W212

The original version of the Chinese Translation

KLW4000N

Series Hydraulic Pump

Operation Manual

Hangzhou WREN Hydraulic Equipment Manufacturing Co.Ltd

Add:No 24 xingxing Road, Xingqiao, Yuhang district, Hangzhou, China
TEL: 0571-88110295
FAX0871-88110210
PC311100
Http//www.wrenchina.com
EMAILinfo@wrenchina.com

Catalog
Safety Guide

Description

External Dimension and Description Of Parts

Characteristic

Warning Plate

Maintenance and Inspection

Noise/Vibration And Transport information

Operation Instruction

Trouble Shooting Guide Of Hydraulic Pump

8-9

Explosion Of KLW4000N Hydraulic Pump

10

Explosion Of the Pump Module

11

Explosion Of the type WE Valve Set Module

12-13

Pneumatic control module exploded diagam

14

Waring For Using High Pressure Hose

15

After-Sales Sernice

15

Hydraulic Principle

15

Pneumatic principle

16

Specification & Parameter

17

EC Declaration Of Conformity

18

OPERATION AND MAINTENANCE MANUAL

FOR KLW4000N Series Hydraulic Pump

WREN Hydraulic
It is operating manual of KLW4000N torque wrench air pump, please read carefully follow
instructionswarnings and cautions before using the tools.

Safety Guide
The hydraulic torque wrench pump's safe usage requires correct operation and
regular inspect. And the user is requested to follow always and carefully .
precaution to avoid direct loss in economic or property.
warning to avoid personal injury.
Please follow herein before!
When using, if something abnormal happens, please shut off the power
immediately, and then consult WREN or WREN`s agent.

1.When using, do not permit any person stand at the oil output in order to avoid personal injury and
equipment damage. Please put the pump far away from the fire.
2.Make sure that the hose and quick coupler be connected before building up the pressure in order
to avoid hydraulic fluid spurting out to cause personal injury.
3.The maximum operating pressure of this pump is 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 which WREN 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.
5.Make sure the power of the pump is shut off before repairing it.
6.Please shut off the switch before starting power; if the switch is on, the pressure may increase.
7.Make sure the equipment be connected with ground to avoid electric shock.
8.Please do not change any part of the pump; if it must be changed, please inform 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.
9.Please do not fill the pump reservoir with too much oil, otherwise, the pressure of the reservoir will
increase and the oil will spill over, so the reservoir will be broken and the environment will be
polluted.
10.Make sure the quick coupler is tightened; if the quick coupler is not tightened enough, the
equipment will not work normally; if it is a synchronic system, the problem may cause one or several
pieces of equipment out of order and the quick coupler may be broken and it may cause personal
injury or equipment damage.
11.Please stand away from the position where the hydraulic oil may be spurt out; hydraulic oil may
penetrate your hand and hurt you.
12.If the hydraulic oil splashed in your eyes, please immediately wash your eyes about 15 minutes
with clean water, then you must go to hospital for help right now.
13.The wrench and power pump are connected by a 700 BAR operating pressure, twin-line hose
assembly. Each end of the hose will have one male and one female connector to assure proper
interconnection between pump and wrench.

FIG1

14.Please do not touch the pressurized hose; if the hydraulic oil splashed out, it will cause serious
injury.
15.Hydraulic hose is easily spoiled fitting; you inspect the hose with eyes regularly and find no
problems, but the inner side may have crack and small hole; WREN suggests you should change
the hose regularly for

PRECAUTION

1.Only WREN hydraudic special oil available.

2.Do not use pressure regulate valve as relief valve.
3.The used hydraulic oil should be put away according to the antipollution ordinance.

DESCRIPTION
1.This pump is used for hydraulic torque wrench and fitted in integrated way, it is an independent
hydraulic unit that mainly consists of pump, control valve, oil reservoir, motor, meter, control-line
fitting, it has the peculiarity of small volume, light weight, simple composition, convenient operation,
high working pressure. The pump can supply oil with one high and one low oil outlet at the same
time, which could make a large quantity of oil outputting. On high pressure, the low pressure pump
will automatically let oil return through the release flow valve, which can reduce power consumption,
and the pressure of the outlet can be arbitrarily adjusted from 70 to 700 bar.
2.Hydraulic oil for this pump:46# anti-wear hydraulic oil.
3.Environmental temperature for using this pump:-10~60
4.Please use Wren's high pressure hose, high pressure coupler, and so on. The maximum operation
pressure of high pressure hose for this pump is 100Mpa; please choose suitable system for it.
5.If you need to use attached hydraulic product for pump, please contact WREN's engineers.
6.Please do not use this pump around the fire.
7.Please do not adjust the pressure valve arbitrarily to avoid personal injury or equipment damage
due to high pressure.
8.Please confirm that the voltage for this pump is the same as the voltage of using on the spot.
9.You'd better use the pump indoors, please protect the pump from rain if it is used outdoors.

EXTERNAL DIMENSION AND DESCRIPTION OF PARTS

KLW4000N
ITEM

NAME
Oil Reservior

Bolt

Air motor

NAME

4
3

12

Oil level guage

Oily water separator

13

Oil leak port

The air input valve

14

Screw

Radiator

15

Cover plate

Air valve

16

Oil port

Pressure gauge

Frame For Protecting

9
10
11
12
13

14
15

281

10

6
7

Adjusting pressure
regulator

11

448

ITEM

16

Quick coupler
428

DESCRIPTIONS OF PARTS
1.Oil reservoir: to store hydraulic oil, make sure there is enough oil to keep the pump working
normally.
2.Bolt: to connect motor and oil reservoir.
3.Air Motor: provide power, 4~8MPa
4.Oily water separator: separator the oill and woter from the air.
5.The air input valve: to let the low preasure air into system.
6.Radiator: to exclude the heat, ensure the operating time and life of the pump.

7.Air valve: its function is output oil when the pressure is very high, control the flow when oil return,
and so on. It can be uset to the maximum pressure and protect system to work normally at the set
up pressure. The threads of oil output port is NPT 1/4`.
8.Pressure gauge: its range is 0~70Mpa(0~10,000psi), in other words, the maximum operating
pressure of this pump is 70Mpa(10,000psi).
9.Frame for protecting: it is fixed on motor for carrying conveniently.
10.Quick coupler: its effect is for oil output or oil returning, also it can help people connect pump and
tool with the hose quickly.
11.The adjusting pressure regulator: it can control the maximum operating pressure for this pump or
set up the pressure for operating the tool.prohibrt to adiust this valve arbitrarily.
12.Oil level measurer: it can help us know the oil level, when the oil less than the 1/3 of total, please
fill the especial oil for hydraulic tools of WREN.
13.Release oil port: G1/4` thread, discharging the hydraulic oil from oil reservoir(when changing
hydraulic oil)
14.Hex head screw: tight coupling oil reservoir.
15.Cover plate: air-tight seal of the oil reservoir.
16.Oil filter port: before you fill the oil in the oil reservoir, please loosen down the cover. There is a
filter inside the port for keeping oil in the oil reservoir cleanness. Also there is an operating on the
cover for releasing the air from oil reservoir.

CHARACTERISTIC
1. KLW4000N is three-stage pump. Pressure relief valve is asslembled in the high pressure port .the
rated pressure in the low pressure port is 5-7Mpg,And the flow is 0.8L/M undcr 70Mpa.
2. Max operating pressure:70Mpa
3. Flow:three-stage,can simultaneity use 4 torque wrenches
4. Motor:4~8MPa air preasure motor
5. Environmental temperature:-10~80C
6. Rerervoir dimension:448428281mm
7. WeightNo oil:KLW4000N:20.5Kg
8. Hydraulic oil:ISO VG 46#

WARNING!!!
1.When operating, do not permit anyone stand at the oil output,The oil output must connect other
components when adjusting the pressure.
2.When using, do not overpass the max operating pressure.
3.If need to check motor tank, please shut off the pump.
4. When working, the oil back to oil reservoir may add the pressure. If open the cover plate,
unnecessary injury and damage will happen.
5.Proihbit to operate without oil
6.Keep the clean of the pump,clean especially the oil inlet, quick couplers.
7.Suggestion: in the condition of not using the pump always, please remember to replace the
hydraulic oil

Warning Plate
Warning plate is shown in table 1

warning table

Meaning

Affixed Position

For Saft Operation,

Please Read

The Equipment
Enclosure

Warning Notices

The Equipment
Enclosure

WARNING

To help avoid personal injury,read the operating

instructions before using this pump.
Disconnect the power supply before any
maintenance is performed on this pump.All
electrical work must be done by a qualified
electrical.
Operators of this hydraulic power supply unit
or operations of equipment powered by this
unit must be knowledgeable of hydraulic
equipment hazards if any hydraulic
equipment is used incorrectly.
Hydraulic fluid recommended in operating
instructions must be used in this pump.
Do not use pump in any type of explosive,
flammable,or gas environment.
Escaping hydrauic fluid under pressure can
have sufficient force to penetrate the skin
and cause serious personal injury.If you are
injured by escaping hydraulic fluid,seek
medical attention immediately.See operating
instructions for further precautions to help
prevent the possibility of hazards occurring
due to escaping hydraulic fluid.

MAINTENANCE AND INSPECTION

1. The inspection before operating
(1).Please shut off the pump and inspect whether the position of the power connection is loose or
not. If it is loose, please tighten it.
(2).Please inspect whether the hydraulic oil in the oil reservoir is enough or not, if it is not enough,
please fill the oil in time.
(3).The pump is still working when the direction of the air valve is changed, please build up pressure
and inspect whether the whole equipment is normal or not.
(4).Please inspect whether the house and other equipments are leaky or not, if this happened,
please inspect to find the reason and repair it or replace it.
2.The inspection in operation
When inspecting the following items, if there is abnormal situation, please shut off the pump and
repair it.
(1)Please inspect whether there are abnormal condition or not in the course of raising the pressure.
(2)Please inspect whether the houses and other equipments are leaky or not.
(3)Please inspect whether there is some abnormal noise, rocking and smell or not during the
operation of the air motor.
(4)Please inspect whether the temperature of hydraulic oil is too high or not.
3.The inspection after finishing the operation of the pump.
(1)Making sure the pump must be turn down.
(2)Please inspect whether there are leaky or abnormal condition or not. If there is abnormal
situation,please inspect to find the reason and repair it
(3)Please clean it after using the pump.
4.Refer to changing the hydraulic oil
The oil should be replaced once a year principally. If there are following abnormal conditions, please
replace the oil immediately.
(1)If dust mixes with the oil, please replace the oil.
(2)If there is abnormal smell, please replace the oil.
(3)If the water mixes with the oil, the colour of the oil has been changed into milkiness, please
replace the oil.
(4)If the colour of the oil has been changed into black-brown, please replace the oil.
5.The way replacing the hydraulic oil
(1)Please loosen the oil filler port of oil reservoir.
(2)Please take down the screw on the flank of the oil reservoir, let hydraulic oil out.
(3)Please clean the inner and filter of the oil reservoir.
(4)Please install the screw and fill the oil reservoir with the hydraulic oil.
WARNING: If the oil splashes into your eyes, please wash with clean water for at least 15 minutes,
and Then see doctor immediately. If the oil splashes to your skin, please wash it with clean water
and soap.
WARNING: Waste hydraulic oil bellows to industrial waste, it should be dealt with by special
companies.

Noise/Vibration And Transport information

1 Hydraulic pump noise declaration
1) Hydraulic pump noise value: 70db

2 Hydraulic pump transport information.

1) Handle with care.
2)The shipment should be vertical upward, as shown in the figure 9-1.

FIG 9-1

3) Product handling, generally using portable, car handling and lifting and moving,
as shown in the figure 9-2 .

FIG 9-2

OPERATION INSTRUCTIONS
1.KLW4000N hydraulic power pump is designed for hydraulic torque wrench. There is a 2-way,
4-position Air control valve on the pump, port A is high pressure point, it can export the oil at the high
pressure, and port B is low pressure point which can return the oil at the low pressure.
(1)Please loosen the valve for adjusting pressure before operating.
(2)Please connect the air line and press the air input valve on the flank of the pump to make the
pump start working and oil exporting.
(3)Please press the working button on the controller and adjust the pressure unit the working
pressure reach to what you need, and then loosen the working button on the controller.
(4)When the desired pressure is reached, the motor stops working, and the pressure will keep the
same. when the pressure falls down, the motor starts to work again.
(5)When the motor is working, if you press the off button on the pump, the motor stops working,
the piston and pressure will also be stopped at the position when the motor stopped working, even
if the pressure fell, the motor would not work again.
(6)After operating, please press the rubber button on the top of the air control valve in order to
release the pressure in hoses and equipments, then you can take down the hose and cover the
Safety cap for the quick couplers.
Turn up the preasure
T Ha ndle
Lock ing Rin g
FIG2

TROUBLE SHOOTING GUIDE OF HYDRAULIC PUMP

The voltage isn't suitable
The pump can't be started
The power hasn't be connected

Confirming whether the voltage

is suitable for the pump's need
Checked the input air, switch and
distribution box and so on, and
connect the air.

The quick coupler hasn't be

connected to the correct position

Take down and reinstall it

No oil in the oil reservoir

Fill in oil

Not enough oil in the oil reservoir

Fill in oil

If the system has a throttle and

hand single-direction valve, please
check if the valve are open

Open the throttle and hand

single-direction valve, and
make sure the system is a circle

After reinstalling the quick

coupler,the system has no
pressure

The quick coupler can't be connected

to the correct position, which causes
no pressure in the system

Take down the quick coupler, check

if the boll is elastic with a rod, if it can't
move, please knock it with a hammer to
eliminate the mist hydraulic oil

Leakage in the quick coupler

The o ring and escape have worn out

Replace the quick coupler

The system has no pressure

The pressure can't reach to

the set pressure

When using under static pressure,

the pressure reduces slowly

The relief valve is adjusted

too low

Check with the gauge, and adjust the

relief valve to the system set pressure

Oil is mixed with water

Change oil

Not enough oil in the reservoir

Fill in oil

Suck in air to the system

Repeat operating the system with no

load for several times to eliminate the air

The throttle and hand single-direction

valve haven't been tightened

Locking valve

The throttle and hand single-direction

valve haven't been adjusted to the
correct position

Adjust to the correct position

The throttle and hand single-direction

valve have broken

Replace the valve

There is foreign matter in

the oil

Wash the pump valve and

change clean oil

The seal is out of control, please

check all the seal

Replace the s eal

EXPLOSION OF KLW4000N AIR PUMP

ITEM

NAME

ITEM

NAME

The tank module

Oily water separator

Pump module

Pneumatic control valve

Oil return pipe(1)

The type WE valve set module

Petroleum Pipeline

10

Fast screwed joint

Oil return pipe(2)

11

Straight thread joint

The cooler module

12

Copper fittings

10

choose one

EXPLOSION OF THE PUMP MODULE

11

ITEM

NAME

NUM

2.1

Seal

2.2

Deep groove ball bearing

2.3

Bearing

2.4

Screw

2.5

Pump flange

2.6

The pump body set

2.7

Unloading valve(1)

2.7.1

Unloading valve body

1/1

2.7.2

Ring

1/1

2.7.3

O Ring

1/1

2.7.4

O Ring

1/1

2.8

Overpressure valve

2.9

Check valve

2.9.1

The one-way valve body

1/1

2.9.2

Ring

1/1

2.9.3

O Ring

1/1

2.9.4

O Ring

1/1

2.9.5

Ring

1/1

2.10

Unloading valve(2)

2.10.1

Unloading valve body

1/1

2.10.2

Ring

1/1

2.10.3

O Ring

1/1

2.10.4

O Ring

1/1

2.11

Filter plate

2.12

Screw

2.13

Separation type pump body

2.14

Plug

10

2.15

Deep groove ball bearing

2.16

The circlip for shaft

2.17

Empty of elastic ring

2.18

Deep groove ball bearing

2.19

Plunger 1

2.20

Plunger 2

2.21

Plunger 3

2.22

Pin

2.23

Bearing end plate

2.24

Elastic washer

2.25

Screw

2.26

Connecting piece

2.27

Screw

16

2.28

Fitter

12

EXPLOSION OF THE TYPE WE VALVE SET MODULE

NAME

The WE connection block

Plug

Pilot operated directional valve

Valve body

Ring

O Ring

O Ring

Ring

Ring

O Ring

O Ring

Check valve

Check valve body

Ring

ITEN

9.1

9.2

9.3

9.3.1

9.3.2

9.3.3

9.3.4

9.3.5

9.3.6

9.3.7

9.3.8

9.4

9.4.1

9.4.2

1/1

1/1

1/1

1/1

1/1

1/1

1/1

1/1

1/1

1/1

12

NUM

9.8.2

9.8.1

9.8

9.7.3

9.7.2

9.7.1

9.7

9.6

9.5.3

9.5.2

9.5.1

9.5

9.4.4

9.4.3

ITEN

O Ring

O Ring

NAME

13

O Ring

Valve body

Pressure regulating valve

O Ring

Pressure meter joint(G1/2

Pressure meter joint(G1/2)

Pressure meter joint

Pressure gauge

O Ring

O Ring

Valve body

Pneumatic reversing valve

EXPLOSION OF THE TYPE WE VALVE SET MODULE

1/1

1/1

1/1

1/1

1/1

1/1

2/1

1/1

1/1

1/1

NUM

9.16

9.15

9.14

9.13

9.12

9.11

9.10

9.9.3

9.9.2

9.9.1

9.9

9.8.3

ITEN

Screw

Washer

Elastic washer

Sealing ring

Plug

Male quick joint

Female quick joint

O Ring

O Ring

Valve body

Pressure regulating valve

O Ring

NAME

1/1

1/1

1/1

1/1

NUM

PNEUMATIC CONTROL MODULE EXPLODED DIAGRAM

NUM ITEN

ITEN

NAME

8.1

Pneumatic motor parts

8.2

Nut

8.3

NAME

NUM

8.12

Inlet pipe

8.13

Nut

Fixed plate

8.14

The village set

8.4

Washer

8.15

Right angle type joint

8.5

Bolt

8.16

Three way ball valve

8.6

Pneumatic reversing valve

8.17

Muffler

8.7

Cover type nut

8.18

External joint

8.8

Trachea

8.19

Internal and external joint

8.9

Miniature quick coupler

8.10

Screw

8.11

Gas control unit

Pneumatic schematic diagram

Hand control
valve(1)

To air control
pressure valve

Hand control
valve(2)

To air motor

In put
Flow

Air control lever

14

Pneumatic control pneumatic

reversing valve

HYDRAULIC PRINCIPLE

WARNING FOR USING HIGH PRESSURE HOSE

1.Please use Wren's JH series high pressure hoses.
2.The minimum bending radius: R>120mm. Too small bending radius will destroy the high pressure hoses.
3.The maximum operating pressure is 70 Mpa, and it is forbidden to overpass the pressure.
4.Do not tighten hoses excessively. Over tightening can cause to premature thread failure or high pressure
fittings to split at a pressure lower than their rated capacities.
5.Should any hydraulic hose rupture, burst, or need to be disconnected, immediately shut off the pump. Never
attempt to grasp a leaking pressurized hose with your hands. The force of escaping hydraulic fluid could cause
serious injury.
6.Do not use the hose to remove attached equipment. Stress can damage the hose, causing personal injury.
7.Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold or heavy
impact. Do not kink, twist, or bend the hose so tightly that oil flowing in the hose is blocked or reduced.
Periodically inspect the hose for wearing, because any of these conditions can damage the hose.
8.WREN JH series 100Mpa high pressure hose's operating pressure is 100Mpa,. Overpass this pressure is
forbidden.

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

15

PNEUMATIC PRINCIPLE

16

Specification & Parameter

Oil

Model

capacity

Control
retrun
circuit

Air Moto
(Power/Rotate Speed/
Pressure Output/
Air Input Value)

Flow L/min

Power
Kw

Oil outlet
connecting

oil retrun
port
connecting

Maxwork
pressure

Low

Mid

High

thread

1.1

1.6

0.8

NPT1/4

NPT1/4

70

1.1

1.6

0.8

NPT1/4

NPT1/4

70

thread

MPa

Power1.1KW
Rotate Speed 3000r/min
KLW4000N

Pressure Output58bar
Air Input Value
1.9m3/min
Power1.1KW
Rotate Speed 3000r/min

KLW4000N1

Pressure Output58bar
Air Input Value
1.9m3/min

17

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

ADDNo.24, Xingxing Road, xingqiao,yuhang district , Hangzhou, China

AUTHORIZED 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:

Manager

PLACE:

Hangzhou

DATE:

2012/8/9

18