AIR/HYDRAULIC INJECTION GUN MODEL INSTRUCTIONS

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1 I. OPERATION & DESCRIPTION The Air / Hydraulic Injection Gun is a high-pressure tool that should be used with caution and according to these instructions. IMPORTANT: The Gun is 0,000 psi rated. Do not exceed 0,000 psi. This Injection Gun transmits material by the use of compressed air as a power source against pressurized hydraulic fluid. One end of the Injection Gun is the Pump containing hydraulic fluid. The other end of the Gun is the Grease Barrel. The Barrel and the Pump are separated by the Gun Body, Hose and other components. During operation, air pressure forces hydraulic fluid from the Pump through the Hose and Body into the space behind the Piston located in the Grease Barrel. The Piston pushes the material out through the Grease Barrel Cap. Numerous options are available for Grease Barrel Cap attachments to transmit material to the desired pump, valve or other equipment. A. To activate the Pump refer to Enerpac. B. To hold Load Pressure refer to Enerpac. C. To release Load Pressure refer to Enerpac. The Handle has a side hole near the threaded end, which will fit over the pin in the Grease Barrel Cap. Using the Handle in this manner makes it a convenient tool to loosen and tighten the Cap. The Handle is marked with approximate -ounce graduations for measuring material. The Handle can be used for pushing the Piston to bottom of Grease Barrel when all material has been transmitted out of the Barrel. To ensure the Air / Hydraulic Injection Gun will perform and operate properly, use after use, keep the gun out of the weather, clean and maintained. II. A. PRIMING THE PUMP B. AIR FILTER REPLACEMENT C. MAINTENANCE D. TROUBLESHOOTING Refer to Enerpac. III. LOADING Each new Air / Hydraulic Inject Gun is ready to use, following this procedure: A. Make sure the Pump cylinder is retracted and the Pump is deactivated and all pressure is released. B. To facilitate easy material loading into Grease Barrel, turn the complete unit 0 onto the frame end plate. C. Remove Grease Barrel Cap with Handle as previously described in I. D. Using Handle push Piston Assembly to bottom of Grease Barrel so it will be flush against Body. E. Load the Barrel with material (Lubricant, Packing, Sealant or Cleaner), in either bulk, prepackaged or stick. F. Replace Grease Barrel Cap and tighten with Handle. G. Replace Handle onto Body and the Gun is ready to operate. Be sure to have the appropriate material transmission apparatus or hose assembly firmly attached to the Grease Barrel Cap. To load from a cartridge, see Material Loaded. IMPORTANT: Always make sure the Grease Barrel Cap is firmly attached to the Grease Barrel and be sure there is full thread engagement between these two parts before each Gun operation. Optional Parts and Tools, including in-line Air Filter/Lubricator, are available. IV. MAINTENANCE Any repair or servicing that requires disassembly of the Injection Gun must be performed in a dirt-free environment by a qualified technician. Dispose of used parts and fluids properly. Page

2 ITEM. INJECTION FLUID The Air / Hydraulic Injection Gun comes filled with Enerpac hydraulic oil. Oil should be added or replaced as necessary using only Enerpac hydraulic oil. Do not contaminate or use any other fluid. Check the oil level in the Pump reservoir after every 0 hours of use. Drain and replenish the Pump reservoir with Enerpac hydraulic oil as specified. The oil is available in several size containers up to -gallon drums. WARNING: Read Material Safety Data Sheet before use. ITEM. REFILLING THE AIR / HYDRAULIC INJECTION GUN PUMP WITH INJECTION FLUID AND PURGING THE SYSTEM OF AIR A. During the first moments of operation or after prolonged use, a significant amount of air may accumulate within the system. This entrapped air may cause the cylinder to respond slowly or behave in an unstable manner. To remove the air, run the system through several cycles (extending and retracting the cylinder) free of any load. The cylinder must be at a lower level than the Pump to allow air to be release through the Pump reservoir. B. Clean the entire area around the Pump filter plug before adding fluid to the Pump reservoir. Remove the Pump filter plug and insert a clean funnel with filter. The cylinder must be fully retracted and the air supply disconnected when adding the fluid to the Pump reservoir. C. Refer to Enerpac. ITEM 3. LUBRICATION If the Gun is operated on continuous cycles for extended periods, it is recommended that an automatic Air Filter / Lubricator be installed on the air inlet line as close to the Pump as possible. Set the Lubricator to fee approximately one drop of oil per minute into the system. Use SAE No. 0 oil. ITEM. PERIODIC CLEANING IMPORTANT: The greatest single cause of failure in hydraulic pumps is dirt. Keep the Pump and attached equipment clean to prevent foreign matter from entering the system. A routine should be established to keep the Pump as free from dirt as possible. All unused couplers must be sealed with thread protectors. All hose connections must be free of grit and grime. Any equipment hooked up to the Pump should also be kept clean. Use only Enerpac hydraulic oil in this Pump and change as recommended. Refer to Enerpac Instruction sheet. ITEM. DRAINING AND FLUSHING THE PUMP RESERVOIR IMPORTANT: Wipe the Pump exterior completely clean before attempting this procedure! Refer to Enerpac Instruction sheet. IMPORTANT: Drain and clean the other hydraulic system components (hoses, cylinders, etc.) before reconnecting them to the Pump. This will prevent contaminated fluid from entering the Pump again. IMPORTANT: Warranty will be voided if the Pump Internal Relief Valve or other Gun components are altered, disassembled, or tampered with. WARNING: Be familiar with all product and pump warranties, maintenance/care procedures and warnings before use. Continuous use at high pressures will shorten the pump life, accelerate wear and tear and void the warranty. For maximum efficiency, long term performance and long life, it is recommended that 0% of operating capacity not be exceeded. Always wear proper personal protective gear when operating hydraulic equipment, such as safety glasses, gloves, etc. Page

3 0 3 No. Description Pump Hydraulic Hose Elbow Frame Piston Return Tube / Cap Wrench Clip Assembly, Includes: Handle Clip ( Required) Pan Head Screw ( Required) Lock Washer ( Required) Cradle Assembly Barrel Assembly Pump Fastener Assembly, Includes: Cap Screw ( Required) Washer ( Required) Nut ( Required) Quick Connect Coupler Quick Connect Plug Elbow NOTE: HOSE ASSEMBLY AND CASE ARE INTEGRAL COMPONENTS OF AIR / HYDRAULIC INJECTION GUN - MODEL 000. FRAME CARRYING CASE Page 3

4 BARREL ASSEMBLY No Description Barrel Assembly Grease Barrel K Body O Ring ( Required) Grease Barrel Cap Plastic Protective Plug Piston Assembly Piston Leather Cup ( Required) O Ring ( Required) Washer Nut ( Required) Gasket Cap Screw CRADLE ASSEMBLY No. 3 Description Cradle Top Plate ( Required) Barrel Cradle (top and bottom) ( Required) Hex Nut 7/ - w/nylon Insert, SS ( Required) Hex Head Cap Screw 7/ - x 3 / lg., SS ( Required) Page

5 AIR/HYDRAULIC INJECTION GUN HOSE ASSEMBLY No Description Hose Assembly Hose 7 O.A.L. / NPT(m) x / UNS Taper (f) x 3/ I.D. Z Swivel Gage Tee,000 PSI Gage Gage Cover Swivel Shut Off / Relief Valve G. B. Coupler Page

6 IMPORTANT RECEIVING INSTRUCTIONS 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 costs resulting from damage in shipment. DESCRIPTION These air-powered hydraulic pumps are designed for use with single-acting cylinders and tools. The pump treadle may be operated by hand or foot for greater versatility. Swivel connection simplifies hydraulic connection and pump operation. 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. CANNOT BE 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 safety precautions or applications. WARNING: Always wear proper personal protective gear when operating hydraulic equipment (i.e. safety glasses, gloves, etc.). WARNING: The system operating pressure must not exceed the pressure rating of the lowest rated component in the system. 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. WARNING: Disconnect air supply when pump is not in use. NEVER remove swivel air connector while air line is pressurized. WARNING: The pump is equipped with an overload valve, preset for maximum operating pressure. DO NOT attempt to adjust the overload valve. If adjustment is required, contact an Enerpac Service Center. Adjustment by other than qualified personnel may cause malfunction, damage to the system and/or personal injury. Page

7 Model No. PA-33, 700 PA- PA-0 Air Pressure Air Consumption Oil Flow at 00 PSI Air Usable Oil Capacity Weight dba 0-00 PSI (. -. bar) CFM ( m 3 /h) 0 cu. in/min at 0 PSI ( cu. cm/min at 0 bar) cu. in/min at 0,000 PSI (3 cu cm/min at 700 bar) 3 cu. in (0 cu. cm) 7 cu. in (0 cu. cm) 0 cu. in (3 cu. cm) lb. (. kg) lb. (7.7 kg) lb. (. kg) dba INSTALLATION Adding Oil to the Reservoir:. Hold pump on end as shown in Figure and remove fill plug. On PA-0 models, the fill plug is located on the side of the pump as shown in Figure. FIGURE FIGURE. Fill to / ( cm) below the fill opening with Enerpac hydraulic oil. Use of fluids other than Enerpac hydrau- oil may cause damage and will void your warranty. WARNING: Attempting to overfill the reservoir will cause the reservoir to become pressurized. If the reservoir is subjected to high pressure, the casing may rupture, causing personal injury and/or equipment damage. lic 3. Replace the fill plug and finger tighten. CAUTION: DO NOT use a wrench. Over-tightening will tear the reservoir bladder.. Tip the pump and check for leakage. If leakage occurs, remove the plug and check the plug seal for cuts or nicks. Replace the seal if necessary,. Replace the fill plug making sure the seal is centered properly on the plug. If leakage still occurs, remove oil and take pump to your nearest Enerpac Service Center. Page 7

8 CONNECT HYDRAULIC HOSE. See Figure 3. Remove pipe plug from the female 3/ NPTF hydraulic swivel connector (A) and install the male end of a 3/ NPTF hydraulic fitting. The fitting can be a high flow coupler, hose, or gauge adaptor. NOTE: Enerpac recommends installing a gauge in line to monitor hydraulic system pressure. FIGURE 3. Seal connection with a high-grade pipe thread sealer, such as teflon tape. NOTE: Use / wraps of teflon tape, leaving the first thread bare to prevent tape from shedding into the hydraulic system and causing damage. See Figure. 3. Tighten pipe connections securely, but DO NOT over-tighten. CONNECT THE AIR SUPPLY FIGURE Recommended are inlet pressure is 0-00 psi (. -. bar).. See Figure. Connect a CFM ( m 3 /h) (minimum) air supple source to the / (0. cm) NPTF pump air inlet swivel connector (B). Use only / (0. cm) B hose or quick disconnect fittings. Larger, heavier fittings are not recommended. Use a high-grade pipe thread sealer to seal the connection. FIGURE. Tighten pipe connections securely, but DO NOT OVER-TIGHTEN. NOTE: To promote long, trouble free pump operation, install an Enerpac air filter regulator in the air line. ADJUST HYDRAULIC PRESSURE The hydraulic pressure output of your air pump is controlled by the air pressure into the pump. Increasing the air inlet pressure will increase hydraulic output pressure and decreasing air inlet pressure will decrease the hydraulic output pressure. WARNING: NEVER remove swivel air connector while air line is pressurized. Removing a pressurized air line may lead to personal injury or equipment damage. AUTOMATIC PRESSURE MAKE-UP. Adjust the air inlet pressure to the pump so that the hydraulic pressure output at stall corresponds to the desired circuit pressure.. Secure the treadle in the advance position. (A treadle clip is supplied with the PA-3 and PA-0). 3. With the air supply pressure continuously applied to the air motor, the pump will automatically cycle when ever circuit hydraulic pressure drops below the pump stall pressure. NOTE: These pumps are not recommended for extended stall cycles. CAUTION: The treadle should only be tied down when continuous oil flow is required to maintain constant pressure. DO NOT tie treadle for normal pump start/stop operations. Page

9 OPERATION ADVANCE. Check the oil level in the pump and add oil if necessary.. Check to make sure all air and hydraulic connections are secure before operating pump. To Activate the Pump: NEUTRAL Depress the ADVANCE end of the treadle as shown in Figure and the air motor will be activated to pump hydraulic oil to the system. To Hold Load Pressure: The air motor will stop and hold load pressure when the treadle is in the free NEUTRAL position. See Figure. RELEASE To Release Load Pressure: To release load pressure or retract a cylinder, depress the RELEASE end of the treadle as shown in Figure. PRIMING THE PUMP FIGURE If pump does not operate properly, it may have lost its prime. Follow the procedure below to prime your pump, if necessary:. Fill pump with Enerpac hydraulic oil, if necessary. See filling instructions on page 7.. Place pump on horizontal surface. 3. Set air supply pressure to 30-0 psi (. -.7 bar).. Move pump treadle to RELEASE position.. Depress the button under the treadle to activate pump. Operate pump in RELEASE position momentarily several times to allow oil to flow back into pump and fill passage ways.. To verify that pump is primed, operate as normal with cylinder attached. If cylinder does not advance, repeat step. If pump still does not deliver oil, contact your Authorized Enerpac Service Center. Page

10 AIR FILTER REPLACEMENT If the air motor does not perform as normal, check for a clogged air filter.. Shut off air pressure to the pump and release pressure in the line to the pump. WARNING: NEVER remove swivel air connector while air line is pressurized.. Note the position of the retaining clip. It can only be secured by the smallest tang of the metal retainer. Grasp air line with one hand and pull the retaining clip with pliers. 3. Pull the swivel air connector out.. Carefully remove air filter.. Clean air filter with an air hose or replace with a new air filter.. Re-insert the air filter. 7. Put a thin film of grease on the o-ring of the swivel air connector.. Reassemble the swivel air connector and retaining clip. Be sure that clip is secured on the smallest tang of the metal retainer.. Check to make sure the swivel air connector is securely attached before turning the air pressure back on. MAINTENANCE STORAGE. 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.. Periodically check the hydraulic oil level in your system. See filling instructions on page Change hydraulic oil after every 00 hours of operation. In dusty or dirty areas, it may be necessary to change the oil more frequently. To change the oil, drain used oil through the fill opening and fill reservoir to / (0. cm) below the fill opening with clean Enerpac hydraulic oil. Dispose of used oil in accordance with local regulations. WARNING: The pump is equipped with an overload valve, preset for maximum operating pressure. DO NOT attempt to adjust the overload valve. If adjustment is required, contact an Enerpac Service Center. Adjustment by other than qualified personnel may cause malfunction, damage to the system and/or personal injury. When the unit will be stored for 30 days or more:. Wipe the entire unit clean.. Disconnect all air pressure and hydraulic lines to prevent accidental operation. 3. Cover the unit.. Store in a clean, dry environment. DO NOT expose equipment to extreme temperatures. Page 0

11 TROUBLE SHOOTING The following information is intended as an aid in determining if a problem exists. DO NOT disassemble the pump. For repair service, contact the Authorized Enerpac Service Center in your area. Problem Pump fails to deliver oil. Pump nose. Possible Cause Low fluid level. Lack of air pressure. Pump has lost its prime. Low fluid level. Lack of air pressure. Air motor section requires lubrication. Solution Check the oil level and add oil according to instructions on page 7. Check air filter and replace if necessary. Check air line and filter-regulator for obstructions or leaks. Check for damage to air motor. Prime the pump according to the instructions on page. Check the oil level and add oil according to instructions on page 7. Check air filter and replace if necessary. Check air line and filter-regulator for obstructions or leaks. Check for damage to air motor. Place a few drops of oil in the air inlet port and cycle the motor several times to distribute the oil. Oil leakage. Worn or damaged parts. Loose connections. Reservoir bladder torn. Contact your local Authorized Enerpac Service Center for repairs. Check that all connections are tight. Have reservoir bladder replaced by a qualified hydraulic technician. For prompt service, contact your Authorized Enerpac Service Center or call toll free: In U.S.A In Canada Page Supplying the Highest Quality Products to the Valve Industry #30, 0 - St Edmonton, AB TP 0B GRMFLOW.COM IST_000_/

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