Wren KLW4010 EX User manual

KLW4010 EX
Operation And Maintenance Manual
Of KLW4010 Explosion-proof Hydraulic Pump
Explosion-proof

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 700Bar(10,000Psi),WREN has set up the pressure to
700Bar before selling this pump. Please do not adjust to a pressure higher than the maximum pressure
whichWREN has not set.
4.If this pump is used for operating other equipments, make sure the maximum operating pressure of the
equipments will be less than 700Bar. Please adjust the pressure to which the equipment need, or else the
equipment would be damaged.(Referrence content 5)
5.Make sure the power of the pump is shut off before repairing it.
6.Please shut off the switch before starting power; if the switch is on, the pressure may increase.
7.Make sure the equipment be connected with ground to avoid electric shock.
8.Do not start the pump without oil in tank.
9.Please do not change any part of the pump; if it must be changed, please inform WREN or Wren's agent
for help. Without allowance of WREN 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 will
increase and the oil will spill over, so the reservoir will be broken and the environment will be polluted.
11.When the pump works,the pressure may be increased with the returning oil.If the oil filler cop is opened
at the moment, this may cause the injury.
12.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 cause personal injury or equipment
damage.
13.Make sure to reep the pump in cleaning.
14.Please stand away from the position where the hydraulic oil may be spurt out; hydraulic
oil may penetrate your hand and hurt you.
15.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.
PICTURE 2
16.Please do not touch the pressurized hose; if the hydraulic oil splashed out, it will cause serious
injury.
17.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; WREN suggests you should change the hose regularly
for smoothing use.When using,try to avoid bending the hose in sudden.
11
disposed

1. Oil reservoir: To store hydraulic oil, make sure the reservoir enough oil to keep the pump work
normally.
2.The adjusting pressure regulator: Adjust this valve for setting the working pressure of power pack
(the)max working pressure has been locked before sales, please do not change the locked pressure
at any time.
3. Pressure gauge: it’s effects 0-1000Bar, showing the working pressure of the power pack.
4. Frame for protecting: it is fixed on motor for carrying conveniently.
5. Motor: provide power.
6. Radiator: to exclude the heat, ensure the operating time and life of the pump.
7. Oil level measurer: it can help us know the oil level, when the oil less than the1/3 of total, please
Fill the especial oil for hydraulic tools of WREN.
8. Release oil port: G1/4.
9. Control system: the integrated electric equipment of the pump.
10. Cover plate for oil tank: seal the oil tank and install the parts of power pack.
11. Solenoid valve: Its function is output oil when the pressure is very high, control the flow when
return oil, and soon. It can be set up the maximum pressure and protect system to work normally at the
pressure set up. The threads of oil output port is NPT1/4”.
12. Quick coupler : it’s function is output oil when the pressure is very high, control the flow when
return oil , and so on, it can be set up the maximum pressure and protect system to work normally at
the pressure set up, the threads of oil output port is NPT 1/4”
13. Valve block: control oil driving in and out; make sure the hydraulic system can be worked normally
under the pressure to be set up.
14. Oil filling port: To be used for filling and replacing oil.
2
, 46# or other same grade
72
Bar
7

EX T ER N A L D I M EN S I O N A N D D E S C RI PT I ON OF PA RT S
Item Description Item Description
1Electrical control system 5Pump Head Assembly
2Motor 6Oil pipe Assembly
3Pressure gauge 7Oil return pipe Assembly
4Oil tank Assembly 8Valve Block Assembly

8.6
1.1
117
,And cover on the dust cap.
380
4
2.2
690×520×476cm
with 1EXKL
1

1.Ready:
1.1 Explosion-proof pump is designed for hydraulic torque wrench. There is a 2-way, 4-position
solenoid operated direction control valve on the pump, port A is high pressure point, it can export
the oil at the high pressure, and port B is low pressure point which can output the oil at the low
pressure.
1.2 Please loosen the high-pressure valve for adjusting pressure before operating.
2.Adjust the pressure:
2.1 Please connect the power and push the switch at the position of “ON”. Then press the lock
button make the power pack working, then the power pack will output the low-pressure.
2.2 Please press the retract button on the controller and adjust the pressure unit the working
Plessure reach to what you need, and then loosen the retract button on the controller.
3. Operation:
3.1 Please press down the retract button on the controller, the pump output. The high pressure,
torque wrench works;Loosen from the retract button, the pump output the low pressure, the
torque wrench retracts; press down the lock button, the button retracts, the pump stops.
3.2 After operating, please turn off the power. Then press the rubber button on the top of solenoid
operated direction control valve in order to release the pressure in hoses and equipments,then you
can take down the hose and cover the safety cap for the quick couplers.
Attention: First time to use or after service, please try several time to operate without any
loading, this ca eliminate the in system.
Adjust
pressure
5

PART LIST FORVALVE SYSTEM
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 Valve Block 1 9 Gauge Fitting Assembly 1
2 Female Coupler 2 9.1 O-Ring 1
3 Male Coupler 2 9.2 Gauge Fitting 1
4 Reversing Valve Assembly 2 9.3 Gauge Fitting 1
4.1 Reversing Valve 2 10 Plug Screw 13
4.2 Retaining Ring 4 11 Check Valve Assembly 1
4.3 O-Ring 4 11.1 Check Valve 1
4.4 Retaining Ring 2 11.2 Retaining Ring 1
4.5 O-Ring 2 11.3 O-Ring 1
4.6 O-Ring 2 11.4 O-Ring 1
5 Steel Ball 5 12 Low Pressure Valve Assembly 1
6 Screw 5 12.1 Low Pressure Valve 1
7 Regulating Valve Assembly 1 12.2 O-Ring 1
7.1 Regulating Valve 1 12.3 O-Ring 1
7.2 O-Ring 1 13 O-Ring 1
7.3 O-Ring 1 14 Plug Screw 2
8 Solenoid Valve Assembly 1 15 Gasket 4
8.1 Solenoid Valve 1 16 Spring Gasket 4
8.2 O-Ring 2 17 Screw 4
8.3 O-Ring 1

PART LIST FOR PUMP HEAD
ITEM
Description QTY
1 Seal gasket 1
２ Bearing １
３ Bearing pole 1
４
Pump head
１
５ Release valve １
５-1
Relief Valve 1/set
5-2
Retaining ring 1/set
5-3
O-ring 1/set
5-4
O-ring 1/set
6 Safety valve 1
7 Unilateralism valve
2
7-1
Check Valve 1/set
7-2
Retaining ring 1/set
7-3 O-ring 1/set
7-4
O-ring 1/set
7-5
Retaining ring 1/set
8 Release valve 2 1
8-1
Relief Valve 1/set
8-2
Retaining ring 1/set
8-3
O-ring 1/set
8-4 O-ring 1/set
9 Clip 1
10 Screw 1
11 Bearing 1
12 Metal Retaining Ri
ng
1
13 Circle 1
14 Piston 1 4
15 Piston 2 2
16 Piston 3 2
17 Bearing 1
18 Pin 1
19 Plate 1
20 Screw 1
21 Connecting plate 1
22 Screw 16
23
Filter 1

Mal function Reason for caused malfunction Solution
The pump can not be started Un-suitable power source Confirm if the power meets pump’s
need
The power is not connected Check the power
The system has no pressure
The coupler is not connected
properly Re-install
No oil in the tank Fill oil
Not enough oil Fill oil
Check if flow control valve, single-
direction valve in the system is open
Open the flow control valve to ensure
the system is connected
The system has no pressure
after reinstall the couplers
The couplers is not connected in
the properly position
Uninstall the couplers, check if the steel
roll is elastic with a rod, if it can not move
please knock it with hammer to elimina
te the mist hydraulic oil.
Leaking in the couplers The o-ring, retaining ring worn
out in the couplers Replace the couplers
The pressure for high-pressure
leaking valve is adjusted too low Please check the gauge, adjust it to
rated value
Oil is mixed with water Replace the oil, please
Ball steel in pressure relief valve
may be broken or the valve seat
may be frayed
Replace them,please
Air may be sucked into the system Repeat operating the system with no
load for several times to eliminate air
The leaking valve may be frayed Replace it, please
High-pressure leaking valve may
not be tightened Tighten it, please
The o-ring for high-pressure leaking
valve may be broken Replace it, please
There may be some inclusion into
the oil
Wash the power pack valve and
replace oil
The system pressure can
not reach to the rated
pressure
There is a strong noise
when the power pack is
operated
The bearing may be broken
Air may be mixed into this power
pack
Replace it, please
Exhaust the air from the system
When using under static
pressure, the pressure
reduces slowly
The seal is out of control,please
check all the seal Replace the seal
Piston or spring may be broken Change them, please
Leaking may be happened at
brushfire position Tighten the couplers and replace
the seals
Oil lever may be too low
High-pressure system may not
eliminate the oil fully
Please try several times without load
before using
Too low oil temperature may make
lead to suck oil difficultly
Control the temperature at -10℃ to
60℃ ,please
Oil temperature may be too high
that cause the damage of pump
If so, the power pack need to be
replaced with new one
High-pressure flux is not
enough
Fill the oil,please
TROUBLE SHOOTING GUIDE OF HYDRAULIC PUMP
8

HYDRAULIC PRINCIPLE
700Bar
9
700Bar
1000Bar

D R A W IN G F O R E L E C T R IC A L E L E M E N T
380V 60HZ electrical configuration table:
ITEM Name Model Remark
1 Explosion-proof control box BXMD81 300*350*280 Warom
2 Explosion-proof button box BZC8050 Warom
3 Explosion-proof plug device BCZ85 380V 16A Warom
4 Explosion-proof line tube BNG 6M Warom
5 Explosion-proof line tube BNG 5M Warom
6 Explosion-proof line tube BNG 1M Warom
7 Switching Power Supply DRH-120W 24V Warom
8 Contacor BC7-30 DC24V Warom
9 Relay RCL424024 Warom
10 Fuse RT18 2A Warom
11 Motor 380V 50HZ 1.1KW ABB

Noise/Vibration And Transport information
1、Hydraulic pump noise declaration
1).Hydraulic pump noise value: ≤ 70db
2、Hydraulic pump transport information.
1). Handle with care.
2).The shipment should be vertical upward, as shown in the figure 9-1.
FIG 9-1
3).Product handling, generally using portable, car handling and lifting and moving,
as shown in the figure 9-2.
FIG 9-2
14

Warning Plate
Warning plate is shown in table 1
15
warning table Meaning Affixed Position
For Saft Operation,
Please Read
Warning Notices
The Equipment
Enclosure
!
WARNIN
G
TO AVOID POSSIBLE SERIOUS PERSONAL INJURY
OR
DEATH PLEASE READ ALL INSTRUCTIONS.
WARNING
AND CAUTIONS CAREFULLY.
A CAUTION is used to indicate correct operating or mal-
ntenance procedures and practices to prevent damage to,
or destruction of equipement or other property.
WARNING:wear proper personal protcetive gear when
operating hydraulic equipement.
WARNING:Do not exceed equipement ratings,the pimps
are designed for a max, pressure of 10,000Psi(700Bar).
Do not connect a jack or cylinder to pump with a higher
pressure rating.
Never set the relief valve to a hgher pressure than the
maximum rated pressureof the pump. higher settings may
result in equipment damage and/or personal injury.
WARNING:The system operating pressure must not
exceed the pressure rating of the lowest rate component in
the system.Install pressure.It is your window to what
is
happening in the system.
CAUTION:Aviod damaging hydraulic hose.Avoid sharp
bends and kinks when routing hydraulic hose.Do not drop
heavy objects on hose wire stands.Applying pressure to a
The Equipment
Enclosure