 46 COIL 115V WITH DIN CONNECTOR 46294 46324 1.00
12 BLANK DECAL 3 X 4 87305 87305 1.00 52 SIGHT GAUGE 46009 46009 1.00
13 MANIFOLD ASM. 1.00 57 1/4 IN NIPPLE 4100067 4100067 1.00
14 VALVE GASKET 69242 69242 1.00 58 1/4" NIPPLE CT210 CT210 1.00
15 SHCS 3/8-16 X 2 3/4 99921 99921 3.00 59 1/4" SELF-LOCKING COUPLER 45765 45765 1.00
16 ADAPTER ASSY. 68963 68963 1.00 62 GAUGE SHROUD ASSEMBLY 46474 46474 1.00
17 HEX PIPE PLUG 3/8" W/ COATING 46513 46513 1.00 68 VELCRO STRAP 1x14 46310 46310 1.00
19 VALVE ASM. 2P/4W 1.00 70 GASKET-MOTOR 1.00
20 SHCS 3/8-16 X 3 1/2 88363 88363 4.00 71 PUMP GASKET G5 1.00
21 LOCK WASHER 3/8 93943 93943 2.00 73 COVER PLATE 1.00
21 LOCK WASHER 3/8 93943 93943 4.00 74 PIN,DOWEL 3/16 1" LONG 69026 69026 1.00
22 ROLL PIN 1/8 X 3/8 LG 561604 561604 1.00 75 SHCS 3/8-16 X 1 93594 93594 2.00
24 MAGNET 66021 66021 1.00 76 1 1/2HP, PM MOTOR 68376 68403 1.00
25 MOTOR SHROUD W/ HANDLE 45534 45534 1.00 78 FHCS 1/4-28 x 0.50 LONG 46279 46279 4.00
27 DECAL OVERLAY 46539 46539 1.00
28 BRACKET ASM - CIRCUIT BOARD 1.00
SEE PAGE 21-22
*
*
SEE PAGE 23
SEE PAGE 19
SEE PAGE 16
SEE PAGE 23
*
SEE PAGE 20
15
14/37

COMMON COMPONENTS
Common components
used in pumps
EP1000 Torque Wrench
Power Pump 230v
NOTE: This illustration is for reference
only. The appearance of your unit
16
EP1000
15/37

SUB PUMP ASSEMBLY
(46335) PUMP ASM.
EP1000
16/37

(46335) PUMP ASM.
SUB PUMP ASSEMBLY
EP1000
Sub Pump Assembly
EP1000 Torque Wrench
Power Pump
(46335) PUMP ASM.
ITEM # DESCRIPTION PART # QTY.
01 PUMP BODY G5 45750 1.00
02 BEARING ROLLER 5/8x13/16x5/8 WIDE 68360 1.00
03 THRUST BEARING 66033 1.00
04 THRUST WASHER 66474 2.00
05 ECCENTRIC SHAFT ASM 5/8" G5 SEE PAGE 18 1.00
06 THRUST BEARING 66106 1.00
07 THRUST WASHER 66108 2.00
08 ECCENTRIC SHAFT ADAPTER G5 45908 1.00
09 O-RING 1 3/4 X 1 7/8 * 1.00
10 RETAINING RING 68978 1.00
11 POW'R BUD DUMP PLUG 43283 1.00
12 O-RING 3/16X5/16 * 3.00
13 BACKUP WASHER 56080087 1.00
14 MALE TEE 1/8" PIPE TO 1/4" TUBE 45426 1.00
15 PIPE PLUG 1/4" FLUSH W/ COATING 46509 1.00
16 UNLOADING PISTON ASSEMBLY SEE PAGE 18 2.00
17 MALE ELBOW 1/4" TUBE 1/4" PIPE 45929 1.00
18 BALL 1/8" 90906 3.00
19 G3 PISTON BLOCK TUBE 45420 1.00
20 OUTLET TUBE PISTON BLOCK 45815 1.00
21 BALL 5/16" 91701 3.00
22 UNLOADING SPRING 43671 1.00
23 ADJUSTING SCREW G5 45903 1.00
24 O-RING 5/8X3/4 URETH * 1.00
25 PIPE PLUG FLUSH 1/16 W/ COATING 40049 7.00
26 WEAR PLATE G5 45909 1.00
27 BOTTOM PLATE 9/32" G5 45900 1.00
28 GEAR PUMP 0.281 45824 2.00
29 SHAFT-IDLER 68850 1.00
30 SCREEN * 1.00
31 TUBE-GUIDE .11 68894 2.00
32 SHCS 1/4-28 X 1 3/4 68255 5.00
33 PLATE-SCREEN MTG. 68927 1.00
34 MALE ELBOW 1/8 PIPE 69354 1.00
35 SPRING 68225 2.00
36 ROLL PIN 1/8 X 3/4 LONG 97782 1.00
37 BALL STOP G5 45904 2.00
38 GASKET 29/64 X 5/8 * 2.00
39 SPRING CAP UNLOADING VALVE 43673 1.00
41 TUBE RETURN 68569 1.00
43 BEARING ROLLER 1 1/4x1 1/2x3/4 WIDE 66030 1.00
44 BEARING ROLLER 1/2x11/16x1/2 WIDE 68891 3.00
45 RING-RETAINING 68892 1.00
46 PIPE PLUG 1/8" FLUSH W/ COATING 46508 1.00
47 CART REL. VAL. ASSEMBLY 66220 1.00
48 SHAFT SEAL G5 * 1.00
49 PISTON BLOCK ASM. 0.255 G5 SEE PAGE 18 2.00
50 SHCS 5/16-24 X 1.75 69392 8.00
REBUILD KIT ( * = COMPONENTS) -- PART # 54488
17/37

(46336) PISTON BLK ASM.
(43766) UNLOADING PISTON ASM.
ITEM # DESCRITPION PART # QTY.
01 UNLOAD PISTON 43765 1.00
02 O RING 1/4X3/8 1.00
03 BACK-UP WASHER TEF 43768 1.00
04 DOWEL PIN 1/8X3/4 LG 43686 1.00
(45820) ECCEMTRIC SHAFT ASM.
ITEM # DESCRIPTION PART # QTY.
01 ECCENTRIC SHAFT 5/8" 45819 1.00
02 ECCENTRIC RING 45907 1.00
03 ROLL BEARING 1 1/8x1 3/8x3/4 WIDE 45926 1.00
04 RETAINING RING EXTERNAL 1 1/8" 45931 1.00
05 THRUST WASHER 68026 2.00
ITEM # DESCRIPTION PART # QTY.
01 GEN II PISTON BLOCK 45539 1.00
02 BALL 1/8" 90906 2.00
03 SPRING 66042 1.00
04 BALL STOP 68810 1.00
05 BALL RETAINER 66043 1.00
06 INTAKE SEAT 66046 1.00
07 GASKET 25/64X19/32 1.00
08 PLUG PISTON BLOCK 68825 1.00
09 GASKET 29/64 X 5/8 1.00
10 ADAPTOR .255 DIA. 68909 1.00
11 SPRING, PISTON 68340 1.00
12 PISTON .255 DIA. 68222 1.00
*
*
*
REBUILD KIT ( * = COMPONENTS) -- PART # 54488
SUB PUMP ASSEMBLY
EP1000
(45820) ECCENTRIC SHAFT ASM.
(46336) PISTON BLK ASM.
(43766) UNLOADING PISTON ASM.
18/37

VALVE SUB ASSEMBLY
Valve Sub Assemblies
(46291) 3 & 4 WAY SOLENOID VALVE 115V. / 230V.
PACKING KIT 3 & 4 WAY SOLENOID VALVE
(* = COMPONENTS) -- PART #54491
ITEM # DESCRIPTION PART # QTY.
01 BODY-VALVE 68708 1.00
02 SLIDER ADV/RET ONLY 44328 1.00
03 BALL 3/16" 90548 4.00
04 SET SCREW 1/4-28 X 1/4 CUP 40254 4.00
06 O-RING 7/32X11/32 * 3.00
07 BACK UP WASHER * 3.00
08 SHEAR SEAL 68383 3.00
09 SPRING 68384 3.00
10 O-RING 2 5/8 X 2 3/4 * 1.00
11 BEARING ROLLER 5/16x1/2x5/16 WIDE 68385 4.00
12 PIN BEARING 68390 2.00
13 PIPE PLUG FLUSH 1/16 W/ COATING 40049 1.00
14 SHCS #10-32 X 1" LG PLATED 68264 2.00
15 VALVE TOP PLATE MACHINED 46272 1.00
17 O-RING 3/16X5/16 * 1.00
19 VALVE PLUG 2 POSITION SLIDER 46271 1.00
26 O-RING SAE PORT #10 * 2.00
27 SPRING 68711 1.00
29 SPACER VALVE SLIDER 46418 1.00
31 O-RING 5/16X7/16 URE * 4.00
32 PUSHER-SOLENOID 68729 1.00
EP1000
19/37