Enerpac PMU-30457 Bedienungsanleitung

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.

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.

ACAUTION is used to indicate correct operating or maintenance

procedures and practices to prevent damage to, or destruction of

equipment or other property.

AWARNING indicates a potential danger that requires correct

procedures or practices to avoid personal injury.

ADANGER 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 800 bar [11,600 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.

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.

Instruction Sheet

11/8HP Titan Torque Wrench Pumps

L1843 Rev. A 10/01

Genesis Series

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.

To avoid personal injury, do not use electric pumps in

an explosive atmosphere. Adhere to all local and

national electrical codes.

Do not use hoses, fittings, or couplers with pressure

ratings below 11,600 psi (800 bar). Equipment with

inadequate pressure ratings can fail and cause

personal injury or equipment damage.

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.

To help prevent pump failure, check hydraulic

reservoir fluid level prior to pump operation. When

gauge reads low, add oil. Always be sure tools are

fully retracted before adding fluid to the reservoir.

To prevent damage to pump electric motor, check

specifications.

3.0 SPECIFICATIONS (see Specification Table below)

4.0 INSTALLATION

4.1 Install Oil Level Gauge

For shipping purposes, a plug is installed in the fill port on the top

of the reservoir. Remove this plug and install the oil level gauge

that was shipped with the pump. (See Fig. 1).

NEVER RUN THE PUMP WITH THE SHIPPING PLUG

INSTALLED. THIS WILL CAUSE DAMAGE TO THE

PUMPING MECHANISM.

4.2 Connect Hydraulic Hoses

Be sure to use hose marked "ENERPAC 800 SERIES–800

BAR/11,600 PSI MAX". Connect hoses as shown in Figure 2. Hand

tighten coupler lock rings. No tools are required.

Specification PMU-30457 PMU-30457R PMU-30452 PMU-30452R

Operating Pressure 0 – 11,600 psi (800 bar) Maximum

Electrical Power 30 Amp / 115 Volt Grounded 15 Amp / 230 Volt

Source Single-phase 50-60 Hz Single-phase, 50-60 Hz

11/8Universal Motor 0.84 kW Universal Motor

Motor Rating

25 Amp @ 10,000 psi (700 bar) and 12,000 RPM 12.5 Amp @ 10,000 psi (700 bar) and 12,000 RPM

operates at 60-125 Volts operates at 115-240 Volts

Sound Level 83 – 88 dBA

Flow Rate 640 in3/min (10,5 l/min) @ 0 psi (0 bar)

55 in3/min (0,90 l/min @ 11,600 psi (800 bar)

Unloading (or Bypass) 1600 psi (110 bar)

Pressure

Operating Oil 150 °F (65 °C) Maximum

Temperature

Reservoir Capacity 1.3 gallons (5 liter)

Shipping Weight 77 lbs. (35 kg) 89 lbs. (40 kg) 77 lbs. (35 kg) 89 lbs (40 kg)

Figure 1

Warning: To ensure proper operation, avoid kinking

or tightly bending hoses. If a hose becomes kinked or

otherwise damaged, it MUST be replaced. Damaged

hoses may rupture at high pressure causing personal injury.

4.3 Check Oil Level

Check the oil level prior to start-up and add Enerpac hydraulic oil,

if necessary (see figure 3). 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.

Figure 3

Warning: Attempting to couple a hose to the pump or

torque wrench while coupler is under pressure can

result in personal injury or fluid leakage.

5.0 OPERATION

When possible, a single user should operate both the torque

wrench and the pump. This prevents accidental activation of the

pump while another person is positioning the wrench.

5.1 Operating the Pump

1. Plug power cord into outlet with appropriate voltage rating.

2. Turn pump on by pressing "I" on the switch (see Fig. 4). The

pump on-off switch is located on the side of the pump shroud.

The pump will run when you operate the pendant switch.

Figure 4

3. Operate the pendant switch. Pendants have a 3-position,

momentary switch. Press the bottom of the pushbutton for

"Advance". When you release the button, the valve shifts to

retract and the motor stops running after 10 seconds. Use the

"Retract" pushbutton if you need to start the unit in the retract

mode. Again, the motor stops running 10 seconds after you

release the switch (see Fig. 5).

Figure 5

Remove shipping plug

ENERPAC 800 SERIES - 800 BAR/11,600 PSI MAX.

Figure 2

Empty

Add Oil

Full

In Use

Oil Level Gauge Press to retract

Press to advance

Tool

Pump

5.2 Removing Air From the System

When the wrench is first connected to the pump, air will be trapped

in the components. To ensure smooth operation, remove air by

cycling the wrench several times without load. Cycle until wrench

advances and retracts without hesitation.

5.3 Gauge and Overlay

Operating Procedure

The pump is supplied with a

pressure gauge installed. A torque

overlay fits over the pressure

gauge dial face which easily

converts pressure readings to

torque readings (see Fig. 6).

The overlay has imperial units

(Ft.lbs) on one side and metric

units (Nm) on the other. To change

scales simply flip overlay over.

WARNING: Each overlay is sized for a specific Enerpac

torque wrench ONLY. Do not use with other

wrenches.

5.4 Changing the Overlay

1. Remove the three black wing

knobs which hold the front

gauge flange in place (see

Fig. 7).

2. Remove the front flange and

overlay (see Fig. 8).

3. Insert new overlay (remember

to verify correct overlay to the

Enerpac torque wrench being

used) onto the flange,

aligning the overlay with the

dimples on the back of the

flange (see Fig. 9).

4. While holding the overlay

behind the flange (see Fig. 8.)

insert the flange onto the knob

studs, repositioning the

overlay as needed, and

secure knobs finger tight (see

Fig. 7).

The flange will press the

overlay onto the gauge and

secure it in place. See torque

wrench instructions for

amount of pressure required

to produce desired torque.

Note that the maximum

pressure varies for different

wrenches and accessories.

5.5 Setting Pump to Torque Value

Pressure and torque are set by adjusting the relief valve. The

external relief valve is located on top of the pump. It is adjustable

from 11,600 psi (800 bar) down to 2000 psi (140 bar). Operating

pressure cannot be adjusted to above 11,600 psi (800 bar). To get

the most accurate relief valve setting, start at a lower pressure and

adjust up to the desired relief valve.

Warning: Make these adjustments BEFORE putting

torque wrench on nut or bolt head. The pump

pressure setting may be above the pressure needed

to provide the required torque for your application. Exceeding

required torque will cause equipment damage and may lead

to serious personal injury.

1. The pump is supplied with a pressure gauge installed. See the

torque wrench instructions for the amount of pressure needed

to produce the required torque. Note that the maximum

pressure varies for the different wrenches and accessories.

2. Loosen the locknut on the relief valve adjustment screw. Using

the knurled knob, turn the adjustment screw counter-

clockwise to decrease pressure setting (see Fig. 10).

3. Turn the pump on, and press and hold "ADV". Observe the

pressure gauge reading. Adjust the relief setting up to the

desired pressure.

4. Verify the setting by running the pump several times.

5. Tighten lock nut to secure setting on relief valve.

Figure 10

6.0 MAINTENANCE

6.1 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.

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Relief Valve

1. No power

2. Wrong voltage

1. Low voltage

2. Power cord too long

3. Relief valve setting too high

1. No power or wrong voltage

2. Valve out of adjustment

1.External leak in system

2. Internal leak in pump or valve

3. Internal leak in system component

1. Relief valve setting too low

2. External leak in system

3. Internal leak in pump or valve

4. Internal leak in system component

1. Job exceeds wrench rating

2. Flow to wrench blocked

1. Return flow restricted or blocked

2. Internal spring damaged or broken

3. Valve malfunction

1. Return flow restricted or blocked

2. Valve misfunction

1. Check electrical power source

2. See voltage specification table

1. Check electrical power source / see voltage

specification table

2. Use shorter power cord

3. Reset relief valve (see section 5.3)

1. Check valve power connection to pump

2. Contact your local authorized Enerpac Service

Center

1. Trace circuit checking all connections and

components

2. Contact your local authorized Enerpac Service

Center

3. Repair or replace leaking system component

1. Reset relief valve (see section 5.3)

2. Trace circuit checking all connections and

components

3. Contact your local authorized Enerpac Service

Center

4. Repair or replace leaking system component

1. Use higher capacity wrench

2. Check for loose coupler connection

1. Loose coupler connection

2. Test circuit using another wrench

3. Contact your local authorized Enerpac Service

Center

1. Loose coupler connection

2. Contact your local authorized Enerpac Service

Center

Pump will not start

Motor stalls under load

Valve will not operate

Pump fails to build pressure

Pump does not reach full pressure

Pressure builds but wrench does not

turn

Single-acting wrench will not retract

Double-acting wrench will not retract

TROUBLE-SHOOTING GUIDE

Problem Possible Cause Solution

2. Remove heat exchanger tubing.

3. Remove heat exchanger and set it to the side.

4. 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.

5. Carefully set the pump down without damaging filter screens.

6. Remove the reservoir gasket and discard it.

7. Pour all oil out of reservoir. Thoroughly clean the reservoir by

wiping and rinsing with a suitable solvent.

8. Use a soft bristle brush and solvent to clean the 3 intake

screens.

9. Reassemble the pump and reservoir, installing a new gasket.

10. Clean the heat exchanger before reinstalling.Use compressed

air to blow dirt out of the heat exchanger.

11. Fill the reservoir with new Enerpac hydraulic oil.

Enerpac Worldwide Locations ✦

e-mail: [email protected]

✦

internet: www.enerpac.com

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 www.enerpac.com

Australia

ENERPAC, Applied Power Australia Ltd.

Block V Unit 3

Regents Park Estate

391 Park Road

Regents Park NSW 2143

(P.O. Box 261) Australia

Tel: +61 297 438 988

Fax: +61 297 438 648

Canada

Actuant Canada Corporation

6615 Ordan Drive, Unit 14-15

Mississauga, Ontario L5T 1X2

Tel: +1 905 564 5749

Fax: +1 905 564 0305

Toll Free:

Tel: +1 800 268 4987

Fax: +1 800 461 2456

China

Applied Power China Ltd.

1F, 269 Fute N. Road

Waigaoqiao Free Trade Zone

Pudong New District

Shanghai, 200 131

China

Tel: +86 21 5866 9099

Fax: +86 21 5866 7156

France, Turkey, Greece,

Africa, Middle East

ENERPAC S.A.

B.P. 200

Parc d’Activités

du Moulin de Massy

F-91882 Massy CEDEX (Paris) France

Tel: +33 1 601 368 68

Fax: +33 1 692 037 50

Germany, Switzerland,

Austria, Eastern Europe

ENERPAC

Applied Power GmbH

P. O. Box 300113

D-40401 Düsseldorf

Germany

Tel: +49 211 471 490

Fax: +49 211 471 49 28

Hong Kong

ENERPAC

Room 907 Workingberg

Commercial Building

41-47 Marble Road

North Point

Tel: +852-2561 6295

Fax: +852-2561 6772

India

ENERPAC

Hydraulics (India) Pvt Ltd

Plot No. A-571

MIDC, TTC Industrial Area

Mahape-400 701

Navi Mumbai, India

Tel: +91 22 769 47 78

Fax: +91 22 769 84 73

Italy

ENERPAC

Applied Power Italiana S.p.A.

Via Canova 4

20094 Corsico (Milano)

Tel: +39 02 4861 1110

Fax: +39 02 4860 1288

Japan

Applied Power Japan Ltd.

1-1-11, Shimomae

Toda-shi

Saitama Pref.

Japan 335-0016

Tel: +81-48-430-2311

Fax: +81-48-430-1117

Mexico

ENERPAC Applied Power

Mexico S.A. de C.V.

Avenida Principal

La Paz #100

Fracc. Industrial La Paz

42092 Pachuca, Hidalgo

Tel: +52 771 337 00

Fax: +52 771 838 00

The Netherlands, Belgium,

Luxembourg, Sweden, Denmark,

Norway, Finland, United Kingdom,

Ireland

ENERPAC B.V.

Storkstraat 25

P. O. Box 269, 3900 AG Veenendaal

The Netherlands

Tel: +31 318 535 911

Fax: +31 318 525 613

+31 318 535 848

UK, Ireland

Tel: +44 01527 598 900

Fax: +44 01527 585 500

Singapore

Applied Power Asia Pte Ltd

No. 8, Ang Mo Kio,

Industrial Park 2

#01-00

Singapore 569500

Thomson Road, P.O. Box 114

Singapore 915704

Tel: +65 484 5108

Fax: +65 484 5669

South Korea

ENERPAC

Applied Power Korea Ltd.

163-12 Dodang-Dong

Wonmi-Ku, Buchun-shi

Kyunggi-Do

Republic of Korea

Tel: +82 32 675 08 36

Fax: +82 32 675 30 02/73

Spain, Portugal

ENERPAC

Applied Power International S.A.

Avda. Camino de lo Cortao

21 - Nave 3

San Sebastian de los Reyes

28709 Madrid

Spain

Tel: +34 91 661 11 25

Fax: +34 91 661 47 89

USA, Latin America

and Caribbean

ENERPAC

P. O. Box 3241

6101 N. Baker Road

Milwaukee, WI 53209 USA

Tel: +1 262 781 6600

Fax: +1 262 783 9562

User inquiries:

+1 800 433 2766

Distributor inquiries/orders:

+1 800 558 0530

092501

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