Wren KLW4000D Operation and Maintenance Manual

.

KLW4000

Operation And Maintenance Manual

Of KLW4000 Series Hydraulic Pump

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 70Mpa(10,000Psi),WREN has set up the pressure to

70Mpa 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 70Mpa. 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

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 0-100Mpa, 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

EXTERNAL DIMENSION AND DESCRIPT ION OF PARTS

Item Description Item Description

1 8

2 9

3 10

4 11

5 12

6 13

7 14

Oil reservoir

Adjusting pressure regulator

Pressure gauge

Frame for protecting

Motor

Radiator

Oil lever measurer

Release oil port

control system

Cover plate for oil tank

Solenoid valve

Quick Coupler

Valve block

Oil filling port

3

0.8

7

/200-240V 60HZ 0.9KW /100-130V 60HZ 0.9KW

27

,And cover on the dust cap.

200-240

4

1.Ready:

1.1 KLW4000hydraulic power 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

Lock button

Retract button

5

1

Valve block

Female coupler

O-ring

1

4

O-ring O-ring

1

5

O-ring

Retaining ring

O-ring

1

8

O-ring

9

O-ring O-ring

2

O-ring

1

12

O-ring

13

O-ring O-ring

1

15

O-ring

16

O-ring

1

ITEM

DESCRIPTION QTY

ITEM

DESCRIPTION QTY

2

1

18

1

3

1

19

6

2

22

2

7

2

23

10

2

26

11

2

27

1

14

1

30

1

1 31 1

1

29

1

28

1

2

25

2

24

4

2

21

1

2

20

1 17 1

Male coupler

Retaining ring

Reversing valve

Adjusting valve

Retaining ring

Unilateralism valve

Adjusting valve

Casing screw

Screw

Connector

Gauge

Solenoid valve

PART LIST FORVALVE SYSTEM

6

Bearing

O-ring

Retaining ring

Unilateralism valve

Safety valve

Release valve 2

Clip

Bearing

Circle

Piston 1

Piston 2

Piston 3

Plate

Screw

Connecting plate

Filter

PART LIST FOR PUMP HEAD

1/set

2

1/set

１

1/set

1

1/set

1

1/set

1

4

2

1

16

1

5-2

7

7-1

２

３

４

５

５-1

5-3

5-4

6

7-2

7-3

7-4

7-5

8

8-1

8-2

8-3

8-4

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

1

Check Valve

Relief Valve

Seal gasket

1

ltem

Description

QTY

Bearing

Bearing pole

Pump head

Release valve

Retaining ring

O-ring

Screw

Relief Valve

Metal Retaining Ring

7

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

70

24~26

9

Drawing for Electrical Principle

Selecting Chart for Electrical Component

1 Pump voltage 100V – 220V

Big type

Standard Remote Controller

Select

Small type

Button (Automatic Lock)

Button (Automatic Retract)

Button (Automatic Lock)

Button (Automatic Retract)

Motor Circuit

Integrated Circuit

10

100-120V 60HZ

Electrical Components Chart:

WARNING:Due to different standard of voltage and Frequency in countries, please

strictly follow manufacturer’s indication before using.

Mark Name Specification and Model Remark

Crun

Cst

YC

QF

M1

M2

SB1

SB2

Work Capacitance

Start Capacitance

Solenoid Valve

Breaker

Single Phase Motor

FAN

Button (Automatic Lock)

Button (Automatic Retract)

Integrated Circuit Board

CBB60 70uF 300V.AC

CD60 300uF 150V.AC

GZ3-1 24V.DC

TRL32A(15A)

0.9KW 115V.AC 60HZ

110V.AC 23/21W

GQ25-11Z

GQ25-11

BY31002

Switch for hot

protecting

LAS2GQH-11Z/S/FP

GQ16H-10/S

Select for big

remote control

Select for big

remote control

Select for samll

remote control

Select for samll

remote control

Mark Name Specification and Model Remark

Crun

Cst

YC

QF

M1

M2

SB1

SB2

Work Capacitance

Start Capacitance

Solenoid Valve

Breaker

Single Phase Motor

FAN

Button (Automatic Lock)

Button (Automatic Retract)

Integrated Circuit Board

CBB60 30uF 450V.AC

CD60 150uF 250V.AC

GZ3-1 24V.DC

TRL32A(10A)

0.9KW 220V.AC 60HZ

220V.AC 23/21W

GQ25-11Z

GQ25-11

BY31002

Switch for hot

protecting

LAS2GQH-11Z/S/FP

GQ16H-10/S

Select for big

remote control

Select for big

remote control

Select for samll

remote control

Select for samll

remote control

200-240V 60HZ Electrical Components Chart:

11

Mark Name Specification and Model Remark

Crun

Cst

YC

QF

M1

M2

SB1

SB2

Work Capacitance

Start Capacitance

Solenoid Valve

Breaker

Single Phase Motor

FAN

Button (Automatic Lock)

Button (Automatic Retract)

Integrated Circuit Board

CBB60 70uF 300V.AC

CD60 300uF 150V.AC

GZ3-1 24V.DC

TRL32A(15A)

0.9KW 115V.AC 50HZ

110V.AC 23/21W

GQ25-11Z

GQ25-11

BY31002

Switch for hot

protecting

LAS2GQH-11Z/S/FP

GQ16H-10/S

Select for big

remote control

Select for big

remote control

Select for samll

remote control

Select for samll

remote control

Mark Name Specification and Model Remark

Crun

Cst

YC

QF

M1

M2

SB1

SB2

Work Capacitance

Start Capacitance

Solenoid Valve

Breaker

Single Phase Motor

FAN

Button (Automatic Lock)

Button (Automatic Retract)

Integrated Circuit Board

CBB60 25uF 450V.AC

CD60 150uF 300V.AC

GZ3-1 24V.DC

TRL32A(10A)

1.1KW 220V.AC 50HZ

220V.AC 23/21W

GQ25-11Z

GQ25-11

BY31002

Switch for hot

protecting

LAS2GQH-11Z/S/FP

GQ16H-10/S

Select for big

remote control

Select for big

remote control

Select for samll

remote control

Select for samll

remote control

100-120V 50HZ Electrical Components Chart:

200-240V 50HZ Electrical Components Chart:

12

Specification & Parameter

13

EC DECLARATION OF CONFORMITY

THIS IS HEREBY DECLARED THAT FOLLOWING DESIGNATED PRODUCT COMPLIED WITH THE

ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF MACHINERY DIRECTIVE 2006/42/EC ON

THE APPROXIMATION OF THE LAWS OF THE MEMBER STATES RELATING TO IT.

MANUFACTURER

Hangzhou WREN Hydraulic Equipment Manufacturing Co.,Ltd

ADD：No.24, Xingxing Road, xingqiao,yuhang district , Hangzhou, China

AU

THORIZED REPRESENTATIVE TO HOLD THE TECHNICAL FILES

Name of authorized person: Fritz Fischer

Address of authorized person: PETER ROSEGGERSTR.12, GERMANY 85293, REICHERTSHAUSEN

MAILBOX: hstfischer@t-online.de

DESCRIPTION OF MACHINERY

PRODUCT NAME: HYDRAULIC PUMP

MODEL TYPE:KLW4000 Series/KLW4100 Series/KLW4000N Series/ MP Series /SMP Series

/HNP Series/SHNP Series

APPLICABLE STANDARD

EN ISO 12100:2010

EN ISO 4413:2010

THIS DECLARATION APPLIES TO ALL SPECIMENS MANUFACTURED IDENTICAL TO THE MODEL

SUBMITTED FOR TESTING/EVALUATION.ASSESSMENT OF COMPLIANCE OF THE PRODUCT WITH

THE REQUIREMENTS RELATING TO SAFETY STANDARDS LISTED ABOVE WAS PERFORMED BY

MANUFACTURE.

SIGNED ON BEHALF OF MANUFACTURER

SIGNATURE:

TITLE:

PLACE:

DATE:

Manager

Hangzhou

2012/8/9

14

ELECTRICAL INTERCONNECTDE FIGURE

15

液压液压泵的安全使用，必须要求正确操作和定期检查。

在阅读和彻底理解本手册中的安全指示条例后才可以使用本液压泵。

注意事项--防止造成直接经济损失或财物损失。

警告事项--防止造成人身伤害。

请确实遵守上述两个事项。

在使用过程中，如发生异常情况，请关闭电源开关，拨出电源插头，然后向WREN 或WREN授权

代理商咨询。

安全指示

本操作手册内容包括WREN液压液压泵的操作规程、警告和注意事项以及故障排除。

使用前，请仔细阅读本手册，彻底理解其内容并妥善保管。

K L W 4 0 0 0

扭矩扳手专用泵

操作保养手册

声明：所有产品图片说明均有可能因产品改进升级而变更，恕不另行通知，均以实物为准！

16

1. 使用本液压泵时，所有人员禁止站在液压油出口处，防止液压油不小心泄漏时可能发生的人身伤

害或财产损失；液压泵必须远离火源。

2. 加压前，应加装软管及执行元件或螺堵，防止高压液压油冲出造成人身伤害。

3. 本液压液压泵的最高工作压力为70MPa；在出厂时工厂已设定压力为70MPa，绝不要将压力调节

到超过设定压力。

4. 如本液压泵用于操作其它配套设备，配套设备的工作压力应小于70MPa，并将压力调定为其配套

设备的工作压力，否则配套设备有可能损坏；调整压力调节阀的操作参见第五项。

5. 充分考虑安全性，在维修前，应将动力源切断。

6. 在接通动力源前，关掉按钮开关,打开液压调节阀。

7. 确保接地，避免触电。

8. 禁止无油启动液压泵站，这将会造成设备损坏。

9. 不要改装本液压泵，如确实需要改装，应先向WREN 或WREN授权代理商咨询。没有WREN的书

面同意，所作改装，不在质保范围内。

10. 不要加注超过可用油量的液压油，否则，贮油箱中的液压油会溢出，造成对环境和设备污染。

11. 液压泵站工作时，返回储油箱的油可能会溢出，如果此时打开储油箱盖，可能会造成设备和环境

的污染。

12. 快速接头互连时，必须保证完全啮合（图1），只有这样才能确保接头内单向阀打开，使油路畅

通。否则，连接后接头内单向阀无法打开，致使油路不通，加压时会出现泵站有压力，而扳手无

法运转、从扳手旋转体上的自动泻荷阀打开,开始泻压等现象，从而可能造成快速接头、扳手损坏，

甚至人身伤害。

此时须切断液压泵动力源，拆开所有软管接头，检查所有快速接头（包括扳手接头）内的单

向阀是否可以用手按动、有弹性。如果不能按动，需要用锤子敲打接头内单向阀（图2），释放接

头里的压力（敲打单向阀时会有液压油喷出，虽没有危险，但需小心液压油溅到身上，弄脏您的

衣服），直至用手可以按动接头内钢珠为止，再重新连接。

13. 必须保持液压泵站的清洁，特别是出油口、快速接头等处，液压油的不清洁是引发液压泵故障的

主要原因。

14. 远离超高压液压油可能溢出的位置；液压油可能穿透你的手，导致严重受伤。

15. 如果液压油喷到你的眼睛里，立即用清水冲洗大约15分钟，然后去医院清洁眼睛。

16. 不要碰带压力的软管；如果液压油喷出，会导致严重伤害。

17. 液压软管是消耗性配件，经过肉眼检查没有问题，内部也可能有破裂和针孔；考虑到良好使用

状况，应定期更换软管，且使用时应避免出现急弯。

1. 只使用WREN液压工具专用油。

2. 使用过的液压油应根据防污染条例处理。

注意事项

警告事项

图（1）

图（2）

17

一概述

为液压扳手专用

二零部件概述及外观示意图

零部件概述

（）

1.1 KLW4000 泵，采用集成方式组装，由动力单元,电气单元,控制装置等组成的

一种独立完整的液压装置，具有流量大、体积小、重量轻、结构简单、操作方便、工作压力

高等特点，并且高压出口（A口）出油压力可在70~700bar间任意调节。

#

1.2 液压液压泵使用的液压油：32 耐磨液压油。严禁使用含水和含对钢或铝有腐蚀性介质的液压

油。

1.3 液压液压泵使用的环境温度：-10~60℃（如更换低温液压油，可在-30℃ 低温下使用）。

1.4 液压液压泵通过高压软管和高压接头与执行元件连接，为工作安全，请使用WREN高压软管

和高压接头。WREN液压液压泵配用的高压软管最大工作压力为70MPa，使用时请选用与之

配套的压力系统。

1.5 此泵如需使用附属液压产品，请咨询WREN工程师。

1.6 请不要在靠近火焰处使用液压液压泵。

1.7 液压液压泵的最大工作压力70MPa，使用时请不要任意调节压力调节阀，以避免超高压引起

的设备损坏和人身伤害。（如有特殊要求，请咨询WREN工程师。）

1.8 请确认WREN液压液压泵的使用电压与现场使用的电压相符。

1.9 请尽可能在室内使用此泵，室外使用必须做好防雨措施。

2.1

1 储油箱：存放工作用液压油，保证系统正常工作（必须有足够油量），提供系统所需的

压力载体。

2 压力调节阀（溢流阀）：调节此阀可以设定液压泵的工作压力，（出厂时已锁定最高工

作压力，禁止调高锁定压力）。

（3）压力表：显示液压泵的工作压力，量程100 Mpa。

（4）油泵保护架：安装在储油箱上，用于提携、保护液压泵站。

（5）电机：提供动力源（根据使用地的电压、频率选用合适电机，具体参数见电机铭牌）。

（6）冷却器：实行强制冷却，降低油泵工作时的油温，从而延长扳手工作时间和使用寿命。

（7）液位计：观察液压油的多少，以保证提供最佳使用油量；液压油低于油标1/3位置时，

必须加WREN泵站专用液压油，否则可能会损坏泵站。

（8）卸油孔：螺塞G1/4”，实现液压油排出储油箱（更换液压油时使用）。

（9）电控系统：液压泵的电气控制部分，实现对液压泵开始打压、高低压转换和停止打压的

控制。

（10）油箱盖：密封油箱及安装液压泵零部件。

（11）换向阀：实现高、低压液压油输出、回油的换向功能。

（12）快速接头：实现液压油输出\回油功能，快速连接油管；含内置式单向阀，凸凹接头的螺

纹套拧紧。齿部卡住后在升压、降压、脉动过程中不会使螺纹套松开，具有防松功能。

（13）阀组：连接液压系统中的各种液压控制阀，实现液压油输出、回油控制，保证系统在设

定压力下正常工作。

（14）通气注油孔：储油箱换气和注入液压油的通道。

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装配示意图2.2

序号说明序号说明

1 储油箱 8 卸油孔

2 压力调节阀（溢流阀） 9 电控系统

3 压力表 10 油箱盖

4 油泵保护架 11 换向阀

5 电机 (参数见铭牌） 12 快速接头

6 冷却器 13 阀组

7 液位计 14 通气注油孔

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Wren KLW4000D Operation and Maintenance Manual

Wren KLW4000D Operation and Maintenance Manual

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