Instruction Sheet 1 1/8 HP TITAN PUMPS SAFETY FIRST

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Instruction Sheet 1 1/8 HP TITAN PUMPS L1824 Rev. D 06/04 1.0 IMPORTANT RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. Shipping damage is not covered by warranty.

Repair Parts Sheets for this product are available from the Enerpac web site at www.enerpac.com, or from your nearest Authorized Enerpac Service Center G e n e s ior s SEnerpac e r i e s Sales office.

1 Instruction Sheet 1 1/8 HP TITAN PUMPS L1824 Rev. D 06/ 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. Repair Parts Sheets for this product are available from the Enerpac web site at or from your nearest Authorized Enerpac Service Center G e n e s ior s SEnerpac e r i e s Sales office. Index: English Italiano SAFETY FIRST 2.0 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. 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. 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.

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.

Excessive heat will soften packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packings.

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.

2 Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture. IMPORTANT: Do not lift hydraulic equipment by the 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. 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. WARNING: Do not use electric pumps in an explosive atmosphere. Adhere to all local and national electrical codes. WARNING: Titan pumps have an internal relief valve installed under the pump cover. This relief valve is factory adjusted and must not be repaired or adjusted except by qualified hydraulic technicians. CAUTION: To prevent damage to pump electric motor, check specifications. Using incorrect power source will damage the motor. 3.0 SPECIFICATIONS SEE TABLE BELOW Specification "B" Version "E" Version Operating Pressure 0-10,000 psi (700 bar) maximum Electrical Power Source 30 Amp/115 Volt Grounded 15 Amp/230 Volt single-phase, Hz single-phase, Hz Motor Rating 11/8 HP Universal Motor, 0.84 kw Universal Motor, 25 psi (700 Bar) and 12,000 RPM 12.5 psi (700 Bar) and 12,000 RPM operates at Volts, dba operates at Volts, dba Flow Rate Unloading (or Bypass) Pressure Operating Oil Temperature Reservoir Capacity Shipping Weight 640 in 3 /min (10,5 0 psi (0 bar) 60 in 3 /min (10,0 10,000 psi (700 bar) 1600 psi 150 F (65.5 C) maximum for operation below 32 F (0- ) C), change oil to MIL-H-5606 (see page 8 for procedure) 1.3, 2.4, 5.2, 10.4 gallon (5, 9, 20, 40 liter) 150 F(65.5 C) maximum 53 lbs. to 165 lbs (116,6 kg to 363 kg) depending on valve and reservoir configuration 2

4.0 INSTALLATION 4.1 Attach Hydraulic Hoses Thread hose(s) or coupler(s) into outlet port(s) of the valve "A" (see Figure 1).

Pumps with 3-way valves have one outlet port, and pumps with 4-way valves have two outlet ports.

2 Install Oil Level Gauge For shipping purposes, a plug is installed in the fill hole on the top of the reservoir.

(See Figure 3). Remove Shipping Plug A Figure 3, Shipping Plug Figure 1, Hose Connection 4.

3 4.0 INSTALLATION 4.1 Attach Hydraulic Hoses Thread hose(s) or coupler(s) into outlet port(s) of the valve "A" (see Figure 1). Use 11/2 wraps of Teflon tape on the hose fitting, leaving the first complete thread free of tape "B" (see Figure 2). Pumps with 3-way valves have one outlet port, and pumps with 4-way valves have two outlet ports. All hoses and components used with this pump must have a working pressure rating higher than, or equal to, the maximum pressure rating of the pump. 4.2 Install Oil Level Gauge For shipping purposes, a plug is installed in the fill hole on the top of the reservoir. Remove this plug and install the oil level gauge that was shipped with the pump. Never run the pump with the shipping plug installed. This will cause damage to the pumping mechanism. (See Figure 3). Remove Shipping Plug A Figure 3, Shipping Plug Figure 1, Hose Connection 4.3 Attach Control Switch If your pump has a solenoid valve, attach a solenoid valve pendant or foot switch to control the valve using the connector as shown in Figure 4. B Figure 2, Applying Teflon Tape Figure 4, Connector 4.4 Set the Relief Valve (if necessary) The external relief valve is located under a hex cap on top of the pump. It is adjustable from 10,000 psi (700 bar) down to 2000 psi (140 bar). Operating pressure cannot be adjusted to above 10,000 psi (700 bar). To get the most accurate relief valve setting, start at a lower pressure and adjust up to the desired relief valve setting. 3

1. Install a pressure gauge in the pump outlet port. 2. Remove the hex cap covering the relief valve adjustment screw. Loosen locknut.

Stop the pump and adjust the relief setting until it is at the desired pressure. 4. Verify the setting by running the pump several times. 5. Tighten lock nut to secure setting on relief valve. 6.

Use 2 and 3-way valves with single-acting, and 4-way valves with double-acting cylinders or tools. Put valve in the neutral or retract position before starting pump.

5 Check Oil Level Check the oil level prior to start-up and add Enerpac Hydraulic Oil, if n e c e s s a r y. Remove the oil level gauge and add oil through the opening in the top of the reservoir.

4 1. Install a pressure gauge in the pump outlet port. 2. Remove the hex cap covering the relief valve adjustment screw. Loosen locknut. Using an Allen wrench, turn the adjustment screw counter-clockwise one full turn. (See Figure 5.) 3. Turn the pump on and run the pump motor, watching the pressure gauge reading. Stop the pump and adjust the relief setting until it is at the desired pressure. 4. Verify the setting by running the pump several times. 5. Tighten lock nut to secure setting on relief valve. 6. Replace the hex cap to cover the adjusting screw. 5.1 Manual Valves Use the pump mounted manual valve to control the direction of the oil flow. Use 2 and 3-way valves with single-acting, and 4-way valves with double-acting cylinders or tools. Put valve in the neutral or retract position before starting pump. See Figures 7 and 8 for valve positions. Retract Figure 7, VM-2 (3-way) Valves Figure 5, Relief Valve Setting 4.5 Check Oil Level Check the oil level prior to start-up and add Enerpac Hydraulic Oil, if n e c e s s a r y. Remove the oil level gauge and add oil through the opening in the top of the reservoir. IMPORTANT: Add oil only when all system components are in the fully retracted position. If oil is added when plungers are advanced, there will be more oil in the system than the pump can hold. When cylinders are retracted oil in the hoses and cylinders will be returned and the reservoir will be overfilled. IMPORTANT: Be sure to monitor oil level while pump is running. If the oil level is full before running the pump, but becomes low during operation, the reservoir is too small for your application. 5.0 OPERATION Add Oil Empty In Use Figure 6, Oil Level Gauge Full Always check oil level gauge before operating pump. See instructions above. Refer to section below or on page 6 that applies to your pump. Operation is explained for manual valves; dump, dump and hold, and jog pendants; and solenoid valve pendants and foot switches. Retract Neutral Figure 8, VM-3, VM-3L (3-way), VN-4, VM-4L (4-way) Valves 5.2 On-Off Switch Operation The on-off switch is located on the side of the pump shroud. For dump and jog versions, the motor is started by the pendant switch. See page 5 for more operating information. Figure 9, Switch Operation 4

5 Control Type How it Works Manual Valve (see page 4) The shroud ON/OFF switch activates the motor and pump. Oil will flow according to position of manual valve. See page 4 for valve positions. Dump Pendant ADV RET Release to Retract The shroud ON/OFF switch enables the pendant. The pendant controls the motor and the dump valve. The pendant switch is momentary. Pressing "Adv" will start the motor and shift the valve causing the cylinder to advance. When the pendant switch is released, the motor will stop, the dump valve will shift to retract, and the cylinder will retract. Dump and Hold Pendant ADV RET Release to Retract The shroud ON/OFF switch enables the pendant. The pendant controls the motor and the dump valve. The pendant switch is momentary. Pressing "Adv" will start the motor and the cylinder will advance. When the switch is released, the motor will stop and the valve will hold the load in its current position. Pressing "Ret" will shift the valve allowing the cylinder to retract (the motor will not run). Jog Pendant Start Motor The shroud ON/OFF switch enables the pendant. The pendant controls only the motor. The pendant switch is momentary. Pressing "Adv" will start the motor and oil will flow from the pump. The direction of oil flow is controlled by the manual valve position (see page 4 for valve positions). When the switch is released, the motor will stop. Solenoid Valve Pendant The shroud ON/OFF switch enables the pendant and starts the motor. The pendant controls the direction of oil flow. The pendant switch is momentary. Press "Adv" to advance cylinder. When you release the pendant switch, the valve will shift to the neutral position and the cylinder will hold. Press "Ret" to retract the cylinder. Retract Solenoid Valve Foot Switch Retract The shroud ON/OFF switch enables the foot switch and starts the motor. The foot switch controls the direction of oil flow. The foot switch is momentary. Press "Adv" to advance cylinder. When you release the foot switch, the valve will shift to the neutral position. Press "Ret" to retract the cylinder. 5

6 6.0 TROUBLESHOOTING Only qualified hydraulic technicians should service the pump or system components. A system failure may or may not be the result of a pump malfunction. To determine the cause of the problem, the complete system must be included in any diagnostic procedure. The following information is intended to be used only as an aid in determining if a problem exists. For repair service, contact your local authorized Enerpac Service Center. For the location of an authorized Enerpac Service Center in your area, use phone numbers listed on back cover. SYMPTOM POSSIBLE CAUSE SOLUTION Pump will not start No power Wrong voltage Check electrical power source See voltage specifications on page 2 Motor stalls under load Low voltage Check electrical power source See voltage specifications on page 2 Use shorter power cord Electrical valve will not operate No power or wrong voltage Valve out of adjustment Check valve power connection to pump Contact your local authorized Enerpac Service Center Pump fails to build pressure External leak in system Internal leak in pump Internal leak in valve Internal leak in system component Trace circuit checking all connections and components Contact your local Authorized Enerpac Service Center Contact your local Authorized Enerpac Service Center Repair or replace leaking system component Pump does not reach full pressure Relief valve setting too low External leak in system Internal leak in pump Internal leak in valve Internal leak in system component Reset relief valve, see pages 3 and 4 Trace circuit checking all connections and components Contact your local authorized Enerpac Service Center Contact your local authorized Enerpac Service Center Repair or replace leaking system component Pump builds full pressure, but load does not move Load exceeds cylinder rating Flow to cylinder blocked Decrease load or use higher capacity (tonnage) cylinder Loose coupler connection, check that all couplers are completely connected and hand tightened Cylinder drifts back when it should be holding load External system leak Internal leak in system component Trace circuit checking all connections and components Repair or replace leaking system component Single-acting cylinder will not return No load on a "load return" cylinder Return flow restricted or blocked Return spring damaged or broken Valve malfunction Load cylinder with enough weight to make it retract Loose coupler connection, check that all couplers are completely connected and hand tightened Test circuit using a cylinder known to work, repair or replace damaged cylinder Contact your local Authorized Enerpac Service Center Double-acting cylinder will not return Return flow restricted or blocked Valve malfunction Loose coupler connection, check that all couplers are completely connected and hand tightened Contact your local authorized Enerpac Service Center 6

7 7.0 MAINTENANCE 7.1 Check Oil Level Check reservoir hydraulic oil level before every use. Remove the oil level gauge and add oil through the opening in the top of the reservoir. IMPORTANT: Add oil only when all system components are in the fully retracted position. If oil is added when plungers are advanced, there will be more oil in the system than the pump can hold. When cylinders are retracted oil in the hoses and cylinders will be returned and the reservoir will be over-filled. 7.2 Change Oil and Clean Reservoir IMPORTANT: You will need a new reservoir gasket to reassemble the pump after changing the oil. 1. Completely drain and clean the reservoir after every 100 hours of operation. Refill with new Enerpac hydraulic oil. If pump is used infrequently, clean the reservoir once a year. NOTE: This procedure requires that you remove the pump from the reservoir. Work on a clean bench and use proper oil disposal methods. 2. Remove the 10 screws holding the pump to the reservoir. After these screws are removed, one of the shroud brackets will be loose, so it is best to lift the pump off of the reservoir by holding the coverplate. 3. Carefully set the pump down without damaging fitter screens. 4. Remove the reservoir gasket and discard it. 5. Pour all oil out of reservoir. Thoroughly clean the reservoir by wiping and rinsing with a suitable solvent. 6. Use a soft bristle brush and solvent to clean the three filter screens. 7. Reassemble the pump and reservoir, installing a new gasket. 8. Fill the reservoir with new Enerpac hydraulic oil. If the pump requires repair work, contact your local authorized Enerpac Service Center. 7

8 Tutti i prodotti Enerpac sono garantiti da difetti di lavorazione e materiali per tutto il periodo in cui rimangono in vostro possesso. Per trovare il Servizio Assistenza Enerpac autorizzato più vicino a Voi, visitate il nostro sito com ECM

Instruction Sheet. 1/2 HP Portable Electric Pumps SAFETY FIRST. L2062 Rev. F 02/ IMPORTANT RECEIVING INSTRUCTIONS 2.

Instruction Sheet. 1/2 HP Portable Electric Pumps SAFETY FIRST. L2062 Rev. F 02/ IMPORTANT RECEIVING INSTRUCTIONS 2. Instruction Sheet 1/2 HP Portable Electric Pumps L2062 Rev. F 02/12 Index: English:...................................... 1-7 Français:.................................... 8-14 Deutsch:...................................