WEBTEC 1 Series User manual

Webtec Products Limited
1, 2 & 3 Series
Portable Hydraulic Testers User Manual
www.webtecproducts.com

English
1
Introduction
Webtec Portable Hydraulic Testers have been designed for easy connection to a hydraulic
circuit so that flow, pressure and temperature can be readily checked.Testers can take full back
pressure up to 210/420/480 bar (3000/6000/7000 psi) depending on the model, and the built-
in loading valve enables many of the operating conditions to be simulated. The tester can be
connected anywhere in the hydraulic system to test pumps, motors, valves and cylinders in both
flow directions.
Bi-Directional Flow Testing
The loading valve gives smooth control of pressure in both flow directions and is protected in
both flow directions by two replaceable safety discs which are designed to rupture at
approximately 7 bar (100 psi) over the maximum working pressure. When these discs rupture,
the oil by-passes the loading valve at low pressure and continues to flow freely through the
hydraulic system. A range of pressure safety discs are available to protect both the tester and
other components in the hydraulic system.
Although the Bi-Directional tester can be used in both flow directions, the preferred direction is
indicated by the larger arrow on the panel. When the tester is used for reverse flow tests, slightly
lower accuracies may be obtained depending on the oil viscosity, density and compressibility.
The tester should be connected to the hydraulic circuit by means of flexible hoses 1 - 2 metres
long. The use of quick-disconnect couplings can save time. Make sure the hoses are long
enough so that the tester can be used conveniently on the machine. The hoses and fittings at
the inlet to the tester must be of adequate size for the flow being tested. lbows, rotary couplings
etc., at the inlet and outlet ports of the tester should be avoided to ensure accurate readings.
The use of the flexible hoses will help to isolate the test unit from vibration which often exists.
After installing the Tester it is important to ensure that all connections are tightened and the oil
can flow freely throughout the hydraulic system B FOR running the machine at full speed.
Check that the circuit is correctly connected and any shut-off valves are opened. Also quick
disconnect couplers MUST be open.
I PORTANT: Start the pump momentarily to ensure there is no obstruction which could cause
pressure build up.
Testers have an automatic electronic system which shuts the power off after approximately 20
minutes should you forget. To reactivate the tester, turn the selector switch to the “OFF /
R S T” position then back to 'ON'.
Do not use with water
The standard Webtec Hydraulic Testers are designed for use with mineral oil having
reasonable lubrication properties.They are not suitable for use with water or fluids with a high
water content. If a tester is used with water it should be flushed immediately after use with
white or methylated spirit or similar and then flushed with mineral oil to minimise any internal
corrosion. This may avoid an expensive repair. Damage to a tester from the use of a non-
approved fluid invalidates our normal warranty.

English
2
Principles of Operation
Flow meter
The flow meter comprises an axial turbine mounted in the aluminium base block. The oil flow
rotates the turbine and its speed is proportional to the oil velocity. The revolutions of the turbine
are measured by means of a magnetic sensing head which feeds a pulse every time a turbine
blade goes by to an electronic circuit. The electronic circuit has a built-in micro processor; the
signal is amplified and linearised to maximise accuracy.The readout is calibrated in lpm or gpm,
units are selectable on some models.
Pressure gauge
The pressure gauge has a spiral Bourdon tube and the gauge case is filled with glycerine to
ensure good dampening on pulsating pressures. The gauge is connected to the turbine block
by a fine bore capillary tube. The Bi-Directional tester gauge has a shuttle valve which
automatically reads the highest pressure in both directions of flow. A gauge port is provided on
the block for the addition of a low pressure gauge.
Temperature
The Thermistor temperature transducer is in contact with the oil flow and readout is on the
meter scale calibrated 32 - 248°F or 0 - 120°C.
Bi-Directional Loading Valve
The reverse flow valve gives positive shut-off and pressure control in both directions of flow. The
loading valve has two easily replaceable safety discs located in the valve assembly which
internally protect the tester and machine in both flow directions.
Spare Safety Discs
Four spare safety discs are supplied in a threaded storage holder on the rear of the flowmeter
body (see illustration above). Safety discs need to be fitted in pairs.
Warning: Open the loading valve prior to testing

English
3
Installing the test unit
1 Connect the Tester to the circuit (see inside back cover for port sizes). The preferred flow
direction is indicated by the larger arrow on the panel. Use hoses and fittings of sufficient
diameter for the flow being tested. Avoid restrictions at inlet and outlet ports of the Tester.
Also avoid sharp bends because high pressure hoses will deflect and straighten under
pressure.
2 nsure that the pressure loading valve is fully opened by turning the knob counter
clockwise.
3 Switch the unit on. On digital models if the display flashes, or on analogue models if the
needle points to the symbol, then the battery needs replacing.
4 Select the desired test using the front panel controls (not applicable on 1 series)
5 When low pressure testing is required, connect the optional low pressure gauge with
automatic cut-out valve to the tester block.
Note: the test point can be connected by hand at full pressure.
Accessories
For 2 series testers only INFRAR D PHOTO TACHOM T R comprises infrared photo tach
head, six metre connecting cable and reflective tape.The BA20 magnetic base with flexible arm
is also available, this is used to secure the tacho head on the machine.
Note: The Photo-Tachometer should not be plugged in when the unit is already switched
on. First switch off the tester, plug in the Tacho and then switch the tester back on. Only
Webtec supplied Photo-Tachometers labelled FT9251 ISSU B should be used with this
tester. Using other brands or earlier unlabeled versions, however similar they may appear,
could cause permanent damage to the Tester and or Photo-tachometer.
For all models of tester LOW PR SSUR GAUG KIT comprises 63 mm Glycerine filled 40
bar (600 psi) gauge with automatic cut-out valve, pressure test point and 300 mm (12”) long
micro bore hose. The test point is fitted permanently into the tester block and the low pressure
gauge can be connected by hand without the need to stop the machine.
ADAPTORS. Fitting kits are available for all testers. Consult Sales Office.

English
4
Safety burst disc information
Instructions for using the portable hydraulic test unit
The tester is designed to measure pressure, flow, temperature and rpm* (* 2 series only). It can
take full system pressure between 210 and 480 bar (3000 and 7000 psi) depending on the
model. It is capable of measuring flow in both directions for motor and cylinder testing.
Make all tests at operating temperatures because as the oil temperature increases it becomes
thinner and any internal leakage becomes greater.
Testing will be easier and faster if quick disconnect couplers are used to connect the Test Unit.
There are two basic ‘set-ups’ when using the Tester.
a) The In Line test to check out pumps, entire systems and also monitoring operating
conditions.
b) The Tee Test to check out pumps, directional control valves and the overall system
condition.
A preliminary check of the hydraulic system’s oil supply, pump rotation, filters, oil lines, cylinder
rods as well as looking for external leaks should be made prior to installing the Hydraulic Tester.

English
5
DHT 1 Series Digital Hydraulic Tester
Digital
display Pressure gauge
Battery
cover
On/Off
switch
●Digital display - Digital display for flow and temperature. Automatically turns off if the unit
is unused for more than 20 minutes.
●Pressure gauge - Analog pressure gauge, filled with glycerine to ensure good dampening
when reading pulsating pressures.
●On/Off switch
●Battery cover - Remove this to replace the battery.
Bi-Directional Loading Valve
The reverse flow valve gives positive shut-off and pressure control in both directions of flow. The
loading valve has two easily replaceable safety discs located in the valve assembly which
internally protect the tester and machine in both flow directions.

English
6
Dimensions (Millimetres)
DHT401: 240 Wide, 200 Deep, 200 High
Weight: Unpacked 6.5 kg, Shipped 7 kg (Approx.)
DHT801: 245 Wide, 225 Deep, 225 High
Weight: Unpacked 10 kg, Shipped 11 kg (Approx.)
odel Flow Range Pressure Range Temperature Inlet/Outlet
Number (gpm) (psi) Range (°F) Ports
DHT401-S-6 4 - 100 6000 32 - 250 1-5/16" - 12 UN #16 O-ring
DHT801-S-7 7 - 210 7000 32 - 250 1-7/8” - 12 UN #24 O-ring
DHT801-F-3 7 - 210 3000* 32 - 250 1.5" C61 4-Bolt Flange
odel Flow Range Pressure Range Temperature Inlet/Outlet
Number (lpm) (bar) Range (°C) Ports
DHT401-B-6 10 - 400 0 - 420 0 - 120 1” BSPF
DHT801-S-7 20 - 800 0 - 480 0 - 120 1 7/8” - 12 UN
Specification
EU Specification
US Specification
Connections
Flow block connection by flexible hoses 1 - 2 metres (3 - 6ft) long.
Adaptors
Adaptor Fitting kits and flanges are available to suit the range of flow blocks. Consult the sales office.
Flow
Measured by the electronic count of an axial turbine designed to minimise the effects of variation in
temperature and viscosity.The U version displays flow in lpm, the US version displays flow in gpm.
Accuracy: ± 1% of full scale.
Pressure
Glycerine filled dual scale pressure gauge bar / psi connected by capillary tube to a shuttle valve
built into the flow block thereby always indicating the high pressure side of the valve regardless of
flow direction.
Accuracy: ± 1.6 % of full scale.
Temperature
Sensed by a thermistor pick-up in the oil flow for fast response. Temperature is permanently
displayed in °C/°F.
Accuracy: ± 1°C, 2°F.
Seals
Viton seals compatible with oil, water/oil emulsion are fitted as standard. P seals for phosphate-
ester are available to special order.
Dimensions (Inch)
DHT401: 9.45" W, 7.87" D, 7.87" H
Weight: Unpacked 14.33 lb
Shipped approximately 15.4 lb
DHT801: 9.65" W, 8.86" D, 8.86" H
Weight: Unpacked 22 lb
Shipped approximately 24.2 lb
* per J508 SA C61 standard

English
7
HT 2 Series Analog Hydraulic Tester
Tachometer
input Pressure gauge Battery voltage low Battery voltage ok
Display
(flow, temp, rpm)
Battery
cover
Selector
switch
●Display - Large analog display. Automatically turns off if the unit is unused for more than
20 minutes.
●Pressure gauge - Analog pressure gauge, filled with glycerine to ensure good dampening
when reading pulsating pressures.
●Tachometer input - Connection socket for the optional infra-red phototachometer.
●Selector switch - Turn the switch to select the required function.
●OFF/RESET - Switches the tester off and resets the unit after automatic power shut off.
●‘B’TEST - Checks the condition of the battery.
●TE P - Temperature is indicated on the display.
●TACH - RPM is indicated on the display.
●FLOW ‘HI’ - Flow is indicated on the ‘Hi’ scale of the display.
●FLOW ‘LO’ - Flow is indicated on the ‘LO’ scale of the display.
●Battery cover - Remove this to replace the battery.
Bi-Directional Loading Valve
The reverse flow valve gives positive shut-off and pressure control in both directions of flow. The
loading valve has two easily replaceable safety discs located in the valve assembly which
internally protect the tester and machine in both flow directions.

English
8
odel Flow Flow Scales Pressure Temperature Speed Inlet/Outlet
Number Range (gpm) Range Range (rpm) Ports
(gpm) Low High (psi) (°F)
HT302-S-6 4 - 80 0 - 20 0 - 80 6000 32 - 250 300 - 3000 1-5/16"-12 UN #16 ORB
HT402-S-6 4 - 100 0 - 25 0 - 100 6000 32 - 250 300 - 4000 1-5/16"-12 UN #16 ORB
HT602-F-3 6 - 160 0 - 40 0 - 160 3000* 32 - 250 300 - 6000 1.5" C61 4-Bolt Flange
HT602-S-7 6 - 160 0 - 40 0 - 160 7000 32 - 250 300 - 6000 1-7/8"-12 UN #24 ORB
HT802-F-3 7 - 200 0 - 50 0 - 200 3000* 32 - 250 300 - 5000 1.5" C61 4-Bolt Flange
HT802-S-7 7 - 200 0 - 50 0 - 200 7000 32 - 250 300 - 5000 1-7/8"-12 UN #24 ORB
Specification
EU Specification
US Specification
Connections
By flexible hoses 1 - 2 meter minimum length (3 - 6 foot). Care should be taken to avoid constrictions
at the inlet or outlet port.
Adaptors
Adaptor Fitting and flanges are available to suit the range of flow blocks. Consult the sales office.
Flow
Measured by the electronic count of an axial turbine designed to minimise the effects of variation in
temperature and viscosity.The large analogue readout meter has high / low scales selected by a switch.
Accuracy: ± 1% of full scale.
Pressure
Glycerine filled dual scale pressure gauge 420 bar / 6000 psi (7000 psi / 480 bar for HT602/802)
connected by capillary tube to a shuttle valve built into the flow block thereby always indicating the
high pressure side of the valve regardless of flow direction.
Accuracy: ± 1.6% of full scale.
Temperature
Sensed by a thermistor pick-up in the oil flow for fast response. Temperature is displayed in °C/°F.
Accuracy: ± 2°C, 4°F.
Speed
Rotational speed of motors, shafts etc., can be measured by optional infra-red phototachometer
using one or more retro-reflective marks. Range: See Table.
Accuracy: ± 2% of full scale.
Seals
Viton seals compatible with oil, water/oil emulsion are fitted as standard. P seals for phosphate-
ester are available to special order.
odel Flow Flow Scales Pressure Temperature Speed Inlet/Outlet
Number Range (lpm) Range Range (rpm) Ports
(lpm) Low High (bar) (°C)
HT302-B-6 8 - 300 0 - 75 0 - 300 0 - 420 10 - 120 300 - 3000 1” BSPF
HT402-B-6 10 - 400 0 - 100 0 - 400 0 - 420 10 - 120 300 - 4000 1” BSPF
HT602-S-7 20 - 600 0 - 150 0 - 600 0 - 480 10 - 120 300 - 6000 1-7/8” -12 UN
HT802-S-7 20 - 800 0 - 200 0 - 800 0 - 480 10 - 120 300 - 5000 1-7/8” -12 UN
Dimensions (Millimetres)
HT302/402: 240 Wide, 200 Deep, 200 High
Weight: Unpacked 6.5 kg, Shipped 7 kg (Approx.)
HT602/802: 245 Wide, 225 Deep, 225 High
Weight: Unpacked 10 kg, Shipped 11 kg (Approx.)
Dimensions (Inch)
HT302/402: 9.45" W, 7.87" D, 7.87" H
Weight: Unpacked 14.33 lb
Shipped approximately 15.4 lb
HT602/802: 9.65" W, 8.86" D, 8.86" H
Weight: Unpacked 22 lb
Shipped approximately 24.2 lb
* per J508 SA C61 standard

English
9
DHT 2 Series Digital Hydraulic Tester
Digital
display Pressure gauge
Battery
cover
External
flow
Tachometer
input
Selector
switch
●Digital display - Digital display for flow and temperature. Automatically turns off if the unit
is unused for more than 20 minutes.
●Change settings indicated by the ^ on the display - using the °C/F and UNITS buttons.
The FAST button changes the screen refresh from 1 to 3 times per second. The ON button
will switch the unit back on after the power has automatically shut-off if the unit is un-used.
●Pressure gauge - Analog pressure gauge, filled with glycerine to ensure good dampening
when reading pulsating pressures.
●Tachometer input - Connection socket for the optional infra-red phototachometer.
●External flow - Connection socket for optional second 'LT' series flow meter, to measure a
second flow and temperature.
●Selector switch - Turn the switch to select the required function.
●OFF - Switches the tester off and disconnects the battery.
●TACH - RPM is indicated on the display.
●INT FLOW - Display flow and temperature measured by the internal flow meter.
●EXT FLOW - Display flow and temperature measured by the optional external flow meter.
●Battery cover - Remove this to replace the battery.
Bi-Directional Loading Valve
The reverse flow valve gives positive shut-off and pressure control in both directions of flow. The
loading valve has two easily replaceable safety discs located in the valve assembly which
internally protect the tester and machine in both flow directions.