Enerpac XLP Series User manual

Operation and Maintenance Manual
To reduce the risk of injury, user must read and understand this document before use.
Document Number: L4611
Document Revision: A
Issue Date: 14-JAN-2022
Language: English EN
Workshop Presses
XLP-Series 25 ton

2L4611_a

L4611_a 3
ABOUT US
Enerpac is a global market leader in high pressure hydraulic
tools, controlled force products, portable machining,
on-site services and solutions for precise positioning
of heavy loads. As a leading innovator with over a 100
year legacy, Enerpac has helped move and maintain
some of the largest structures on earth. When safety and
precision matter, elite professionals in industries such as
aerospace, infrastructure, manufacturing, mining, oil & gas
and power generation rely on Enerpac for quality tools,
services and solutions. For additional information, visit
www.enerpac.com.
WARRANTY
Refer to the Enerpac Global Warranty document for terms and conditions of the product warranty. Such warranty
information can be found at www.enerpac.com.
NAMEPLATE
Refer to the nameplate decal for the press model number. Decal appearance and text may vary depending on
location of product manufacture.
CAUTION: READ INSTRUCTIONS
BEFORE USING OR REPAIRING
XLPXXXXXXXX
AVAILABLE LANGUAGES
An electronic copy of this document is available online in multiple languages:
• EN English - For other languages, visit www.enerpac.com.
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4L4611_a
Contents
1. SAFETY.......................................................................................................................................................... 5
1.1 HYDRAULIC PRESS SAFETY PRECAUTIONS.................................................................................... 5
1.2 ADDITIONAL SAFETY PRECAUTIONS................................................................................................ 6
2. COMPLIANCE ............................................................................................................................................... 6
2.1 CONFORMANCE TO NATIONAL AND INTERNATIONAL STANDARDS ............................................ 6
3. FEATURES & COMPONENTS ...................................................................................................................... 7
4. PRODUCT DATA............................................................................................................................................ 8
4.1 DIMENSIONS......................................................................................................................................... 8
4.2 SPECIFICATIONS ................................................................................................................................. 8
5. INSTALLATION .............................................................................................................................................. 9
5.1 ASSEMBLING THE PRESS FRAME..................................................................................................... 9
5.2 MOUNTING THE PRESS FRAME......................................................................................................... 9
5.3 HYDRAULIC CYLINDER INSTALLATION............................................................................................. 9
6. OPERATION................................................................................................................................................. 10
6.1 SYSTEM SET-UP ................................................................................................................................. 10
6.2 REMOVING AIR FROM THE HYDRAULIC SYSTEM ......................................................................... 10
6.3 HAND PUMPS ..................................................................................................................................... 10
6.4 AIR POWERED PUMPS ...................................................................................................................... 10
6.5 REPOSITIONING THE CYLINDER .................................................................................................... 10
6.6 BED ADJUSTMENT (RAISING AND LOWERING) ............................................................................. 10
7. STORAGE .................................................................................................................................................... 11
7.1 RECOMMENDED STORAGE .............................................................................................................. 11
8. MAINTENANCE........................................................................................................................................... 11
8.1 HYDRAULIC SYSTEM......................................................................................................................... 11
8.2 PRESS FRAME .................................................................................................................................... 11
9. TROUBLESHOOTING ................................................................................................................................. 12
10. PARTS LIST ................................................................................................................................................ 13
10.1 EXPLODED VIEW, XLP-SERIES 25 TON........................................................................................... 13
10.2 PARTS TABLE, XLP-SERIES 25 TON (REFER TO DIAGRAM IN SECTION 10.1) ........................... 13

L4611_a 5
1. Safety
1.1 Hydraulic Press Safety
Precautions
Failure to observe and comply with the following
precautions could result in death or serious personal
injury. Property damage could also occur.
• Ensure force application point on workpiece
is centered under the press cylinder and that
the entire cylinder saddle is in contact with the
workpiece.
• Avoid side loading the press cylinder and
workpiece as significant damage or physical injury
could occur.
• Where possible, use a safety screen for safety
purposes.
• Ensure the material placed on the press bed is
rated for press capacity.
• Verify hydraulic components (pump, cylinder,
hoses, and accessories) remain in good working
condition.
• Use only accessories (such as press plates and
V-Blocks) of adequate design and sufficient rating
to safely secure the workpiece during application.
Use of Enerpac V-Blocks (Model VB-25 - optional
accessory) is strongly recommended.
• Do not use the press for pulling applications. The
XLP-Series Hydraulic Press is designed only for
pressing applications.
• Do not position or hold workpieces when load is
being applied or while workpieces are under load.
• Keep all body parts away from the press cylinder
and workpieces while press is in use.
• Ensure that press frame is secured to the floor,
workbench or other solid surface.
• Ensure area around the press is safe and secure
before operating press.
• Ensure proper personal protective equipment
(PPE) is in place when using the press.
• Be certain that the operator has read and
understood all operating instructions provided with
the press, pump and all accessories.
• Be sure the operator has completed appropriate
safety training, specific to the work surroundings.
The operator should be thoroughly familiar with the
controls and the proper use of the press.
WARNING
Read all instructions carefully. Follow all recommended
safety precautions to avoid personal injury as well
as damage to the product and / or damage to other
property. Enerpac cannot be responsible for any
damage or injury from unsafe use, lack of maintenance,
or incorrect operation. Do not remove warning labels,
tags, or decals. In the event that any questions or
concerns arise, contact Enerpac or a local Enerpac
distributor for clarification.
Save these instructions for future use.
If you have never been trained on high-pressure
hydraulic safety, consult your distributor or service
center for information about Enerpac hydraulic safety
courses.
This manual follows a system of safety alert symbols,
signals, words, and safety messages to warn the user of
specific hazards. Failure to comply with these warnings
could result in death or serious personal injury, as well
as damage to the equipment or other property.
The Safety Alert Symbol appears throughout
this manual. It is used to alert you to potential
physical injury hazards. Pay close attention
to Safety Alert Symbols and obey all safety
messages that follow this symbol to avoid the possibility
of death or serious injury.
Safety Alert Symbols are used in conjunction with certain
Signal Words that call attention to safety messages or
property damage messages and designate a degree or
level of hazard seriousness. The Signal Words used in
this manual are WARNING, CAUTION, and NOTICE.
WARNING
Indicates a hazardous situation that, if not
avoided, could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate personal
injury.
NOTICE
Indicates information considered important,
but not hazard related (e.g. messages related to property
damage). Please note that the Safety Alert Symbol will
not be used with the signal word.

6L4611_a
1.2 Additional Safety Precautions
WARNING
Failure to observe and comply with the following
precautions could result in death or serious personal
injury. Property damage could also occur.
• Always wear and/or use appropriate personal
protective equipment (PPE) such as hard hat,
hearing protection, safety shoes and gloves (at a
minimum rigger type gloves).
• Ensure that protective clothing will not interfere
with safe operation of the tool or restrict the ability
to communicate with co-workers.
• The operator must be of at least the minimum age
required by applicable local regulations, laws and
the facility standard operating procedures.
• Be sure your workplace is safe. Follow the
instructions in your workplace’s standard
operating procedures and be sure to observe all
communicated safety precautions.
• Be sure appropriate guards (user-supplied) are
securely in position and free from damage.
• Maximum allowable hydraulic system operating
pressure is 10,000 psi [700 bar]. Do not exceed this
pressure setting.
• Alwaysbe surethatpumpis stoppedandallpressure
is fully relieved (0 psi/bar) before disconnecting or
connecting the hydraulic hose. The sudden and
uncontrolled release of pressurized hydraulic oil
could occur if hose is disconnected while under
pressure.
• Never attempt to connect or disconnect hoses while
the pump is on and/or the system is pressurized.
• Before use, be certain that all hose couplers are
fully connected. There should be no threads visible
between the male and female coupler halves.
• Never apply more hydraulic pressure to any tool,
hose, fitting or accessory than the maximum
allowable pressure as stated in the manufacturer’s
specifications. The system operating pressure
must not exceed the pressure rating of the lowest
rated component in the system.
• Do not abuse or overstress hoses in any way. Do
not bend hoses excessively.
• Take every precaution to prevent oil leaks from
occurring. High pressure oil leaks can penetrate
the skin, resulting in serious injury.
Failure to observe and comply with the following
precautions could result in property damage and/or
void the product warranty.
• Never carry the pump by its hose.
• If oil leakage is present from hydraulic cylinder,
replace seals as required before placing the press
back into service.
• If the press becomes damaged in any way, have it
repaired and checked for proper operation before
placing it back into service.
• Always follow the inspection and maintenance
instructions contained in this manual. Perform
maintenance and inspection activities at the
specified time intervals.
• Always use Enerpac pumps and hoses.
• Always use Enerpac replacement parts.
2. Compliance
2.1 Conformance to National and
International Standards
Enerpac declares that the product(s) have been tested
and conforms to applicable standards and the product(s)
are compatible to all EU and UK Requirements.
Copies of the EU Declaration as well as the UK Self-
Declaration are enclosed with each shipment
NOTICE
These tools conform with
the requirements for
CE and UKCA.
•XLP256XA11G

L4611_a 7
Key:
1. Hydraulic Cylinder
2. Hydraulic Hose
3. Hydraulic Pressure Gauge
4. Gauge Adapter
5A. Hydraulic Pump, Hand Operated
(Models XLP256P392 and XLP256P392U only)
5B. Hydraulic Pump, Air Operated
(Models XLP256XA11G and XLP256XA11GU
only)
6. Frame
6
1
2
3
4
5a
5B
3. Features & Components

8L4611_a
4.1 Dimensions
4. Product Data
4.2 Specifications
Press Model
Number
Press
Capacity
Maximum
Daylight mm[in]
Power Source Cylinder
Pump Type Valve
Type Pump
Model No.
Stroke
mm[in]
Model
No.
Tons kN Vertical Horizontal Man. Air Man.
XLP256P392 25 232 1211
[47.68]
510
[20.08]   P392 158/6.25 RC256
XLP256P392U 25 232 1211
[47.68]
510
[20.08]   P392 158/6.25 RC256
XLP256XA11G 25 232 1211
[47.68]
510
[20.08]   XA11G 158/6.25 RC256
XLP256XA11GU 25 232 1211
[47.68]
510
[20.08]   XA11G 158/6.25 RC256
Press Model
Number
XLP256P392
XLP256P392U
XLP256XA11G
XLP256XA11GU
Rapid Advance
mm/sec [in/sec] {3,4 [0.13]}** 10,0 [0.39]
Pressing
mm/sec [in/sec] {0,7 [0.03]}** 1,3 [0.05]
Dimensions
mm [in]
A 270 [10.63] 270 [10.63]
B 140 [5.51] 140 [5.51]
C 510 [20.08] N/A
D 32 [1.26] 32 [1.26]
E 510 [20.08] 510 [20.08]
F 630 [24.80] 630 [24.80]
G 710 [27.95] 710 [27.95]
H 1620 [63.78] 1620 [63.78]
J 1705 [67.143] 1705 [67.143]
K
357-1211
[14.06-47.68]
357-1211
[14.06-47.68]
L 770 [30.31] 770 [30.31]
M 140 [5.51] N/A
N 218 [8.58] 218 [8.58]
O 1072 [42.20] 1072 [42.20]
P 122 [4.80] 122 [4.80]
Q 140 [5.51] 140 [5.51]
Weight
kg [lb] 156 [364] 170 [375]
** {…} = advance speed in mm[in] per handpump stroke.

L4611_a 9
5.1 Assembling the Press Frame
Assemble press legs to press using press leg fasteners
supplied.
Assemble winch handle to the winch using hardware
upplied
5.2 Mounting the Press Frame
WARNING
Mount the press securely. Unstable
positioning may cause the press to tip, resulting in
serious personal injury or equipment damage.
If the press is to be mounted to the floor or some other
foundation, lower press bed to lowest set of holes before
drilling and bolting down. This will ensure that the press
does not twist and that the bed will line up with all sets
of holes in the legs.
5.3 Hydraulic Cylinder Installation
Check all hydraulic hoses to be sure that
fittings and couplers are tight and leak free. Check
hose positions to be sure the hoses are located to
avoid damage during press operations. Tighten all
connections fully, but not excessively.
1. Models with hand pumps
a. Connect the gauge adaptor (GA2) to the outlet
port of the pump.
b. Attach the gauge into the ½” NPTF port of the
gage adaptor (GA2).
c. Attach the swivel coupler (XSC1) into the 3/8”
NPTF port of the gage adaptor (GA2).
d. Connect the threaded end of the hose to the
swivel coupler.
2. Models with air pumps
a. Connect the swivel coupler to the outlet port
on the side of the pump.
b. Connect the threaded end of the hose to the
swivel coupler.
3. Connect the hydraulic hose with the coupler end
to the cylinder.
CAUTION
5. Installation
Notes:
• Threaded NPT and NPTF connections: Apply PTFE
tape to male threads and tighten each item to 1.5 to 3
turns past finger tight (minimum of 40 ft-lbs
[54.2 Nm]).
• Pressure gauge and adapter:
Orient as desired by first torquing to this minimum
torque specification and then continuing to tighten until
desired orientation is achieved.
• Tighten cylinder coupler halves by hand only. Be
certain they are fully tightened (no gap or threads
visible between coupler halves).

10 L4611_a
6.1 System Set-Up
WARNING Check all press set-ups and load fixtures
for safe operation.
Center the work piece and all parts of the set-up on
the line of force. If spacers are used in the set-up, they
should be constructed in one solid piece or tack welded
together for stability.
WARNING
Before operating the press, make sure all
bed support pins are fully inserted and retaining rings are
installed on ends of the bolster pins before pressurizing
the cylinder or loading the press.
6.2 Removing Air From The Hydraulic
System
NOTICE
Air removal will go faster if hose(s) are bled of
air before connecting them to cylinder port(s).
Advance and retract the cylinder several times, avoiding
pressure build-up. Air is fully removed from the system
when the cylinder advances and retracts smoothly.
6.3 Hand Pumps
1. Close release valve finger tight
2. Operate the pump handle to build pressure.
Pressure will be maintained until the release valve
is opened
3. Open release valve to release pressure.
6.4 Air Powered Pumps
Depress the pressure side of the treadle to activate the
throttle and advance the cylinder to desired stroke. To
retract the cylinder depress release.
6.5 Repositioning the Cylinder
(see figure 1)
1. Loosen, DO NOT REMOVE , the wing nut (D)
located under the lower cylinder support bracket
2. Slide the cylinder mounting block assembly (A) to
the desired position on the press frame
3. Tighten wing nut (D) securely when cylinder is in
the desired location
Figure 1: Repositioning the cylinder
6.6 Bed Adjustment (Raising and
Lowering)
Remove all items from the press bed/
bolster before raising or lowering bed/bolster.
Keep hands away from the press bed/
bolster and frame when raising/lowering bed/bolster.
1. The winch has a self-locking feature and can be
stopped in any position.
2. Remove retaining pins from the bed/bolster pins.
3. Turn the winch to raise the bed/bolster until
the bed/ bolster pins become loose and can be
removed from the press.
4. The bed/bolster can be raised/lower to the desired
height.
5. When desired height is reached, install the 2 bed/
bolster pins back into the press and reinstall the
retaining pins.
6. Slowly turn the winch so the bed/bolster moves
down and sits on the pins.
Before operating the press, make sure all
bed/ bolster support pins are fully inserted, retaining
pins are installed and the bed/bolster is sitting on the
bed/bolster support pins.
The bed/bolster support pins must be
installed before operating the press. The winch cable
is only used to raise/lower the bed/bolster, it is not
designed to support the bed/bolster while pressurizing
the cylinder or loading the press.
WARNING
WARNING
WARNING
WARNING
6. Operation

L4611_a 11
7. Storage
7.1 Recommended Storage
Enerpac tools should be stored in a cool, dry place.
Tools should always be cleaned, serviced and lubricated
prior to storage. Ensure that tools are stored in their
designated packing cases.
8. Maintenance
8.1 Hydraulic System
1. Keep all hydraulic components free of dirt, grease,
chips, and unnecessary equipment
2. Periodically check hydraulic system for damaged
components, loose connections, or leaks. Replace
or repair damaged or leaking components
immediately
3. Change hydraulic oil in your system every 50 hours
of operation
4. Use only Enerpac hydraulic oil. Use of fluids other
than Enerpac hydraulic oil may cause damage to
your system and may void your Enerpac warranty
5. For complete hydraulic component instructions,
refer to the instructions enclosed with your pump
and cylinder.
8.2 Press Frame
1. Keep work area and press bed free of dirt, chips,
and unnecessary tools and fixtures
2. Periodically check frame parts are undamaged.
Replace or repair damaged parts immediately
3. If the paint becomes badly chipped, the unit should
be repainted to prevent rusting and to keep frame
appearance neat.

12 L4611_a
9. Troubleshooting
The information in the Troubleshooting Guide is intended as an aid to help diagnose and correct various possible
problems that may occur. For repair service, contact your nearest Enerpac Authorized Service Center.
Troubleshooting Guide
Problem Possible Cause Action
Cylinder plunger does not
advance, advances slowly or in
spurts.
1. Oil level in pump is low 1. 1. Add oil according to the pump
instructions
2. Pump release valve open 2. Close pump release valve
3. Loose hydraulic coupler 3. Check that all couplers are fully tightened
4. Load is too heavy 4. Do not attempt to exert more than rated
tonnage
5. Air trapped in the system 5. Remove air according to the instructions
section 6.2
6. Cylinder plunger binding. 6. Check for damage to cylinder. Have
cylinder serviced by a qualified hydraulic
technician.
Cylinder advances, but does
not hold pressure.
1. Leaking connection 1. Check that all connections are tight and
leak free
2. Leaking cylinder seals 2. Locate leak(s) and have equipment
serviced by a qualified hydraulic
technician
3. Internal leakage in pump. 3. Have pump serviced by a qualified
hydraulic technician.
Single-acting systems:
Cylinder does not retract,
retracts part way or retracts
more slowly than normal.
1. Release valve closed 1. Open pump release valve
2. Cylinder retraction spring broken or
other cylinder damage
2. Have cylinder serviced by a qualified
hydraulic technician
3. Cylinder attachments are too heavy for
a single-acting cylinder
3. Remove attachments, check cylinder for
damage.
4. Coupler not connected fully. 4. Tighten cylinder coupler halves by hand
only. Be certain they are fully tightened
(no gap or threads visible between
coupler halves)

L4611_a 13
10.1 Exploded View, XLP-Series 25 ton
10. Parts List
6
1
2
5b
5A
10.2 Parts Table, XLP-Series 25 ton (Refer to diagram in Section 10.1)
Item Description Qty. Part Numbers
XLP256P392 XLP256P392U XLP256XA11G XLP256XA11GU
1 Cylinder 1 RC256 RC256 RC256 RC256
2 Hose, Hydraulic 1 HC7210 HC7210 HC7210 HC7210
3 Gauge, Pressure* 1 GF20B GF20P --- ---
4 Adapter, Gauge* 1 GA2, XSC1 GA2, XSC1 --- ---
5A Hyd. Pump, Hand Operated 1 P392 P392 --- ---
5B Hyd. Pump, Air Operated 1 --- --- XA11G XA11G
6 Frame 1 SPR54015S SPR54015S SPR54015S SPR54015S
7 Decal, Product Type* 2    
8 Decal, Caution Warning* 2    
9 Decal, Capacity* 2    
10 Decal, Enerpac* 2    
11 Decal, Caution* 2    
--- Enerpac V-Block Kit* - VB25 VB25 VB25 VB25 
  Indicates items included and available only as part of Label Kit, XLP25LK
 Optional accessory. Two V-blocks are included in each Kit. Order as required
* not shown

NOTES
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NOTES
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