SV1000

OPERATION AND MAINTENANCE

MANUAL
Auto Cycle Pump
MODELS SV1000, SV1000-230V

1025 Conroy Place, Easton PA 18040 * U.S.A.

Phone: +1 610-250-5800 * Fax: +1 610-250-2700
Toll Free: 1-888-TORCUP-1
Email: [email protected] * Website: www.torcup.com
 Operational and Maintenance Manual for TorcUP
SV1000 Auto Cycle Pump
Version 1: 2014 December

Industrial grade membrane switch with tactile response buttons and highly visible embedded LED tool
selection. Auto-cycle feature allows for continuous rotation and operation of the hydraulic wrench.
Low voltage pendant and circuitry for added safety for the operator.
Pendant controlled auto-cycle or standard tool operation.
Rugged & secure roll-cage protects against damage, while providing additional lifting points.
Advance electronic circuitry mazimizes the hydraulic tools speed and torque output.
Removeable, easy to read 4” PSI/BAR industrial gauge for ease of pressure verification and calibration.

TorcUP Inc. is not responsible for customer modification of tools for applications on
which TorcUP Inc. was not consulted.

IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING PUMP.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS
MANUAL INTO THE HANDS OF THE OPERATOR.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

CONTENTS
Manual Index……………………................1 Control Valves…………………………………..8
General Warnings………………………….2 Power Control Switches……………………....8
Safe and Correct Use…………………......4-6 Pendant…………………………………………..8-9
Technical Specifications…………….……5-8 Operation Procedures.………………………..10
Working Pressure………………….....……5 Pressure Torque Setting……………………...11
Install Vent Plug……………………..……..5 After Completing the Job……………………..11
Adding Oil……………………………....…..5 Periodic Maintenance………………………....11
Install Hydraulic Connections…………...6 Maintain Oil Level…………………………...….12
Electrical…………………………………….7 Clean Oil Intake Screen…………………...…..12
Connecting Hydraulic Tools……………..7 Flushing the Pump………………………….… 12
Starting the Pump for the first time…….7 Troublineshooting................………………….13
Pump Mounting…………………………....8 SV1000 Parts Index……………………………14-26

TorcUP has taken every care in preparing this Operational Manual that is intended as a technical guideline only. TorcUP
accepts no liability in relation to any use or reliance made of any information in this Operational Manual. All information,
illustrations and specifications in this Operational Manual are based on the latest information available at the time of publica-
tion. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be respon-
sible for ensuring that a safe working environment and safe systems of work are in place before operating the equipment.

The use of other than genuine TorcUP replacement parts may result in safety For Technical Support & Information Contact:
hazards, decreased tool performance, and increased maintenance, and may TorcUP Inc.
invalidate all warranties. Repairs should be made only by authorized 1025 Conroy Place, Easton, PA 18040 USA
personnel. Consult your nearest TorcUP Authorized Service Center. Phone: +1 610-250-5800 Fax:+1 610-250-2700
Refer All Communications to the Nearest TorcUP Office or Distributor. email: [email protected]

1/26
 FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY

Do NOT exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.

Do not use damaged, Always wear eye

frayed or deteriorated protection
air/pneumatic hoses when
and fittings. operating or
performing
maintenance
on this tool.

Always wear ear protection

when operating this tool. Do not carry
the tool
by the hose.

Keep body stance The Torque Reaction Arm must be

balanced and firm. positioned against a positive stop.
Do not use the arm as a dead
Do not overreach
handle. Take all precautions to
when operating this make certain the operator’s hand
tool. cannot be pinched between the
arm and a solid object.

USING THE TOOL

• Keep hands, loose clothing & long hair away from the reaction arm and working area during operation.
• This tool will exert a strong reaction force. Use proper mechanical support and correct reaction arm
positioning to control these forces. Do not position the reaction arm so that it tilts the tool off the axis of
the bolt and never use the swivel inlets as a reaction stop.
• Avoid sharp bends and kinks that will cause severe back-up pressure in hoses an lead to premature
hose failure.
• Use accessories recommended by TorcUP.
• Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.
• Use only sockets and accessories that correctly fit the bolt or nut and function without tilting the tool off
the axis of the bolt.
• This tool is not insulated against electric shock.
• This equipment must not be operated or serviced unless the operator read the operating instructions
and fully understands the purpose, consequences and procedure of each step.

Depending on the working environment your local health and safety regulations may require
you protective gear (i.e. Ear Protection, Safety Shoes, Hard Hat, Gloves, Coveralls, etc.) In
case external forces are exerted on the equipment, non-compliance with these regulations may
result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.

2/26
 SAFE AND CORRECT USE
Operation of the Equipment in Accordance with Specified Use
1. Inspect, maintain, operate and install the tool in accordance with all applicable standards and
regulations (local, state, country, federal, etc.)
2. Do not remove any labels. Replace any damaged labels immediately.
3. Be sure all hoses and fittings are the correct size and tightly secured.
4. Do not use damaged, frayed or deteriorated hydraulic hoses and fittings. Do not paint hoses.
5. Do not lubricate tools with flammable or volatile liquids such as kerosene, diesel or jet fuel. Use
only TorcUP recommended lubricants.
6. Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet current
safety and health standards. Use cleaning solvents in a well ventilated area.
7. Keep work area clean, uncluttered, ventilated and illuminated.

Safety Information When Using The Tool

1. When wearing gloves always be sure that the gloves will not prevent the throttle mechanism from
being released.
2. Always wear eye protection when operating or performing maintenance on this tool.
3. Always wear hearing protection when operating this tool.
4. Always use personal protective equipment appropriate to the tool used and material worked.
This may include dust mask or other breathing apparatus, safety glasses, ear plugs, gloves,
apron, safety shoes, hard hat and other equipment.
5. Keep others a safe distance from your work area, or ensure they use appropriate personal
protective equipment.
6. Be aware of buried, hidden or other hazards in your work environment. Do not contact or dam-
age cords, conduits, pipes, or hoses that may contain electrical wires, explosive gases or harmful
liquids.
7. Keep hands, loose clothing, long hair and jewelry away from working end of tool.
8. Power tools can vibrate in use. Vibration, repetitive motions or uncomfortable positions may be
harmful to your hands and arms. Stop using any tool if discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming.
9. Keep body stand balanced and firm. Do not overreach when operating this tool. Anticipate and
be alert for sudden changes in motion, reaction torques, or forces during start up and operation.
10. DO NOT USE THIS TOOL WHEN TIRED, UNDER THE INFLUENCE OF MEDICATION,
DRUGS OR ALCOHOL.
11. Never use a damaged or malfunctioning tool or accessory.
12. Do not modify the tools, safety devices or accessories.
13. Do not use this tool for purposes other than those recommended
14. Never exceed rated pressure of tool.

3/26
 SAFE AND CORRECT USE
IMPORTANT - READ CAREFULLY
This manual contains important information for the correct installation, operation and maintenance of
this equipment. All persons involved in the installation, operation and maintenance of this equipment
must be thoroughly familiar with the contents of this manual. To safeguard against the possibility
of personal injury or property damage, follow the recommendations and instructions of this manual.
Keep this manual for reference.

WARRANTY STATEMENT
TorcUP products are warranted to be free of defects in materials and workmanship under normal use
for as long as the original purchaser owns them, subject to the guidelines and limitations listed. This
warranty does not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, im-
proper fluid, or use in a manner for which they are not intended. If the customer believes a product is
defective, the product must be delivered, or shipped freight prepaid, to the nearest TorcUP Authorized
Service Center for evaluation and repair. This pump offers 13 month warranty.

RECEIVING INSTRUCTIONS
Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify
carrier at once. Shipping damage will not be covered by warranty. The carrier is responsible for all
loss associated with shipping damage.

SAFETY
Make sure to read the instructions, warnings and precautions carefully. Follow any recommended
safety precautions to avoid personal injury or damage to the unit. TorcUP cannot be responsible for
any damage or injury from unsafe use, lack of maintenance or incorrect operation. In the event any
questions or concerns arise, contact TorcUP or a local representative for clarification.
The pump’s maximum working pressure is 10,000 PSI(700kg/cm2). Make sure that all hydraulic
equipment such as rams, hoses, etc. used with this pump are rated at 10,000 PSI (700kg/cm2) oper-
ating pressure.
If you have never been trained on high-pressure hydraulic safety, consult your representative for a
free TorcUP Hydraulic Safety Course.
Failure to comply with the following cautions and warnings could cause equipment damage, property
damage or personal injury.
DANGER is only used when your action or lack of action may cause serious injury or even death.

WARNING indicates a potential danger that requires correct procedures or practices to avoid per-
sonal injury.
CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent
damage to, or destruction of equipment, or other property.

4/26
 SAFE AND CORRECT USE
WARNING: Wear proper personal protective gear when operating hydraulic equipment.

DANGER: To avoid personal injury, keep hands and feet away from work-piece during operation.

WARNING: Do not exceed equipment ratings. Overloading causes equipment failure and possible 2
personal injury. The pump tools are designed for a maximum pressure of 10,000 PSI (700kg/cm ).
Do not connect a jack or cylinder to a pump. Never set the relief valve to a higher pressure than the
maximum rated pressure of the pump. Higher settings may result in equipment damage and/or per-
sonal injury.

WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated
component in the system. Install pressure gauges in the system to monitor operating pressure.

CAUTION: Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic
hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will inter-
nally damage the hose, leading to premature hose failure. Do not drop heavy objects on hose. A sharp
impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may
cause it to rupture.

IMPORTANT: Do not lift hydraulic equipment by the hose or swivel couplers. Use the carrying handle
or other means of safe transport.

CAUTION: Keep hydraulic equipment away from flames and heat. Excessive heat will soften seals,
resulting in fluid leaks. Heat also weakens hose materials. For optimum performance do not expose
equipment to temperatures of 65° C (170° F) or higher. Protect hoses and cylinders from weld spatter.

TECHNICAL SPECIFICATIONS
WORKING PRESSURE

The pump’s2 maximum working pressure is 10,000 PSI

(700kg/cm ). Make sure that all hydraulic equipment
such as tools, hoses, etc. used
2
with this pump are
rated at 10,000 PSI (700kg/cm ) operating pressure.

INSTALL VENT PLUG

Remove shipping plug from reservoir and install

vent plug supplied with pump.

ADDING OIL

Remove oil filler cap and add TorcUP hydraulic oil

into reservoir. Oil level should not exceed 1” from
the reservoir cover. Oil should be ISO 32 or 46
weight.
*As a “rule of thumb” oil should be filled about an inch below the
top of the reservoir when the unit is powered down and all
connected tools or cylinders are retracted.
5/26
 TECHNICAL SPECIFICATIONS
LUBRICATION

Usable Reservoir
A B C D E
Capacity
(Gal.) (litre) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
1.5 5,7 8.75 222.25 5.96 151.38 15.13 384.3 18.1 459.74 16.85 427.99

Weight is without oil.

Reservoir Valve Weight
Model
Pendant Motor Specification Flow Rate
Number Gal. Litre Model Style Function lbs. Kg

700 cu.in./min. @ 1,100 psi

Motor/
Auto Advance/ 1.5 HP @115VAC 55 cu.in./min.@10,000 psi
SV1000 1.5 5,7 Torque Solenoid Single Phase (9.4 litres / min. @ 75 bar
65.75 29,8
Retract Retract
Control 0.9 / min. @ 700bar)

700 cu.in./min. @ 1,100 psi

Motor/
Auto Advance/ 1.5 HP @230VAC 55 cu.in./min.@10,000 psi
SV1000-230V 1.5 5,7 Torque Solenoid Single Phase (9.4 litres / min. @ 75 bar
65.75 29,8
Retract Retract
Control 0.9 / min. @ 700bar)

INSTALL HYDRAULIC CONNECTIONS

Use only tools,
2
hoses and accessories rated at 10,000 PSI
(700kg/cm ). Remove the shipping plugs from the ports
to connect your coupling(s) or hose(s) to manifold. Use
1.5 wraps of Teflon tape (or suitable thread sealant) on all
threads, leaving the first complete thread free of tape to
ensure no foreign matter enters the hydraulic circuit.

When making connections with quick disconnect couplings,

make sure the couplings are fully engaged. Threaded connec-
tions such as fittings, gauges, etc. must be securely tightened
and leak free.

6/26
 TECHNICAL SPECIFICATIONS
Loose or improperly threaded fittings can be potentially dangerous if pressurized;
however, severe over tightening can cause premature thread failure. Fittings need
to be tightened secure & leak free. Never hold or stand directly in line with any
hydraulic connections while pressurizing. Never grab, touch or in any way come in
contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and a
serious injury can result.

CAUTION: Do not subject the hose to potential hazards such as sharp surfaces, extreme heat or
heavy impact. Do not allow the hose to kink or twist. Inspect each hose for wear before it is used.

ELECTRICAL
Check for proper electrical supply before connecting. Be sure the electrical connection is grounded.
Check that your power supply agrees with the motor nameplate and/or TorcUP model decal.

NOTE: MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN THE

PRESENCE OF CONDUCTIVE LIQUIDS.
1. Do not use a power or extension cord that is damaged or has exposed wires.
2. All single phase motors come equipped with a three prong grounding type plug to fit the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the
pump’s motor must be grounded.

CONNECTING HYDRAULIC TOOLS

2
Use only tools, hoses and accessories rated at 10,000 PSI (700kg/cm ). When making connections
with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections
such as fittings, gauges, etc. must be securely tightened and leak free. Use 1.5 wraps of Teflon tape (or
suitable thread sealant) on all threads, leaving the first complete thread free of tape to ensure no foreign
matter enters the hydraulic circuit.

STARTING THE PUMP FOR THE FIRST TIME

1. Check for any leaks, repair as needed.
2. When first plugged in the solenoid makes 4 “clicks” relieving any pressure still in the system.
When the button to turn off the pump is pressed it goes through the same sequence for the
same reason. It is then safe to remove tool and hoses.
3. Shift pendant to the advance position to advance tool and release to retract tool. Look for
movement in tool, check for any leaks, repair as needed.

CAUTION: Never operate the pump without tool movement for more than 1 minute. Leaving the valve
in the advance or retract position without the tool’s piston rod moving will overheat the oil.

CAUTION: Never disconnect or connect any hydraulic hoses or fittings without first unloading the tool,
then unplug the electrical cord of the pump. Open manual relief valve to assure that the system has
been depressurized.

7/26
 TECHNICAL SPECIFICATIONS
PUMP MOUNTING
Refer to the chart for mounting dimensions to
secure the pump to a fixed surface.
1 gal. 1.5 gal. 2.5 gal. 5 gal
(4L) (6L) (10L) (20L)
A 11 15.13 17 19.6
B 0.56 1.68 2.75 4.69
C 0.56 3.57 4.37 5.03
D 1.16 1.43 1.93 2.93
E 8.19 9.75 9.75 11.75
F 1/4-2unc 1/4-2unc 1/4-2unc 1/4-2unc
(4 places) (4 places) (4 places) (4 places)

CONTROL VALVES

2 Position
2-Postion – 4 Way Solenoid Valve for -
Hydraulic Torque Wrenches. 4 Way Solenoid

To Advance......depress the Advance Switch

To Retract.........release advance switch to Retract Tool.

POWER CONTROL SWITCHES

Remote pendant.
Configured with motor control pendant:

Press UP or Down Press UP or Down

To Manually Cycle Pump To Auto Cycle Pump

NOTE: In the event multiple buttons

are depressed for longer than 5 sec-
onds, the unit is programmed to shut
down. To restart, you will need to
depress the motor “ ON” to continue,
or unplug/replug the unit into power
supply, then depress the motor “ ON”
to continue. Press Either Button To Turn Pump On

8/26
 SV1000 PENDANT

ITEM # PART# DESCRIPTION QTY

01 69083 Pendant body 1.00
02 689151 2 Switch Junction Box 1.00
03 69487 Toggle Switch 2.00
04 68375 Cord Fitting 1.00
05 DS1309052 Pendant Wire 1.00

9/26
 OPERATION PROCEDURES
SV1000 & SV1000-230V
NOTES: The following procedures should be preformed after the desired pressure setting has
been set on the pump (See pressure torque setting section on page 11 of the manual).

The SV1000 will perform a self diagnostic once the unit has been plugged in. This is noticeable by
the pump making three (3) audible “Clicks” once plugged in. The SV1000 WILL NOT turn itself on
during this diagnostics.

Selecting tool for auto cycle operation.

1. SELECTING TOOL:

Select the torque wrench to be used by pressing the UP & DOWN scroll arrows (A) until the desired
tool is highlighted. The red LED light (B) will blink two times after the tool has been selected, con-
firming tool selection.

A
B D

2. MODE SELECTION: C
The mode selection button allows the user to operate the TLM ultrasonic device in conjunction with
the SV series auto cycling pumps.

WITHOUT TLM - To operate the SV1000 pump in normal and auto cycle mode, press the MODE
button (C) until the confirmation LED light (D) is NOT highlighted.

WITH TLM – To operate the SV1000 pump with the TLM unit, the pump will need to have a TLM
Interface Modules (TLM-IM) adapted to the pump. Contact TorcUP for more information. Once the
Interface module has been adapted and the tool has been selected (see above), press the MODE
button (C) until the confirmation LED light (D) IS ON or highlighted.

3. OPERATING TOOL IN AUTO CYCLE

3a. Press and HOLD the “Auto” button switch to operate the wrench in auto cycle mode, until
nut rundown has been achieved. Press momentary switch for normal “Advance”, and repeat
this procedure until final torque has been achieved.

3b. Release “Auto” button and torque wrench piston will retract.

REFER TO TORQUE WRENCH INSTRUCTIONS FOR WRENCH OPERATING PROCEDURE

10/26
 OPERATION PROCEDURES

PRESSURE TORQUE SETTING

Make these adjustments BEFORE putting torque wrench on nut or bolt

head. The pump pressure setting may be above the pressure needed
to provide the required torque for your application.
Exceeding required torque will cause equipment damage and may lead
to serious personal injury.

1. See torque wrench instructions for amount of pressure required

to produce desired torque.
2. Loosen lock nut and back out relief valve to prevent unintended
pressure builds up.
3. Turn pump on. Press and the “ADVANCE” switch, and read
pressure gauge.
4. While holding the switch, turn relief valve in (clockwise)
to increase pressure or out (counter-clockwise)
to decrease maximum pressure. Repeat until
correct pressure is obtained.
5. Tighten lock nut on the relief valve to maintain setting.
6. Run pump several times to test this setting before
setting tool on the nut.

AFTER COMPLETING THE JOB

Before disconnecting hoses, fittings, etc., first be sure the tool is unloaded and retracted, then unplug
the power cord. The pump is designed to cycle valve upon power down “off.”

PERIODIC MAINTENANCE

Completely change the hydraulic oil and clean the intake screen and magnet (located in the reservoir)
twice a year. If equipped, change the external oil filter twice a year (Use TorcUP oil only, Model # AO1,
1 gallon). Change the oil more frequently when used in extremely dusty areas or when the oil has been
overheated. Using oil other than TorcUP Brand may void the pump’s warranty.

The following conditions require more frequent oil changes.

•Rigorous duty, where oil temperature may reach 150˚ F.
•High humidity environment and extreme changes in temperature that can result in condensation

The electrical power cord must be disconnected from electrical outlets

before performing maintenance or repair procedures.

11/26
 OPERATION PROCEDURES

MAINTAIN OIL LEVEL

Check hydraulic oil level every 30 hours of operation (sight gauge should be completely covered in
oil when all tools are retracted. Add TorcUP oil (Model # AO1 – 1 gallon) when necessary. Oil level
should be no more than 1” from top of reservoir plate – with cylinders retracted and motor off.

CLEAN OIL INTAKE SCREEN ONCE A YEAR

Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not to damage
the gasket.

Applies to 1, 1.5, 2, 2.5 gallon reservoirs:

Remove the five allen socket head cap screws, securing the screen to the 1st stage gear pump. Care
should be taken not to remove the center plate and gears. Remove and clean with nonflammable
solvent, blow dry clean. Reinstall in reverse order and torque bolts to 75 inch pounds. Keep the motor
and pump as clean as possible.

Applies to the 5 and 10 gallon reservoirs:

Unscrew screen from bottom of pump unit and clean
with nonflammable solvent. Blow dry and reassemble.
Keep areas around pump unobstructed to provide good
air flow around the motor and pump. Keep the motor
and pump as clean as possible.

FLUSH THE PUMP

If you suspect your pump has been contaminated or
discover sludge or other deposits on internal
components, you should thoroughly flush the pump.
Remove the old oil from the reservoir, then thoroughly
clean the reservoir and refill with a clean, nonflammable
flushing oil. Reassemble the pump and motor to the
reservoir.

Run the pump in no load condition for 1 or 2 minutes maximum. Unplug the pump and remove the
motor and pump assembly again. Now drain the flushing oil and re-clean the inside of the reservoir.
(Make sure flushing fluid is also drained from pump assembly). Reassemble the pump and refill the
reservoir with TorcUP hydraulic oil and reassemble the pump.

12/26
 TROUBLESHOOTING

PROBLEM CAUSE-SOLUTION

Sporadic Tool Action: • Air in the hydraulic system. Bleed the hydraulic circuit.
• Check reservoir oil level.

Motor Will Not Start: • Be sure power cord is not damaged.
• Check for tripped circuit breaker; be sure breaker is of
adequate size.
• Have motor checked for proper operation.
• Have qualified electrician inspect for loose or faulty wiring or
switch.
• Press Mode Button until LED is NOT highlighted
.
Noisy Operation: • Air in system.
• Be sure the oil reservoir is filled to normal level.
• Check all points where air might leak into system.
• Clogged or blocked intake screen.

Pump Oil is Over Heating: • Inspect for high pressure leakage at the pump (leaking at
plug or relief valve).
• Oil level is low. Fill reservoir to normal level, or retrofit the
pump with larger reservoir or heat exchanger.

Pump Runs But Will Not Pump Oil: • Pump is not primed. Run pump a few minutes tipping from
side to side.
• Inspect to make sure that external adjustable relief valve is
set properly.
• Defective control valve, take to nearest TorcUP Authorized
Service Center for repair.
• Incorrect motor rotation, take to nearest TorcUP Authorized
Service Center for repair.
• Check to make sure the intake screen is not clogged. Clean
if needed.
• Check oil reservoir is low. Fill as needed.
• Oil viscosity is too high. Replace with TorcUP oil.

13/26
 PARTS INDEX

This illustration is for reference purposes only.

The appearance of your unit may differ from the unit shown.

Electrical Brackets Wiring

Page 24
Valve Sub Assemblies
Page 22

Pendants
Page 9
Manifold
Assembly
Page 23

Common Components
Page 16

Pump Sub Assemblies

and Sub-Components
Pages 23, 24, & 25
Reservoir
Page 25

14/26
 PARTS INDEX

How to Identify Parts for Your Model.

MODEL NUMBER & DATE CODE LOCATION

For example, the date code and serial number

J = October
07 = Year 2007
42 = Week number in year

J 07 42
ABCD E FG HI J K L
1 2 3 4 5 6 7 8 9 10 11 12

MODEL DECAL PLACEMENT

DATE CODE COVER PLATE

STAMPING LOCATION

15/26
 COMMON COMPONENTS
Note: This illustration is for reference only. The appearance of your unit may differ from unit shown.

16/26
 COMMON COMPONENTS
ITEM # PART # & DESCRIPTION QTY ITEM # PART # & DESCRIPTION QTY
46335 1 44491 2
2 PUMP ASM. G5 2 STAGE 37 QUICK DISCON. FLAG BLUE
DS1328025 1 69917 1
3 RESERVOIR 1.5 GALLON TORC- 38 RING TERMINAL 1/4"
85469 1 45175 1
4 RESERVOIR GASKET 39 SHCS #10-32X1/4" LG PLATE
46348 1 46405 4
5 BREATHER VENT 3/8 NPT 42 HOLE PLUG 1/4
CN815006 1 69353 2
6 PIPE PLUG 43 SPACER 1"
46118 1 84417 2
7 SAE #12 HEX PLUG WITH PORT 44 HHCS 1/4-20 X 1.50
65891 14 88429 2
8 HHCS 1/4-20 X .75 PLT 45 WASHER 1/4" SS
65892 14 46294 1
9 SEALING WASHER 46 COIL 115V WITH DIN CONNECT
68068 1 46009 1
11 LABEL SAFE USE ELEC 52 SIGHT GAUGE
87305 1 4100067 1
12 BLANK DECAL 3 X 4 57 1/4IN NIPPLE
46292 1 CT210 1
13 MANIFOLD ASM. TORQUE WRENC 58 1/4"NIPPLE
69242 1 45765 1
14 VALVE GASKET 59 1/4" SELF-LOCKING COUPLER
99921 3 46474 1
15 SHCS 3/8-16 X 2 3/4 62 GAUGE SHROUD ASSEMBLY TORQ
68963 1 44559 4
16 ADAPTER ASSY. 64 BHCS10-24X.50 316SS
R515245-2 1 46588 2
17 PLUG 65 GAUGE SHROUD MOUNTING PLAT
46291 1 46310 1
19 VALVE ASM. 2P/4W TORQUE WR 68 VELCRO STRAP 1x14
88363 4 66012 1
20 SHCS 3/8-16 X 3 1/2 70 GASKET-MOTOR
93943 6 46032 1
21 LOCKWASHER 3/8 PLATED 71 PUMP GASKET G5
561604 1 46334 1
22 ROLL PIN 1/8 X 3/8 LG 73 COVER PLATE G5 TORQUE WREN
66021 1 69026 1
24 MAGNET 74 PIN,DOWEL 3/16 1" LONG

17/26
 COMMON COMPONENTS

ITEM # PART # & DESCRIPTION QTY ITEM # PART # & DESCRIPTION QTY
45862 1 93594 2
25 MOTOR SHROUD W/O HANDLE G 1 75 SHCS 3/8-16 X 1 1
46539 68376
27 DECAL OVERLAY 1 76 1 1/2HP, PM MOTOR 4
DS1038900 46279
28 BRACKET ASSEMBLY G5 TORC-U 2 78 FHCS 1/4-28 x 0.50 LONG 1
69234 45620
29 HEAVY HEX JAM NUT 1/4-20 111 MULTIPORT ADAPTER BLOCK
69236 4 45622 2
30 BHCS 10-24 x 3/8 LG 112 VALVE ADAPTER MULTIPORT AS
A1007245 4
113 1/8 FLUSH PLUG W/SEALANT
81907 2
114 SHCS 1/4-20 X 2 LG
A8069006 7
115 PIPE PLUG

18/26
 SUB PUMP ASSEMBLY
(46335) PUMP ASM.

19/26
SV1000 Torque Wrench Sub Pump Assembly
Power Pump
SUB PUMP ASSEMBLY
(46335) PUMP ASM.
(46335) PUMP ASM.
ITEM # DESCRIPTION PART # QTY.
01 PUMP BODY G5 45750 1.00
02 BEARING ROLLER 5/8x13/16x5/8 WIDE 68360 1.00
03 THRUST BEARING 66033 1.00
04 THRUST WASHER 66474 2.00
05 ECCENTRIC SHAFT ASM 5/8" G5 SEE PAGE 19 1.00
06 THRUST BEARING 66106 1.00
07 THRUST WASHER 66108 2.00
08 ECCENTRIC SHAFT ADAPTER G5 45908 1.00
09 O-RING 1 3/4 X 1 7/8 * 1.00
10 RETAINING RING 68978 1.00
11 POW'R BUD DUMP PLUG 43283 1.00
12 O-RING 3/16X5/16 * 3.00
13 BACKUP WASHER 56080087 1.00
14 MALE TEE 1/8" PIPE TO 1/4" TUBE 45426 1.00
15 PIPE PLUG 1/4" FLUSH W/ COATING 46509 1.00
16 UNLOADING PISTON ASSEMBLY SEE PAGE 7 2.00
17 MALE ELBOW 1/4" TUBE 1/4" PIPE 45929 1.00
18 BALL 1/8" 90906 3.00
19 G3 PISTON BLOCK TUBE 45420 1.00
20 OUTLET TUBE PISTON BLOCK 45815 1.00
21 BALL 5/16" 91701 3.00
22 UNLOADING SPRING 43671 1.00
23 ADJUSTING SCREW G5 45903 1.00
24 O-RING 5/8X3/4 URETH * 1.00
25 PIPE PLUG FLUSH 1/16 W/ COATING 40049 7.00
26 WEAR PLATE G5 45909 1.00
27 BOTTOM PLATE 9/32" G5 45900 1.00
28 GEAR PUMP 0.281 45824 2.00
29 SHAFT-IDLER 68850 1.00
30 SCREEN * 1.00
31 TUBE-GUIDE .11 68894 2.00
32 SHCS 1/4-28 X 1 3/4 68255 5.00
33 PLATE-SCREEN MTG. 68927 1.00
34 MALE ELBOW 1/8 PIPE 69354 1.00
35 SPRING 68225 2.00
36 ROLL PIN 1/8 X 3/4 LONG 97782 1.00
37 BALL STOP G5 45904 2.00
38 GASKET 29/64 X 5/8 * 2.00
39 SPRING CAP UNLOADING VALVE 43673 1.00
41 TUBE RETURN 68569 1.00
43 BEARING ROLLER 1 1/4x1 1/2x3/4 WIDE 66030 1.00
44 BEARING ROLLER 1/2x11/16x1/2 WIDE 68891 3.00
45 RING-RETAINING 68892 1.00
46 PIPE PLUG 1/8" FLUSH W/ COATING 46508 1.00
47 CART REL. VAL. ASSEMBLY 66220 1.00
48 SHAFT SEAL G5 * 1.00
49 PISTON BLOCK ASM. 0.255 G5 SEE PAGE 19 2.00
50 SHCS 5/16-24 X 1.75 69392 8.00

REBUILD KIT ( * = COMPONENTS) -- PART # 54488 20/26

20
 (46336) PISTON BLK ASM.

SUB PUMP ASSEMBLY

ITEM # DESCRIPTION PART # QTY.
01 GEN II PISTON BLOCK 45539 1.00
02 BALL 1/8" 90906 2.00
03 SPRING 66042 1.00
04 BALL STOP 68810 1.00
05 BALL RETAINER 66043 1.00
06 INTAKE SEAT 66046 1.00
07 GASKET 25/64X19/32 * 1.00
08 PLUG PISTON BLOCK 68825 1.00
09 GASKET 29/64 X 5/8 * 1.00
10 ADAPTOR .255 DIA. 68909 1.00
11 SPRING, PISTON 68340 1.00
12 PISTON .255 DIA. 68222 1.00

(45820) ECCEMTRIC SHAFT ASM.

ITEM # DESCRIPTION PART # QTY.

01 ECCENTRIC SHAFT 5/8" 45819 1.00
02 ECCENTRIC RING 45907 1.00
03 ROLL BEARING 1 1/8x1 3/8x3/4 WIDE 45926 1.00
04 RETAINING RING EXTERNAL 1 1/8" 45931 1.00
(45820) ECCENTRIC SHAFT ASM. 05 THRUST WASHER 68026 2.00

(43766) UNLOADING PISTON ASM.

ITEM # DESCRITPION PART # QTY.

01 UNLOAD PISTON 43765 1.00
02 O RING 1/4X3/8 * 1.00
03 BACK-UP WASHER TEF 43768 1.00
04 DOWEL PIN 1/8X3/4 LG 43686 1.00

REBUILD KIT ( * = COMPONENTS) -- PART # 54488

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 Valve Sub Assemblies
VALVE SUB ASSEMBLY
(46291) 3 & 4 WAY SOLENOID VALVE 115V. / 230V.

ITEM # DESCRIPTION PART # QTY.

01 BODY-VALVE 68708 1.00
02 SLIDER ADV/RET ONLY 44328 1.00
03 BALL 3/16" 90548 4.00
04 SET SCREW 1/4-28 X 1/4 CUP 40254 4.00
06 O-RING 7/32X11/32 * 3.00
07 BACK UP WASHER * 3.00
08 SHEAR SEAL 68383 3.00
09 SPRING 68384 3.00
10 O-RING 2 5/8 X 2 3/4 * 1.00
11 BEARING ROLLER 5/16x1/2x5/16 WIDE 68385 4.00
12 PIN BEARING 68390 2.00
13 PIPE PLUG FLUSH 1/16 W/ COATING 40049 1.00
14 SHCS #10-32 X 1" LG PLATED 68264 2.00
15 VALVE TOP PLATE MACHINED 46272 1.00
17 O-RING 3/16X5/16 * 1.00
19 VALVE PLUG 2 POSITION SLIDER 46271 1.00
26 O-RING SAE PORT #10 * 2.00
27 SPRING 68711 1.00
29 SPACER VALVE SLIDER 46418 1.00
31 O-RING 5/16X7/16 URE * 4.00
32 PUSHER-SOLENOID 68729 1.00
PACKING KIT 3 & 4 WAY SOLENOID VALVE 22/26
(* = COMPONENTS) -- PART #54491
 MANIFOLD ASSEMBLY
(46292) MANIFOLD ASM.

ITEM # DESCRIPTION PART # QTY.

01 VALVE MANIFOLD 46270 1.00
02 CARTRIDGE RELIEF VALVE 45423 1.00
03 1/16 PIPE PLUG-FLUSH 40049 3.00
04 PIPE PLUG 1/8" FLUSH 81093 3.00
05 PIPE NIPPLE 1/8 NPT 68917 1.00
06 PIPE COUPLING 1/8 68918 1.00
07 INT.RELIEF ASM HF 68999 1.00

(68999) INT. RELIEF ASM.

ITEM # DESCRIPTION PART # QTY.

01 CARTRIDGE 66096 1.00
02 CONE REL VLVE 66086 1.00
03 POPPET RELIEF SPRING 44641 1.00
04 RELIEF VALVE ADJUSTING SCREW 66083 1.00
21
05 HEX NUT 7/16-20 68920 1.00

23/26
BRACKET SUB ASSEMBLY

24/26
 RESERVOIR
(DS1328025) 1.5 GALLON RESERVIOR
(DS1328025) S/B 1.0 GALLON RESERVOIR
(45996P) 1.5
(45996P) 1.5GALLON
GALLON RESERVIOR
RESERVOIR
(46213P) 2.5 GALLON RESERVIOR
(46213P) 2.5 GALLON RESERVOIR

73 7

52

1.5 GALLON RESERVOIR 3

6 NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY.
THE APPEARANCE OF YOUR UNIT MAY DIFFER
FROM UNIT SHOWN.

ITEM # DESCRIPTION 1.0 GALLON QTY. 1.5 GALLON QTY. 2.5 GALLON QTY.
03 RESERVOIR DS1328025 1 .00 4 5995 1 .00 46213P 1.00
04 RESERVOIR GASKET 43565 1.00 85469 1.00 85469 1.00
05 BREATHER VENT 3/8" NPT 68000 1.00 46348 1.00 46348 1.00
06 1/4 SOC PIPE PLUG 93950 1.00 93950 1.00 93950 1.00
07 SAE #12 HEX PLUG WITH PORT N/A 0.00 46118 1.00 46118 1.00
08 HHCS 1/4-20 x 3/4 LG PLATED 65891 9.00 65891 14.00 65891 14.00
09 SEALING WASHER 65892 9.00 65892 14.00 65892 14.00
52 SIGHT GAUGE 46009 1.00 46009 1.00 46009 1.00
73 COVER PLATE 46350 1.00 45928 1.00 45928 1.00

NOTE: ALL RESERVOIRS ARE POWDER COATED BLACK

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 SAVE THESE INSTRUCTIONS DO NOT DESTROY

NOTES:

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Phone: +1 610-250-5800 * Fax:+1 610-250-2700
Toll Free: 1-888-TORCUP-1
Email: [email protected] * Website: www.torcup.com

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