HYDRA-PAC SYNCHRONOUS HYDRAULIC POWER UNIT

Transcription

1 HYDRA-PAC SYNCHRONOUS HYDRAULIC POWER UNIT SAFETY, OPERATING AND MAINTENANCE MANUAL ELECTRIC MODELS: E E E December 9,

2 1.0 INTRODUCTION Contact Information Original Operator s Manual General Information Machine Description SAFETY General General Safety Precautions START-UP & OPERATION General Recommendations Electric Power Unit Start-Up Control Valve Operating Instructions JACKING DOUBLE-ACTING JACKS SET-UP MODE SYNCHRONIZATION MODE LIFTING MODE LOWERING MODE FEATHERING/FINE ADJUSTMENT MODE COMBINING PORTS SINGLE-ACTING JACKS SET-UP MODE LOWERING WITH SINGLE-ACTING JACKS SKIDDING SET-UP MODE SYNCHRONIZATION MODE PUSHING MODE RETRACTING MODE: FEATHERING/FINE ADJUSTMENT MODE COMBINING PORTS MAINTENANCE TROUBLESHOOTING TRANSPORTATION & STORAGE APPENDIX A - PRESSURE SETUP. 22 2

3 1.0 INTRODUCTION 1.1 Contact Information Hydra-Slide Ltd th Line RR # 3 Rockwood Ontario, Canada N0B 2K0 (519) info@hydra-slide.com 1.2 Original Operator s Manual The English version of this manual is the Original Operator s Manual. All other language versions are translations of the original Operator s Manual. 1.3 General Information This manual provides instructions on the setup, operation, maintenance, safety and troubleshooting for Hydra-Slide s HYDRA-PAC SYNCHRONOUS HYDRAULIC POWER UNIT. Before any operation involving the use or maintenance of the Power Unit, please read this Operation Manual carefully. It is recommended that service work on the HYDRA-PAC POWER UNIT be provided by qualified technicians only. We recommend that only Hydra-Slide original spare parts be used for repair. Hydra- Slide does not accept responsibility for damages caused by the use of unsuitable spare parts. Please contact Hydra-Slide if any problems occur during the operation of the HYDRA-PAC POWER UNIT or if any spare parts are required for repair. 1.4 Machine Description The HYDRA-PAC POWER UNIT is a multi-circuit, synchronized flow, hydraulic power pack with a maximum operating pressure of 10,000 psi and is designed to work with most standard 10,000 psi double acting and single acting hydraulic cylinders (optional flow control valves are required when using with single-acting cylinders). 3

4 The system contains the following main components: MODEL E E E Motor 20 HP electric 30 HP electric 40 HP electric Voltage As specified As specified As specified Pump Dynex PF1000 Dynex PF4000 Dynex PF4000 Oil Reservoir 30 gal (115 litre) 30 gal (115 litre) 30 gal (115 litre) Master Control valve 1 x PowerTeam x PowerTeam x PowerTeam 9500 Manual Control valves 4 x Enerpac VC4 6 x Enerpac VC4 8 x Enerpac VC4 Pressure Relief Valves 5 x Enerpac V152 7 x Enerpac V152 9 x Enerpac V152 Pairing Valves 2 x Enerpac V82 3 x Enerpac V82 4 x Enerpac V82 Pressure Gauges 5 x Enerpac (0-15,000psi) 7 x Enerpac (0-15,000psi) 9 x Enerpac (0-15,000psi) Pressure Port Outlets 4 x CR400 6 x CR400 8 x CR400 Counterbalance Valves 4 x Simplex V2 6 x Simplex V2 8 x Simplex V2 Return Port Outlets 4 x CR400 6 x CR400 8 x CR400 Approximate Weight 1300 lbs (590 kg) 1375 lbs (625 kg) 1400 lbs (635 kg) Approximate Size (in) 84 x 42 x x 42 x x 42 x 56 Approximate Size (cm) 213 x 107 x x 107 x x 107 x 160 The HYDRA-PAC SYNCHRONOUS POWER SYSTEMS are ideally suited for most jacking and skidding operations. Their operation is different than most conventional hydraulic pumps so it is important to fully understand the basic functions. One of the keys to the synchronous function is the split-flow, checkball piston pump. It incorporates multiple independent pistons driven by a common shaft which ensures that each piston generates the same flow rate. Because of the relative incompressibility of oil and the sealing ability of the checkballs, the flow rate is virtually unaffected by the pressure. The outlet from each piston is connected to a separate circuit of the power unit that is controlled by a separate CONTROL VALVE. In this way, each circuit will provide the same flow rate even if the pressure in one or more circuits is considerably different than the others. If you are jacking a load with an offset center of gravity, all jacks will extend at the same rate but the pressure readings in each circuit may be different. With double-acting jacks this same function works on the retract stroke also meaning that all cylinders will lower synchronously. This allows the simultaneous jacking of all lift points without the usual end-to-end jacking. Of course, it is always possible to jack end-to-end if there is some other reason. Note that when using single-acting jacks they will extend synchronously but they will not retract synchronously it will be necessary to ensure your load remains stable when retracting with singleacting jacks. 4

5 The MASTER CONTROL VALVE provides a dump function for all of the circuits. In its neutral position the open center allows all the oil flow to go directly to tank. Only when the MASTER CONTROL VALVE is shifted, can any pressure develop in any of the circuits. This allows the user to select any or all of the circuits that he wishes to use and open those CONTROL VALVES but nothing will happen yet because the oil is being dumped by the Master Valve. When the Master Control is shifted, all of the chosen circuits will be activated at the same time. Because it is acting as a dump valve, it should not be feathered as this could result in loss of synchronization. The MASTER CONTROL VALVE should be fully ON or fully OFF. If any fine adjustment or feathering of individual circuits is needed, the CONTROL VALVES can be feathered or adjusted as necessary and will act completely independent from the other circuits. To do this, shift the MASTER CONTROL VALVE first and then adjust each CONTROL VALVE as required. Another important feature of the Hydra-Pac Power System is the COUNTERBALANCE VALVE on each circuit. A Counterbalance Valve is an improved version of a Pilot Operated Check Valve and will act as a load holding valve on the pressure port line until an equal amount of return pressure is applied. If a cylinder or jack is under load, the Counterbalance Valve will prevent any outflow of oil until a sufficient return pressure is applied and it will then open. When using double-acting cylinders it will control the lowering as a brake and the loaded cylinder will retract at about the same rate as if it were not under load. Again, the counterbalance valve will control the retract rate of double-acting jacks only. It will be necessary to ensure your load remains stable when retracting with single-acting jacks. 2.0 SAFETY 2.1 General This section contains information required for the safe operation of the HYDRA-PAC POWER UNIT. In order to prevent accidents and damage, please read and follow these instructions carefully before commencing work. The HYDRA-PAC POWER UNIT has been designed and manufactured exclusively for the purpose of actuating standard 10,000 psi double-acting or single-acting hydraulic cylinders (optional flow control valves are required when using with single-acting cylinders). The maximum operating pressure of the system is 10,000 psi. Use in any other manner or for any other purpose is not intended and is not recommended by the manufacturer. The operational safety of the system is only assured if used as intended. 5

6 2.2 General Safety Precautions Always read and understand instructions and safety warnings that come with the equipment and always follow safe work practices. Only qualified operators should install, operate, adjust, maintain, clean, repair or transport this equipment. Only use this equipment in accordance with its intended use and follow all setup and operating instructions. Never exceed recommended maximum pressure and stroke ratings. Good practice recommends using only 80% of these ratings. Always wear appropriate personal protective equipment. Protect all equipment from potential hazards such as fire, explosion, sharp surfaces, extreme heat/cold, corrosives or heavy impact. Anticipate possible problems and take steps to avoid them. If in doubt, ask. Keep work area clean and tidy. Eliminate tripping or other hazards. Never operate any equipment without all provided guards and safety devices in place and in good working condition. Provide a level and solid support for all equipment. Lift/move slowly and check often. Control the load at all times. Avoid standing in the line of force of hoses or any hydraulic components. Do not walk on lubricated skidding surfaces. These surfaces can be very slippery. Lift or move equipment and components using only the provided lift lugs or handles, etc. and only employ proper lifting equipment and techniques. Never lift by the hoses or hydraulic fittings. Never place any part of your body under the load unless the load is on a solid support. Never place any part of your body between a moving load and a solid obstacle where there is danger of crushing. Take steps to keep all equipment clean and free from possible damage. This is particularly important for hoses and couplers. Don t allow hoses to kink, twist, crush, cut or bend tightly. Bending radius should be at least 4 ½ inch. Inspect hoses and couplers before each use and remove from service if any signs of damage are noted. Never attempt to repair a hose. Never handle hoses or couplers while they are under pressure even when wearing personal protective equipment. There is risk of serious personal injury from hose leaks, faulty or improperly connected couplers. 6

7 Never use unsafe practices to bleed a pressurized hose or coupler. Use only a specially designed coupler bleed tool such as a CT-604 Safety Tool available through Hydra-Slide Ltd. Always ensure that jacks and cylinders are used parallel and in line with their axis. Never use a jack or cylinder at an angle or to kick or move a load sideways. Use only specially designed alignment devices such as an AS-500 Alignment Shoe available from Hydra-Slide Ltd. If jacking a load, always use appropriate blocking or cribbing to guard against a falling or out of control load 3.0 START-UP & OPERATION 3.1 General Recommendations These instructions apply only to the HYDRA-PAC POWER UNIT. It should be set up and operated only under the direction and supervision of experienced and qualified personnel. The Operator should be experienced in the safe operation of high pressure hydraulic systems. Use with only proper hydraulic fluids and hoses and do not exceed 10,000 psi. NOTE: For starting in Cold Weather refer to APPENDIX A. 3.2 Electric Power Unit Start-Up 1. Ensure that shut off valves for hydraulic oil are in OPEN position. (Two hydraulic oil valves are located near the bottom of the storage tank on the inside of the power unit.) 2. Check the Hydraulic Oil level and color. Add to reservoir if necessary. If oil has a cloudy appearance, there could be an air or water leak in the system and the power unit should be serviced. 3. Ensure that all V82 Valves are in fully CLOSED, unless pairing ports for increased flow rate. 4. If using V10E Valves, make sure all are in fully OPENED position before starting. 5. Make sure all control valves are in the NEUTRAL position (center location). 6. Push START button to turn on motor. 7. To turn off motor, push STOP button. For emergency stop, push E-STOP 7

8 RECOMMENDATION: Run cylinders for two complete extension and retraction cycles before any loading to ensure proper operation, especially if new. CAUTION: If the hydraulic oil temperature rises above 50 C (~120 F), turn on oil cooling fan. The switch for the cooling fan is located on the frame leg of the Power Unit, above the Hydraulic Oil reservoir. DO NOT let the oil temperature exceed 55 C (~130 F). This can result in rapid deterioration of oil performance. 8

9 3.3 Control Valve Operating Instructions Note: Pictorial figures below depict a 4-circuit power unit layout however the directions apply to all 4, 6 and 8-circuit Hydra-Pac synchronous power units. Valves will be numbered 1-4, 1-6 or 1-8 as appropriate JACKING DOUBLE-ACTING JACKS SET-UP MODE 1. All CONTROL VALVES and MASTER CONTROL VALVE must be in neutral or center position prior to start up. 2. V82 Valves must be closed. 3. Ensure that all pressure gauges are reading zero. (if not, refer to Troubleshooting) 4. Connect cylinders (jacks) to the coupler manifold with appropriate 10,000 psi rated hydraulic hoses. Connect the bottom port of each jack to the POWER PORT (P) and the top port of the jack to the RETURN PORT(R). Ensure that all couplers are fully engaged and hand tight otherwise the hose check valves will not open up and the cylinders will not function properly. 5. Start engine (see 3.2 Power Unit Start-Up) 9

10 SYNCHRONIZATION MODE 1. Shift MASTER CONTROL VALVE to the left (ON) position. This puts pressure to the CONTROL VALVES. 2. Shift each CONTROL VALVE one at a time to the left position. NOTE: You can use any or all of the circuits as required. Advance the corresponding cylinder until it just makes contact with the load then return CONTROL VALVE to neutral (center) Repeat this process for each of the lift points. 10

11 3. Ensure all hydraulic cylinders are safely in position just contacting the load. 4. Shift the MASTER CONTROL VALVE to center or neutral position. The synchronous lift is ready to begin. 11

12 LIFTING MODE 1. Shift required CONTROL VALVES to left position. (Lifting Position) Note: You can use any or all of the circuits as required. 2. When ready to lift, shift the MASTER CONTROL VALVE fully to the left position. (do not feather this valve as it may cause the system to lose synchronization) The system is in synchronous lift mode and will lift the load evenly throughout the cylinder stroke. 3. At any time the lift can be stopped by shifting the MASTER CONTROL VALVE back to center or neutral position. 4. If a re-synchronization is required at any time refer to synchronization instructions above. 12

13 LOWERING MODE 1. Shift CONTROL VALVES to the right position 2. When ready to lower, shift the MASTER CONTROL VALVE fully to the left position. (do not feather this valve as it may cause the system to lose synchronization). - The system is now in synchronous lower mode and will lower the load evenly. - Again watch for lowering deviations and correct accordingly as in synchronization instructions above. 13

14 FEATHERING/FINE ADJUSTMENT MODE If at any time during raising or lowering, it becomes necessary to make small or fine adjustments it is possible to feather the CONTROL VALVES either individually or together either up or down. 1. Start with all CONTROL VALVES and MASTER CONTROL VALVE in neutral or center position 2. Shift MASTER CONTROL VALVE to the left (ON) position. 3. Shift individual CONTROL VALVE(S) as required to make adjustment. 4. Return MASTER CONTROL VALVE to neutral. CAUTION: MASTER CONTROL VALVE should always be in center position when the system is not in lifting or lowering operation. 14

15 COMBINING PORTS The Hydra-Pac synchronous power units allow for combining of ports to increase the flow rate to selected ports while maintaining full synchronization. The number of usable ports is however reduced. Up to half of the lifting points can achieve twice the lifting or lowering speed. To double the lifting/lowering speed at a particular port: 1. Open the V82 VALVE located between two CONTROL VALVES 2. Connect the hydraulic hoses to the CONTROL VALVE PORTS to be used. 3. Shift the other (unused) CONTROL VALVES to the retract position. Do not attach any hoses to this valve. 4. Shift the CONTROL VALVES (with the hoses attached) to the left or right as in the lifting or lowering modes above. 5. When ready to lift/move, shift the MASTER CONTROL VALVE fully to the left position. NOTE: At all other times thev82 must be remain closed. CAUTION: When lifting with hydraulic cylinders it is always advised to follow the lifting/lowering with appropriate cribbing timber supports in the event of any type of failure. This is a standard recommended safety practise for all free lift applications. 15

16 SINGLE-ACTING JACKS SET-UP MODE 1. All CONTROL VALVES and MASTER CONTROL VALVE must be in neutral or center position prior to start up. 2. V82 must be closed. 3. Install the V10E VALVES in the Return Port (R) couplers as required. 4. Connect the single-acting cylinders to the V10E VALVE coupler. 5. Ensure V10E VALVES are fully closed. 6. Ensure that all couplers are fully engaged and hand tight otherwise the hose check valves will not open up and the cylinders will not function properly. 7. Start engine (see 3.2 Power Unit Start-Up) 8. Shift required CONTROL VALVES to right position. (power to R port) Note: You can use any or all of the circuits as required. 9. When ready to lift, shift the MASTER CONTROL VALVE fully to the left position. (do not feather this valve as it may cause the system to lose synchronization) 10. Jacks will rise synchronously. At any time the lift can be stopped by shifting the MASTERCONTROL VALVE back to center or neutral position. 16

17 LOWERING WITH SINGLE-ACTING JACKS 1. All CONTROL VALVES and MASTER CONTROL VALVE must be in neutral or center position. 2. Ensure V10E VALVES are fully closed. a. Shift required CONTROL VALVES to the left position b. Leave MASTER CONTROL VALVE in the neutral or center position. c. Gradually open the V10E Flow Control valves about ¼ turn. d. Jacks will lower but not synchronously. The lowering speeds may be adjusted by adjusting the V10E valves. e. It will be necessary to ensure your load remains stable when retracting with singleacting jacks and may require lowering end-to-end in steps using only 2 jacks at a time. f. When the jacks are fully retracted, close the V10E VALVES and return the CONTROL VALVES to the center or neutral position. SAFETY NOTE: All couplers, when not connected to a hose, MUST have the steel dust caps installed securely and no person should be present on the back side of the unit during operation. 17

18 3.3.2 SKIDDING SET-UP MODE 1. All CONTROL VALVES and MASTER CONTROL VALVE must be in neutral or center position prior to start up. 2. V82 VALVES must be closed. 3. Connect push cylinders to the coupler manifold with appropriate 10,000 psi rated hydraulic hoses. Connect the bottom port of each jack to the control valve POWER PORT (P) and the top port of the cylinder to the control valve RETURN PORT (R). Ensure that all couplers are fully engaged and hand tight otherwise the hose check valves will not open up and the cylinders will not function properly. 4. Start engine SYNCHRONIZATION MODE 1. Shift MASTER CONTROL VALVE to the left position. This puts pressure to the CONTROL VALVES. 2. Shift each CONTROL VALVE one at a time to the left position. NOTE: You can use any or all of the circuits as required. Advance the corresponding cylinder until it just makes contact with the load. Shift the CONTROL VALVE to the centre position. 3. Repeat this process for each of the push cylinders. 4. Ensure all hydraulic cylinders are fully set in the track slots and just contacting the load. 5. Shift the MASTER CONTROL VALVE to center or neutral position. The synchronous skidding operation is ready to begin PUSHING MODE 1. Shift required CONTROL VALVES to left position. (Lifting Position) NOTE: You can use any or all of the circuits as required. 2. When ready to push, shift the MASTER CONTROL VALVE fully to the left position. (do not feather this valve as it may cause the system to lose synchronization) The system is in synchronous skidding mode and will push the load evenly throughout the cylinder stroke. 3. At any time the skidding can be stopped by shifting the MASTERCONTROL VALVE back to center or neutral position. 4. If a re-synchronization is required at any time refer to synchronization instructions above. 18

19 RETRACTING MODE: 1. Shift CONTROL VALVES to the right position 2. When ready to retract the push cylinders, shift the MASTER CONTROL VALVE fully to the left position. The system is now in synchronous retract mode FEATHERING/FINE ADJUSTMENT MODE If at any time during raising or lowering, it becomes necessary to make small or fine adjustments it is possible to feather the CONTROL VALVES either individually or together either push or retract. 1. Start with all CONTROL VALVES and MASTER CONTROL VALVE in neutral or center position 2. Shift MASTER CONTROL VALVE to the left (ON) position. 3. Shift individual CONTROL VALVE(S) as required to make adjustment. 4. Return MASTER CONTROL VALVE to neutral COMBINING PORTS The Hydra-Pac synchronous power units allow for combining of ports to increase the flow rate to selected ports while maintaining full synchronization. The number of usable ports is however reduced. Up to half of the Pressure Ports can achieve twice the flow rate. To double the skidding speed: 1. Open the V82 VALVE located between two CONTROL VALVES 2. Connect the hydraulic hoses to one of the CONTROL VALVES. 3. Shift the other CONTROL VALVE to the retract position. Do not attach any hoses to this valve. 4. Operate the CONTROL VALVE (with the hoses attached) as in the skidding or retracting modes above. NOTE: At all other times thev82 must be remain closed. CAUTION: MASTER CONTROL VALVE should always be in center position when the system is not in lifting or lowering operation. SAFETY NOTE: All couplers, when not connected to a hose, MUST have the steel dust caps installed securely and no person should be present on the back side of the unit during operation. 19

20 4.0 MAINTENANCE Regularly check all engine fluids and hydraulic oil levels and top up as necessary. Inspect complete unit regularly at least prior to each use. Repair or replace any broken, worn or damaged components. Contact Hydra-Slide Ltd. for any replacement parts. 5.0 TROUBLESHOOTING Symptom Probable Cause Recommended Action Cylinders do not extend at the - Attempting to feather Master - Do not feather Master Control Valve same rate Control Valve Cylinder(s) advance part way - A coupler is not fully engaged - Check and tighten all couplers - Oil level in pump is low - Add oil to reservoir Cylinder(s) will not extend - A coupler is not fully engaged - Check and tighten all couplers - Load exceeds capacity - Reduce load - Skid shoe is jamming in track - Realign track - Oil level in pump is low - Add oil to reservoir - Cylinder seals leaking - Repair/replace cylinder Cylinder(s) advance in spurts - Air in hydraulic system - Bleed hydraulic system A cylinder will not retract - Coupler is not fully engaged - Check and tighten all couplers Push cylinder will not extend and oil is coming from pressure relief valve or top of cylinder - Coupler on return line is not fully engaged - Check and tighten all couplers Pressure gauge(s) are reading pressure but there is no load on jacks Pressure gauge(s) are reading pressure but there is nothing connected - A coupler is not fully engaged and counterbalance valve is holding the pressure - System has been inadvertently pressurized and counterbalance valve is holding the pressure - Shift Control Valve to retract and then shift Master Control valve. - Return Master Control Valve to neutral. - Shift Control Valve to neutral - Shift Control Valve to retract and then shift Master Control valve. - Return Master Control Valve to neutral. - Shift Control Valve to neutral 20

21 6.0 TRANSPORTATION & STORAGE When not in use, store the Power Unit in a covered, dry location and protected from damage. Take special care of all hydraulic components, hoses and fittings, etc. Wipe clean inside and outside of all hose couplers using a clean, non-fibrous cloth before connecting and always use protective caps when not in use. When transporting the power unit, ensure it is blocked under the main frame to take the weight off the wheels and adequately secured to the transport vehicle using appropriate rigging gear attached only to the designated lifting lugs or forklift pockets. 21

22 APPENDIX A INSTRUCTIONS FOR PRESSURE SETUP ON HYDRA-PAC SYNCHRONOUS POWER UNIT SYSTEMS 1. Disconnect all hoses from Power Unit. All couplers, when not connected to a hose, must have the steel dust caps installed securely and no person should be present on the back side of the unit during operation. 2. Shift the MASTER CONTROL VALVE to the left (This is the valve situated to the far right on its own.) 3. Then shift the individual VC4 CONTROL VALVES either individually or all together to the left position. a. The individual pressure gauges will read the pressure setting of the CONTROL VALVE that it is attached to. The gauge at the MASTER CONTROL VALVE will read the highest pressure setting of all shifted valves. b. NOTE: Do not run any circuit or circuits in this position for longer than 5 minutes. This will cause the hydraulic oil temperature to rise and could damage component seals and cause the hydraulic oil to degrade. c. Hydraulic oil temperature should be kept at maximum 125 degrees Fahrenheit or 52 degrees Celsius. 4. To set pressure on each or all circuits, unlock the wing nut locking device of each V152 EXTERNAL RELIEF VALVE, then turn the adjusting lever of the V152 clockwise to increase pressure and counter clockwise to decrease pressure. Relock the wing nut locking device CAUTION: pressure adjustment must not exceed 10,000 PSI. Recommended maximum operating pressure should be 8,000 PSI. NOTE: MASTER CONTROL VALVE should always be maintained in the center, neutral position when pressure is not required. CAUTION: The V152 external pressure relief valve situated under the table top is the main system safety valve and must not be adjusted. Refer to Enerpac literature supplied for more technical information 22

23 SPECIFICATIONS Split-Flow Pumps DYNEX High Pressure Hydraulics

24 GENERAL INFORMATION Hydraulic Products Used With Confidence Throughout the World Dynex manufactures hydraulic components and systems which operate under difficult conditions including high pressure, contamination, dirty environments, fluids with low lubricity, extreme temperature variations and long duty cycles. High flow piston pumps and control valves operate with extended life at pressures from 6000 to psi (420 to 1380 bar). The company s history dates to The two divisions, Dynex and Rivett, were incorporated as Dynex/Rivett Inc. in Today, customers use high-performance Dynex products for stronger, more efficient and reliable designs for machines that can be used with confidence around the world. We are committed to responding to customers special requirements. Our flexible product design and manufacturing can shorten new-product development time, as well as support regular production needs. For more information visit our web site: BROCHURE NOTES: Maximum pressures indicated throughout are the maximum intermittent pressures a component can sustain for occasional, short periods of operation without appreciably reducing the life expectancy. Contact the Dynex sales department for a review of any application which requires operating above the rated pressures, flows, speeds or higher than normal operating temperatures. Specifications shown were in effect when published. Since errors or omissions are possible, contact your sales representative for the most current specifications before ordering. Dynex reserves the right to discontinue products or change designs at any time without incurring any obligation. USA Headquarters Dynex/Rivett Inc. 770 Capitol Drive Pewaukee, WI Tel: FAX: sales@dynexhydraulics.com Power Units & Systems Dynex/Rivett Inc. 54 Nickerson Road Ashland, MA Tel: FAX: ashland@dynexhydraulics.com European Sales Dynex/Rivett Inc. Unit C5 Steel Close, Little End Road, Eaton Socon, Huntingdon, Cambs. PE19 8TT United Kingdom Tel: +44 (0) FAX: +44 (0) sales@dynexhydraulics.co.uk Copyright Dynex/Rivett Inc. Printed in U.S.A. Bulletin dynexpessplitspecs-0901

25 SPLIT-FLOW CHECKBALL PUMPS Split-Flow Pumps Provide Flexibility to Simplify Circuits ISOLATED PUMPING CHAMBERS The unique Split-Flow checkball design isolates the pumping chambers, allowing the output of each piston to be used separately. Individual outputs are grouped together in the pump cover or barrel, providing smooth, multiple flows to meet system requirements. 500 PSI 10,000 PSI 8 GPM 2 GPM SPLIT-FLOW CHECKBALL PUMP OUTLET A OUTLET B SPLIT-FLOW CHECKBALL PUMP TYPICAL HI-LO CIRCUIT TYPICAL 2-FUNCTION CIRCUIT A B A B A B A B P T P T P T P T All pistons can be isolated, supplying up to ten independent flows, for example, from a ten piston pump. TYPICAL CIRCUITS Multiple Function Systems One pump can simultaneously supply independent flows to multiple functions in a circuit with separate loads. These pumps can reduce system costs by supplying independent, fixed or variable flows to multiple functions in a system. A single pump can eliminate separate dedicated pumps or mechanical gear boxes. The result is a simplified circuit, with fewer components and less piping. Hi-Lo Circuit Split-Flow pumps can efficiently supply flow in a circuit with changing flow and pressure requirements. These pumps are ideal for clamping, pressing and high torque tool applications. Combined flow from both pump outlets is supplied to the actuator, until load pressure rises to the unloading valve setting, for example, 500 psi (35 bar). The higher output flow, 8 U.S. gpm (30 L/min), is then unloaded to tank. The remaining 2 U.S. gpm (8 L/min) is supplied at high pressure up to the relief valve setting of psi (700 bar). Synchronous Movement Split-Flow pumps can be used for synchronous movement of cylinders and motors without using flow dividers. They provide unique advantages for lifting, jacking and skidding operations, increasing the flexibility of systems for handling heavy loads. The pumps provide greater accuracy than flow dividers which operate over a narrow band width and are likely to SPLIT-FLOW CHECKBALL PUMP FOUR OUTLET 8 PISTON PUMP PROVIDES SYNCHRONIZED CYLINDER MOVEMENT have flow variations in the secondary branches, especially when cascaded in series circuits. Hydrostatic Drive Circuits A typical open-loop circuit uses a ten piston PV6000 hydraulic variable pump with two outlets. Each five piston pump output supplies independent variable flow to a motor. Dynex DP Series valves in the circuit control the low pressure signals which regulate the independent pump outputs. As a result, the speed of each motor is controlled by its own variable supply. Refer to dynexpespvspecs.pdf for information on PV6000 hydraulic variable pumps and volume controls. 3

26 SPLIT-FLOW PUMP SELECTION Selecting Split-Flow Pump Models INLET PORT INLET CHECKBALL OUTLET CHECKBALL ISOLATOR VALVE MODELS The checkball design, with its isolated pumping chambers, allows the output of each piston to be used separately. One or more individual pistons can be isolated from the main outlet. Up to ten separate outlet flows are possible, for example, from a 10 piston pump. Note that high pressure pump models are limited to a maximum pressure of 6000 psi (420 bar) when using isolator valves. The table below lists pump series available with isolators valves. SPLIT-FLOW-COVER MODELS In split-flow-cover models, the individual outputs are grouped together in the pump cover or barrel providing smooth, multiple outlet flows. Select from various piston flow splits to match requirements. For example, an eight piston PF3000 Series pump is available as a 4+4 split. The output of the four even numbered pistons (2 through 8) is combined separately from that of the four odd numbered pistons (1 through 7). Individual portions of a circuit are supplied by the output from each group of four pistons. Other splits available for this pump include a 5+3 split, a 6+2 split or a 7+1 split, as well as an eight-way (8x1) split with separate outputs from each of the eight pistons. On PV6000 Series hydraulic variable pumps, each output can be independently controlled. Two control pressure signals are directed to the rear pump cover to independently control the variable delivery mechanism of each variable output. The table on page 5 lists the most common split-flow-cover models. ISOLATOR VALVE MODELS Pump Series ➀ Number of Pistons MODEL PF2006 WITH ISOLATOR VALVE INLET INLET PORT CHECKBALL OUTLET PORT 1 PF1000 SERIES WITH SPLIT-FLOW-COVER Rated Flow Per Piston ➁ 1200 rpm 1800 rpm U.S. gpm L/min U.S. gpm L/min Isolator Valve Model Number ➃ ISOLATOR OUTLET PORT ISOLATOR VALVE MAIN OUTLET PORT OUTLET CHECKBALL OUTLET PORT 2 Port Size PF2006 ➂ , ,54 VC /8 N.P.T.F. PF2008 ➂ , ,67 VC /4 N.P.T.F. PF , ,84 VC S.A.E. No. 4 PF , ,97 VC S.A.E. No. 4 PF , ,68 VC S.A.E. No. 4 PF4018, PV , ,81 VC S.A.E. No. 6 PF4026, PV , ,85 VC S.A.E. No. 6 PF4033, PV , ,40 VC S.A.E. No. 6 PF , ,16 VC S.A.E. No. 6 PF , ,11 VC S.A.E. No. 8 ➀ Contact your sales representative for complete model numbers and a review of your application. ➁ Output flow based on typical performance at rated pressure with pressurized inlet where required. ➂ These models are special mounting. ➃ Note that high pressure pump models are limited to a maximum pressure of 6000 psi (420 bar) when using isolator valves. 4

27 SPLIT-FLOW SELECTION SPLIT-FLOW-COVER MODELS Pump Series ➀ Number of Pistons Number of Pistons per Outlet (Port Size) Outlet 1 Outlet 2 Outlet 1 At 1200 rpm Outlet 2 Rated Flow per Outlet ➁ Outlet 1 At 1800 rpm Outlet 2 U.S. gpm L/min U.S. gpm L/min U.S. gpm L/min U.S. gpm L/min PF , , , ,65 PF Pistons + 2 Pistons , , , ,97 PF (S.A.E. No. 4) (S.A.E. No.4) , , , ,84 PF , , , ,81 PF , , , ,32 PF Pistons + 1 Piston , , , ,97 PF (S.A.E. No. 8) (S.A.E. No.4) , , , ,42 PF , , , ,41 PF , , , ,76 PF Pistons + 3 Pistons , , , ,98 PF (S.A.E. No. 8) (S.A.E. No.8) , , , ,98 PF , , , ,09 PF , , , ,19 PF Pistons + 2 Pistons , , , ,31 PF (S.A.E. No. 6) (S.A.E. No.6) , , , ,31 PF , , , ,71 PF , , , ,57 PF Pistons + 1 Piston , , , ,67 PF (S.A.E. No. 8) (S.A.E. No.4) , , , ,67 PF , , , ,37 PF , , , ,71 PF Pistons + 4 Pistons , , , ,55 PF (S.A.E. No. 8) (S.A.E. No.8) , , , ,14 PF , , , ,82 PF , , , ,77 PF Pistons + 3 Pistons , , , ,93 PF (S.A.E. No. 12) (S.A.E. No.8) , , , ,62 PF , , , ,86 PF , , , ,87 PF Pistons + 2 Pistons , , , ,27 PF (S.A.E. No. 12) (S.A.E. No.6) , , , ,05 PF , , , ,93 PF , , , ,94 PF Pistons + 1 Piston , , , ,62 PF (S.A.E. No. 12) (S.A.E. No.6) , , , ,53 PF , , , ,96 PF , , , ,19 5 Pistons 5 Pistons PF , , , ,87 (S.A.E. No. 8) (S.A.E. No.8) PF , , , ,39 PF Pistons + 3 Pistons , , , ,52 PF (S.A.E. No.8) (S.A.E. No.8) , , , ,92 PF4018, PV , , , ,03 5 Pistons 5 Pistons PF4026, PV , , , ,25 (S.A.E. No. 12) (S.A.E. No.12) PF4033, PV , , , ,01 PF Pistons + 5 Pistons , , , ,80 PF (1 Inch Flange) ➂ (S.A.E.No.12) , , , ,56 PF6054, PV , , , ,24 5 Pistons 5 Pistons PF6070, PV , , , ,73 (1 Inch Flange) PV (1 Inch Flange) ➂ , , , ,09 ➀ PF1, PF2 and PF3 Series pumps are also available with all pistons isolated. For complete model numbers for all split-flow-cover models and a review of your application, contact your Dynex sales representative. ➁ Output flow based on typical performance at rated pressure with pressurized inlet where required. ➂ Pattern for standard S.A.E. 4-bolt flange. 5

28 SPECIFICATIONS PF4000 Series Fixed Displacement Pumps Also refer to "Checkball Pump Installation and Operating Recommendations" Bulletin PSI.CB (dynexpumpinstallation.pdf) CONTACT INFORMATION USA Headquarters Dynex/Rivett Inc. 770 Capitol Drive Pewaukee, WI U.S.A. Tel: FAX: Power Units & Systems Dynex/Rivett Inc. 54 Nickerson Road Ashland, MA U.S.A. Tel: FAX: European Sales Dynex/Rivett Inc. Unit C5 Steel Close, Little End Road, Eaton Socon, Huntingdon, Cambs. PE19 8TT United Kingdom Tel: +44 (0) FAX: +44 (0) Download Dynex Product Specifications! BROCHURE NOTES: Specifications shown were in effect when published. Since errors or omissions are possible, contact your sales representative or the sales department for the most current specifications before ordering. Dynex reserves the right to discontinue products or change designs at any time without incurring any obligation. DYNEX High Pressure Hydraulics Copyright Dynex/Rivett Inc. Bulletin dynexpespf4000specs-1204

29 PF4000 SERIES Specifications PUMP DESCRIPTION Fixed displacement checkball pumps, with bi-directional shaft rotation, provide constant direction of output flow regardless of the direction of drive shaft rotation. Mounting S.A.E. D 4-bolt pattern with 0.25 inch (6,4 mm) pilot engagement. Shaft Options Standard keyed shaft, inch (31,75 mm) diameter; Optional spline shaft, 1.248/1.247 inch diameter standard S.A.E. 14 tooth, 12/24 D.P. 30 involute spline. Outlet Port Options Standard pressure models have S.A.E. ports. High pressure H option models require the use of outlet port option A (Autoclave Medium Pressure, Butech M/P or equivalent fittings), or outlet port option B (British Standard Pipe fittings). Refer to Outlet Port Configurations on page 6 and Typical Model Code on page 4 to specify outlet port. Inlet Conditions Pumps may require pressurized inlet conditions at higher speeds. Failure to meet minimum inlet requirements will result in slight flow reduction. Refer to the table. Seal Options Standard seals are Buna-N (Nitrile). Options include Fluorocarbon (Viton or Fluorel ) or EPR for use with some phosphate ester fluids. Weight (Mass) 111 lb (50 kg) Pump Models Output Flow at 1500 rpm➀ U.S. gpm L/min Output Flow at 1800 rpm➀ Rated Pressure Maximum Intermittent Pressure U.S. gpm L/min psi bar psi bar Rated Speed rpm➁ Maximum Speed rpm➁ PF , , PF , , PF , , PF , , PF4011H , , PF4016H , , PF4018H , , PF4020H , , ➀ Output flow based on typical performance at rated pressure with pressurized inlet where required, as shown in the table below. ➁ Contact the sales department for applications requiring operation above rated speed. High speed operation may require a pressurized inlet. Refer to Inlet Conditions. Minimum Inlet Pressure ➀ Pump Models Operating Speed 1200 rpm 1500 rpm 1800 rpm 2400 rpm psi bar psi bar psi bar psi bar PF ,4 PF ,4 PF ,4 10 ➁ 0,7 ➁ PF ,4 10 ➁ 0,7 ➁ 15 ➁ 1,0 ➁ ➀ Values shown are based on fluid viscosity of 100 SUS (20 cst). ➁ Inlet pressures higher than 10 psig (0,7 bar) require a high-pressure shaft seal. Refer to "Typical Model Code" on page 4 for seal options. PUMP SELECTION The table shows specifications for standard pressure and high pressure H option models. Ordering a PF4000 Series, 10 Design, pump requires a complete model code specifying shaft, seal and outlet port options. Refer to Typical Model Code on page 4. Maximum Pressure Checkball pumps are especially suited for applications susceptible to excessive pressure spikes. The intermittent pressures listed are the maximum pressures a pump can sustain for occasional, short periods of operation without appreciably reducing life expectancy. Fluid Guidelines See page 5 for Fluid Recommendations. Some pump models may require reduced operating pressures when using lowlubricity fluids. The optional Low Lubricity Kit provides an additional internal passage for improved bearing lubrication when using lowlubricity fluids. Refer to Typical Model Code on page 4. Because of the wide range of fluid characteristics, contact the sales department for a review of any application using non-petroleum based fluids. Split-Flow Provides Multiple Outlets PF4000 models with split-flow covers efficiently supply flows for multiple function circuits. Piston outputs are grouped together in the cover, with various piston flow splits available in this ten-piston pump. Refer to Typical Model Code on page 4 and contact the sales department for availability. 2

30 PF3000 PF4000 SERIES, SERIES 10 DESIGN Typical Performance Curves Typical performance curves are based on 100 SUS (20 cst) mineral oil with pressurized inlet where required. Refer to the Minimum Inlet Pressure table on page 2. INSTALLATION All dimensions are shown in inches (millimeters in parentheses) and are nominal. See page 2 for spline shaft data. Refer to Bulletin PSI.CB for general installation and operating recommendations. The thickness of the cover and the location of the outlet port varies as shown, dependent on the port option. Variable Dimensions Variable Dimension Models PF4011, PF4016 S.A.E. or B.S.P Port Models PF4018, PF4020 Outlet Port Option Models PF4011, PF4016 Coned and Threaded Models PF4018, PF4020 A 8.59 (218,2) 8.66 (220,0) 8.46 (214,9) 8.53 (216,7) B 3.94 (100,2) 3.94 (100,2) 4.09 (103,8) 4.09 (103,8) C 9.49 (241,1) 9.56 (242,9) 9.49 (241,1) 9.56 (242,9) (161.65) (80,82) SQUARE KEY.31 x 1.18 (7,9 X 30,0) 1.50 (38,1) 4.06 (103,2) A INLET PORT NO. 24 S.A.E. OUTLET PORT NO. 12 S.A.E.; OR 3/4 MEDIUM PRESSURE CONED AND THREADED, N.P.S.M. THREADED (AUTOCLAVE MEDIUM PRESSURE, BUTECH M/P, OR EQUIVALENT); OR G 3/4 (B.S.P.) ,40 ( 152,35 ) , ( 35,15) ( ) , (3,4) B 4.63 (117,5) 4.00 (101,6) 8.00 (203,2).812 (20,62) 4 MOUNTING HOLES.25 (6,4).58 (14,7) 2.25 (57,2).75 (19,1) BLEED PORTS (3) NO. 6 S.A.E., 90 APART C 7.50 (190,5).50 (12,7) BLEED PORT FOR VERTICAL MOUNTING NO. 4 S.A.E. 3

31 PF3000 PF4000 SERIES, SERIES 10 DESIGN TYPICAL MODEL CODE PF40 11 H S XV A L PF Output Flow (At 1800 rpm, at rated pressure) ➀ Standard: 7.7 gpm (29,1 L/min) H Option: 7.3 gpm (27,6 L/min) Standard: 11.1 gpm (42,0 L/min) H Option: 10.5 gpm (39,7 L/min) Standard: 12.4 gpm (46,9 L/min) H Option: 12.1 gpm (45,8 L/min) Standard: 14.0 gpm (53,0 L/min) H Option: 13.7 gpm (51,9 L/min) ➀ Output flows based on typical performance at rated pressure. Refer to performance curves for flows at lower pressures. No Code H Pump Type Fixed Displacement Checkball Pump Operating Pressure Standard Pressure High Pressure ➀ ➀ Requires A or B port option. No Code S No Code XE XV Drive Shaft Keyed, inch (31,75 mm) diameter S.A.E. Spline, inch (31,75 mm) All Buna-N (Nitrile) ➀ Seals All EPR with High Pressure Shaft Seal ➀ All Fluorocarbon (Viton or Fluorel ) with High Pressure Shaft Seal ➀ Not available with High Pressure H option. Contact the sales department for recommended operating conditions. No Code A B Options No Code Standard L Low Lubricity Kit ➀ ➀ Provides an additional internal passage for improved bearing lubrication when using lowlubricity fluids. Ports Inlet No. 24 S.A.E.; Outlet No. 12 S.A.E. ➀ Inlet No. 24 S.A.E.; Outlet 3/4 Medium Pressure Coned and Threaded, 3/4-14 N.P.S.M. Threaded ➁ Inlet No. 24 S.A.E.; Outlet G 3/4 (B.S.P.) ➂ ➀ Not recommended for operation above 8000 psi (560 bar). Contact the fitting manufacturer for the pressure rating of the fitting. ➁ High pressure port uses Autoclave Medium Pressure, Butech M/P or equivalent fitting. ➂ Outlet port uses British Standard Pipe fitting. Not recommended for operation above psi (700 bar). Design Number Modification Number Split-Flow Options (10 Piston Pump) ➀ No Code Full flow from single outlet Split-Flow Cover Models: 55 Five-pistons output + Five-pistons output 64 Six-pistons output + Four-pistons output 73 Seven-pistons output + Three-pistons output 82 Eight-pistons output + Two-pistons output 91 Nine-pistons output + One-piston output 10X Ten ports, each with one-piston output 5 Five pistons output + Five inactive pistons ➀ For outlet port sizes, locations and pump cover dimensions, contact the sales department. 4

32 FLUID GUIDELINES FLUID RECOMMENDATIONS Mineral Oil A high-grade premium petroleum-based fluid should be used to assure long component and system life. The fluid should have a combination of anti-wear, demulsibility, rust protection, oxidationresistant and foam-resistant properties. Special Fluids Various pump models are available for use with water-based fluids, diesel calibration fluids, phosphate ester fluids, machining coolant, brake fluid, various military fluids and other special fluids. PF4300 Series pumps are compatible with a variety of water-based fluids. These models, which are specifically rated for use with low-lubricity fluids. Some pump models may require reduced operating pressures when using lowlubricity fluids. Because of the wide range of fluid characteristics, contact the sales department for a review of any application using non-petroleum based fluids. Viscosity Specifications Using fluid with the correct viscosity range is critical to achieving long component life. Fluid conditions outside the Optimum range shown in the table may result in reduced pump output, requiring pressurized inlet conditions. For more information, contact the sales department. Hydraulic Fluid Viscosity ➀ Operating Minimum Maximum Start-up➁ Optimum Pump Models SUS cst SUS cst SUS cst SUS cst Fixed Displacement Pumps: PF to to 70 PF to to 70 PF to to 70 PF2000 ➁ 34 2, to to 70 PF to to 70 PF , to to 70 PF , to to 70 PF , PF , to to 70 Mechanical Variable Delivery Pumps: PV , to to 70 PV , to to 70 Hydraulic Variable Delivery Pumps: PV , to to 70 ➀ Fluid conditions outside the Optimum range may result in reduced output, requiring pressurized inlet conditions. Contact the sales department. ➁ Models with special mounting. MINIMUM FILTRATION LEVELS Pump inlet: 150 µ nominal; Pressure or return line: 25 µ nominal. While finer filtration levels than these are desirable and will result in longer component life, restricting flow to the pump inlet should be avoided. Minimum recommended inlet conditions must be maintained. If a system component fails resulting in fluid contamination, it is important to drain and clean the reservoir, all lines, filter screens and all components. Refill with new fluid. INSTALLATION AND OPERATION Refer to separate Bulletin PSI.CB for general installation and operating recommendations. That brochure includes information on mounting, shaft loading, sizing inlet pipe and hose, air bleed procedures and initial start-up. Guidelines for maintenance, repair and trouble-shooting are also included. 5

33 OUTLET PORT CONFIGURATIONS PORT DESCRIPTIONS Dynex pumps are available with outlet ports suitable for use at various pressure ranges. Refer to the appropriate Specification Table or Typical Model Code to specify the required port. Contact the fitting manufacturer to ensure the selected fittings are rated for the maximum pump operating pressure. S.A.E. Straight Thread Ports O-RING PUMP COVER Typical S.A.E. Straight Thread port connection COUPLING The Straight Thread connection (S.A.E. J1926/1) is sometimes referred to as an S.A.E. O-ring Boss, or ORB. The port consists of a machined spotface surface, a tapered seal cavity and a straight thread port. The fitting forms a seal by compressing the o-ring in the seal cavity with the underside of the flanged wrench flat. Some adjustable fittings, such as elbows and tees, use a locknut with a captive backup washer for compression. S.A.E. Straight Thread ports are not recommended for operation above 8000 psi (560 bar). Also, the maximum pressure of pumps with No. 12 S.A.E. outlet ports may be limited by the pressure rating of the available fitting. Contact the fitting manufacturer for ratings. Coned and Threaded Ports TUBING SLEEVE PUMP COVER High-pressure pumps are available with coned and threaded outlet ports, which use Autoclave Medium Pressure, Butech M/P, or equivalent fittings. These fittings provide a metal-to-metal seal with an interference fit, not requiring an o-ring. The gland nut holds the sleeve and tubing against the cone surface. A weep hole, visible on the outside of the pump cover, acts as an indicator of any abnormal leakage caused by system conditions (i.e., excessive pressure). It allows any fluid which does leak past the sealing surfaces to escape, preventing pressure build-up and possible damage. British Standard Pipe Ports PUMP COVER GLAND NUT Typical Coned and Threaded port connection COUPLING SEAL RING SHOULDER Typical port connection with British Standard Pipe (Parallel) fitting with shoulder WEEP HOLE High-pressure pumps are available with flat face ports with British Standard Pipe (B.S.P.) parallel threads (BS 2779 or ISO 228), ideal for use on some European applications. The fitting forms a seal by compressing a flat elastomer ring on a machined spotface surface. There are several sealing methods for these ports. The recommended fitting has a recessed seal cavity formed by a shoulder on the underside of the flanged wrench flat (Voss Peflex, Form B Shoulder Seal; or Parker Type E, EOlastic Seal; or equivalent). B.S.P. ports are not recommended for operation above psi (700 bar). Contact the fitting manufacturer, to ensure the selected fittings are rated for the maximum pump operating pressure. S.A.E. 4-Bolt Flange Ports BOLTS O-RING PUMP COVER Typical S.A.E. 4-Bolt Flange port connection FLANGE Flange connections are often used for higher flows requiring larger diameter tubing. The port consists of an unthreaded port with four bolt holes in a rectangular pattern on a machined face around the port (S.A.E. J518). A typical fitting consists of a flanged head with a welded tube and a captive flange with bolt holes. A seal is formed by an o-ring in the groove on the underside mounting surface of the flange head. As the flange bolts are alternately tightened, the o-ring is compressed between the flange head and the machined face on the pump. To make mounting easier in tight spaces a two-piece split-flange is often used. 6

34 B ITEM 6 B A (2) D ITEM 3 ITEM 7 A ITEM 2 A A (ONLY USED ON KEYED SHAFT) ITEM 5 ITEM 1 A A A (4) A (4) B (4) TORQUE TO 120 LB-FT B A PRESS BALL (B ).31 DEEP INTO COVER. ASSEMBLE SET SCREW (A ) USING LOCTITE #271 OR EQUIV. A A B TORQUE TO 160 LB-IN USE LOCTITE #271 OR EQUIV. B (4) B (4) ITEM 4 B (6) TORQUE TO 30 LB-FT A A A SECTION A-A

35 Counterbalance Valves OVERVIEW A counterbalance valve is an improved pilot operated check valve and is the preferred load holding valve for double-acting jacking systems. An important and major difference between these two valves is: With a pilot operated check valve, the opening pressure depends on the pressure (applied by the load) behind the valve; With a counterbalance valve, the opening pressure depends on the spring pressure behind the valve. The dynamic performance of a counterbalance valve is many times better than the dynamic performance of a pilot operated check valve. The counterbalance valve acts as a 'brake valve ' on hydraulic systems to maintain a positive control on a hydraulic cylinder or motor with a negative load. DIAGRAM FUNCTIONING When the left side of the direction control valve is activated the cylinder will make its 'OUT-stroke'. The oil flows freely through the check valve which is integrated in the housing of the counterbalance valve. In order to lower the cylinder, the right side of the direction control valve has to be activated. From that moment on pressure is built up at the rod side of the cylinder. This pressure opens the counterbalance valve and the oil at the bottom side of the cylinder flows through the counterbalance valve and through the direction control valve back to the reservoir.

36 As the load helps lowering the cylinder, the cylinder might go down faster than the oil is applied to the rod side of the cylinder (the cylinder isn't under control at that moment). However, the pressure at the rod side of the cylinder and therefore the pilot pressure on the counterbalance valve will decrease and the spring moves the counterbalance valve to the direction 'close' until it finds a new 'balance'. PRODUCT INFORMATON All HYDRA-PAC Power Units include Simplex V2 Counterbalance Valves. V2 - Inline System Valves Model # Name Order # Max. Pressure : V2 : Inline System Valves : V2 : psi Description V2 Over Center Check Valve can be mounted at the cylinder to hold the load in the event of system failure. Provides controlled retraction without "chatter"

37 Instruction Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. L1057 Rev. C 08/12 VM/VC-3/3L/4/4L/15/15L/20/20L, VM33/33L/43/43L MANUALLY OPERATED CONTROL VALVES Index: English Français Deutsch Italiano Español Nederlands Portuguese Swedish Repair Parts Sheets for this product are available from the Enerpac web site at or from your nearest Authorized Enerpac Service Center or Enerpac Sales office. MAKE SURE ALL HYDRAULIC CONNECTIONS ARE MADE TO THE PROPER PORTS. 1.0 IMPORTANT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. Shipping damage is not covered by warranty. If shipping damage is found, notify carrier at once. The carrier is responsible for all repair and replacement costs resulting from damage in shipment. 2.0 SAFETY ISSUES SAFETY FIRST Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic safety, consult your distribution or service center for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of equipment or other property. A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury. A DANGER is only used when your action or lack of action may cause serious injury or even death. WARNING: Wear proper personal protective gear when operating hydraulic equipment. WARNING: Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting device, should never be used as a load holding device. After the load has been raised or lowered, it must always be blocked mechanically. WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. Carefully select steel or wood blocks that are capable of supporting the load. Never use a hydraulic cylinder as a shim or spacer in any lifting or pressing application. Rounded Edge Down Bord arrondi vers le bas Runde Kante unten Bordo arrotondato verso il basso Borde redondeado hacia abajo Afgeronde kant omlaag Lateral arredondada para baixo. Rundad kant nedåt DANGER: To avoid personal injury keep hands and feet away from cylinder and workpiece during operation. WARNING: Do not exceed equipment ratings. Never attempt to lift a load weighing more than the capacity of the cylinder. Overloading causes equipment failure and possible personal injury. The cylinders are designed for a max. pressure of 700 bar [10,000 psi]. Do not connect a jack or cylinder to a pump with a higher pressure rating. 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 personal 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. It is your window to what is happening in the system. 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 internally damage the hose leading to premature hose failure. rupture. Handtagsenhet Loctite 222 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 IMPORTANT: Do not lift hydraulic equipment by the hoses 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 packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance do not expose equipment to temperatures of 65 C [150 F] or higher. Protect hoses and cylinders from weld spatter. DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately.

38 WARNING: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the cylinder becomes extremely overloaded, components can fail catastrophically causing severe personal injury. WARNING: BE SURE SETUP IS STABLE BEFORE LIFTING LOAD. Cylinders should be placed on a flat surface that can support the load. Where applicable, use a cylinder base for added stability. Do not weld or otherwise modify the cylinder to attach a base or other support. Avoid situations where loads are not directly centered on the cylinder plunger. Off-center loads produce considerable strain on cylinders and plungers. In addition, the load may slip or fall, causing potentially dangerous results. Distribute the load evenly across the entire saddle surface. Always use a saddle to protect the plunger. IMPORTANT: Hydraulic equipment must only be serviced by a qualified hydraulic technician. For repair service, contact the Authorized ENERPAC Service Center in your area. To protect your warranty, use only ENERPAC oil. WARNING: Immediately replace worn or damaged parts with genuine ENERPAC parts. Standard grade parts will break causing personal injury and property damage. ENERPAC parts are designed to fit properly and withstand high loads. 3.0 GENERAL INFORMATION The Enerpac valve design incorporates the following features into a single unit: 10,000 psi [700 bar] operating pressure Load holding The Enerpac valves are specifically designed for use with Enerpac pumps User adjustable relief valve Gauge ports 3.1 Capacity Capacity is 900 cu. in/min (14.8 l/min) [3.9 gpm]. CAUTION: If using pipe sealants on male pipe threads, use sparingly and never over ends of fittings where it can be torn loose and get into system. 4.0 INSTALLATION 1. Install valve onto Enerpac pump using gasket and fasteners included. Take needed steps to ensure pump's pressure tube o-ring and backup are not damaged. CAUTION: If you are not trained and familiar with installing a valve have an Authorized Enerpac Service Center perform this step. 2. Install pressure gauge, if required, into proper port. Pressure can be monitored at the GP ports, the GB port or the GA port or any combination of these, depending on system requirements. CAUTION: If using pipe sealants on male pipe threads, use sparingly and never over ends of fittings where it can be torn loose and get into the hydraulic system. 5.0 OPERATION 1. Connect and secure hoses and cylinders noting that the proper ports are connected. 2. Quick disconnects must be fully engaged and locking collars drawn up fully to ensure free flow of oil between valve and attached component. 3. Place valve handle in proper position before starting pump. Tandem centered valves should be in neutral position. Closed centered valves should be in a position which will ensure a safe start up when the pump is started. VM33, VM33L, VM43, VM43L (See Fig. 1) 1. Advance 2. Retract 3. Neutral 4. Valves equipped with a positive locking feature will not permit movement of the load when the handle is moved between positions (VC3L, VC15L, VM3L, VM33L, VC4L, VC20L, VM4L, VM43L). Valves not equipped with this feature will lower or drop the load during handle movement. The amount of loss or load movement will depend on the speed of handle movement between detent positions. 5. VM33, VM43 valves are equipped with an integral system check valve. To "hold" load, keep valve handle in position and simply turn pump off. Rotate handle to lower load. NOTE: Enerpac valves are either tandem or closed center. Tandem centered valves allow oil to flow from the pump to tank when in the NEUTRAL position. Closed centered valves block the flow of oil from the pump when in the NEUTRAL position. Selecting the type of valve that best meets your needs is important for satisfactory operation. 5.1 Relief Valve Adjustment (Models VM33/33L/43/43L) Z-Class pumps are equipped with one user adjustable relief valve (see Figure 2.) It can be adjusted as follows: 1. Install a gauge on the pump. If a unit is equipped with optional pressure transducer, verify SET PRES valve is higher than desired relief valve setting or Auto Mode is off. 2. Start the pump to allow the oil to warm. 3. Loosen the set screw locking nut. 4. Shift the valve and build pressure in the system. Using an Allen wrench, turn the set screw counter-clockwise to decrease pressure and clockwise to increase pressure. NOTE: To get an accurate setting, decrease the pressure to a point below the final setting and then slowly increase the pressure until it reaches the final setting. 5. Tighten the locking nut when the desired pressure is set. 6. Shift the valve to the neutral position, allowing the system pressure to return to 0 psi. 7. Recheck the final pressure setting by shifting the valve and pressurizing the system In Use B 3 Figure 1 A 1 2

39 Relief valve body (DO NOT TURN relief valve body.) B A Set screw Locknut 6.0 TROUBLE SHOOTING Figure 2 1. System will not build pressure. Check relief valve in the control valve or in the pump, for proper setting (see pump repair sheet or valve repair sheet). Check and secure all hose connections. If trouble is not corrected, remove cylinder and hoses from the valve. Now place a gauge directly in valve port A and place the valve in advance. If pressure cannot be developed, the unit should be taken to the nearest authorized ENERPAC Service Center. If pressure develops, the cylinder, hoses or couplers are the problem. 2. The cylinder will not hold load. This is an indication of worn valve seals or load holding check valve that must be replaced by an authorized Enerpac Service Center. 7.0 MAINTENANCE 1. Periodically check all hydraulic and air connections to be sure they are tight. Loose or leaking connections may cause erratic and/or total loss of operation. Replace or repair all defective parts promptly. 2. Periodically check the hydraulic oil level in your system. 3. Change hydraulic oil approximately every hours of operation. In dusty or dirty areas, it may be necessary to change the oil more frequently. 8.0 HYDRAULIC SYSTEM 1. Keep all hydraulic components free of dirt, grease, chips, etc. 2. Keep the hydraulic component operating in areas that are uncluttered and free of unnecessary equipment. 3. Periodically check your hydraulic system for possible loose connections, leaks, etc. Replace or properly repair damaged or leaking hydraulic components immediately. 4. Check hydraulic oil in your hydraulic system every 40 hours of operation or more frequently in unusually dirty or dusty areas. 5. Oil temperature must be maintained less than or equal to 150 F (65 C) by way of a heat exchanger or other methods. 9.0 STORAGE INSTRUCTIONS In the event that the unit would be stored for any great length of time (30 days or more), prepare as follows: 1. Wipe the entire unit clean. 2. Disconnect all hydraulic lines to prevent accidental operation. 3. Cover the unit with some type of protective cover. 4. Store in a clean, dry environment that is NOT exposed to extreme temperatures. 3

40 3-WAY MANUAL VALVE DIAGRAMS Manual Valves Advance-Neutral/Hold-Retract VC-3 Manual 3-Way A Directional Valve Mounts at any convenient location in system where control point is needed. P T TANDEM CENTER Manual Locking Valves Remote Mounted Advance-Hold-Retract VC-3L Manual 3-Way Locking Valve A Same as VC-3 but with built-in locking feature. P T TANDEM CENTER VC-15L Manual 3-Way Locking Valve A VC-15 Manual 3-Way Directional Valve A Same as VC-15 but with built-in locking feature. Closed center version of VC- 3 for multiple independent cylinder operation. P T CLOSED CENTER Pump Mounted P T CLOSED CENTER VM-3 Manual 3-Way Directional Valve Provides centralized control of pump output. Minimum restriction of hydraulic oil flow during cylinder cycles. A P T TANDEM CENTER VM-3L Manual 3-Way Locking Valve Same as VM-3 but with built-in locking feature. A P T TANDEM CENTER VM33 Pump Mounted VM33L "GA" NPTF pump pressure gauge port GP A NPTF pump pressure gauge port GP NPTF pump pressure gauge port GP "GA" A NPTF pump pressure gauge port GP "GP" "GP" P T T User adjustable relief valve NPTF advance/retract port "GP" "GP" P T T NPTF advance/retract port Port permanently plugged NPTF gauge port GA NPTF auxiliary tank return T NPTF auxillary tank return T NPTF gauge port GA 4

41 4-WAY MANUAL VALVE DIAGRAMS Manual Type Valves Advance-Neutral/Hold-Retract VC-4 Manual 4-Way Directional Valve Manually operated remote valve. Allows finger tip P T control for powered advance TANDEM CENTER and retraction of cylinders with holding in center position. Can be readily mounted at any convenient point in the system. VC-20 Manual 4-Way Directional Valve Closed center version of above for multiple valve operation VM-4 Manual 4-Way Directional Valve Allows finger tip control for powered advance and retraction of a cylinder. A B A B P T CLOSED CENTER A B P T TANDEM CENTER Remote Mounted VC-4L Manual 4-Way Locking Valve Same as VC-4 but with built-in locking feature. VC-20L Manual 4-Way Locking Valve Same as VC-20 but with built-in locking feature. Pump Mounted VM-4L Manual 4-Way Locking Valve Same as VM-4 but with built-in locking feature. Manual Locking Type Valves Advance-Neutral/Hold-Retract A A P T P T B TANDEM CENTER TANDEM CENTER B CLOSED CENTER Advance-Hold-Retract A P T B VM43 Pump Mounted VM43L NPTF pump pressure gauge port GP NPTF pump pressure gauge port GP A B NPTF pump pressure gauge port GP "GA" A B "GB" NPTF gauge port GB "GA" "GB" NPTF gauge port GB "GP" "GP" T User adjustable relief valve NPTF advance port "GP" "GP" P T T User adjustable relief valve NPTF advance port P T NPTF retract port NPTF retract port NPTF auxiliary tank return T NPTF gauge port GA NPTF gauge port GA NPTF auxiliary tank return T 5

42 Repair Parts Sheet Manual Valves L1257 Rev. I 11/10 For Date Codes Beginning with the Letters B and C To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil. Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product. 1 Apply Loctite Torque item 7 to ft. lbs. [38-46 Nm] TANK Torque to in. lbs. [8-11 Nm] Torque to ft. lbs. [15-18 Nm] Figure 1

43 Previous Models Manual Valve Identification Manual valves are stamped at the time of manufacture with a valve code letter and valve code number. This letter and number are used to identify the valve model. Example: ENERPAC CBxxx.900 X CxxxxC Location of Code Letter Date Code Location of Code Number Code Letter Code Number Model Number Code Letter Code Number Model Number A CB VM-4 G CB VM-3 B CB VC-4 H CB VC-3 C CB VM-4L I CB VC-20 D CB VC-4L J CB VC-20L E CB VM-3L K CB VC-15L F CB VC-3L L CB VC-15 Present Models Manual Valve Identification Manual valves are stamped at the time of manufacture with a valve code number. The number is used to identify the valve model (see Valve Code Number Chart). Example: Date Code ENERPAC XXXXX CxxxxC Code Number Valve Code Number Chart 1st Postion 2nd Postion 3rd Position 4th Postion 5th Postion 3 3- Way Valve 4 4-Way Valve O C Open Center Closed Cener P R Pump Mounted Remote B V E Buna Viton EPA X O Locking Valve Setion No Locking Valve Section 2

44 Repair Parts List for Figure 1 Item Part Number Qty. Description Item Part Number Qty. Description 1 A Screw 16 CH537950SR 1 Disk Assembly (Valve code begins with 4C) 2 B Washer 3 Y Handle CH541950SR 1 Disk Assembly (Valve code 4 A Disk begins with 3C) 5 B /32" Ball 17 B Roll Pin 6 A Spring 18 DA SR 3 Shear Seal (incl. items 10, 7 B Bolt (for non-locking valve) 19, 20, 22) B Bolt (for locking valve) 19 B Back-Up Washer 8 B Roll Pin 20 B O-Ring 9 CB Valve Cap 22 CB Spring 10 B O-Ring 23 CH Body 11 CB Bearing Plate 24 B Bolt 12 CB Bearing 25 B O-Ring (non-locking valve) 13 CH Shaft B O-ring (for locking valve) 14 B Back-up Washer 26 CB Base (Remote mounted) 15 B O-Ring 27 CB Base (Pump mounted) 16 CH542950SR 1 Disk Assembly (Valve code beginning with 40) CH538950SR 1 Disk Assembly (Valve code beginning with 40) Items included in and availble only as part of Repair Kit VM4K3 28 A Pipe Plug 29 DA Pipe Plug 30 B Pin Figure 2 Coin Seat at 800 psi on a ten ton ram with 9 /32" ball Torque item 31 to ft. lbs. [ Nm] Note: Use with valve codes star ting with 4O and 4C and ending with X Repair Parts List for Figure 2 Item Part Number Qty. Description Item Part Number Qty. Description 31 CR Spring Guide 37 B Washer 32 CR Gasket 39 Y126290SR 2 Seat (Incl. #36, 37) 33 B O-Ring 40 B Back-Up Washer 34 CJ Spring 41 B O-Ring 35 B /32" Ball 42 Y Piston 36 B O-Ring 43 DC Valve Body Items included in and availble only as part of Repair Kit VM4K3 3

45 Figure 3 Coin Seat at 800 psi on a ten ton ram with 9 /32" ball Torque item 31 to ft. lbs. [ Nm] 33 Repair Parts List for Figure 2 Item Part Number Qty. Description Item Part Number Qty. Description 31 CR356013SR 2 Spring Guide (Incl #32, 33) 37 B Washer 32 CR Gasket 39 Y126290SR 2 Seat (Incl. #36, 37) 33 B O-Ring 40 B Back-Up Washer 34 CJ Spring 41 B O-Ring 35 B /32" Ball 42 Y Piston 36 B O-Ring 43 DC Valve Body Items included in and availble only as part of Repair Kit VM4K3 info@enerpac.com ENERPAC Middle East FZE Office 423, JAFZA 15 P.O. Box Jebel Ali, Dubai United Arab Emirates Tel: +971 (0) Fax: +971 (0) Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 2143 (P.O. Box 261) Australia Tel: Fax: Power Packer do Brasil Ltda. Rua dos Inocentes, Sao Paulo (SP) Tel: Fax: Toll Free in Brazil: Tel: vendasbrasil@enerpac.com Actuant Canada Corporation 6615 Ordan Drive, Unit Mississauga, Ontario L5T 1X2 Tel: Fax: Toll Free: Tel: Fax: Technical Inquiries: techservices@enerpac.com Actuant Industries Co. Ltd. No. 6 Nanjing Road Taicang Economic Dep Zone Jiangsu, China Tel: Fax: B Diyang Building Xin No. 2 Dong San Huan North Rd. Beijing City China Tel: Fax: ACTUANT - ENERPAC France S.A., ZA de Courtaboeuf 32, avenue de la Baltique Villebon / Yvettte France Tel: Fax: ENERPAC GmbH P.O. Box D Düsseldorf Willstätterstrasse13 D Düsseldorf Germany Tel: Fax: ENERPAC Hydraulics (India) Pvt. Ltd. No. 1A, Peenya Industrial Area, llnd Phase Bangalore, India Tel: Fax: ENERPAC S.p.A. Via Canova Corsico (Milano) Tel: Fax: Applied Power Japan LTD KK Besshochou 85-7 Kita-ku, Saitama-shi Japan Tel: Fax: ENERPAC Middle East FZE Office 423, JAFZA 15 P.O. Box Jebel Ali, Dubai United Arab Emirates Tel: +971 (0) Fax: +971 (0) Actuant LLC Admiral Makarov Street Moscow, Russia Tel: Fax: ENERPAC Scandinavia AB Fabriksgatan Gothenburg Sweden Tel: Fax: scandinavianinquiries@enerpac.com Actuant Asia Pte. Ltd. 37C, Benoi Road Pioneer Lot, Singapore Tel: Fax: Toll Free: Technical Inquiries: tech.service-sg@enerpac.com Actuant Korea Ltd. 3Ba 717, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea Tel: Fax: ENERPAC SPAIN, S.L. Avda. Los Frailes, 40 Nave C & D Pol. Ind. Los Frailes DAGANZO DE ARRIBA (Madrid) Spain Tel: Fax: Enerpac Scandinavia AB Fabriksgatan Gothenburg Sweden Tel: +46 (0) Fax: +46 (0) Inquiries: Scandinavianinquiries@enerpac.com ENERPAC B.V. Galvanistraat 115, 6716 AE Ede P.O. Box 8097, 6710 AB Ede The Netherlands Tel: Fax: beneluxinquiries@enerpac.com Technical Inquiries Europe: techsupport.europe@enerpac.com Bentley Road South Darlaston, West Midlands WS10 8LQ, United Kingdom Tel: +44 (0) Fax: +44 (0) ENERPAC P.O. Box N. Baker Road Milwaukee, WI USA Tel: Fax: User inquiries: Inquiries/orders: Technical Inquiries: techservices@enerpac.com 704 W. Simonds Dallas, TX USA Tel: Fax: /30/09 All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them. For your nearest authorized Enerpac Service Center, visit us at

46 VALVES 4-WAY/3-POSITION (TANDEM CENTER) VALVE WITH POSI-CHECK Application Single or double-acting cylinders. Actuation Lever operated, detent positioned. Functions Advance, hold and return. The Posi-Check feature guards against pressure loss when shifting from advance to hold position. Used on these pumps P460, PA6D, PA17, PA46, PA55, PE17, PE21, PE30, PE46, PE55, PE84, PE90, PE120, PE200, PE400, PED, PG30, PG55, PG120, PG400, PQ60 and PQ120 series No way/3-position (tandem center) manual valve. Wt., 5.1 lbs. 4-WAY/3-POSITION (TANDEM CENTER) AND (OPEN-CENTER) MANUAL VALVES Application Single- or double-acting cylinders. Actuation Lever operated, detent positioned. Functions The 9500 provides advance, hold and return. The 9511 (open center) valve can be used if holding is not a requirement, as when running two separate hydraulic tools. Provides advance and return only. Used on these pumps P460, PA17, PA46, PA55, PE17*, PE21, PE30, PE46, PE55, PE84, PE90, PE120, PE200, PE400, PG30, PG55, PG120, PG400, PQ60 and PQ120 series. *Does not mount without No way/3-position (tandem center) manual valve. Wt., 4.2 lbs. No Same as 9500, except has an open center. 4-WAY/3-POSITION (CLOSED CENTER) MANUAL VALVE WITH POSI-CHECK Application Single- or double-acting cylinders. Actuation Lever operated, detent positioned. Functions Similar to 9506, but is a closed center valve with Posi-Check. Generally used to operate multiple cylinders with a single pump. Provides advance, hold and return. The Posi-Check feature guards against pressure loss when shifting from the advance to hold position. See note on page 124 regarding plugging of ports and resulting heat build-up. Used on these pumps P460, PA17, PA46, PA55, PA60, PA6D, PE17, PE21, PE30, PE46, PE55, PE84, PE90, PE120, PE200, PE400, PQ60 and PQ120 series. No way/3-position (closed center) manual valve. Wt., 5 lbs. 4-WAY/3-POSITION (CLOSED CENTER) MANUAL VALVE Application Single- or double-acting cylinders. Actuation Lever operated, detent positioned. Functions Advance, hold and return. Closed center design makes valve suitable for operating multiple cylinders from a single pump. See note on page 52 regarding plugging of ports and resulting heat build-up. Used on these pumps P460, PA17, PA46, PA55, PA60, PE17, PE21, PE30, PE46, PE55, PE84, PE90, PE120, PE200, PE400, PQ60 and P120 series. No way/3-position (closed center) valve. Wt., 4.2 lbs. H y d r a u l i c P u m p M o u n t e d 4 Way/3 Position Manual 10,000 PSI., 3/8" PORTS, 5 GPM MAX FLOW RATE. POS. B POS. C POS. B POS. B POS. C POS. B POS. C POS. B POS. C POS. B POS. C P A P A P P A P P P P A P P A T B T T T POS. A POS. A B T T TPOS. A B T B T T POS. A POS. A B B 9506 Port A Port B Port A Port B 9500 Port B Port A 9511 Port A Port B ACCESSORIES P T B Port A Port B NOTE: A pressure switch and/or gauge may be attached to valves 9500, 9501, 9506, 9511 if desired (see pages , 131). Also, all valves on this page may be remote mounted with a 9510 subplate (see page 131). P O W E R T E A M. C O M 1 2 5

47 SPX Corporation th Street Rockford, IL USA Internet Address: Tech. Services: (800) Fax: (800) Order Entry: (800) Fax: (800) SPX Corporation 655 Eisenhower Drive Owatonna, MN USA Phone: (507) Tech. Services: (800) Fax: (800) Order Entry: (507) Fax: (800) International Sales: (507) Fax: (507) Parts List for: Form No MHI BOC 9509 VALVE ASSEMBLY Sheet No. 1 of 3 SPX Corporation Rev. 4 Date: 27 Oct. 2000

48 Parts List, Form No , Back sheet 1 of 3 Item Part No. No. No. Req'd Description Plastic Knob Stud 3 * O-ring (1/2 X 3/8 X 1/16; Nitrile) O-ring (1/2 X 3/8 X 1/16; Viton) O-ring (1/2 X 3/8 X 1/16; EPR) End Cap Pin (7/32 dia. X 5/8 Lg.; On valves manufactured before ) Pin (7/32 dia. x 15/16 Lg.; On valves manufactured after ) 6 * O-ring (1.956 X X.118; Nitrile) O-ring (1.956 X X.118; Viton) O-ring (1.956 X X.118; EPR) Thrust Bearing Washer Roller Thrust Bearing Roll Pin (5/16 dia. X 1-1/2 Lg.; On valves manufactured before ) Roll Pin (5/16 dia. x 1" Lg; On valves manufactured after ) Compression Spring (1/4 O.D. X 5/8 Lg.) Ball (1/4 dia.) Rotor (For 9506, 9509, & 9506-MHI) Rotor (For 9507, 9508, & 9508-BOC) Valve Body Cap Screw (1/4-20 X 5/8 Lg.; Torque to 60/80 in. lbs.) Decal Stem End Stem Cap Screw (5/16-18 X 1" Lg.; Torque to 300/320 in. lbs.) Shear Seal Seal 20 * Backup Washer (1/2 X 3/8 X 1/16) Spring Washer Cap Screw (1/4-20 UNC X 2-1/2 Lg.) Note: When using this valve on a PE30 Series pump order (4) Cap Screws for mounting valve to pump Drain Tube (For 9506, 9507, & 9506-MHI only) Ball (3/8 dia.) Compression Spring (3/16 I.D. X 13/32 Lg.) 26 * Copper Washer (.700 X 1/2 X 1/32) Valve Screw (Torque to 30/35 ft. lbs.) Pipe Plug (1/4 NPTF) Spacer 30 * Shaft Seal Pipe Plug (1/16 NPTF) PARTS INCLUDED BUT NOT SHOWN Patent Decal Part numbers marked with an asterisk (*) are contained in Repair Kit No Note: Alternate material seals listed for special valves factory equipped with viton or EPR seals. Refer to any operating instructions included with this product for detailed information about operation, testing, disassembly, reassembly, and preventive maintenance. Items found in this parts list have been carefully tested and selected. Therefore: Use only genuine replacement parts! Additional questions can be directed to our Technical Services Department. Note: Shaded areas reflect last revision(s) made to this form.

49 Parts List Form No SPECIFICATIONS 9506 & 9506-MHI (Pump Mounted) & 9509 (Remote Mounted) Manual (Posi-check) 3-Position, 4-Way Tandem Center Valve END CAP BOTTOM VIEW ROTOR TOP VIEW For 9506-MHI only ROLL PIN LOCATION (POSITION OPENING AS SHOWN) ROTOR BOTTOM VIEW VALVE BODY TOP VIEW FUNCTION Center (Hold) Position: "A" and "B" Ports blocked "Pressure" Port to tank Advance Position: Pressure to "A" Port (Reverse flow checked) "B" Port to tank Return Position: Pressure to "B" Port (Reverse flow checked) "A" Port to tank NOTE: "A" and "B" Ports are blocked with the pressure port open to tank during transition between valve positions. (Non-Interflow) 9507 (Pump Mounted) & 9508 (Remote Mounted) Manual (Posi-check) 3-Position, 4-Way Closed Center Valve FUNCTION Center (Hold) Position: All Ports blocked Advance Position: Pressure to "A" Port (Reverse flow checked) "B" Port to tank Return Position: Pressure to "B" Port (Reverse flow checked) "A" Port to tank NOTE: "A" and "B" Ports are blocked with the pressure port open to tank during transition between valve positions. (Non-Interflow) Sheet No. 2 of 3 Rev. 4 Date: 27 Oct. 2000

50 Parts List, Form No , Back sheet 2 of 3 PRESSURE DROP AND FLOW CHARTS

51 Parts List Form No #9510 VALVE SUBPLATE REMOTE MOUNTED (INCLUDED WITH 9508, 9508-BOC, AND 9509) Item Part No. No. No. Req'd Description Pipe Plug (3/8 NPTF) 2 * O-ring (1-3/8 X 1-3/16 X 3/32; Nitrile) O-ring (1-3/8 X 1-3/16 X 3/32; Viton) O-ring (1-3/8 X 1-3/16 X 3/32; EPR) 3 * O-ring (1/2 X 3/8 X 1/16; Nitrile) O-ring (1/2 X 3/8 X 1/16; Viton) O-ring (1/2 X 3/8 X 1/16; EPR) 4 * Backup Washer (1/2 X 3/8 X 1/16) Bushing Retaining Ring Manifold Body Warning Decal Part numbers marked with an asterisk (*) are contained in Repair Kit No Note: Alternate material seals listed for special valves factory equipped with viton or EPR seals. Sheet No. 3 of 3 Rev. 4 Date: 27 Oct. 2000

52

53

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56 Instruction Sheet Hydraulic Technology Worldwide V-82, V-182, V-8F, V-66, V-66F, V66NV L1966 Rev. C 04/06 Index: English: Français: Deutsch: Italiano: Español: Nederlands Repair Parts Sheets for this product are available from the Enerpac web site at or from your nearest Authorized Enerpac Service Center or Enerpac Sales office. 1.0 IMPORTANT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. Shipping damage is not covered by warranty. If shipping damage is found, notify carrier at once. The carrier is responsible for all repair and replacement costs resulting from damage in shipment. 2.0 SAFETY ISSUES SAFETY FIRST Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic safety, consult your distribution or service center for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of equipment or other property. A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury. A DANGER is only used when your action or lack of action may cause serious injury or even death. WARNING: Wear proper personal protective gear when operating hydraulic equipment. WARNING: Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting device, should never be used as a load holding device. After the load has been raised or lowered, it must always be blocked mechanically. WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. Carefully select steel or wood blocks that are capable of supporting the load. Never use a hydraulic cylinder as a shim or spacer in any lifting or pressing application. DANGER: To avoid personal injury keep hands and feet away from cylinder and workpiece during operation. WARNING: Do not exceed equipment ratings. Never attempt to lift a load weighing more than the capacity of the cylinder. Overloading causes equipment failure and possible personal injury. The cylinders are designed for a max. pressure of 700 bar [10,000 psi]. Do not connect a jack or cylinder to a pump with a higher pressure rating. 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 personal 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. It is your window to what is happening in the system. 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 internally damage the hose leading to premature hose failure. rupture. V-82 V-66 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 IMPORTANT: Do not lift hydraulic equipment by the hoses 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 packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance do not expose equipment to temperatures of 65 C [150 F] or higher. Protect hoses and cylinders from weld spatter. DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. WARNING: Only use hydraulic cylinders in a coupled system. Never use a cylinder with unconnected couplers. If the cylinder becomes extremely overloaded, components can fail catastrophically causing severe personal injury.

57 WARNING: BE SURE SETUP IS STABLE BEFORE LIFTING LOAD. Cylinders should be placed on a flat surface that can support the load. Where applicable, use a cylinder base for added stability. Do not weld or otherwise modify the cylinder to attach a base or other support. Avoid situations where loads are not directly centered on the cylinder plunger. Off-center loads produce considerable strain on cylinders and plungers. In addition, the load may slip or fall, causing potentially dangerous results. Distribute the load evenly across the entire saddle surface. Always use a saddle to protect the plunger. IMPORTANT: Hydraulic equipment must only be serviced by a qualified hydraulic technician. For repair service, contact the Authorized ENERPAC Service Center in your area. To protect your warranty, use only ENERPAC oil. WARNING: Immediately replace worn or damaged parts by genuine ENERPAC parts. Standard grade parts will break causing personal injury and property damage. ENERPAC parts are designed to fit properly and withstand high loads. 3.0 DESCRIPTION V-82, V182 and V8F Two-Way Manual Needle Valve V-82 and V182 Designed to operate at 10,000 psi [700 bar] from either port this valve can be used as a shut-off valve or metering valve in hydraulic circuits. V-8F The V-8F valve operates only as a metering valve and features increased metering capability for control of cylinder speed during load lowering. CAUTION: V-8F valves are not designed for use a shutoff valves. 4.0 INSTALLATION 1. For most applications, including load holding, install the valve so that the load pressure acts against the seat, not the valve stem seals. This will increase safety and protect the life of the valve. Install V-82, V-182, and V-8F valves so that the direction of flow is the same as the direction of the arrow on the side of the valve. Install V-66, V-66NV and V-66F valves so that the fitting from the check ball port is plumbed directly into the cylinder port. 2. Use correct fittings. V-82 and V-8F valves have 3/8 NPT male fittings. V-66, V-66NV and V66F valves have 3/8 NPT male fitting attached. V-182 valves have 1/4 NPT fittings. 3. Use 11/2 wraps of teflon tape (or similar thread sealant) on fittings, leaving the first complete thread free of tape or sealant to prevent sealant from entering the hydraulic system. Tighten fittings securely. CAUTION: Connections should be snug and leak-free. Overtightening connections promotes thread failure and may cause high pressure fittings to rupture at less than rated capacity. WARNING: Shut-off and safety valves should be closecoupled to cylinders. NEVER allow pressurized hoses in a load-holding circuit. 4. Tighten handle to close valve. Loosen handle to open valve. NOTE: V-8F and V-66F valves have knurled knobs rather than handles. WARNING: Turn handle only as far as the stop. Overtightening or subjecting the handle to excessive force will weaken and strip internal spindle threads, creating a safety hazard. Use only fingers to tighten knurled knobs. NEVER use extension handles. V-66 and V-66NV Two-way Manual Flow Control Check Valve V-66 and V-66NV When this valve is opened, flow is free in both directions. When this valve is closed, flow is checked from the cylinder. The cylinder port is marked CYL. The V-66 and V-66NV valve can also be used to hold a load in case system pressure is lost. V-66F With careful monitoring of system operation, this valve can be used as a flow control and metering valve for applications requiring slow lowering of loads. 2

58 5.0 SPECIFICATIONS All dimensions in inches [mm] 3

59 Repair Parts Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. Manual Shut-Off Valves V82, V182, V91, AM21 & AM41 L4042 Rev. A 10/12 For Date Codes Beginning with the Letter O To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil. Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product. Figure 1 - Manual Shut-Off Valve Identification V82 V182 V91 AM21 AM41 1

60 Figure 2 - Valve Spindle Assembly TORQUE TO 50 FT-LBS [67.7 Nm] KIT V82K (ASSEMBLED VIEW) BODY OR MANIFOLD (APPEARANCE WILL VARY) Repair Parts List (Refer to figure 2) Item Part Number Qty. Description Item Part Number Qty. Description 1 B O-Ring, Viton 5 1 Dust Cap 2 B Backup Ring 6 1 T-Handle 3 1 Stem 7 1 Set Screw 4 1 Bonnet 8 (not available) 1 Roll Pin, 5/32 x 1/2" Steel Included in V82K Valve Spindle Repair Kit. Items can be ordered separately. Notes: The parts included in the V82K Valve Spindle Repair Kit will fi t all valve models shown in Figure 1 (see previous page). Items 1 and 2 can be ordered seperately if needed. Items 3 through 7 are available only in the V82K repair kit. Item 8 is not available for purchase from Enerpac (obtain part locally). Valve body or manifold is not available as a service part. If damaged, a complete replacment valve must be ordered. 2

61 Valve Spindle Replacement instructions: 1. Relieve all pressure. Be sure that pressure gauge indicates zero (0) psi/bar. 2. Carefully remove roll pin (item 8). Save roll pin for later use during reassembly. 3. Loosen bonnet (item 4). Unscrew and remove old valve assembly (items 1 through 7). 4. Inspect body or manifold for wear and contamination. Note: Use new parts from V82K Valve Spindle Repair Kit during the following steps: 5. Screw the stem (item 3) all the way into the bonnet (item 4). 6. Install stem and bonnet assembly (items 1 through 4) into the body or manifold. 7. Torque the bonnet (item 4) to 50 ft-lbs [67.7 Nm]. 8. Place dust cap (item 5) onto bonnet (item 4) and then place T-handle onto stem. 9. Line-up the set screw (item 7) with the fl at on the stem. Tighten set screw until snug. 10. Reinstall roll pin (item 8) into appropriate hole in body or manifold. NOTES: 3

62 Instruction Sheet V-152 Relief Valve L2290 Rev. C 4/98 IMPORTANT RECEIVING INFORMATION Visually inspect all components for shipping damage. If any shipping damage is found, notify carrier at once. Shipping damage is not covered by warranty. The carrier is responsible for all repair or replacement cost resulting from damage in shipment. SAFETY INFORMATION To avoid personal injury or property damage during system operation, read and follow all CAUTIONS, WARNINGS, and INSTRUCTIONS included with or attached to each product. ENERPAC CANNOT BE HELD RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE USE OF PRODUCT, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION. Contact Enerpac when in doubt as to applications or safety precautions. A WARNING Always wear proper personal protective gear when operating hydraulic equipment (i.e. safety glasses, gloves, etc.). A WARNING The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. A WARNING Make sure that all system components are protected from external sources of damage, such as excessive heat, flame, moving machine parts, sharp edges, and corrosive chemicals. DESCRIPTION Pressure Relief Valve V152: Limits pressure developed by the pump in hydraulic circuit, thus limiting the force imposed on other components. Valve opens whenever preset pressure is reached. Features: 0,9 meter (3 ft.) return line hose kit 3% repeatability bar (800-10,000 psi) adjustment range (1)

63 A A B D C A Pump B Gauge E E C D Cylinder B D V152 Valve C E External Tank Line Typical configurations showing the V152 with single-acting cylinders. OPERATION System pressure is applied to the piston C. The hydraulic pressure on piston C will act against the compression spring B and lift the cone off of the seat, allowing oil to flow through orifice A to tank. The oil passes through the orifice until the oil pressure is equal to the compressive force of the spring. At that time, the cone will move upon the seat. This process is then repeated over and over again. Just enough oil from the system is allowed to pass through the orifice, automatically maintaining the system pressure as set by the valve. B To increase setting, turn the handle clockwise. The handle may be removed to prevent tampering with the valve s settings The V152 is not a load-holding valve. From Pump C A Removable Plug To Tank (2)

64 Repair Parts Sheet A UNIT OF APPLIED POWER INC. L758 Rev. C 08/97 V-152 For date codes beginning with "O". Torque item 10 to ft-lbs. [68-95Nm]. Torque item 5 to ft-lbs. [68-95 Nm]. TO PROTECT YOUR WARRANTY, USE ONLY ENERPAC HYDRAULIC OIL.

65 R Parts List Item Number Part Number Quantity Description 1 R Pressure Plug 2 B O-Ring 3 B O-Ring 4 CB Compression Spring 5 DA Seat 6 CB Valve Body 7 CB Piston Guide 8 CB Piston 9 CB Spring Guide 10 CB Plug 11 CB Spacer 12 CB Back-Up Ring 13 F Wing Nut 14 P Oval Head Machine Screw 15 P Lock Washer 16 P Valve Lever 17 Y Valve Spindle 18 B Ball Indicates items included in and available only as a part of Repair Kit V152K. Australia ENERPAC Applied Power Australia, Ltd. P.O. Box 261 Regents Park Sydney, N.S.W Tel: (61) (2) Fax: (61) (2) CIS Applied Power Moscow Leninsky Prospekt 95A Moscow, Russia Tel: (7)(95) Fax: (7)(95) France, Switzerland, Turkey, Greece, Africa, Middle East ENERPAC S.A. Parc d'activitié du Moulin de Massy 1 rue du Saule trapu, BP200 F Massy CEDEX (Paris) France Tel: (33) Fax: (33) Germany, Scandinavia, Eastern Europe, Austria, Switzerland ENERPAC Applied Power GmbH P.O. Box Mündelheimer Weg Düsseldorf 30 Germany Tel: (49) (211) Fax: (49) (211) /940 Holland, Belgium, and Luxemburg ENERPAC B.V. P.O. Box 269, Storkstraat AG Veenendaal Holland Tel: (31) (318) Fax: (31) (318) / Hong Kong ENERPAC Room No. 907, Workingberg Commercial Building Marble Road, North Point Tel: (852) Fax: (852) India ENERPAC Hydraulics (India) Pvt Ltd. 203 Vardhaman Chamber Plot #84, Sector 17 Vashi, New Bombay India Tel: Fax: Italy ENERPAC Applied Power Italiana S.p.A. Via Canova, Corsico (Milano) Italy Tel: /2/3 Fax: Japan Applied Power Japan LTD Sasame Kita-cho Toda-City Saitama 335, Japan Tel: Telex: J26275 Fax: Mexico ENERPAC Applied Power Mexico S.A. de C.V. Av. Principal La Paz #100 Fracc. Industrial La Paz Pachuca. Hidalgo, Mexico Tel: (52) Fax: (52) Singapore Applied Power Asia Pte Ltd. 47 Jalan Pemimpin # Sin Cheong Building Singapore 2057 Thomson Road P.O. Box 114 Singapore 9157 Tel: (65) Fax: (65) South Korea ENERPAC Applied Power Korea Ltd , Dodang-Dong Wonmi-gu, Buchun-Shi, Kyunggi-Do Korea Tel: (82) (32) Fax: (82) (32) Spain, Portugal United States, Canada, ENERPAC Latin America and Applied Power International, S.A. Caribbean Calle de la Imprenta, 7 ENERPAC Polígono Industrial West Silver Spring Drive Alcobendas (Madrid) Butler, Wisconsin 53007, USA Spain Tel: (414) Tel: (34) (End User) Fax: ( 34) (Distributor) Fax: (414) United Kingdom, Ireland ENERPAC Ltd. Unit 3 Canada Colemeadow Road Tel: (End User) North Moons Moat Tel: (Distributor) Redditch, Worcester B98 9BP Latin America and Caribbean England Tel: (414) ext. 263 Tel: Fax: (414) Fax: All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them. Under this guarantee, free repair or replacement will be made to your satisfaction. For prompt service, contact your Authorized Enerpac Service Center or call toll free: In U.S.A In Canada PRINTED IN U.S.A.

66 Hydraulic Couplers Shown: FH-604, FR-400, A-630 disassembled, C-604, AH-604, AR-400 Quick Connection of Hydraulic Lines Thread Sealer To seal NPTF threads use one of the new anaerobic thread sealers or Teflon paste. When using Teflon tape, apply the tape one thread back from the end of a fitting to prevent it from entering the hydraulic system. ⅜" High Flow Couplers Standard equipment on most Enerpac cylinders Recommended for use on all Enerpac pumps and cylinders where space and porting permits Include 2-in-1 dust cap for use on male and female coupler halves ⅜" High Flow Flush-face Couplers Featuring Push-to-connect operation, to guarantee good connection every time Flush-face, zero-leak operation for minimal spillage HTMA* recognized for safety and performance ⅜" Regular Spee-D-Coupler For medium duty applications; for use with hand pumps Includes female steel dust cap ¼" Regular Coupler For use with small cylinders and hand pumps Includes female steel dust cap WARNING! Couplers should be pressurized only when completely connected, and should not be coupled or uncoupled when pressurized. More safety instructions in our Yellow Pages. Page: S- and W-Series Torque Wrench Couplers 242 S- and W-Series Torque Wrenches require 1/4" spin-on couplers and THQ hoses. Page: 183 With the use of Enerpac High Flow Couplers, hoses are easily installed for multiple hydraulic line connections in this 34 points PLC-controlled lifting system. * Hydraulic Tool Manufacturers Association 116

67 F-Series Flush-faced couplers provide reduced pressure drop verses other types and are preferred in dirty, grimy construction and mining environments due to easy clean, non-dirt trapping faces. Metal Dust Caps Steel dust caps are available for the C-604 series couplers. Order model number: CD-411M for female half CD-415M for male half Hydraulic Couplers A C F Series Maximum Flow Capacity: 2,500 in 3 /min. A B Thread: ¼" and ⅜" NPTF E C D C Maximum Operating Pressure: 10,000 psi C-604 F G E C F-604 E C F A D A D B G B C C CT-604 Safety Tool Use the Enerpac CT-604 to relieve hydraulic back pressure by safely bleeding the hydraulic coupler. Minimize injuries from projectile parts and under-skin hydraulic fluid injections by eliminating unsafe coupler bleeding practices. The CT-604 is Enerpac-engineering safe for use at 10,000 psi (700 bar). NOTE: C-Series only. F A-604, A-630 Maximum Flow Capacity (in 3 /min) Coupler Type Complete Set Model Numbers Female Half Male Half Dimensions (in) A* B C D E F G Dust Cap(s) 2,500 2,500 High Flow Coupler Flush-face coupler C-604 F-604 CR-400 FR-400 CH-604 FH ⅜" NPTF ⅜" NPTF (2x) CD-411 Included 462 Regular Spee-D-Coupler A-604 AR-400 AH ⅜" NPTF Z-410 female only Included 462 Regular Coupler A-630 AR-630 AH ¼" NPTF Z-640 female only * Value A is total length when male and female halves are connected. Included 117

68 English Metric CT-604 Safety Tool Enerpac coupler bleed tool eliminates unsafe pressure relieving and bleeding activities such as: using a hammer and punch to unseat check balls, cones & poppets using a wrench to loosen a coupler. Coupler Bleed Tool Model Number Fits on High Flow Couplers Maximum Operating Pressure Female Half Male Half psi bar CT-604 CR-400 CH

69 Instruction Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. CT-604 Hydraulic Coupler Bleed Tool L2755 Rev. C 02/11 Index: English Français Deutsch Italiano Español Nederlands Portuguese Finnish Norwegian Swedish IMPORTANT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. Shipping damage is not covered by warranty. If shipping damage is found, notify carrier at once. The carrier is responsible for all repair and replacement costs resulting from damage in shipment. 2.0 INTENDED USE The Enerpac CT-604 coupler bleed tool is designed to safely relieve pressure from hydraulically locked highfl ow hydraulic couplers, Enerpac coupler models CH- 604 (male half), CR-400 (female half) and C-604 (male and female set). 3.0 SAFETY ISSUES Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic safety, consult your distribution or service center for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. A CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of equipment or other property. A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury. A DANGER is only used when your action or lack of action may cause serious injury or even death. WARNING: Wear proper personal protective gear when operating hydraulic equipment. 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 personal 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. It is your window to what is happening in the system. 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 internally 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. DANGER: Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. IMPORTANT: Hydraulic equipment must only be serviced by a qualifi ed hydraulic technician. For repair service, contact the Authorized ENERPAC Service Center in your area. To protect your warranty, use only ENERPAC oil. WARNING: Immediately replace worn or damaged parts with genuine ENERPAC parts. Standard grade parts will break causing personal injury and property damage. ENERPAC parts are designed to fi t properly and withstand high loads. 1

70 4.0 INSTRUCTIONS DANGER: Never attempt to relieve hydraulic pressure by loosening a coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly with great force. Serious personal injury or death will result if the coupler becomes a projectile and strikes persons working in the area. WARNING! Loosening a coupler may result in an escape of high pressure oil that can penetrate the skin. Serious personal injury or death can result. Always use coupler bleed tool to safely depressurize and remove couplers. WARNING! Be sure that loads are supported with blocking and cribbing before using bleed tool. Actuator movement may occur when hydraulic pressure is relieved. Serious personal injury or death could occur if load shifts or drops. WARNING! The CT-604 coupler bleed tool is designed for a maximum hydraulic pressure of 10,000 psi [700 bar]. Do not use the tool on systems and components operating at higher pressures. Depressurize a hydraulically-locked coupler as described in the following steps: 1. I f the hydraulic device is supporting a load, block and crib the load as required, so that the load will not shift or drop when hydraulic pressure is relieved. 2. Check that the threads on the coupler half to be depressurized are clean and in good condition. Do not attempt to bleed a coupler if threads are damaged. 3. Check that all threads on the bleed tool main body and cap/bolt assemblies are clean and in good condition. Do not use bleed tool if threads are damaged. Note: Hand-tighten the bleed tool main body onto the coupler half as described in steps 4 and 5. See Figure 1, below. Note: The bleed tool main body is marked male coupler on one end and female coupler on the other. Be sure to use the proper end. 4. If bleeding a male coupler half: Thread the bleed tool main body onto the male coupler half and tighten it hand-tight. 5. If bleeding a female coupler half: Thread the bleed tool main body into the retaining collar of the female coupler half. Tighten the retaining collar hand-tight. 6. The bleed tool includes two cap/bolt assemblies as shown in Figure 1, below. Be sure to use the correct one: For MALE coupler halves, use the cap/bolt assembly with the SHORT bolt. For FEMALE coupler halves, use the cap/bolt assembly with the LONG bolt. Note: Before proceeding, ensure that the cap is tight on the bolt. 7. Thread the cap/bolt assembly into the bleed tool main body. Slowly turn the cap/bolt assembly clockwise until the coupler check ball opens and hydraulic pressure is relieved. If necessary, use an adjustable wrench on the bolt. Note: When the cap/bolt assembly is tightened, pressurized hydraulic oil will fl ow through the bleed tool main body and into the cap. Allow any excess oil to drain into a suitable container. 8. Remove coupler half, main body and cap/bolt assembly from the hydraulic device (manifold, cylinder, etc.) as a complete unit. Important: Keep bleed tool parts installed on coupler while it is being loosened and removed. 9. Disassemble bleed tool components from the coupler half. Clean bleed tool components and store in provided container. CAUTION: Discard the coupler half removed in the previous steps. Never attempt to repair or reuse a worn or damaged coupler! Figure 1 Male Coupler Half Short Cap/Bolt Assy (use with male coupler halves) Long Cap/Bolt Assy (use with female coupler halves) Main Body Female Coupler Half 2