Figure 1A: WalkPac Battery Powered Pump

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1 Repair Parts Sheet A UNIT OF APPLIED POWER INC. L-864 Rev. D 06/98 PC2805 WalkPac Portable Pump Date code starting with "O" 40 Warning: To avoid possible injury or death read all instructions. 42 Contents CAUTION: Before attempting to separate the case halves, remove all 8 outer case screws, including the screw and nut located behind the WalkPac decals. WARNING: To ensure that the internal relief valve setting is correct, check the model number when servicing the product. The setting may require adjustment based on the pressure setting designated by the dash code (-XXXX) of the model number. Pump Side View Case Assembly Pump Assembly Figure A: WalkPac Battery Powered Pump Manual Valve Assembly Pendant Assembly Electrical Schematic

2 NOTE: Make sure wires are not pinched during reassembly. Install perimeter screws following reservoir screws and starting with the front 55 upper screw. Figure B: Side View During reassembly, install reservoir screws first to ensure that case halves align properly CAUTION: Do not remove coupler fitting, item, without first separating case 34 halves and removing setscrew, item 5 (see View A-A). A A NOTE: Hold coupler fitting, item, using a wrench on the flats when installing or removing the hose or coupler. Torque hose or coupler to ft-lbs [40,7-43,4 Nm.]. Seal threads with Loctite 545. Section B-B Item : Torque to 0-2 ft-lbs. [3,6-6,3 Nm.] with Loctite pipe sealant 545. Item 3: Torque to 5-9 [,70-2,5 Nm] in-lbs with Loctite 290. Crown of nut (item 3) must face grommet (item 2). Item 5: Attach bumpers using Loctite GEL 454. View A-A 47 Pump Body Valve Body B CAUTION: Do not disassemble the valve assembly Stud to be assembled flush to pump surface or below surface with Loctite sealant B Torque to ft-lbs. [20,3-27, Nm.] Torque to in-lbs. [5,09-6,22 Nm.] with Loctite 242. Front View 3** 2

3 Repair Parts List for Figure DA Coupler Fitting 2 DA Grommet 3 DA Jam Nut 4 DA Manual Valve (See Figure 4) 4 DA Dump Valve 4 DA Dump and Hold Valve 5 DA Bumper 6 DA Self Threading Nut 7 DA Relay 8 DA Fitting, (.375 ID Tube) 9 DA Isolator 0 DA Vent Tubing (.250 ID) CBE05020-D 3 Hex Nut 2 DA56268 Fill Tubing (.375 ID) 3 DA Bushing 4 DA02222SR Pump Assembly (See Figure 3) Includes motor 5 DA652900SR Auxiliary Reservoir (incl. items 0, 2, 42) 6 DA SR Contact Assembly (incl. item ) 7 DA954440SR Battery Receptacle (incl. items 6,, 6, 8, 50) 8 DA97750 Ejection Spring 9 DA SR Vent Fill Cap Assembly (incl. item 54) 20 DA Control Board and Switch Assembly (Dump and Hold Valves) 20 DA87900 Control Board and Switch Assemlby (Manual and Dump Valves) 22 DA Electrical Receptacle 28 DA96302 Nylon Locknut 30 DA Stud 35 DA28222 Cap Nut 36 HB03803 O-Ring 37 HB02803 O-Ring 40 HCH Warning Decal 42 HDA Walk-Pac Decal 43 HDA Gasket 44 E0087 Connector 45 E00020 Ring Connector 46 DA Female Connector 47 B Wire ( 8 AWG)t 49 DA Elbow (.250 ID Tube) 50 DA08020 Spring 5 CCA C Set Screw 53 A Clamp (Vent Tube) 54 HDA Gasket 55 B03503 O-Ring H Items included in Repair Kit WPPK. 3

4 Figure 2: Case Assembly and Battery Box 50* 8* 6* SECTION A-A Top View 7* 39 A A Used only on models with manual valves. Black Orange - + Bottom View Torque to 0-4 in-lbs. [,3-,58 Nm.] * See Repair Parts List for Figure on page 3. Orange 2 Gauge Blue Orange Motor 2 Gauge Repair Parts List for Figure 2 CBE05020-D 7 Hex Nut - M5 2 2 DC539530SR DC539530SR Yellow Case Halves - Electric Valves Yellow Case Half - Manual Valves 24 CAE A 7 Screw - M5 x 50 mm 25 DA Hanger 26 DA Support Post 27 CAE A 2 Screw - M5 x 2 mm 34 DA Grommet (Manual Valve Models Only) 39 DA36009 Hole Plug (Manual Valve Models Only) 4

5 Figure 3: Pump Assembly NOTE: DO NOT DISASSEMBLE THE PUMP ASSEMBLY. The repair kit does not contain all parts necessary for re-assembly. Repair Parts List for Figure 3 DC24259SR Electric Motor 2 DC25053 Magnet 3 DC268 Filter 4 HB O-Ring 5 DC Tube 7 HDC O-Ring 20 HDC U-Sit Ring 2 DC Torque Screw 22 DC205900SR Relief Valve 23 HDC Gasket H Items included in Repair Kit WPPK. NOTE: #22 contains repair kit WPPK. 5

6 Figure 4: Manual Valve Assembly 2 B B D D Apply Loctite 222 to threads. 6 7 Crown of nut (item 0) must face grommet (item ) SECTION B-B SECTION D-D Repair Parts List for Figure 4 DA024900SR Valve Assembly 2 F Expander Plug 3 DA Knob 4 DA96500 Spindle 5 HB /32 " Ball 6 HDA Screw 7 CCA C Set Screw 8 HB O-Ring 9 HB O-Ring 0 DA Jam Nut (Figure ) DA Grommet (Figure ) 2 DA Coupler Fitting (Figure ) 6

7 7 2 Figure 5: Pendant Assembly 6 5 RP WIRING CODE CHART "MANUAL" SWITCH TERMINAL WIRE COLOR N.O. WHITE CENTER POSITION GREEN WIRING CODE CHART "PRESSURE" SWITCH TERMINAL WIRE COLOR N.O. WHITE CENTER POSITION GREEN WIRING CODE CHART "RELEASE" SWITCH TERMINAL WIRE COLOR N.O. RED CENTER POSITION GREEN "JUMPER" Wiring Chart (Dump or Manual) Switch Terminal Wire Color Normally Open White Center Position Green Repair Parts List for Figure 6 RP 2-Position Pendant DA32390 Pendant Body 2 DA06379 Pushbutton 3 DA Strain Relief 4 DA Electric Cord Assembly 5 DA000 Mounting Plate 6 DC Pop Rivet 7 DA02689 Boot Guard RP2 3-Position Pendant DA32390 Pendant Body 2 DA Pushbutton 3 DA Strain Relief 4 DA Electric Cord Assembly 5 DA00 Mounting Plate 6 DC Pop Rivet 7 DA Boot Guard 8 B Wire 7

8 R Figure 6: Electrical Schematic +24V PRESSURE 4 PINK WHITE 2 RELEASE LAMP 3 RED VIOLET PENDANT CONNECTOR BLACK GND BLACK 2GA WIRE W2 VIOLET BATTERY RECEPTACLE +24V 2GA WIRE W2 RED W3 W4 WHITE PINK PC BOARD W5 W7 W6 W3 W9 TEST W4 W0 POINTS W W W8 BLACK GREY BROWN GREEN BLUE YELLOW BLUE WHITE 2GA WIRE SUPPLY ON MOTOR RELAY BLACK 2GA WIRE SUPPLY ON MOTOR YELLOW DUMP & HOLD AND DUMP VALVE 2 4 PRESSURE TRANSMITTER DC MOTOR NOTE:.) ALL WIRES ARE TO BE 22 AWG WIRE UNLESS OTHERWISE SPECIFIED. Australia Block V, Unit 3 Regents Park Estate 39 Park Road Regents Park NSW 243 Tel: (6) (2) Fax: Belgium, Holland, and Luxemburg B.V. P.O. Box 269, Storkstraat AG Veenendaal Holland Tel: (038) 5359 Fax: (038) or Canada 3000 West Silver Spring Drive Butler, Wisconsin 53007, USA Tel: (800) User Tel: (800) Distributor Fax: (44) CIS Applied Power Moscow Leninski Prospekt 95A 733 Moscow Tel: (095) Fax: (095) Eastern Europe and Other European Countries, Middle East, and Africa 47, avenue Blanc P.O. Box 67, CH-2 Geneva 2, Switzerland Tel: (4) Telex: Fax: (4) Far East 47 Jalan Pemimpin #0-02 & 0-03 Sin Cheong Building Singapore 2057 Thomson Road P.O. Box 4 Singapore 957 Tel: (65) Telex: RS24882 APOWR Fax: (65) France B.P. 200 Parc d'activitiés du Moulin de Massy 9882 Massy Cedex, France Tel: (33) Fax: (33) Germany Mündelheimer Weg 5 P.O. Box D-4040 Düsseldorf 30 Tel: (49) (22) Telex: Fax: (49) (2) Italy Via Canova, Corsico Milano, Italy Tel: Fax: Hongkong Room No. 907, Workingberg Commercial Building 4-47 Marble Road, North Point Tel: (852) Fax: (852) India Hydraulic Technology (India) Pvt Ltd 203 Vardhaman Chamber Plot #84, Sector 7 Vashi, New Bombay Maharashtra Tel: Fax: Japan Applied Power Japan 0-7 Sasame Kita-cho, Toda-Shi Saitama 335, Japan Tel: (Administration) (Sales) Telex: J26275 Fax: Latin America and Caribbean 3000 West Silver Spring Drive Butler, Wisconsin Tel: (44) ext. 263 Fax: (44) Mexico Blvd. Gral. Felipe Angeles 604 P.O. Box 362 Pachuca. Hidalgo Mexico Tel: (52) Fax: (52) or (52) South Korea 63-2, Dodang-Dong Wonmi-Ku, Buchun-Shi, Kyunggi-Do Republic of Korea Tel: (82) (32) Fax: (82) (32) All 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. Spain Calle de la Imprenta, 7 Poligono Industrial 2800 Alcobendas, Madrid Spain Tel: (34) Fax: ( 34) United Kingdom Leacon Road Ashford, Kent TN23 4TU England Tel: Telex: Fax: United States 3000 West Silver Spring Drive Butler, Wisconsin 53007, USA Tel: (44) (End User) (Distributor) Fax: (44) For prompt service, contact your Authorized Service Center or call toll free: In U.S.A In Canada RECYCLED PAPER PRINTED IN U.S.A.