Airetool PATP-9400-P Instruction and safety manual

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Operating & Service Manual
90120-IM
05/25/2011
PATP-9400-P
Pneumatic Powered Hydraulic Pump
Model Number Part Number (Order)
PATP-9400-P 2999307
Airetool®

2
SAFETY FIRST
IMPORTANT RECEIVING
INSTRUCTIONS
Visually inspect all components for shipping damage.
Shippingdamageisnot coveredby warranty. If shipping
damage is found, notify carrier at once. The carrier is
responsible for all repair and replacement costs result-
ing from damage in shipment.
SAFETY ISSUES
Read all instructions, warnings, and cau-
tions carefully. Follow all safety precau-
tions to avoid personal injury or property
damageduringsystem operation. Cooper
Power Tools cannot be responsible for damage or injury
resulting from unsafe product use, lack of maintenance
or incorrect product and/or system operation. Contact
Cooper Power Tools when in doubt as to the safety pre-
cautions and operations. If you have never been trained
on high-pressure hydraulic safety, consult your distribu-
tionorservice center for a free Enerpac Hydraulic safety
course.
Failure to comply with the following cautions and warn-
ings could cause equipment damage and personal in-
jury.
ACAUTIONisusedtoindicate correct operatingormain-
tenance procedures and practices to prevent
damage to, or destruction of equipment or other prop-
erty.
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 ac-
tion may cause serious injury or even death.
WARNING:Wearproperpersonalprotective
gear when operating hydraulic equipment.
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 pres-
sure than the maximum rated pressure of
the pump. Higher settings may result in
equipmentdamageand/orpersonalinjury.
WARNING: The system operating pressure
must not exceed the pressure rating of the
lowestratedcomponentinthe system. Install
pressure gauges in the system to monitor
operatingpressure. Itis your window to what is happen-
ing in the system.
CAUTION: Avoid damaging hydraulic
hose. Avoid sharp bends and kinks when
routing hydraulic hoses. Using a bent or
kinkedhose willcausesevereback-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 dam-
age to hose wire strands. Applying pres-
sure to a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic equip-
mentbythehosesor swivel couplers. Use
thecarryinghandle or other means of safe
transport.
CAUTION: Keep hydraulic equipment
away from flames and heat. Excessive
heatwillsoften packings and seals, result-
ing in fluid leaks. Heat also weakens hose
materials and packings. For optimum performance do
not expose equipment to temperatures of 65°C [150°F]
orhigher.Protecthosesandcylindersfromweldspatter.
WARNING: Only use hydraulic cylinders
in a coupled system. Never use a cylinder
withunconnected couplers.Ifthe cylinderbe-
comes extremely overloaded, components
can fail catastrophically causing severe personal injury.
IMPORTANT: Hydraulicequipmentmust only
beserviced by aqualifiedhydraulic technician.
For repair service, contact the Authorized
ENERPAC Service Center in your area. To protect your
warranty, use only ENERPAC oil.
WARNING:Immediatelyreplacewornordam-
aged parts with genuine ENERPAC parts.
Standard grade parts will break causing per-
sonal injury and property damage. ENERPAC parts are
designed to fit properly and withstand high loads.

3
Vent Plug
See Figure 1. Remove the shipping plug from the vent
port and replace it with the vent/fill gauge cap supplied
with the pump. Tighten the vent/fill gauge cap hand tight
only.
Hydraulic Connection
2. Connect one end of the hose tube assembly to the
pump connections and the other to the tube puller ram.
Connect the pneumatic control tube to the pendant con-
trol or to the Patp ram. The hydraulic connectors are
push-to-connect and the pneumatic control connections
arekeyedwiththreadedretainingring (HandTIght Only).
Air Connection
This pump requires 100 psi air at 40 scfm. A regulator
filter lubricator has been installed on the pump to aid in
providing clean lubricated air. and to allow for air pres-
sure adjustment. Attach incoming air supply to 3/4 NPT
port on air valve with thread sealant.
INSTALLATION Oil Level
Check the oil level of the pump prior to start-up and add
Enerpachydraulicoil,ifnecessary,by removing the vent/
fill gauge cap (See Figure 1). When the gauge needle
points to the end of the green zone the reservoir is full.
CAUTION: Addoilonly when all system components are
in the retract position, or the system will contain more oil
than the reservoir can hold.
OPERATION
1. Check oil level of the pump and add oil if necessary.
See Oil Level instructions.
CAUTION: During system operation, the oil level should
never fall below the yellow zone or pump damage may
occur.
2. Make sure that the pump reservoir is vented (Vent/Fill
Gauge Cap is installed.)
CAUTION: Reservoirmustbevented whenever pump is
running. Failure to vent the pump will cause cavitation
and pump damage.
3. To start the pump, press the trigger on the PATP ram
or the pendant button if using the HDP, HDQ, or RAV
ram. The ram will advance as long as the button is held
down.
4. Release the button to retract the ram. The motor will
remain on.
5.Press the redOFFbuttononthe pump tostopthepump
motor. With the motor off, both hoses are de-
pressurized.Oil from the retract line will return to tank.
Pressure Adjustment
Pressure is factory preset and should not require adjust-
ment.
PATP 9400 P Pump Specifications:
Air Requirement for maximum Pressure 100 PSI@ 40 SCFM
@ 50 PSI(3.5 bar) 850 in3/min
(
13.9 1/min
)
Hydraulic Flow @ 1000 (69bar) 105 in3/min
(
1.72 1/min
)
@ 10000 PSI(690 bar) 30 in3/min (0.5 1/min)
External Relief Valve Adjustment 1100 10000 PSI (69-690 bar)
Sound Pressure Level 80-85 dBA
Reservoir Capacity 2 Gallon (7.57 Liters)
Dimensions:
Over All Length 30 inches (762 mm)
Height 29 1/2 Inches (749 mm)
Width 19 3/4 Inches (502 mm)
Weight 160 Lbs. (72.7 Kilo.)
Vent/Fill/GaugeCap

4
MAINTENANCE
1. Maintain proper oil level.
2. When the pump is run for prolonged periods of time,
icemayformon themufflerelementandmust beremoved.
3. Change the oil every 250 hours or more frequently if
used in dirty environments. To remove the oil from the
pump, remove the vent/fill/gauge cap and insert a siphon
tube to siphon the oil from the pump. It may be neces-
sary to tilt the pump to get the remaining oil in the reser-
voir. Always use clean Enerpac hydraulic oil when refill-
ing the pump. See page 44 for oil filling instructions.
4. Periodically the filter will need to be drained. Turn the
knob(H)atthebottomofthefilterclockwisetodrain. Use
a shallow pan or a cloth to catch drainage. Turn knob
counterclockwise to seal filter.
5. The air inlet filter should be cleaned every 250 hours.
Toreplace thefilter,depressurize thesystemandunscrew
thebowl.Removethefilter element and replace with new
filterelement.

5
TROUBLESHOOTING
Only qualified hydraulic technicians should service the
pump or system components. The following information
is intended to be used as an aid in determining if a prob-
lem exists. For repair service, contact the Authorized
Enerpac Service Center in you area.
Symptom Possible Cause
Pump will not start Air turned off or line blocked
Motor stalls under load Low air pressure
Muffler plugged
Contaminated air
Pump fails to build pressure External leak in system
Internal leak in pump
Internal leak in valve
Internal leak in system component
Pump builds less than full pressure Relief valve set low
External system leak
Internal leak in pump
Internal leak in valve
Internal leak in system component
Ram will not react Valve malfunction
Return flow line restricted or blocked
Pump overheats Tubing to heat exchanger disconnected
Thermostat malfunction
Low oil flow rate Resevoir not vented
Inadequate air supply
Dirty air filter
Clogged inlet filter

6
PATP 9400P PARTS LIST
ITEM MODEL NUMBER DESCRIPTION QTY ITEM MODEL NUMBER DESCRIPTION QTY
1DA10001401 ENCLOSURE 121C ZB2BZ009P BASE 1
2DA10597101 MOUNTING PLATE 122A KDVF5/7562 CONNECTOR 1
3DA10526660 AIR PILOTED VALVE 222B KDV-1/8-242697 INSERT 3
4DA10527660 AIR PILOTED VALVE 1 23 MAV 4 VALVE 1
5DA10528660 SHUTTLE VALVE 1 24 MSV1 SHUTTLE VALVE 1
6DA10596095 FITTING 2 25 MPA 5P PILOT 1
7DA10594095 ELBOW FITTING 226A 15002-6 TEE FITTING 1
8DA10595095 ELBOW FITTING 326B 11761-3 GASKET 1
9DA10593095 BRANCH TEE FITTING 4 27 H2F NIPPLE 1
10 DA10592095 TEE FITTING 1 28 V500P-8 BALL VALVE 1
11 FZ1642 REDUCER BUSHING 3 29 06F31AC FILTER 1
12 DA10612024 BREATHER VENT 2 30 06R318AC REGULATOR 1
13 A8069006 PIPE PLUG 1 31 16L31BE LUBRICATOR 1
14 A8014095 FITTING 1 32 PS705P BOWL GUARD 1
15 DA10635268 5/32 AIR TUBE 6" LONG 4 33 ECS3AP RECLASSIFIED 1
16 DA10636268 5/32 AIR TUBE 8" LONG 1 34 DA9885668 AIR VALVE 1
17 DA10637268 5/32 AIR TUBE 10" LONG 1 35 DA10699118 AIR FILTER 1
18 DA10638268 5/32 AIR TUBE 12" LONG 1 36 DA10738024 BREATHER VENT 1
19 DA10639268 5/32 AIR TUBE 18" LONG 1 37 SEE FIGURE 3 AIR VALVE 2
20 DA10704046 HEX HEAD SCREW 2 38 FH-371-6FP COUPLING 1
21A PXBB1911P SWITCH 1 39 FH-372-6FP NIPPLE 1
21B
ZB2BC4P
OPERATOR
1
40
DA10538471
HEAT EXCHANGER
1

7
PATP HT Hose Tube Assembly 5524903
12
ITEM PART NO. PART NAME QTY
12999929 HYD HOSE ASSY 10000 2
25525236 PATP TUBE ASM W/ SLEEVE 1
HYD HOSE ASSY 10000 REPLACEMENT HYD FITTINGS
ITEM PART NO. PART NAME QTY
12900094 10,000 PSI NIPPLE 1
22900095 10,000 PSI COUPLING 1
PATP TUBE ASM REPLACEMENT PARTS
ITEM PART NO. PART NAME QTY
12999071 PATP 7 CONDUIT 16.4'
22999072 PATP CONDUIT CONNECTOR 2
32999073 PATP 8 I CON INSERT 6
42999074 PATP 9 PU3 TUBING 49.2'
52990300 A 100 59 SLEVE 12'
61715741 PG5 BAND 2
CAUTION: Avoid damaging hydraulic hose.
Avoid sharp bends and kinks when routing hy-
draulic 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.
IMPORTANT: Do not lift hydraulic equip-
ment by the hoses or swivel couplers. Use
the carrying handle or other means of safe
transport.
WARNING: Only use hydraulic cylinders in a
coupled system. Never use a cylinder with un-
connected couplers. If the cylinder becomes ex-
tremely overloaded, components can fail catastrophically
causing severe personal injury.
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.

8
PATP HDP PENDANT ASSEMBLY 5524904
Pendant Operating Instructions
With the pump properly connected, but off, and the HDP or RAV spear or the HDQ gripper properly inserted
into the tube to be pulled, push and hold the pendant pushbutton.
The pump motor starts and the ram extends, pulling the tube.
When the tube pulls free or the ram reaches the end of its stroke, release the pushbutton, and the ram will
reverse, retract fully, and stop.
The pump will continue to run until the red pushbutton on the pump is pushed.
ITEM PART NO. PART NAME QTY
1 2999646 PATP 13 PENDANT BODY 1
2 2999647 PATP 14 VALVE 1
3 2999648 PATP 15 TUBE FITTING 2
4 2999649 PATP 16 TOP PLATE 1
5 2999650 PATP 17 PLATE RETAINER 1
6 2999069 PATP 6 BOX CONNECTOR 1
7 2999070 PATP 6 I CON INSERT 2
8 2999246 PATP 12 5/32OD X 3/32ID TUBING 1.333
9 8010910 6 X 5/16 PHT SCREW B PH 18 8 7
10 8010911 9/16 BLACK NYLON HOLE PLUG 1

9

10

11

12
Figure 2

13
Figure 3

14
Figure 4B

15
Figure 4A

16
Figure 5

17
Figure 6

Sales & Service Centers
Note: All locations may not service all products. Please contact the nearest Sales & Service Center for
the appropriate facility to handle your service requirements.
Dallas, TX Detroit, MI Houston, TX Lexington, SC
Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group
Sales & Service Center Sales & Service Center Sales & Service Center 670 Industrial Drive
1470 Post & Paddock 2630 Superior Court 6550 West Sam Houston Lexington, SC 29072
Grand Prairie, TX 75050 Auburn Hills, MI 48326 Parkway North, Suite 200 Tel: [phone]
Tel: [phone] Tel: [phone] Houston, TX 77041 Tel: [phone]
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Fax: [phone]
Los Angeles, CA Seattle, WA York, PA Canada
Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group
Sales & Service Center Sales & Service Center Sales & Service Center Sales & Service Center
15503 Blackburn Avenue 2865 152nd Avenue N.E. 3990 East Market Street 5925 McLaughlin Road
Norwalk, CA 90650 Redmond, WA 98052 York, PA 17402 Mississauga, Ont. L5R 1B8
Tel: [phone] Tel: [phone] Tel: [phone] Canada
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Cooper Power Tools Cooper Power Tools Cooper Power Tools SAS Cooper (China) Co., Ltd.
GmbH & Co. OHG GmbH & Co. OHG a company of a company of
a company of a company of Apex Tool Group, LLC Apex Tool Group, LLC
Apex Tool Group, LLC Apex Tool Group, LLC 25 rue Maurice Chevalier 955 Sheng Li Road,
Industriestraße 1 C/O Spline Gauges 77330 Ozoir-La-Ferrière Heqing Pudong, Shanghai
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Cooper Tools Cooper Tools Industrial Ltda. Cooper Tools Hungaria Kft.
de México S.A. de C.V. a company of a company of
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Parque Industrial Querétaro 18087-170 Sorocaba 9027 Györ
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90120-IM/Printed in USA 05/2011/Copyright © Apex Tool Group, LLC
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1000 Lufkin Road
Apex, NC 27539
Phone: [phone]
Fax: [phone]
www.apextoolgroup.com
Airetool®