TRITORC BEL-8 Series User manual

Safety Guide
Electrical Tensioner Pump's safe usage requires correct operation and regular
inspect, the user is always requested to follow always and carefully regular inspect.
▲precaution to avoid direct loss in economic or property.
▲warning to avoid personal injury.
Please follow herein before!
When using, if something abnormal happens, please shut off the power
TRITORC TRITORC s
OPERATION AND MAINTENANCE MANUAL
BEL-8 series
TRITORC Hydraulic
It is operating manual of BEL-8 series Electrical Tensioner Pump, please read
carefully follow instructions warnings and cautions before using the tools.
1
Electrical Tensioner Pump

PRECAUTION
Only TRITORC hydraulic special oil available.
Do not use pressure regulate valve as relief valve.
The used hydraulic oil should be put away according to the antipollution ordinance.
1. When using, do not permit any person stand at the oil output in order to avoid personal injury
and equipment damage. Please put the pump far away from the fire.
2. Make sure that the hose and quick coupler be connected before building up the pressure in
order to avoid hydraulic fluid spurting out to cause personal injury.
3. The maximum operating pressure of this pump is 2000bar (29000psi), TRITORC has set up
the pressure to 2000bar before selling this pump. Please do not adjust to a pressure higher than
the maximum pressure which TRITORC has not set.
4. If this pump is used for operating other equipment’s, make sure the maximum operating
pressure of the equipment’s will be less than 2000bar. Please adjust the pressure to which the
equipment needs, or else the equipment would be damaged.
5. Make sure the power of the pump is shut off before repairing it.
6. If the rapid release of pressure, lifting jack in the load will fall or spring open, may cause
injuries; please refer to TRITORC or TRITORC authorized agents, they will recommend you the right
valve.
7. Please shut off the switch before starting power; if the switch is on, the pressure may increase.
8. Make sure the equipment be connected with ground to avoid electric shock.
9. Please do not change any part of the pump; if it must be changed, please inform TRITORC
or TRITORC' s agent for help. Without allowance of TRITORC or its agent, any refit of it will be
out of our warranty range.
10. Please do not fill the pump reservoir with too much oil, otherwise, the pressure of the
reservoir r will increase and the oil will spill over, so the reservoir will be broken and the
environment will be polluted.
11. Make sure the quick coupler is tightened; if the quick coupler is not tightened enough, the
equipment will not work normally; if it is a synchronic system, the problem may cause one or
several pieces of equipment out of order and the quick coupler may be broken and it may ca
-use personal injury or equipment damage.
12. Please stand away from the position where the hydraulic oil may be spurt out; hydraulic oil
may penetrate your hand and hurt you.
13. If the hydraulic oil splashed in your eyes, please immediately wash your eyes about 15
minutes with clean water, then you must go to hospital for help right now.
14. Please do not touch the pressurized hose; if the hydraulic oil splashed out, it will cause serious
injury.
15. Hydraulic hose is easily spoiled fitting; you inspect the hose with eyes regularly and find no
problems, but the inner side may have crack and small hole; TRITORC suggests you should
change the hose regularly for.
2

DESCRIPTION
1. Tensioner pump is an integrated assembly; by the oil pump, control valve, oil tank, Electrical motor,
coolers, instrument consisting of an independent and complete hydraulic device, has the
advantages of small volume, light weight, simple structure, convenient operation, high work pressure.
Pump for high, low pressure oil pump and oil supply, it can obtain the larger oil output. High pressure,
low pressure pump by unloading overflow valve automatic no-load return oil, can reduce the power
consumption, output pressure is 90~2000bar arbitrary regulating.
2. Hydraulic oil:46# wear-resistant hydraulic oil.
3. working environment temperature: - 10~60 C
4. Use TRITORC high-pressure hose, quick coupler. The maximum using pressure of hose is
1800bar, please use the selection and matching pressure system.
5. This pump for use of hydraulic products, please consult the TRITORC engineer.
6. Please don't use the electric hydraulic pump near flame.
7. Please do not arbitrarily adjustable pressure regulating valve, in order to avoid the high pressure
caused by equipment damage and personal injury.
DESCRIPTIONS OF PARTS
1. Oil tank: working with hydraulic oil storage, to ensure the normal work of the system (must have enough
oil ), to provide the required pressure carrier system.
2. Motor: provide power source (based on the use of the voltage, frequency selecting motor, see
specific parameters in the motor nameplate).
3. Pump protection frame: installed in the storage tank, used for carrying, protection of hydraulic pump
station.
4. Electronic control box: Built-in micro electronic control system, control the entire
pump.
3

2ª2
Item
Description
Item Description
1
Protective Frame
Y
Electrical Control Box
Z
I
Pressure Gauge
8
Cooler
7
I
Regulating Valve ª
k
I
Valve Block
10
Check Valve
5
I
Oil Tank I1 Oil Filling Port
6
I
Oil Releasing Port 1Z Oil Gauge

5. Electronic control box: Built-in micro electronic control system, control the entire pump.
6.Ventilation hole: The realization of hydraulic oil discharge tank (replacement of hydraulic
oil used in oil); cover with ventilation holes, filling the oil cover, a filtering net is arranged
to ensure that no impurities into the tank; tightening oil cover ensure system of air
discharged smoothly.
7. Liquid level gauge: Observation of hydraulic oil to ensure that the number, provide the best use of
oil; hydraulic oil below the oil standard1 /3 position, must add TRITORC pumping station hydraulic
oil, or may damage the pump station.
8. Oil unloading hole: Plug G1/ 4", realize hydraulic oil discharge tank ( replacement of hydraulic oil
in use);
9. Fast joint : The realization of hydraulic oil output \ return oil function, fast connecting pipe built-in
type check valve;
10. Six angle screws: Sealing connecting tank.
CHARACTERISTIC
1.BEL-8 Electric Tensioner Pump is a double stage pump with 2000bar
maximum operating pressure
3.Motor voltage:220V
4.Temperature: - 10~6 0 ℃
5.Oil tank:5.5L
6.ISO VG 46# anti-wearing hydraulic oil
WARNING !!!
1. When operating, do not permit anyone stand at the oil output,The oil output must connect other
components when adjusting the pressure.
2. When using, do not overpass the max operating pressure.
3.If need to check motor tank, please shut off the pump.
4. When working, the oil back to oil reservoir may add the pressure. If open the cover plate, unnec
-essary injury and damage will happen.
5.Proihbit to operate without oil.
6. Keep the pump clean,clean especially the oil inlet, quick couplers.
7. Suggestion: in the condition of not using the pump always, please remembe r to replace
the hydraulic oil.
Warning Plate
Warning plate is shown in table 1
warning table
Meaning
Affixed Position
For Safe Operation,
Please Read
The Equipment
Enclosure
Warning Notices
The Equipment
Enclosure
! WARNING
To help avoid personal injury , read the opera
-ting instructions before using this pump .
Disconnect the power supply before any
maintenance is performed on this pump . All
electrical work must be done by a qualified
electrical .
Operators of this hydraulic power supply unit
or operations of equipment powered by this
unit must be knowledgeable of hydraulic
equipment hazards if any hydraulic
equipment is used incorrectly .
Hydraulic fluid recommended in operating
instructions must be used in this pump .
Do not use pump in any type of explosive ,
flammable , or gas environment .
Escaping hydrauic fluid under pressure can
have sufficient force to penetrate the skin
and cause serious personal injury . If you are
injured by escaping hydraulic fluid , seek
medical attention immediately . See operating
instructions for further precautions to help
prevent the possibility of hazards occurring
due to escaping hydraulic fluid .
4

NOISE/VIBRATIONAND TRANSPORT INFORMTION
NOISE/VIBRATIONANDTRANSPORT INFORMATION
1. Electrical Tensioner Pump noise declaration
1.1. Noise: ≤ 6 5db
2. Electrical Tensioner Pump transport information.
2.1 Handle with care.
2.2 The shipment should be vertical upward as shown in the figure 9-1.
FIG 9 - 1
2.3 Product handling, generally using portable, car handling and lifting and moving,
as shown in the figure 9-2 .
FIG 9 - 2
6

OPERATION INSTRUCTIONS
1. PREPARE
1.1 Use super high-pressure hose to do connect the high-pressure outlet of the pump and the
high-pressure outlet of the bolt Tensioner. Insert the quick coupler till to the end, please be sure to
achieve reliable connection.
1.2 Loosen the pressure regulating valve, then tighten the check valve to show it is working stage.
2. ADJUSTING THE HIGH PRESSURE
2.1 Put through the current source, turn the circuit breaker of the electrical box shell to “on” position.
2.2 Hold on the resettable buttons on the line switch, adjust the pressure regulating valve on
the pump, to set the desired pressure; then loosen the resettable buttons on the line
switch, Release cut-off valve to show the pressure gauge pointer to zero, retighten the cut
-off valve; pressed the resettable button, observe the pressure gauge pointer, repeat the
above steps, until transferred to the required pressure, lock the nut, complete the process of the
pressure regulation.
3. OPERATION
3.1 Press on the wire control switch self-locking button, the pump will output the pressure,
hydraulic bolt tensioner will start to work; when the pressure is close to the set value,
release the self-locking button, Press the self-resettable button on the control switch; to make the
pressure reaches the desired pressure.
3.2 When the working pressure is same as the set required pressure, press the self-locking
on the wire control switch, when gauge pointer stability, read the pump output pressure as
the setting pressure, you may release the button.
3.3 Release cut-off valve so the pressure gauge will drop to zero, retighten the cut-off valve;
Repeating above steps until the whole process is over.
3.4 After the end of the operation, loosen the valve venting in the hose and the pressure in
the hydraulic machinery, remove the high-pressure hose, cover the dustproof cap; turn off
the source, turn the circuit breaker of the electrical box shell to the “off” position.
REMARK: For initial work or repair, please run the motor for several times, this will help remove
the air from the high-pressure pump, then normal operation can be used upon the normal oil.
7

TROUBLE SHOOTING GUIDE OF HYDRAULIC PUMP
The pump can't be started
The voltage isn't suitable
Confirming whether the voltage
is suitable for the pump's need
The power hasn't been connected
Checked the input air, switch and
distribution box and so on, and
connect the air.
The system has no pressure
The quick coupler hasn't been
connected to the correct position
Take down and reinstall it
No oil in the oil reservoir
Fill in oil
Not enough oil in the oil reservoir
Fill in oil
If the system has a throttle and
hand single-direction valve, please
check if the valve is open
Open the throttle and hand
single-direction valve, and
make sure the system is a circle
After reinstalling the quick
coupler, the system has
no pressure
The quick coupler can't be connected
to the correct position, which causes
no pressure in the system
Take down the quick coupler, check
if the boll is elastic with a rod, if it can't
move, please knock it with a hammer
to eliminate the mist hydraulic oil
Leakage in the quick coupler
The o ring and escape have worn out
Replace the quick coupler
The pressure can't reach to
the set pressure
The relief valve is adjusted
too low
Check with the gauge, and adjust the
relief valve to the system set pressure
Oil is mixed with water
Change oil
Not enough oil in the reservoir
Fill in oil
Suck in air to the system
Repeat operating the system with no
load for several times to eliminate the air
The throttle and hand single-direction
valve haven't been tightened
Locking valve
The throttle and hand single-direction
valve haven't been adjusted to the
correct position
Adjust to the correct position
The throttle and hand single-direction
valve have broken
Replace the valve
There is foreign matter in
the oil
Wash the pump valve and
change clean oil
When using under static pressure,
the pressure reduces slowly
The seal is out of control, please
check all the seal
Replace the seal
Pump during operation with
strong noise
Radial plunger pump bearing
damage
Replace the radial plunger
8

Part List with drawing for Pump body
Item
Name
Q††
Seal Gasket
Screw
Bearing
Connect Flange
Body Sleeve
Screw
Block for High Pressure
Pipe
Pipe Fitting
Connect Fitting
Connector 2 (high
pressure)
Screw 2
Pump head (low pressure)
Checking valve
Regulating valve
Relief valve (low
pressure)
Fitting
Fitting
0 ring
Bearing
Sleeve
Pump head (high
pressure)
Screw
Filter press
Retaining ring
Piston 1
High pressure piston
Piston 2
Deep groove ball
bearing ²
Retaining ring
Eccentric Sleeve
Copper Sleeve
Bearing outer ring
Eccentric Block
Multi–tooth Gasket
Nut
Screw 4
Screw 5
Filter Cover

9
Part List with drawing for Valve Block
Item
DESCRIPTION
Quantity
Item
DESCRIPTION
Øuantity
Gauge
SC REW 1
Gauge adaptor
SC REW 2
Regulating valve
Plug
Needle valve
0 ring
CONNECTOR
Flat gasket
Steel ball 5
Spring gasket
EJECTOR PIN
S CREW
Spring
Steel ball 6.3±

Electronic Principium (Single Phase 115V/220V)
Electronic Principium
circuit board
work components
control components
Motor
Fan
symbol
Description
working capacitence
Self locking SB (+)
+
+
O
start capacitence
Self locking
O
breaker
Self retract
+
+
relay
Self retract SB2 (-)
remote control button 1
Remark: + mean› connect and work
– mean› break and stop
O mean› no connection, does not work
remote control button 1
motor
fan
circuit broad

Electronic Principium (three Phase 220V)
Work Components
Control Components
Motor
Symbol
Description
Breaker
Self locking
transformer
Self locking
remote control button 1
Self retract
remote control button 2
Self retract
high flow relay
Remark:+ mean› ×onne×t and work
– mean› break and ›top
12
O mean› no ×onne×tion,doe› not work
motor
fan

Hydraulic Principium
Warning for using high pressure hose
1. Please use TRITORC's JH series high pressure hoses.
2. The minimum bending radius: R>120mm. Too small bending radius will destroy the high-pressure hoses.
3. The maximum operating pressure is 1800bar, it is forbidden to overpass the pressure.
4. Do not tighten hoses excessively. Over tightening can cause to premature thread failure or high-pressure
fittings to split at a pressure lower than their rated capacities.
5. Do not use the hose to remove attached equipment. Stress can damage the hose, causing personal injury.
6.Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold or heavy
impact. Do not kink, twist, or bend the hose so tightly that oil flowing in the hose is blocked or reduced.
Periodically inspect the hose for wearing, because any of these conditions can damage the hose.
7.Should any hydraulic hose rupture, burst, or need to be disconnected, immediately shut off the pump.
Never attempt to grasp a leaking pressurized hose with your hands. The force of escaping hydraulic fluid
could cause serious injury.

Parameter Chart
Model
Tank
Capacity
(L)
Control
Valve
Motor (V/Hz)
Power
(Kw)
Flow Rate
(L/min)
Oil Port
Max
Pressure
BEL-8 A
5.5
BV
220V/50HZ
1.1
4.2 – 0.30
G1/4
200
BEL-8 B
5.5
BV
220V/60HZ
0.9
4.2 – 0.30
G1/4
200
BEL-8 C
5.5
BV
115V/50HZ
1.1
4.2 – 0.30
G1/4
200
BEL-8 D
5.5
BV
115V/60HZ
0.9
4.2 – 0.30
G1/4
200

All TRITORC products are guaranteed against defects in workmanship and materials
for as long as you own them. Under this guarantee, free repair or replacement will be
made to your satisfaction.