BTE10K-BTA10K Torque Pump

REVISION 0
03/2010

ATTENTION!

THIS MANUAL IS INTENDED TO COVER SUCH TOPICS AS

OPERATION, PREVENTATIVE MAINTENCE, AND
TROUBLESHOOTING. BECAUSE OF THE EXTENSIVE TRAINING
AND PARTS NEEDED FOR REPAIR, IT IS RECOMMENDED
THAT BROKEN PUMPS BE SENT BACK TO THE DISTRIBUTOR
FOR REPAIR.
 

Bolttech-Mannings Inc.
501 Mosside Blvd.
North Versailles, PA 15137
Phone: 724-872-4873
www.bolttechmannings.com 
 ELECTRIC OR AIR POWERED  
 

TWO-STAGE HYDRAULIC PUMP

10,000 PSI

 
RESERVOIR 

 
NOTE:

 Carefully inspect the pump upon arrival. The carrier, not the manufacturer,
is responsible for any damage resulting from shipment.

 Read and carefully follow these instructions. Most problems with new
equipment are caused by improper operation or installation.
 The hydraulic power unit can be ordered with "building block" flexibility.
The customer can choose from a variety of motors, controls, reservoirs,
and other options. Because of the many options available, these
instructions will include directions for options that your particular pump
may not have.
 Do not change motors without consulting the pump manufacturer's
Technical Services Department.

SAFETY PRECAUTIONS
WARNING: To help prevent personal injury,

HYDRAULIC HOSE

 Before operating the pump, all hose connections must be tightened with the
proper tools. Do not over tighten. Connections should only be tightened securely
and leak-free. Over tightening can cause premature thread failure or high
pressure fittings to split at pressures lower than their rated capacities.
 Always shut off the electric motor before breaking any connections in the
system.
 Should a hydraulic hose ever 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.
 Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme
heat or cold, or heavy impact Do not let the hose kink, twist, curl or bend so
tightly that oil flow within the hose is blocked or reduced. Periodically inspect the
hose for wear, because any of these conditions can damage the hose.
 Do not use the hose to move attached equipment. Stress can damage the hose,
causing personal injury.
 Hose material and coupler seals must be compatible with the hydraulic fluid
used. Hoses also must not come in contact with corrosive materials such as
creosote-impregnated objects and some paints. Consult the manufacturer before
painting a hose. Never paint the couplers. Hose deterioration due to Corrosive
materials can result in personal injury.
PUMP
 Do not exceed the PSI hydraulic pressure rating noted on the pump nameplate
or tamper with the internal high pressure relief valve. Creating pressure beyond
rated capacities can result in personal injury.
 Before replenishing the oil level, retract the system to prevent overfilling the
pump reservoir. An over fill can cause personal injury due to excess reservoir
pressure created when the cylinders are retracted.

CYLINDER

 Do not exceed the rated capacities of the cylinders. Excess pressure can result
in personal injury.
 Do not set poorly balanced or off-center loads on a cylinder. The load can tip and
cause personal injury.

POWER SUPPLY (Electric)

 Never use an ungrounded power supply with this unit.

 The pump must be compatible with existing line voltage.
 Disconnect the pump from the power supply when performing maintenance or
repair on the unit.
 If the unit's power supply is damaged or the inner wiring is exposed in any way,
replace immediately.
 Any electrical work must be done by a qualified electrician.
 If the power cord is damaged or wiring is exposed, replace or repair immediately.
 Changing the voltage on the jet motor (single, or three phase) is a complicated
and, 'if not done correctly, dangerous procedure. Consult the pump
manufacturer's Technical Services Department for specific information before
attempting any rewiring. Rewiring voids CSA approval.
 All voltages must be wired for CW rotation when viewed from the lead end (top)
of the motor.
 Check the total amperage draw for the electrical circuit you will be using. (For
example: Do not plug a motor or motors that may draw 25 amps into a 20 amp
fused electrical circuit.)
 Do not attempt to increase the powerline capacity by replacing a fuse with
another fuse of higher value. Overheating of the powerline and the possibility of
a fire will result.
 To rewire a motor from one voltage to another or when a flow control valve is
changed between manual and solenoid, consult the electrical schematic in the
pump's parts lists Circuit Breakers: If motor stops due to an overload or power
outage, Universal Motor: Move motor switch to OFF and control valve to neutral.
 Let motor cool or wait until power is restored. Reset circuit breaker switch in
power panel. (The pump motor doesn’t have a circuit breaker.) Single-phase
Motor: Thermal overload switch will break circuit to the motor. Move motor switch
to OFF and control valve to neutral. Allow motor to cool before switching on
again, or wait until power is restored. Three-phase Motor: A magnetic starter
switch breaks circuit to the motor. Move the motor switch to OFF and control
valve to neutral. Remove the cover on motor control box. Let the motor cool or
wail until power is restored. One of three reset buttons must be pushed in to
reset motor. Replace cover.

Power Supply (Air Driven Motor)

 Disconnect air supply when pump is not in use or when breaking any connection
in the hydraulic system.
 A shut-off valve or quick disconnect should be installed in the air line to the pump
unit. Close the shut-off valve before connecting the air line to the pump.
HYDRAULIC PUMP SET-UP PROCEDURE

Motor Hook-up and Operation

Universal Motor: The universal motor is wired for 115 or 230 volts, 50/60 cycles according
to the customer's request.
This motor cannot be rewired.

Air Motor: Remove the thread protectors from the air inlet, and install the air supply fittings
(not supplied) as shown in Figure 1. Air supply must be minimum 50 CFM and 80 PSI, with
100 PSI maximum.

IMPORTANT: Seal all external pipe connections with a high-quality, no hardening

thread sealant, such as Teflon. Teflon tape can be used to seal hydraulic
connections if only one layer of tape is used. Apply the tape carefully, two threads
back, to prevent it from being pinched by the coupler and broken off inside the
system. Any loose pieces of tape could travel through the system and obstruct the
flow of oil or cause jamming of precision-fit parts.
SET-UP AND OPERATION

Filling The Reservoir

NOTE: The pump has been shipped without oil in the reservoir. High-grade hydraulic oil
has been shipped with the pump in a separate container. If additional oil is required, use
high-grade, approved hydraulic oil.

1. Clean the area around the filler cap to remove all dust and grit. Any dirt or dust in the
oil can damage the polished surfaces and precision-fit components of the pump.
2. Retract all cylinders to the return position.
3. Remove the filler cap, and insert a clean funnel and filter. Fill with hydraulic oil to 1/2"
from the top of the filler hole. Replace filler cap with the breather-hole in the filler cap
open.
4. Cycle the pump (with cylinders attached) several times. Retract the cylinders, and
check the oil level in the pump reservoir again.

Hydraulic Connections

1. Clean all the areas around the oil ports of the pump and cylinder.
2. Inspect all threads and fittings for signs of wear or damage, and replace as needed.
3. Clean all hose ends, couplers or union ends.
4. Remove the thread protectors from the hydraulic oil outlets. Connect the hose
assembly to the hydraulic oil outlet, and couple the hose to the cylinder. Although a
high-grade, non-hardening thread sealant is preferred, teflon tape may be used to
seal hydraulic connections 'if only one layer of tape is used. Apply carefully to
prevent the tape from being pinched by the coupler and broken off inside the pipe
end. Any loose pieces of tape could travel through the system and obstruct the flow
of oil.
Priming The Pump
When operating the pump for the first time:
1. Valve and hose connections must be tight, and the reservoir must be filled to the
proper oil level. Start the motor.
2. Jog the pump several times to build pressure. If the pump doesn't build pressure, it
may not be primed. Disconnect a hose from the system and route it back to the
pump reservoir. Run the pump until a steady flow of oil is observed free of
suspended air bubbles. Reconnect the hose to the system.
3. Run cylinder out to its full travel several times to eliminate air from the system. For
more complete instructions, refer to the section titled "Bleeding Air From The
System."
4. The pump is ready to be put into regular operation.

IMPORTANT: After eliminating trapped air from a large work-holding system, retract
the cylinders and refill the pump reservoir to 1/2" from the top of the filler hole.

Adjusting The Pressure Regulating Controls

The pressure regulating valve and pressure switch are shown in Figure 4. The pressure
regulating valve can be adjusted to bypass oil at a given pressure setting while the pump
continues to run. The pressure switch can be adjusted to stop the pump at a given
pressure setting. To ensure accuracy and low pressure differential (approx. 300 PSI)
throughout the pressure range (1,000 to 10,000 PSI depending on the pump model), the
pressure switch should be used with the pressure regulating valve. The pressure switch
must be set at a pressure lower than the pressure regulating valve to work properly.

Adjusting The Pressure Regulating Valve

NOTE: For easy adjustment of the pressure regulating valve, always adjust the
pressure by increasing to the desired pressure setting.
1. Loosen the locknut on the pressure
regulating valve (C), and back the
adjusting screw (B) out a few turns with a
thumb screw by turning in a
counterclockwise direction. This will
decrease the setting to a lower than
desired pressure.
2. The pump must be completely
connected. Set the motor control toggle
switch on "Run" and push the "Start"
button.
3. Slowly turn the adjusting screw (B) in a
clockwise direction. This gradually
increases the pressure setting. When the desired pressure is reached, lock the
adjusting screw in position b) tightening the locknut.
IMPORTANT:
 The pressure range is from 1,000 to 10,000 PSI depending on the pump
model.
 The pressure switch must be set at a higher pressure than working range to
prevent shut down during adjustment. It is also possible to bypass the
pressure switch contacts by holding the start switch or remote control switch
so that the motor runs continuously.slv

Adjusting The Pressure Switch

Generally, the pressure switch should be used with the pressure regulating valve. A
pressure switch can be used alone for operating electrical devices such as motors,
solenoids, relays, etc., which are located elsewhere in the circuit. Refer to Figure 4.
1. Loosen the locknut on the pressure switch (D), and turn adjusting screw (A) in a
clockwise direction. This increases the pressure setting to a higher than desired
pressure
2. Adjust the pressure regulating valve to the desired pressure setting by using the
procedure previously outlined.
3. With the pump running and bypassing oil at the desired pressure, slowly turn the
pressure switch adjusting screw (A) in a counterclockwise direction, decreasing the
pressure switch setting until the pump motor shuts off. Then lock the adjusting screw
(A) in position by tightening the locknut.
4. Release pressure. Run the pump to check the pressure setting and cut-out of the
motor. If may be necessary to make a second adjustment.

NOTE: When the pressure switch setting is reached, the motor will shut off.
However, the "coast" of the motor continues to deliver oil for a brief period. The
pressure regulating valve bypasses this surplus oil, preventing it from going into the
system. As a result, the pressure differential can be held to approximately 300 PSI.
PREVENTIVE MAINTENANCE
WARNING: To help prevent personal injury,
 Disconnect the pump from the power supply before performing
maintenance & repair procedures.
 Repairs and maintenance are to be performed in a dust-free area by a
qualified technician.

Bleeding Air From The System

Air can accumulate in the hydraulic system if the reservoir oil level is too low. This air
causes the cylinder to respond in an unstable or slow manner. To remove the air:

1. The hydraulic cylinders must be positioned on their side with the couplers located
upward.
2. Remove any load from the cylinders, and cycle the hydraulic system through several
cycles (fully extend and retract the cylinders).

IMPORTANT: Some of the single-acting spring return cylinders have a cavity in the
rod that forms an air pocket. This type of cylinder must be positioned upside down
when the hydraulic system is bled.

Hydraulic Fluid Level

1. Check the oil level in the reservoir after each 10 hours of use. Proper oil level is 1/2"
from the top of the fill hole when all cylinders are retracted.
2. Drain, flush, and refill the reservoir with an approved, high-grade hydraulic oil after
approximately every 300 hours of use. The frequency of oil changes will depend
upon the general working conditions, severity of use, and overall cleanliness and
care given the pump.

Lubrication (Air Driven Motor Only)

If the pump is operated on a continuous duty cycle or a maximum speeds for extended
periods, an automatic air line oiler should be installed in the air inlet line as close to the
pumping unit as possible. Set the unit to feed 1-3 drops of oil per minute (one drop for
every 50-75 CPM of air) into the system, or refer to the pump manufacturer's instructions.
Use SAE No. 10 oil.
Maintenance Cleaning

1. Keep the pump's outer surface as free from dirt as possible.

2. Seal all unused couplers with thread protectors.

3. Keep all hose connections free of dirt and grime.

4. The breather-hole in the filler cap must be clean and unobstructed at all times.

5. Equipment connected to the pump must be kept clean.

6. Use only an approved, high-grade hydraulic oil in this pump. Change as every 300
hours.

IMPORTANT: Clean the pump exterior before the

pump interior is removed from the reservoir.

1. Remove the ten screws fastening the motor

and pump assembly to the reservoir.

IMPORTANT: Do not damage the gasket or

pump the filter or pressure regulating valves
when lifting the pump and motor off the
reservoir. See Figure 5.

2. Clean the inside of the reservoir and fill with

suitable flushing oil. Rinse the filter clean.

3. Place the pump and motor assembly back onto the reservoir, and secure with two
machine screws assembled on opposite comers of the housing.

IMPORTANT: The hydraulic flow control valve must be in the neutral position for the
following step. If the pump is equipped with a valve that has only an advance or
retract position, place the valve in the advance position, and connect a hose to the
advance port on the valve. Place the other end of the hose into the oil filler plug hole.

4. Run the pump for several minutes. Then disconnect the motor and pump assembly, and
drain and clean the inside of the reservoir.

5. Pill the reservoir with an approved, high-grade hydraulic oil (HD46). Place the pump and
motor assembly (with gasket) on the reservoir, and thread the ten screws. Tighten
securely and evenly.
Adding Oil To The Reservoir

1. Cylinder(s) must be fully retracted and the power supply disconnected when adding oil
to the reservoir.

2. Clean the entire area around the filler plug before removing the filler plug.

3. Use a clean funnel with filter when adding oil.

4. Use an approved, high-grade hydraulic oil (HD46 © 100° F) only.

2 Position, 4-Way Pump or Remote Mounted - Solenoid Operated
VALVE ASSEMBLY

NOTE:

• Read and carefully follow the operating instructions before installation and use
of this valve. Most problems with new equipment are caused by improper
operation or installation.

• Inspect the valve upon arrival. The carrier, not the manufacturer, is responsible
for any damage resulting from shipment.

SAFETY PRECAUTIONS

WARNING: To help avoid personal injury,

HYDRAULIC HOSE

 Before operating the pump, tighten all hose

connections using the proper tools.
 Do not over tighten the connections.
Connections need only the tightened securely
and leak-free. Over tightening may cause
premature thread failure or high pressure
fittings to split at pressures lower than their rated capacities.
 Hydraulic Line Disconnections:
 Fully retract the cylinder and remove any load. Then slightly advance the cylinder
and shut the pump motor off. Cover the connections with protective material and
disconnect the connection slowly to release line pressure.
 Should a hydraulic hose ever burst or rupture, immediately shut off the pump.
Never attempt to grasp a leaking hose under pressure with your hands. The force
of the escaping hydraulic fluid could cause serious and permanent injury.
 Avoid any conditions which could damage the hose and impair the pump or
valve's performance. Never allow the hose to kink, twist, curl or bend so tightly
that the oil flow within the hose is blocked or reduced. This could damage the
hose and possibly result in serious injury to persons working in the immediate
vicinity.
  Do not subject the hose to any potential hazard (ex: fire, extreme heat or cold,
heavy impact or sharp surfaces) which might rupture or weaken the hose.
 Do not use the hose to lift or move the equipment connected to it.
 Periodically inspect the hose for signs of wear. Never use a defective hose with

any pressurized equipment

 Always consult the manufacturer before painting the hose(s). Never paint the
couplers!

 Hose material and coupler seals must be compatible with the hydraulic fluid
used.
 Avoid contact with creosote-impregnated timber or fabrics.

CONTROL VALVE

 Do not install quick couplers or allow restrictions in the hydraulic return line
located between the hydraulic pump and a remote valve set-up.
 Do not allow the valve case pressure (as measured on the return line from valve
to pump at the valve) to exceed 500 PSI. Refer to case pressure check as
detailed in the valve set-up procedure in these instructions.

OPERATION

This valve can be wired into a N.C. Machine set-up or a remote control hand switch for the
operation of the solenoid valve. The hydraulic hoses from the hydraulic pump are
connected to the pressure and return ports located on the side or the back of the valve (see
Figure 1 and 2). The hydraulic cylinders) connect to valve cylinder ports "A" and "B".
SOLENOID “A” ENERGIZED: Pressure to Port “A”- Port “B” to tank.

SOLENOID “B” ENERGIZED: Pressure to Port “B”- Port “A” to tank.

NOTE:

• All ports open to tank during transition between valve positions.

• Solenoid wiring, Red wire = 60 Hz., Yellow wire = 50 Hz. Systems.

 
OPERATION (Continued)

The 2-position 4-way, 9592, is a solenoid operated valve. If the pump is equipped with an
internal outlet check, a hold position can be obtained by stopping the pump. The pump may
be stopped by using a pressure switch or the proper type remote hand control.

The valve is designed to be used with either spring return or double-acting cylinders. When
the valve is used with spring return cylinders, the valve must have one port plugged (either
"A" or "B"). Both ports must be used with double-acting cylinders.

When using more than one remote control valve in a system, each control valve should
have a check valve in both the pressure and tank ports. See the Power Team catalog for
additional check valve information and part numbers. The tank port check valve prevents
the uncontrolled extension of a retracted single-acting cylinder when other valves are
shifted. The pressure port check valve prevents the uncontrolled pressure loss and
possible resulting retraction of an extended single-acting cylinder when other valves in the
system are shifted.

Single-Acting Cylinder

Either oil port "A" or "B" must be plugged on the valve. With port "B" plugged, the sequence
of operation is as follows: When the solenoid is energized to position "A", oil port "A"
becomes pressurized. When the solenoid is energized to position "B", oil port "A" becomes
the return port.

Multiple Single-Action Cylinders

When operating multiple single-acting cylinders, one pressure line from one bank can be
connected to oil port "A" and the other can be connected to oil port ° B" on the valve. The
sequence of operation is as follows: When energized to position "A", oil port "A" becomes
pressurized and clamps the fixture connected to oil port "A". At the same time, oil port "B"
becomes a return port for the cylinder connected to oil port "B° and retracts 'it. The
opposite happens when solenoid "B" is energized.

Double-Acting Cylinders

When operating double-acting cylinders, oil port "A" can be connected to either the
advance or return port of the cylinder and oil port "B" will be connected to the remaining
port. Sequence of operation is as follows: When solenoid is energized to position A, oil port
"A" becomes pressurized and extends the cylinder and oil port "B" becomes the return port.
The opposite happens when solenoid B is energized.

The application in Figure 3 represents a typical set-up using a control valve and multiple
double-acting cylinders (one double-acting cylinder may also be used).
The application in Figure 4 represents a typical set-up using a control valve for each of the
double-acting cylinders. Check valves should be used with each control valve in this
system.

SET-UP
1. With the drain tube attached to the valve, mount the valve to the pump reservoir.
IMPORTANT: Seal all external pipe connections with a highquality,
nonhardening thread sealant, such as Teflon. Teflon tape can be used to seal
hydraulic connections if only one layer of tape is used. Apply the tape
carefully, two threads back, to prevent 'it from being pinched by the coupler
and broken off inside the system. Any loose pieces of tape could travel
through the system and obstruct the flow of oil or cause jamming of precision-
fit parts.

2. Remove the port plugs from the required connecting ports.

WARNING: All electrical work must be done by a qualified electrician.

3. Attach all hoses and wiring required to complete the set-up. Refer to Figure 1 for
valve port information.

4. Cycle the system several times to bleed the set-up.

MAINTENANCE
WARNING: Disconnect all electrical power and release all hydraulic pressure before
starting any maintenance procedure. Regularly oil the cam and cam plunger located
inside the valve. Remove the outside valve cover to gain access to the cam and
plunger. The cam has a hole in the end for oiling.

ELECTRICAL SCHEMATIC FOR 2POSITION,

4-WAY SOLENOID VALVE

Note: Solenoid wiring, red wire = 60 Hz. yellow wire = 50 Hz. Systems.

RECOMMENDED MINIMUM WIRE SIZE-AWG (mm2) OF EXTENSION CORDS FOR

BOLTTECH-MANNINGS ELECTRIC PUMPS

CURRENT AT FULL LOAD 
(AMPS)                 CORD SIZEAWG (mm2) 3.2 VOLT DROP    
                   LENGTH OF CHORD       
25‐50 FT (8‐ 50‐100 FT (15‐
   0‐25 FT (0‐8M)  15M)  30M) 
30  12  10  6