OPERATION AND MAINTENANCE MANUAL

FOR APL Series Hydraulic Pneumatic Pump

TRITORC Hydraulic
It is operating manual of APL torque wrench air pump, please read carefully follow
instructions、warnings and cautions before using the tools.

Safety Guide
The hydraulic torque wrench pump's safe usage requires correct operation and
regular inspect. And the user is requested to follow always and carefully .
▲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
immediately, and then consult TRITORC or TRITORC agent.
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), TRITORC has set up
the pressure to 70Mpa 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 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.
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.Please do not change any part of the pump if it must be changed, please inform or
agent for help. Without allowance of TRITORC or its agent, any refit of it will be out of our warranty
range.
9.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.
10.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.
11.Please stand away from the position where the hydraulic oil may be spurt out hydraulic oil may
penetrate your hand and hurt you.
12.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.
13.The wrench and power pump are connected by a 700 Bar operating pressure, twin-line hose
assembly. Each end of the hose will have one male and one female connector to assure proper
interconnection between pump and wrench.

FIG1

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
PRECAUTION
 Do not use pressure regulate valve as relief valve.
 The used hydraulic oil should be put away according to the antipollution ordinance.
DESCRIPTION
1.This pump is used for hydraulic torque wrench and fitted in integrated way, it is an independent
hydraulic unit that mainly consists of pump, control valve, oil reservoir, motor, meter, control-line
fitting, it has the peculiarity of small volume, light weight, simple composition, convenient operation,
high working pressure. The pump can supply oil with one high and one low oil outlet at the same
time, which could make a large quantity of oil outputting. On high pressure, the low pressure pump
will automatically let oil return through the release flow valve, which can reduce power consumption,
and the pressure of the outlet can be arbitrarily adjusted from 70 to 700 bar.
2.Hydraulic oil for this pump 46# anti-wear hydraulic oil.
3.Environmental temperature for using this pump:-10~60 ℃
4.Please use TRITORC high pressure hose, high pressure coupler, and so on. The maximum
operation pressure of high pressure hose for this pump is 1000Bar please choose suitable system
for it.
5.If you need to use attached hydraulic product for pump, please contact TRITORC engineers.
6.Please do not use this pump around the fire.
7.Please do not adjust the pressure valve arbitrarily to avoid personal injury or equipment damage
due to high pressure.
8.Please confirm that the voltage for this pump is the same as the voltage of using on the spot.
9.You'd better use the pump indoors, please protect the pump from rain if it is used outdoors.

EXTERNAL DIMENSION AND DESCRIPTION OF PARTS

APL

86
5

ITEM NAME ITEM NAME

79
43

1 Oil Reservior Adjusting pressure

11
2 Bolt regulator
2

3 Air motor 12 Oil level guage

4 Oily water separator 13 Oil leak port

1

5 The air input valve 14 Screw

6 Radiator 15 Cover plate

7 Air valve 16 Oil port

8 Pressure gauge

9 Frame For Protecting

10 Quick coupler
428

DESCRIPTIONS OF PARTS
1.Oil reservoir to store hydraulic oil, make sure there is enough oil to keep the pump working
normally.
2.Bolt to connect motor and oil reservoir.
3.Air Motor: provide power, 4~8Bar
4.Oily water separator separator the oill and woter from the air.
5.The air input valve: to let the low preasure air into system.
6.Radiator to exclude the heat, ensure the operating time and life of the pump.
7.Air valve its function is output oil when the pressure is very high, control the flow when oil return,
and so on. It can be uset to the maximum pressure and protect system to work normally at the set
up pressure. The threads of oil output port is NPT 1/4".
8.Pressure gauge: its range is 0~700Bar(0~10,000psi), in other words, the maximum operating
pressure of this pump is 700Bar(10,000psi).
9.Frame for protecting it is fixed on motor for carrying conveniently.
10.Quick coupler its effect is for oil output or oil returning, also it can help people connect pump and
tool with the hose quickly.
11.The adjusting pressure regulator it can control the maximum operating pressure for this pump or
set up the pressure for operating the tool.prohibrt to adiust this valve arbitrarily.
12.Oil level measurer it can help us know the oil level, when the oil less than the 1/3 of total, please
fill the especial oil for hydraulic tools of TRITORC.
13.Release oil port: G1/4” thread, discharging the hydraulic oil from oil reservoir(when changing
hydraulic oil)
14.Hex head screw tight coupling oil reservoir.
15.Cover plate air-tight seal of the oil reservoir.
16.Oil filter port before you fill the oil in the oil reservoir, please loosen down the cover. There is a
filter inside the port for keeping oil in the oil reservoir cleanness. Also there is an operating on the
cover for releasing the air from oil reservoir.

CHARACTERISTIC
1. 4VN is three-stage pump. Pressure relief valve is asslembled in the high pressure port .the
rated pressure in the low pressure port is 50-70Bar,And the flow is 1.4 L/min under 700Bar.
2. Max operating pressure 700Bar
3. Flow:three-stage,can simultaneity use 4 torque wrenches
4. Motor:4~8Bar air preasure motor
5. Environmental temperature:-10~80°C
6. Rerervoir dimension:448×428×281mm
7. Weight（No oil）:4VN 20.5Kg
8. Hydraulic oil:ISO VG 46#

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,
unnecessary injury and damage will happen.
5.Proihbit to operate without oil
6.Keep the clean of the pump,clean especially the oil inlet, quick couplers.
7.Suggestion: in the condition of not using the pump always, please remember to replace the
hydraulic oil
MAINTENANCE AND INSPECTION
1. The inspection before operating
(1).Please shut off the pump and inspect whether the position of the power connection is loose or
not. If it is loose, please tighten it.
(2).Please inspect whether the hydraulic oil in the oil reservoir is enough or not, if it is not enough,
please fill the oil in time.
(3).The pump is still working when the direction of the air valve is changed, please build up pressure
and inspect whether the whole equipment is normal or not.
(4).Please inspect whether the house and other equipments are leaky or not, if this happened,
please inspect to find the reason and repair it or replace it.
2.The inspection in operation
When inspecting the following items, if there is abnormal situation, please shut off the pump and
repair it.
(1)Please inspect whether there are abnormal condition or not in the course of raising the pressure.
(2)Please inspect whether the houses and other equipments are leaky or not.
(3)Please inspect whether there is some abnormal noise, rocking and smell or not during the
operation of the air motor.
(4)Please inspect whether the temperature of hydraulic oil is too high or not.
3.The inspection after finishing the operation of the pump.
(1)Making sure the pump must be turn down.
(2)Please inspect whether there are leaky or abnormal condition or not. If there is abnormal
situation,please inspect to find the reason and repair it
(3)Please clean it after using the pump.
4.Refer to changing the hydraulic oil
The oil should be replaced once a year principally. If there are following abnormal conditions, please
replace the oil immediately.
(1)If dust mixes with the oil, please replace the oil.
(2)If there is abnormal smell, please replace the oil.
(3)If the water mixes with the oil, the colour of the oil has been changed into milkiness, please
replace the oil.
(4)If the colour of the oil has been changed into black-brown, please replace the oil.
5.The way replacing the hydraulic oil
(1)Please loosen the oil filler port of oil reservoir.
(2)Please take down the screw on the flank of the oil reservoir, let hydraulic oil out.
(3)Please clean the inner and filter of the oil reservoir.
(4)Please install the screw and fill the oil reservoir with the hydraulic oil.

WARNING: If the oil splashes into your eyes, please wash with clean water for at least 15 minutes,
and Then see doctor immediately. If the oil splashes to your skin, please wash it with clean water
and soap.

WARNING: Waste hydraulic oil bellows to industrial waste, it should be dealt with by special
companies.
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 FIG -2.

FIG - 2

3) Product handling, generally using portable, car handling and lifting and moving,
as shown in the FIG-3.

FIG - 3
OPERATION INSTRUCTIONS
1.4VN hydraulic power pump is designed for hydraulic torque wrench. There is a 2-way,
4-position Air 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 return the oil at the low pressure.
(1)Please loosen the valve for adjusting pressure before operating.
(2)Please connect the air line and press the air input valve on the flank of the pump to make the
pump start working and oil exporting.
(3)Please press the working button on the controller and adjust the pressure unit the working
pressure reach to what you need, and then loosen the working button on the controller.
(4)When the desired pressure is reached, the motor stops working, and the pressure will keep the
same. when the pressure falls down, the motor starts to work again.
(5)When the motor is working, if you press the “off” button on the pump, the motor stops working,
the piston and pressure will also be stopped at the position when the motor stopped working, even
if the pressure fell, the motor would not work again.
(6)After operating, please press the rubber button on the top of the air 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.

Turn up the preasure

T Handle
Locking Ring

FIG-4

TROUBLE SHOOTING GUIDE OF HYDRAULIC PUMP

Confirming whether the
The voltage isn't suitable
voltage is suitable for the
The pump can't be started pump's need
Checked the input air, switch
The power hasn't be connected and distribution box and so
on, and connect the air.

The quick coupler hasn't be

Take down and reinstall it
connected to the correct
position
The system has no pressure 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 Open the throttle and hand
hand single-direction valve, single-direction valve, and
please check if the valve are make sure the system is a
open circle
After reinstalling the The quick coupler can't be Take down the quick coupler, check
quick coupler,the connected to the correct if the boll is elastic with a rod, if it
system has no pressure position, which causes no can't move, please knock it with
pressure in the system a hammer to eliminatethe mist
hydraulic oil
Leakage in the quick coupler The o ring and escape have worn Replace the quick coupler
out
 The relief valve is Check with the gauge, and adjust
adjusted too low the relief valve to the system set
pressure
Oil is mixed with water Change oil
Not enough oil in the reservoir Fill in oil
Repeat operating the system with
Suck in air to the system
no load for several times to
The pressure can't reach eliminate the air
to the set pressure
The throttle and hand single- Locking valve
direction valve haven't been
tightened
The throttle and hand single-
direction valve haven't been Adjust to the correct position
adjusted to the correct
position

The throttle and hand single- Replace the valve

direction valve have broken

There is foreign matter Wash the pump valve

in the oil and change clean oil

When using under static The seal is out of control,

Replace the seal
pressure, the pressure reduces please check all the seal
slowly
EXPLOSION OF 4VN PNEUMATIC PUMP

ITEM NAME ITEM NAME

1 The tank module 7 Oily water separator

2 Pump module 8 Pneumatic control valve
3 Oil return pipe(1) 9 The type WE valve set module
4 Petroleum Pipeline 10 Fast screwed joint
5 Oil return pipe(2) 11 Straight thread joint choose one
6 The cooler module 12 Copper fittings
EXPLOSION OF THE PUMP MODULE
EXPLOSION OF THE TYPE WE VALVE SET MODULE
EXPLOSION OF THE TYPE WE VALVE SET MODULE
 PNEUMATIC CONTROL MODULE EXPLODED DIAGRAM

ITEN NAME NUM ITEN NAME NUM

Pneumatic schematic diagram
8.1 Pneumatic motor parts 1 8.12 Inlet pipe 1

8.2 Nut 4 8.13 Nut 2

8.3 Fixed plate 1 8.14 The village set 2 Hand control

valve(1)

8.4 4 8.15 2
To air control
Washer Right angle type joint
pressure valve

8.5 Bolt 4 8.16 Three way ball valve 1

8.6 Pneumatic reversing valve 1 8.17 Muffler 1

Hand control

8.7 2 8.18 1
valve(2)
Cover type nut External joint

8.8 Trachea 1 8.19 Internal and external joint 1 To air motor

In put
8.9 Miniature quick coupler 1 Flow

8.10 Screw 2
Air control lever Pneumatic control pneumatic
8.11 Gas control unit 1 reversing valve
HYDRAULIC PRINCIPLE

WARNING FOR USING HIGH PRESSURE HOSE

1.Please use TRITORC APL 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 700 Bar, and 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.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.
6.Do not use the hose to remove attached equipment. Stress can damage the hose, causing personal injury.
7.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.
8. TRITORC APL series 1000Bar high pressure hose's operating pressure is 1000Bar, Overpass this
pressure is forbidden.

AFTER-SALES SERNICE
1. TRITORC guarantees quality of the material used for manufacturing products and quality of your
technical fulfillment. The guarantee period of the products is 12 months from the date of selling.
2.If any quality issue due to the defects of the materials or craftsmanship is found within the guarantee
period. TRITORC will be responsible and repair or replace the defective products for free.
3.If the equipment is damaged because of happenstance, wrong operating and modifying or repairing the
parts without consulting TRITORC te c h nic a l service department,TRITORC will not guarantee these cases.
PNEUMATIC PRINCIPLE

Hand Controlling Valve

Hydraulic Direction
Valve

Hand Controlling
Valve

Air Motor
Input Air Pressure

Air Consumption
3.4m
Air Remote Controller Air Direction Valve

Name Specification Remark

Air Direction Valve

Air Remote Controller

Hand Controlling Valve

Hand Controlling Valve

 Specification & Parameter
Oil connecting
Flow （L/min） Oil outlet Maxwork
capacity
Operating Power
Model Air Motor connecting pressure
（HP）
Low Mid High thread （Bar)
（L）

Rotate Speed:
3000r/min Pressure

4VN-2 5.5 AIR Output: 4～8 bar 4.0 8.2 2.8 1.4 NPT1/4 NPT1/4 700
Air Consumption:
≥ 3.4m3/min

Rotate Speed:
3000r/min Pressure
4VN-4 5.5 AIR Output: 4～8 bar 4.0 8.2 2.8 1.4 NPT1/4 NPT1/4 700

Air Consumption:
≥ 3.4m3/min

* 4VN-2 series can be operated with one or two Torque Wrenches.

* 4VN-4 series can be operated with 4 Torque Wrenches.

TRITORC, INC.
2006, Wichita Street, Pasadena, Texas - 77502
Tel.: +1-704-749-4050 E-mail: [email protected]
Website: www.tritorc.com