Enerpac DuroTech Series Operating and installation instructions

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POWERFUL SOLUTIONS. GLOBAL FORCE.
Service Information Sheet
Pump Element Seal Replacement
DuroTech™ Series
Air-Driven Hydraulic Pumps
L4241 Rev. A 11/18
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.
2.0 SAFETY
2.1 Introduction
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 any questions or concerns
arise, contact Enerpac or a local Enerpac distributor for
clarification.
If you have never been trained on high-pressure hydraulic
safety, consult your distributor or service center for information
about an Enerpac Hydraulic Safety Course.
This manual follows a system of safety alert symbols, signal
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 personal 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
relating to property damage). Please note
that the Safety Alert Symbol will not be used
with this signal word.
2.2 Hydraulic Pump Safety Precautions
(DuroTech Series)
WARNING
Failure to observe and comply with the following
precautions could result in death or serious personal
injury. Property damage could also occur.
• Read and completely understand the safety precautions
and instructions in this manual before operating the pump or
preparing it for use. Always follow all safety precautions and
instructions, including those that are contained within the
procedures of this manual.
• Operating procedures will vary, depending on the system
arrangement and the specific components being used.
Always read, follow and completely understand all
manufacturer's instructions when operating cylinders,
valves and any other hydraulic devices used with the pump.
Follow all safety precautions contained in the manufacturer's
manuals.
Table of Contents:
Section Page
1.0 IMPORTANT RECEIVING INSTRUCTIONS ........ 1
2.0 SAFETY ................................... 1
3.0 REPAIR PROCEDURES ....................... 3
3.1 Pump Disassembly........................ 3
3.2 Pump Element Disassembly................. 3
3.3 Piston Seal Removal ...................... 4
3.4 Piston Seal Replacement ................... 4
3.5 End Cap Seal Removal and Replacement ...... 4
3.6 Rod Seal Removal ........................ 4
3.7 Rod Seal Replacement..................... 5
3.8 Pump Element Reassembly ................. 5
3.9 Pump Installation ......................... 5
4.0 REPAIR PARTS INFORMATION ................. 6

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• Always wear appropriate personal protective equipment
(P.P.E.) when operating hydraulic equipment. Be sure to
wear eye protection, work gloves and protective clothing.
Use of additional P.P.E. safety items such as dust mask,
non-skid safety shoes, hard hat, and hearing protection
(used as appropriate for the conditions) will reduce the
chance of personal injuries. The use of these items may also
be required by local regulations or laws.
• Do not handle pressurized hoses. Escaping oil under
pressure can penetrate the skin. If oil is injected under the
skin, see a doctor immediately.
• Do not pressurize disconnected couplers.
• Only use hydraulic cylinders in a coupled system. Never use
a cylinder with uncoupled couplers. If the cylinder becomes
extremely overloaded, components can fail catastrophically,
causing severe personal injury.
• The pump is equipped with a hydraulic safety relief valve that
is factory preset to the pump's maximum operating pressure.
DO NOT attempt to adjust, bypass or alter the safety relief
valve. This valve is not user-adjustable. Adjustment should
be performed only by an Enerpac Authorized Service Center.
• The system operating pressure must not exceed the
pressure rating of the lowest rated component in the system.
Refer to the instruction sheet provided with your pump for
the maximum rated working pressure for your pump model.
• Install pressure gauge(s) in the system to monitor operating
pressure. It is your window to see what is happening in the
system.
• Never set the pump hydraulic pressure to a higher setting
than the maximum rating of the hoses and connected
devices. The pressure setting should not exceed the setting
of the lowest rated component (pump, cylinder or other
hydraulic component) in the circuit.
• Do not exceed equipment ratings. Overloading may cause
equipment failure and possible personal injury.
• Always perform a visual inspection of the pump before
placing it into operation. If any problems are found, do not
use the pump. Have the pump repaired and tested before it
is returned to service.
• Fill the pump reservoir with hydraulic oil only to the
recommended level. Fill only when cylinders (or other
hydraulic actuators) are in their normal de-energized position.
• Never use the pump if it is leaking oil. Do not use the pump if
it is damaged, has been altered or is in need of repair.
• Always lift the pump using only the provided lifting handles.
• Allow only trained and experienced personnel to operate the
pump.
• Be certain that hydraulic pressure is fully relieved from the
cylinder (or other hydraulic actuator) before disconnecting
hydraulic hoses, loosening hydraulic fittings, or performing
any disassembly or repair procedures.
• If hydraulic equipment is damaged, do not touch or go near
any area where high-pressure oil is spraying. Promptly stop
usage of the hydraulic equipment and replace the damaged
parts with new ones before using the equipment again.
• Do not put your hands or body in line with the face of a
disconnected coupler. If the coupler becomes pressurized
and leakage occurs, the high-pressure oil stream could
penetrate the skin.
• Skin penetration from high-pressure hydraulic oil can result
in death or serious personal injury. If oil is injected under the
skin, see a doctor immediately.
CAUTION
Failure to observe and comply with the following
precautions could result in minor or moderate personal
injury. Property damage could also occur.
• Be careful to avoid damaging hydraulic hoses. Avoid sharp
bends and kinks when routing hydraulic hoses. Do not
exceed the minimum bend radius specified by the hose
manufacturer. 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 hoses. A sharp impact may
cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.
• Do not lift hydraulic equipment by the hoses or couplers.
• Make sure that all system components are protected from
external sources of damage, such as moving machine parts,
sharp edges and corrosive chemicals.
• Keep hydraulic equipment away from flames. Flames near
a hydraulic oil leak could cause the hydraulic oil to ignite,
resulting in a fire.
• For optimum performance, do not expose hydraulic
equipment to temperatures of 150˚F [65˚C] or higher.
Excessive heat will soften packings and seals, resulting in
possible hydraulic fluid leaks.
• Protect all hydraulic equipment from weld spatter.
• Protect the pump against rain, mud, dust, and humidity
when using it outdoors.
• Disconnect air supply hose when pump is not in use for
a prolonged period of time. NEVER remove a swivel air
connector while the air hose is pressurized.
• Immediately replace worn or damaged parts with genuine
Enerpac parts. Enerpac parts are designed to fit properly
and to withstand high loads. Non-Enerpac parts may break
or cause the product to malfunction.
NOTICE
• Hydraulic equipment must only be serviced by a qualified
hydraulic technician. For repair service, contact the Enerpac
Authorized Service Center in your area.
• To help ensure proper operation and best performance, use
only genuine Enerpac hydraulic oil.
2.3 Additional Safety References
Consult the applicable industry and/or government standards
in your country or region for additional safety precautions
and work rules applicable to hydraulic pumps, hydraulic
workholding devices and related components.

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3.0 REPAIR PROCEDURES
3.1 Pump Disassembly
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Refer to maintenance
preparation procedures in Section 8.1 of instruction sheet
L4184.
2. Remove cover assembly (Figure 1, Item 4) from pump
assembly. Refer to procedure in Section 6.3 of instruction
sheet L4184.
3. Using a 3/4" [19 mm] box end wrench, disconnect the
pipe-elbow connector (Figure 1, Item 1) from manifold
assembly (Figure 1, Item 8).
4. Using a 3/4" [19 mm] box end wrench, disconnect the
pipe-elbow connector (Figure 1, Item 3) from piston rod
assembly (Figure 1, Item 7).
5. Remove elbow pipe from tank and manifold assemblies
(Figure 1, Items 6 and 8).
6. Usinga3/4"[19mm]boxendwrench, disconnect connector
(Figure 1, Item 2) from tank assembly (Figure 1, Item 6).
7. Repeat steps 3 through 6 for opposite side.
8. Remove four screws (Figure 1, Item 5) from bottom of tank
assembly (Figure 1, Item 6).
9. Remove pump element subassembly (Figure 1, Item 7)
from manifold and tank assemblies (Figure 1, Items 6 and
8).
3.2 Pump Element Disassembly
1. Place pump element subassembly in a non-marring vise.
2. Remove four tie-rods (Figure 2, Item 2) from piston rod
assembly (Figure 2, Item 1).
3. Using a soft mallet, separate the end caps (Figure 3, Item
1) from cylinder tube (Figure 3, Item 2).
4. Using a soft mallet, drive piston rod (Figure 3, Item 3) out
of the cylinder tube (Figure 3, Item 2).
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2
3
46
8
7
5
Figure 1, Pump Element Subassembly
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1
Figure 2, Tie Rod Removal (View 1 of 2)
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3
1
Figure 3, Tie Rod Removal (View 2 of 2)

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NOTICE
Some residual oil will be contained in cylinder tube.
Dispose of any used oil in accordance with all applicable laws
and regulations.
3.3 Piston Seal Removal
1. Place the pump on a workbench or other substantial work
surface.
2. Pry and remove wear band (Figure 4, Item 2) starting at the
scarf cut (Figure 4, Item 1).
3. Repeat step 1 for second wear band.
4. Using same non-marring blade, pry up outer piston seal
(Figure 4, Item 3). While retaining the seal with blade,
rotate the blade around the piston until the outer piston
seal is loose. Remove outer piston seal.
5. Remove inner piston seal O-ring (Figure 5, Item 1) that was
exposed in step 4.
3.4 Piston Seal Replacement
1. Using a clean, lint-free rag, remove old grease and seals
(Figure 4, Item 1) from end cap (Figure 4, Item 2).
2. Using a small brush, lightly grease piston grooves and
seals before installation.
3. Install inner piston seal O-ring (Figure 5, Item 1) on piston.
4. Install outer piston seal (Figure 4, Item 3) on top of inner
piston seal O-ring (Figure 5, Item 1).
5. Install wear band on piston (Figure 4, Item 2).
3.5 End Cap Seal Removal and Replacement
Perform steps 1 through 3 for each end cap:
1. Using a clean, lint-free rag and suitable cleaning agent,
remove old grease and seal (Figure 6, Item 1) from end cap
(Figure 6, Item 2).
2. Using a small brush, lightly grease grooves and seals
before installation.
3. Install end cap seal on end cap with care so as not to tear
the seal.
3.6 Rod Seal Removal
1. Secure end cap assembly in a non-marring vise with the
seals accessible.
2. Identify the two peening indentations (Figure 7, Item 1).
3. Using a 1/8" inch drill bit, drill an approximately 1/8" deep
hole at each peening indentation.
1
2
3
2
Figure 4, Piston Seal Removal (View 1 of 2)
1
Figure 5, Piston Seal Removal (View 2 of 2)
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Figure 6, End Cap Seal Removal
1
1
Figure 7, Peening Indentations

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4. Using a spanner wrench, remove stop ring, guide ring, and
O-ring (Figure 8, Item 1) from end cap assembly.
NOTICE
To prevent permanent damage to pump components
when parts are reinstalled, be certain that all old grease and
drilling debris is completely removed as described in step 5.
5. Using a clean, lint-free rag, remove all old grease and
drilling debris from end cap assembly.
6. Separate stop ring, guide ring and O-ring (Figure 9, Items
1, 2 and 3) that were removed in step 4. Discard O-ring
(Figure 9, Item 2).
7. Remove U-cup (Figure 10, Item 1) and O-ring (Figure 10,
Item 2).
3.7 Rod Seal Replacement
1. Using a small brush, lightly grease grooves and seals
before installation.
2. Install O-ring (Figure 10, Item 1).
3. Install U-cup (Figure 8, Item 1) in end cap.
4. With a spanner wrench, install stop ring, guide ring and
O-ring (Figure 9, Items 1, 2 and 3).
5. Tighten until snug.
3.8 Pump Element Reassembly
1. Place cylinder tube in a non-marring vise.
2. Using a soft mallet, drive piston rod (Figure 3, Item 3) into
the cylinder tube (Figure 3, Item 2).
3. Using a soft mallet, press the end caps (Figure 3, Item 1)
onto the cylinder tube (Figure 3, Item 2).
4. Install four tie-rods (Figure 2, Item 2) on piston rod
assembly (Figure 2, Item 1).
5. Torque tie-rods to 18-20 ft-lbs [25-30 Nm].
3.9 Pump Installation
1. Install piston rod assembly (Figure 1, Item 7) on manifold
and tank assemblies (Figure 1, Items 6 and 8) with four
screws (Figure 1, Item 5).
2. Tighten screws to 7.4-11 ft-lbs [10-15 Nm].
3. Install elbow-pipe from tank and manifold assemblies
(Figure 1, Items 6 and 8).
4. Using a 3/4" [19 mm] box end wrench, tighten the pipe-
elbow connector (Figure 1, Item 1) onto manifold assembly
(Figure 1, Item 8).
5. Using an adjustable or 3/4" [19 mm] box wrench, tighten
the pipe-elbow connector (Figure 1, Item 3) onto piston
rod assembly (Figure 1, Item 7).
6. Using a 3/4" [19 mm] box end wrench, tighten connector
(Figure 1, Item 2) onto tank assembly (Figure 1, Item 6).
7. Repeat steps 3 through 6 for opposite side.
8. Install cover assembly (Figure 1, Item 4) onto pump
assembly. Refer to procedure in Section 6.3 of instruction
sheet L4184.
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1
3
Figure 9, Stop Ring, Guide Ring, and O-ring (View 2 of 2)
2
1
Figure 10, U-cup and O-ring
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Figure 8, Stop Ring, Guide Ring and O-ring (View
1 of 2)

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1
3 4
2
12
5
11 67
8
9 10
Figure 11, Pump Element Seals
Parts List for Figure 11
Item Part Number Qty. Description Item Part Number Qty. Description
1✦DX9158503 2O-ring 8 ✦DX7034514 2GT Ring (WAP07)
2✦DX9157503 2O-ring ✦DX7034514-2 2GT Ring (WAP15)
3✦DX7071155 2Wear Ring ✦DX7034514-4 2GT Ring (WAP30)
4✦DX7070503 1O-ring 9 ✦DX7037449 2Retaining Ring (WAP07)
5✦DX7048503 3O-ring ✦DX7037449-2 2Retaining Ring (WAP15)
6✦DX7038503 2O-ring (WAP07) ✦DX7037449-3 2Retaining Ring (WAP30)
✦DX7038503-2 2O-ring (WAP15) 10 ✦DX7036503 2O-ring (WAP07)
✦DX7038503-3 2O-ring (WAP30) ✦DX7036503-2 2O-ring (WAP15)
7✦DX7035338 2GT Ring Mount (WAP07) ✦DX7036503-3 2O-ring (WAP30)
✦DX7035338-2 2GT Ring Mount (WAP15) 11 ✦DX7038503 1O-ring
✦DX7035338-3 2GT Ring Mount (WAP30) 12 ✦DX7060503 2O-ring
✦Items are available in seal kit WAP pump seal kit (DX1701900SR).
4.0 REPAIR PARTS INFORMATION

Notes:

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