Operation, Repair, Parts Renegade TSP Torque Series Pump 3A6884B Renegade TSP is a hydraulic power pack for use with bolt torquing wrenches only. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations. Models: 17U632, 17U633, 17U634, 17U635 10,000 psi (68.9 MPa, 700 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and on the unit before using the equipment.
Contents Contents Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models Models Model No. 17U632 17U633 17U634 17U635 3A6884B Name Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump Renegade TSP Torque Series Pump Voltage Pendant 120V Corded 120V 230V 230V Maximum Working Pressure psi (MPa, bar) 10,000 psi (68.9 MPa, 700 bar) Wireless 10,000 psi (68.9 MPa, 700 bar) Corded 10,000 psi (68.9 MPa, 700 bar) Wireless 10,000 psi (68.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING SKIN INJECTION HAZARD High-pressure leaks are able to inject oil into the body and cause serious bodily injury that can result in amputation. In the event that injection occurs, get immediate surgical treatment. • Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. • Do not stop or deflect leaks with your hand, body, glove or rag. • Do not leave the unit energized or under pressure while unattended.
Warnings WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect extension cord before servicing equipment. • Connect only to grounded electrical outlets. • Use only 3-wire extension cords. • Ensure ground prongs are intact on electrical inlet and extension cords. • Store indoors. LIFTING HAZARD This equipment is heavy.
Component Identification Component Identification A B C D E F G H J K Pendant Oil Fill Cap (Breather) Oil Level Sight Electrical Inlet 15/20A Switch (120V only) Pressure Relief Button Pressure Setting Valve Hose Connection – Advance Hose Connection – Return Pendant Connector 3A6884B L M N P Q R T U W X Manual Advance Switch On/Off Switch Display Display Button Wireless Remote Signal Indicator Pendant Advance Switch Pressure Gauge Port Pump Stop Switch Lift Point Pump Rod Puller 7
Component Identification Controls and Indicators Item Description On/Off Switch 15A/20A Switch Turns TSP power pack on or off. Sets TSP power pack to either 15A or 20A. Select setting based on your circuit rating. Select 20A when a 20A circuit is available. Using the (120V only) 20A setting provides the maximum performance. Select 15A when a 15A circuit is available. Pressure Setting Valve Controls pressure at the tool. Turn clockwise to increase pressure.
Grounding Grounding Power Requirements The equipment must be grounded to reduce the risk of electric shock. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 100-120 VAC, 50/60 Hz, 15A/20A, single phase. 220-240 VAC, 50/60 Hz, 10A, single phase. Extension Cords Use a 3-wire extension cord with an undamaged ground contact.
Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. 1. Verify displayed pressure goes to zero when motor stops. 2. If pressure is not zero, then press Pressure Relief Button. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure before cleaning, checking, or servicing the equipment.
Setup Setup Pendant Setup Corded Pendant Attach Corded Pendant by lining up the tab on the plug with the socket located on the power pack control. Insert the plug and turn clockwise until you hear the lock click. The Corded Pendant must be selected to be the active control, see Select Control Device page 17. Fill Oil Tank Unit is shipped without hydraulic oil. Before the first use, fill tank with hydraulic oil, see Recommended Oil Temperature Ranges for Various Hydraulic Oil Weights page 52. 1.
Setup Modes 5. The TSP power pack has three modes: prime, calibration, and operation. Cycle through primary menu by short pressing the control Display Button until PRIME appears on Display. The prime mode removes air from the pump. The calibration mode calibrates the pressure sensor. See Calibration Procedure page 28. The operation mode is the normal mode in which the TSP power pack is ready to torque bolts. Prime TSP Power Pack Procedure Priming is required after initial oil fill or pump replacement.
Setup Connect Hose and Tool Hose Prime Procedure The TSP power pack uses flush-face quick-release couplings that are durable and easy to clean. To connect hose and tool, follow the steps below. Prime and flush the hoses each time a hose is replaced or when swapping tools. Continuous use of a hose and tool combination should not require a prime and flush procedure unless the hoses lose oil. 1. 2.
Operation Operation FIRE AND EXPLOSION WARNING To avoid serious injury, do not use in explosive atmospheres or hazardous (classified) locations. AMPUTATION OR CRUSH HAZARD Unexpected pump activation can cause serious injury. Ensure hands are clear of wrench crush points when activating TSP power pack. 5. High pressure leaks are able to inject oil into the body and cause serious bodily injury.
Operation Shut Down Cleaning 1. Turn ON/OFF switch to OFF position. Unplug the TSP power pack. 2. Disconnect hoses from TSP power pack. Proper care and maintenance is recommended for best experience with the TSP power pack. For proper maintenance activity and intervals, see Maintenance page 19. To clean, wipe TSP power pack and hoses with a rag to remove any accumulated oil and dirt after every use. Wash TSP power pack with mild soap and water as needed. High pressure washing is not recommended.
Display Display Main Menu Operation 1. 2. 3. Turn power ON. Display will show as unit powers on. Once powered on, Display will show PRESSURE (in PSI, bar, or MPa - as selected). Refer to Change Display Units page 17. 4. NOTE: LIFETIME HOURS displays a lifetime hour meter and cannot be reset. 5. Short press Display Button and name of the selected control device will scroll past on screen. If no control device is selected, SELECT CONTROL DEVICE will scroll past on screen.
Display Change Display Units Select Control Device NOTE: To change display units you must be in the pressure screen with the pressure display at zero. 1. Short press Display Button three times to move to SELECT CONTROL DEVICE mode. 2. Press the Advance Switch on desired control device to select it. Options available are: 1. Press and hold the Display Button for 5 seconds to change pressure units (psi, bar, MPa) to desired units. Selection of bar or MPa changes gallons to liters x 10. a.
Display Secondary Menu (Stored Data) 4. Short press Display Button and SOFTWARE REVISION scrolls past on the Display. 5. Short press Display Button and LAST CODE scrolls past on the Display. NOTE: Secondary Menu contains the calibration procedure plus information that may be useful during troubleshooting or repair. 1. 2. To enter Secondary Menu turn power switch on while holding Display Button. Continue to hold Display Button until CALIBRATE appears. CALIBRATE scrolls past on the Display. a. 3.
Maintenance Maintenance Routine maintenance is important to ensure proper operation of your TSP power pack. Maintenance includes performing routine actions that keep your TSP power pack in operation and prevent trouble in the future. Activity Inspect pump, hoses, and tools for damage or leaks. Inspect fan opening for blockage. Pressure calibration. Change hydraulic oil. Interval Daily. Daily. Per company, customer, or job specification. 40 motor hours.
Troubleshooting Troubleshooting Problem Unit does not start when plugged in and power switch is “ON”. Motor stops under load. 1. Follow Pressure Relief Procedure page 10, before troubleshooting or repairing TSP power pack. 2. Check all possible problems and causes before disassembling TSP power pack. Cause Solution Extension cord. Check extension cord continuity with ohmmeter. Replace extension cord. Low Voltage. Meter must read: 85-130 VAC (120V),. Meter must read: 170-260 VAC (240V).
Troubleshooting Problem Cause Solution Maximum pressure is ~3,300 psi. High pressure pump issue. Replace high pressure pump, see Pump Replacement page 30. Unit runs slow. Air in hydraulic system. Check oil level and fill as needed. Perform Prime TSP Power Pack Procedure page 12 and Hose Prime Procedure page 13. Unit set to 15A setting (120V only). Connect to a 20 Amp circuit and set switch to 20A setting. Hose connection filter plugged. Switch hose connection to other connectors.
Troubleshooting Problem TSP power pack does not run at all. Display shows CODE 04. TSP power pack does not run at all. Display shows CODE 05. Cause Control board detected voltage surges. Solution 1. 2. Control is commanding motor to run, but motor shaft does not rotate. 1. 2. 3. 4. 5. 6. 7. 22 Set TSP power pack to OFF and disconnect power to TSP power pack. Locate a good voltage supply to prevent damage to electronics. Remove pumps and try to run TSP power pack.
Troubleshooting Problem 3A6884B Cause Solution 23
Troubleshooting Problem Cause TSP power pack does not run at all. Control is commanding motor to run, but motor shaft does not rotate. Display shows CODE 05. Solution 8. Perform Field Short Test: Test at large 6-pin motor field connector. There should not be continuity from pin 4, the ground wire, and any of the remaining pins. If motor field connector tests fail, replace motor. 9. Check Motor Thermal Switch: Unplug thermal wires. Set meter to ohms.
Troubleshooting Problem TSP power pack does not run at all. Display shows CODE 06. Cause Motor overheated. Solution Note: Motor must be cooled down for the test. 1. 2. 3. 4. 5. 6. Keep TSP power pack in cooler location with good ventilation. Make sure motor air intake is not blocked. Set TSP power pack to OFF and disconnect power to TSP power pack. Open control box by removing 8 screws that attach control assembly to control box. Check thermal switch inside control box. Disconnect 6-pin connector.
Troubleshooting Problem Cause TSP power pack does not run at all. Incoming voltage too low for TSP power pack operation. Display shows CODE 08. TSP power pack does not run at all. Display shows CODE 10. TSP power pack does not run at all. Display shows CODE 12. TSP power pack does not run at all. Display shows CODE 15. Control board is over heating. Solution 1. Set TSP power pack to OFF and disconnect power to TSP power pack. 2. Remove other equipment that uses the same circuit. 3.
Troubleshooting Problem TSP power pack does not run at all. Display shows CODE 16. Cause Motor position sensor not working. Solution 1. 2. 3. TSP power pack does not run at all. Display shows CODE 17. TSP power pack plugged into wrong voltage. 4. 5. Reconnect sensor. Turn power ON. If code continues, replace motor. 1. Set TSP power pack to OFF and disconnect power to TSP power pack. Locate a good voltage supply to avoid damage to electronics. 2.
Repair Repair Calibration Procedure 4. Enter the secondary menu, see Secondary Menu (Stored Data) page 18. 5. CALIBRATE scrolls on the Display. 6. Press and hold the Display Button for a few seconds to start the calibration procedure. Calibration mode has been entered when RUN TO 8000 PSI PRESS DISPLAY BUTTON TO SAVE scrolls on the Display. The TSP power pack should be re-calibrated after replacing the transducer or control assembly.
Repair 7. Press the TSP power pack Advance Switch. Set pressure to 8000 psi per the calibration gauge or data acquisition system. While keeping the power pack running at 8000 psi, press the Display Button to lock in the 8000 psi value for the controller. NOTE: If the calibration procedure was unsuccessful, the following message will scroll on the Display: CALIBRATION FAILED. Press Display Button to continue.
Repair Pump Replacement Tools Required: 13 mm wrench. 3. Remove pump bolts (qty 6). 4. Slowly slide pump out of the drive housing. Allow filter to drain into reservoir during removal. Pump Removal (High flow displacement pump shown) Pump removal includes disassembling the pump guard and pump bolts and removing the pump. 1. Perform Pressure Relief Procedure, page 10 and disconnect power to the TSP power pack. Tilt unit 90 degrees backwards to keep oil from running out when pump is removed. 2.
Repair Pump Installation (High flow displacement pump shown) 2. Slide pump assembly into drive housing while ensuring the piston rod head is properly aligned in the assembly housing. Pump installation includes securing the pump and connecting to the fluid inlet and outlet. 1. Install pump tank o-ring and manifold seals. NOTICE Failure to properly align piston rod head into housing during reassembly could severely damage the TSP power pack during operation.
Repair 3. Attach pump housing to manifold with four screws and flat washers. Torque screws to 50-70 in-lbs. (5.6-7.9 N•m). 2-Way, Poppet Valve Replacement Tools Required: Phillips screwdriver, 7/8 in. wrench, 3/4 in. wrench. 4. Attach pump housing to reservoir with two screws and flat washers. Torque to 20-25 ft-lbs (27.1-33.4 N•m). 5. Replace pump guard (50) with retaining bolt (43). 32 1. Perform Pressure Relief Procedure, page 10 and disconnect power to the TSP power pack. 2.
Repair 5. Lift the black solenoid to gain clearance to the 7/8 in. hex on the body of the poppet valve. Loosen and remove. Pressure Set Valve Replacement Tools Required: 1-1/16 in. wrench. 6. Install new solenoid valve without the new 3/4 in. top retaining nut. 7. Torque the 7/8 in. hex to 19-21 ft. lbs (25.8-28.5 N•m). 8. Reinstall the top 3/4 in. retaining nut, torque to 4-5 ft. lbs (5.4-6.8 N•m). 9. Reconnect the terminal and tighten Phillips head screw. 1.
Repair 4-Way Valve Replacement 4. Remove finger-tight nut on top of valve. Remove coil from valve. 5. Use a 5 mm Allen wrench to remove the four M6 screws that secure the 4-Way Valve to the diverter block. Remove the 4-way valve. Save the M6 screws for reuse later. Tools Required: Phillips screwdriver, 5 mm Allen wrench, 10 mm wrench. Remove 4-Way Valve 1. Perform Pressure Relief Procedure, page 10 and disconnect power to the TSP power pack. 2. Remove top half of frame and shroud. 3.
Repair 6. 7. Use a 5 mm Allen wrench to remove the three M6 screws that secure the diverter block to the manifold. Remove the diverter block. Install 4-Way Valve 1. Remove finger-tight nut on top of new valve. Remove coil from new valve. 2. Using a 5 mm Allen wrench, carefully separate the 4-way valve from the diverter block. Ensure o-rings remain in place on 4-way valve. Set valve aside on a clean surface. 3.
Repair 4. 5. 36 Ensure new o-rings are installed in diverter block and remain in place. Position diverter block on the manifold. Align the three screws in the diverter block with the corresponding holes in the manifold. Secure with the three M6 screws. Torque to 6-8 ft-lbs (8.1-10.8 N•m). 6. Position the 4-way valve on the diverter block, it will only fit in one position. Secure with the four M6 screws. Torque to 6-8 ft-lbs (8.1-10.8 N•m). 7.
Repair Transducer Replacement Tools Required: 15/16 in. wrench. Remove Transducer Install Transducer 1. Apply sealant to transducer threads. 2. Start threading transducer into the manifold. 3. 1. Perform Pressure Relief Procedure page 10 and disconnect power to the TSP power pack. Using a 15/16 in. socket, tighten transducer to 50-55 ft-lbs (68.8-75.6 N•m). 4. 2. Lift connector locking tab on transducer electrical connector. Plug electrical connector into the transducer. 5.
Pendant Battery Replacement Pendant Battery Replacement CR123A BATTERY 38 3A6884B
Hydraulic Schematic Hydraulic Schematic Ref 7 8 19Y108 17U675 KIT, transducer, high pressure VALVE, pressure relief, 1500 psi 54 56 19Y113 17U671 9 17U685 73 17U696 10 11 18 17Z470* 17U703 19Y106 VALVE, pressure relief, 12000 psi VALVE, check, high pressure RESERVOIR, machined PUMP, high flow Description PUMP, high pressure FILTER, fluid FITTING, filter, 1/4 NPT male FITTING, QD, male, high pressure KIT, manifold, distribution FITTING, QD, female, high pressure COOLER, oil 81 19Y215 FITTING
Wiring Diagram - 120V Wiring Diagram - 120V See Control Box Parts 120V page 48 for 120V control box wiring Ref 1 2 6 7 13 22 40 Part Description Ref Part 19Y111 KIT, motor, hydraulic power 26 120660 pack 19Y107 KIT, valve, 4-way, directional 27 17U610 19Y353 VALVE, 2-way, poppet 74 19Y115 19Y108 KIT, transducer, high pressure 79 17U625 17S588 WIRE, green, 16 AWG 8”, #10, 85 17U743 serrated 17U721 FAN, oil cooler (120V) Description SWITCH, rocker BOX, control (120V) ASSEMBLY, control HARNESS, main, w/ s
Wiring Diagram - 230V Wiring Diagram - 230V See Control Box Parts - 230V page 50 for 230V control box wiring Ref 1 2 6 7 13 22 Part Description Ref Part 19Y111 KIT, motor, hydraulic power 26 120660 pack 19Y107 KIT, valve, 4-way, directional 27 17U629 17U666 Valve, 2-way, poppet 74 19Y115 19Y10 KIT, transducer, high pressure 79 17U625 17S588 WIRE, green, 16 AWG 8”, #10, 85 17U743 serrated 18B723 FAN, oil cooler (230V) 3A6884B Description SWITCH, rocker BOX, control (230V) ASSEMBLY, control HARNESS, main
Renegade TSP Torque Series Pump Parts Renegade TSP Torque Series Pump Parts Ref. Torque Ref. Torque 20-25 ft-lbs (27.1-33.4 N•m) 5 13 40-45 in-lbs (5.1-6.2 N•m) 9 10 42 Ref. Torque 30-40 in-lbs (3.4-4.5 N•m) 24 110-120 in-lbs (12.4-13.6 N•m) 10-12 in-lbs (1.1-1.4 N•m) 19 95-105 in-lbs (10.7-11.9 N•m) 40-45 in-lbs (4.5-5.
Renegade TSP Torque Series Pump Parts Renegade TSP Torque Series Pump Parts List Ref.
Manifold Assembly Parts Manifold Assembly Parts Ref. Torque Ref. Torque 50-55 ft-lbs (68.8-75.6 N•m) 1 6-8 ft-lbs (8.1-10.8 N•m) 7 57-61 ft-lbs (77-83 N•m) 2 19-21 ft-lbs (25.8-28.5 N•m) 8 4-5 ft-lbs (5.4-6.
Manifold Assembly Parts Manifold Assembly Parts List 7 Ref.
Motor Assembly Parts Motor Assembly Parts Ref. Torque 4 190-210 in-lbs (21.5-23.7 N•m) Ref. Torque 10 20-25 ft-lbs (27.1-33.4 N•m) 5 50-70 in-lbs (5.6-7.9 N•m) 12 155-175 in-lbs (5.6-6.8 N•m) 7 10-12 in-lbs (1.1-1.4 N•m) 19 40-45 ft-lbs (54.2-61.0 N•m) 23 145-155 in-lbs (16.4-17.5 N•m) 57-61 ft-lbs (77-83 N•m) 26 30-40 in-lbs (3.4-4.5 N•m) 13 45-55 in-lbs (5.1-6.2 N•m) 46 Ref. Torque 5-7 ft-lbs (6.8-9.5 N•m) 11 6 9 95-105 in-lbs (10.7-11.
Motor Assembly Parts Motor Assembly Parts List Ref.
Control Box Parts - 120V Control Box Parts - 120V Ref. Torque 2 3 48 10-12 in-lbs (1.1-1.4 N•m) 17-21 in-lbs (1.9-2.4 N•m) Ref. Torque 5 21 15-20 in-lbs (1.7-2.3 N•m) 40-45 in-lbs (4.5-5.
Control Box Parts - 120V Control Box Parts List Ref.
Control Box Parts - 230V Control Box Parts - 230V Ref. Torque 2 3 50 10-12 in-lbs (1.1-1.4 N•m) Ref. Torque 5 15-20 in-lbs (1.7-2.3 N•m) 17-21 in-lbs (1.9-2.
Control Box Parts - 230V Control Box Parts List Ref. Part 1 2 278893 17U638 8 114528 9 17U767 10 17U637 11 17U621 12 17Z458 13 17S588 14 15 16 100166 24W147 124131 17 17U616 3A6884B Description BOX, control, 120V BOARD, assembly, display SCREW, mach, Phillips, PNHD BRACKET, IEC connector HARNESS, IEC power inlet PLATE, backer, power connection STUD, terminal, ground WIRE, green, 16 AWG, 8”, #10 serrated NUT, full hex BOARD, filter, 230V SCREW, mach, pan head CONNECTOR, pendant Qty.
Technical Specifications Technical Specifications Hydraulic Power Pack Pressure Maximum delivery Fluid outlet npt Generator minimum Motor (brushless DC) 120V, A, Hz 230V, A, Hz Environmental temperature range Oil reserve capacity Recommended hydraulic oil Operating oil viscosity range (centistokes) Dimensions Weight (dry) Height Length Width Ingress Protection Power pack assembly Pendants Noise (dBa)* Maximum sound power US 10,000 psi Metric 700 bar, 68.9 MPa 1.7 gpm 6.4 lpm 1/4 in. 1/4 in.
Compliance Compliance Radio Frequency Approvals Transmitter Frequency (all models): 433.92 MHz Transmitter Power (all models): -9.50 dBm NOTE: FCC/IC Notice (all models) FCC ID: JHICED2 IC: 4840A-CED2 The enclosed device complies with Part 15 of the FCC Rules and with Industry Canada license-exempt RSS standard(s).
Graco Standard Warranty Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
Graco Information Graco Information For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 3A6884 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2019, Graco Inc.
