Enerpac DuroTech Series User manual

1
POWERFUL SOLUTIONS. GLOBAL FORCE.
Instruction Sheet
DuroTech™ Series
Air-Driven Hydraulic Pumps
L4184 Rev. C 10/20
Table of Contents:
Section Page
1.0 IMPORTANT RECEIVING INSTRUCTIONS ......1
2.0 SAFETY .................................1
3.0 PRODUCT DESCRIPTION ...................4
4.0 PRODUCT DATA...........................4
5.0 INSTALLATION AND SETUP .................6
6.0 OPERATION ..............................8
7.0 INSPECTION, MAINTENANCE & STORAGE .....9
8.0 ROUTINE MAINTENANCE PROCEDURES ......9
9.0 TROUBLESHOOTING .....................14
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.
• 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.

2
• 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
Section 4.1 of this manual 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 General Workholding Safety Precautions
WARNING
Failure to observe and comply with the following
precautions and instructions could result in death or
serious personal injury. Property damage could also occur.
• Although hydraulic operation moves the control of the
clamping fixture to an area of greater safety, operators must
still remain alert and use common sense practises during
their work.
• Use care when selecting components for the workholding
application so that safe operation is ensured. Be certain that
all components and devices are of adequate rated capacity
to perform their intended functions.
• Verify that all appropriate safety measures have been taken
to avoid the risk of injury and property damage from your
application or system.
• Be sure that all personnel involved with operating or
servicing the workholding devices read and understand the
information contained in the manuals included with these
devices. Observe and follow all safety instructions and
precautions contained in the manuals.
• Design the control units of power operated clamping
systems to avoid inadvertent or unauthorized activation.
• Be sure that clamping cylinders and other similar workholding
devices are properly positioned before clamping forces are
applied.
• Maintain a safe distance from clamping elements and
workpiece to avoid personal injury. Stay clear of pinch
points. Keep your hands, feet and body away from the
clamping area.
• Use mechanical devices and not fingers to hold a part in
place until the clamping hydraulics are activated.

3
3.0 PRODUCT DESCRIPTION
The Enerpac DuroTech Series Air Driven Hydraulic Pump
is intended for high-use, high-flow industrial workholding
applications.
Three dierent maximum pressure ratings are available to suit
a wide variety of user requirements. In addition, a choice of two
dierent valve manifold styles is available to accommodate
D03 or CETOP type valves.* Refer to Table 4.1 for details.
Each valve manifold contains four stations, allowing for up to
four control valves to be installed. Control valves are available
from Enerpac (sold separately).
The dual action pump element combines smooth operation
with maximum durability. A built in air filter/regulator allows
easy adjustment of pump hydraulic pressure and helps protect
the pump air components from containments.
The large 1.8 gallon [6.8 liter] hydraulic reservoir provides
ample oil capacity to power multiple hydraulic devices.
A removable metal shroud allows easy access to the pump
element for routine inspection and maintenance activities.
* Note: CETOP style manifolds are subject to delayed
availability. Contact Enerpac for additional information.
• To avoid unexpected operation of clamping devices, be sure
that control valves are in the neutral position before starting
the pump.
• Be certain that clamping devices are activated before the
main spindle is started.
• Do not apply an o-center load to the part being machined.
Clamping force must be applied directly over the support
point.
• Use check valves to maintain hydraulic pressure to clamping
devices in the event of a hydraulic line failure.
• Contact your Enerpac oce or representative for guidance
if in doubt regarding the proper safety precautions to be
taken when designing and setting-up your system.
2.4 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.
12
1
11
16
15
14
17
13
6
75
3
4
2
9
8
10
Key:
1. Hyd. Pressure Gauge
2. Cover Plate/Valve Station
3. Hyd. Manifold
4. Hyd. Hose Ports
9. Hyd. Pressure
Sensor Port
6. Hyd. Reservoir
7. Vent Screw
8. Sight Gauge
9. Drain Plug
10. Carrying Handle
11. Hyd. Oil Fill Plug
12. Air On-O Control
13. Metal Shroud
14. Mounting Hole
15. Air Pressure Gauge
16. Air Pressure Control
17. Air Inlet Connection
Figure 1 - Major Features and Components

4
4.0 PRODUCT DATA
4.1 Specifications, Pressure, Flow and Air Consumption
Pump
Series
Hydraulic Pressure Pressure
Ratio
Hydraulic
to Air
Max. Hydraulic
Flow
@100 psi Air 2)
[6.9 bar]
Air Pressure
Range
Max Air
Consumption
@ 100 psi Air
[6.9 bar]
Max. Hyd.
Working
Pressure1)
Max. Hyd.
Pressure
@100 psi Air
2)
[6.9 bar]
Hyd. Safety
Relief Valve
Setting
psi bar psi bar psi bar - in3/min l/min psi bar scfm m³/min
WAP07 1920 132 1595 110 2000 138 16:1 612 10.0 30-120 2.0-8.2 24 0.68
WAP15 2760 190 2320 160 3000 207 23:1 465 7.6 30-120 2.0-8.2 24 0.68
WAP30 5280 364 4785 330 5500 379 48:1 252 4.1 30-110 2.0-7.6 20 0.57
1) Based on 120 psi [8.3 bar] air pressure for the WAP07 and WAP15 Series, and 110 psi [7.6 bar] air pressure for the WAP30 Series.
2) At zero (0) psi/bar hydraulic pressure.
4.2 Additional Specifications
Pump Series
Reservoir Usable
Oil Capacity Hydraulic Oil
Approximate Weight
(not including
hydraulic oil or
control valves)
Operating
Temperature
Range
Sound Level
Gallons in3Liters Type lb kg °C °F dBA
WAP07
WAP15
WAP30
1.8 415 6.8 Enerpac HF
(Refer to Section 5.3) 71 32.2 0 to 60 32 to 150 75
Pump Series Air inlet
connection
Hydraulic Hose Connections Hydraulic Valve Manifold Stations Number of
Stations
Model No.
ending in D
Model No.
ending in C
Model No.
ending in D
Model No.
ending in C
WAP07
WAP15
WAP30
1/4" NPT #8 SAE G3/8" D03 CETOP 4
4.3 Schematic Diagram
Description of Operation:
Air is automatically ported and
vented to the pump piston.
The piston plunger contains a
pressurizing ram at each end. Every
time the piston moves, one of the
rams sends pressurized hydraulic oil
to the manifold.
Shop air is connected to the built-
in pressure regulator, allowing the
operator to adjust the air pressure,
that in turn sets the maximum
hydraulic oil pressure.
The air is ported through a built-
in shut-o valve. With the shut-o
valve open, the pump automatically
starts and stops to obtain and then
maintain the customer selected
pressure.

5
4.4 Pump Dimensions
Item inch mm
B
A
B
A
B
A
B
A
A
E
FG
D
C
B
A8.9 226
B
ø 0.31
x
0.09
ø 7.9
x
2.3
C2.0 51
D15.8 402
E13.2 338
F16.6 424
G12.7 328
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
WAP07 - Hydraulic Pressure vs Flow
WAP07-Hydraulic Pressure vs Flow
Oil flow (in3/min) 

Hydraulic Pressure (psi)
Oil flow (in3/min) 

Hydraulic Pressure (psi)
700
600
500
400
300
200
100
0
0 500 1000 1500 2000 2500 3000
900
800
700
600
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800
350
300
250
200
150
100
50
0
0 1000 2000 3000 4000 5000 6000
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
60 psi
80 psi
100 psi
Air pressure
Oil flow (in3/min) 

Hydraulic Pressure (psi)
WAP07 - Hydraulic Pressure vs Flow
Oil flow (l/min) 

Hydraulic Pressure (bar)
Oil flow (l/min) 

Hydraulic Pressure (bar)
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0 34 69 103 138 172 207
14.8
13.1
11.5
9.8
8.2
6.6
4.9
3.3
1.6
0
0 14 28 41 55 69 83 97 110 124
5.7
4.9
4.1
3.3
2.5
1.6
0.8
0
0 69 138 207 276 345 414
4.1 bar
5.5 bar
6.9 bar
Air pressure
Oil flow (l/min) 

Hydraulic Pressure (bar)
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.1 bar
5.5 bar
6.9 bar
Air pressure
4.5 Performance Curves (hydraulic pressure vs. flow)
Imperial
Metric
WAP07 Series WAP15 Series WAP30 Series
WAP07 Series WAP15 Series WAP30 Series
NOTICE
Performance will be significantly diminished if air pressure falls below 50 psi [3.4 bar]. Actual performance may vary
from values shown, due to seal friction, internal pressure drops and manufacturing tolerances.

6
5.0 INSTALLATION AND SETUP
5.1 Mounting
Install the pump on a solid and level horizontal surface that is
capable of supporting the weight of the pump, control valves
and any associated equipment.
Four slotted mounting holes are provided on the pump bottom
flange. See Figure 2. Secure the pump with 5/16" SAE or M8
ISO screws (user supplied).
NOTICE
Pump must be operated only in the horizontal
position (with the pump bottom flange facing down). To avoid
damage to pump and possible oil leakage, do not attempt to
mount the pump on a wall or other vertical surface.
Figure 2 - Mounting Holes
5.2 Valve Installation
The pump is available with a choice of D03, CETOP or VP style
control valve ports.
Control valves are sold separately and are not included with
the pump. Refer to the Enerpac website or catalog for a
description of available control valves and related accessories.
Consult your Enerpac distributor or authorized service center if
additional valve selection guidance is needed.
NOTICE
Tandem center control valves should not be used
with DuroTech Series pumps.
When installing control valves, always work in a clean and dry
area. Take all appropriate precautions to avoid contamination and
dirt entry. Follow the valve manufacturer's instructions carefully to
ensure proper installation. Be sure that the cover plates remain
tightly installed over all unused valve stations. See Figure 3.
The Enerpac MC-2 cross over cover plate (optional accessory)
can be used to covert A and B outlet ports to P and T ports for
use with remote mounted valves.
Figure 3 - Control Valve Mounting Station
and Cover Plate (D03 Manifold Shown)
5.3 Hydraulic Reservoir
The pump is shipped without oil. Reservoir must be filled with
oil before pump is operated.
Use of Enerpac HF Series ISO 32 hydraulic oil is strongly
recommended. Enerpac HF oil is available at your local
Enerpac Distributor or Authorized Service Center.
NOTICE
• Failure to use the correct oil type (high-quality ISO 32
hydraulic oil) may result in damage to pump hydraulic
components and will void the product warranty.
• Be sure that the oil is clean. The oil cleanliness should be
maintained to a maximum level of 18/16/13 per the ISO
4406 standard. If the oil develops a milky, cloudy or dark
appearance, it should be changed immediately.
• To avoid overfilling and possible equipment damage, add
oil to the pump reservoir only after all connected hydraulic
devices are de-energized and system pressure is completely
relieved.
Add oil as described in the following steps:
1. Be certain that the air shut-o valve is in the OFF position
2. Verify that the pump hydraulic pressure gauge and pump
air pressure gauge both read zero (0) psi/bar.
3. Be sure that all connected hydraulic devices are fully de-
pressurized.
4. Loosen the vent screw one full turn to provide reservoir
venting.
5. Loosen and remove the oil fill plug. See Figure 4.
6. Slowly pour oil through the oil fill port while watching the
level in the reservoir sight gauge. Stop pouring when the
reservoir is 1/2 to 3/4 full. DO NOT OVERFILL. Refer to
Section 5.4 for additional information.
7. Reinstall the oil fill plug after adding oil. Tighten oil fill plug
snug tight.
Figure 4 - Oil Fill Plug
5.4 Oil Level
The oil level sight gauge is located on the left-hand side of the
pump,
The reservoir should be 1/2 to 3/4 full with all cylinders or other
hydraulic actuators fully retracted. See Figure 5.
Never allow the oil level to rise above the top (high) line or fall
below the bottom (low) line.
NOTICE
Always check oil level with the air on-o control in
the OFF position and the hydraulic system fully depressurized.
Be certain that all hydraulic actuators are fully retracted. Failure
to observe this instruction may result in the reservoir becoming
overfilled.

7
Figure 5 - Oil Level Sight Gauge
Oil Level
Add oil if the oil level drops below 1/2 full. A small amount of
additional oil may need to be added to the reservoir after the
pump has been operated for the first time.
5.5 Hydraulic Hose Connections
The advance and retract ports are located on the front of the
hydraulic manifold. See Figure 6. Note that the top ports are
labeled “B” and the bottom ports are labeled “A”.
Port type and thread size will vary, depending on pump model.
Refer to Section 4.2 of this manual for additional information.
All hoses, fittings and other hydraulic components in the
circuit must be rated at or above the pump maximum working
pressure. Refer to sections 4.1 and 6.2 of this manual for
additional maximum pressure information.
Figure 6 - Hydraulic Connections
B
A
B
A
B
A
B
A
Refer to Section 4.2 for port
type and thread size.
5.6 Air Requirements
CAUTION Before connecting the air supply hose,
ensure that the air on-o control is in the OFF position.
Failure to follow these directions may result in unintended
pump startup when air supply hose is connected.
To ensure optimum performance, the air source must be
capable of providing a constant supply of air at the required
pressure and flow rate for your pump model. Refer to Table 4.1
for additional information.
NOTICE
Supply air pressure should not exceed 110 psi [7.5
bar] static for WAP30 Series models. Supply air pressure
should not exceed 120 psi [8.2 bar] static for WAP07 and
WAP15 Series models.
Figure 7 - Pump Air Inlet
Air coupler
(user-supplied)
Air Inlet
1/4" NPT
Use only dry and filtered compressed air. Use of a water
separator is strongly recommended. Pump internal
components are self-lubricating. Lubricated air is permitted
but NOT required.
The pump air inlet connection is a 1/4" NPT fitting. See Figure 7.
A suitable male air coupler (user supplied) must be installed
between the pump air inlet connection and the air supply line
or hose. Use PTFE sealing tape (or other suitable pipe sealant)
on the threads and torque to 7.4-11.0 ft-lb [10-15 Nm].
To ensure sucient air flow, the inside diameter of the air
supply hose or line must be not less than 0.39 inch [10 mm].
5.7 Venting
A vent screw is located on the pump reservoir. Before using
the pump, loosen the vent screw one full turn to open the vent.
See Figure 8.
NOTICE
Reservoir must be vented during pump operation.
Failure to open the vent may result in cavitation and damage to
pump components.
The vent should also be opened before adding oil to the
reservoir. This will allow the oil to flow more easily into the tank.
The vent should be fully closed during sustained periods of
inactivity or whenever the pump is stored. When closing the
vent, tighten the vent screw snug tight, so that the underside
of the screw head only slightly compresses the O-ring seat.
Figure 8 - Vent Screw
Vent Screw

8
5.8 Air On-O Control
The pump air on-o control operates as follows:
ON position:
• Air from the plant air supply is directed to the pump pneumatic
circuit, activating the pump element. Hydraulic pressure will
start building immediately, and will be indicated on the pump
hydraulic pressure gauge.
• Pump will stop automatically when the user-adjustable
pressure setting is reached. Refer to Section 6.1 for additional
details.
NOTICE
The user-adjustable pressure setting must be
adjusted before the pump is placed into operation. Refer to
directions in Section 5.9.
OFF position:
• Air from the plant air supply to the pump pneumatic circuit is
blocked (shut-o).
• Some residual air pressure may still be present in the pump
pneumatic circuit.
WARNING
Air downstream of the air on-o control is NOT vented
when the OFF position is selected. Residual air pressure
may be present downstream of the control. Movement
of hydraulic actuators could occur when control valves
are shifted, even when the air on-o control is in the OFF
position.
To prevent possible injury, stay clear of hydraulic actuators
until all pressure is completely relieved. With the air on-o
control in the OFF position, shift the control valve(s) through
all positions several times to relieve any residual pressure.
Figure 9 - Air On-Off Control
5.9 Air Pressure Adjustment
Adjustment of the pump air pressure setting results in a
corresponding change to the pump hydraulic pressure setting.
Adjust the pressure setting as described in the following steps:
1. Move the air on-o control to the OFF position.
2. Connect the air supply hose to the pump air inlet
connection.
3. Pull up the air pressure adjustment knob. See Figure 10.
4. Turn the air pressure adjustment knob slowly
counterclockwise until the pump air pressure gauge
indicates about 43.5 psi [3 bar].
5. While watching the pump air pressure gauge, slowly
rotate the air pressure adjustment knob clockwise until the
gauge indicates the air pressure setting that corresponds
with the hydraulic pressure setting required for your
application.
NOTICE
The hydraulic-to-air pressure ratio varies, depending
on pump model. Refer to the ratios listed in the table in Section
4.1 and to the pressure-flow graphs in Section 4.5.
6. To prevent unexpected actuator operation from occurring
in the next step, be sure that all control valves are in the
neutral position.
Figure 10 - Air Pressure Adjustment Knob
and Pressure Gauge
LOCKED
Air Pressure Gauge
ADJUSTMENT
KNOB
UNLOCKED
7. Move the pump air on-o control to the ON position.
8. Check the pump hydraulic pressure gauge. If necessary,
readjust the air pressure up or down as required, until the
corresponding hydraulic pressure setting is correct for
your application.
WARNING
The pressure reading shown on the pump
hydraulic pressure gauge must not exceed the maximum
rating of the lowest rated hydraulic component in the
circuit. Failure to observe this instruction may result in
catastrophic failure, high pressure oil leakage and/or skin
penetration. Serious personal injury or death could result.
9. After confirming the proper setting, press down on the air
adjustment knob to lock the setting.
5.10 Air Removal
Trapped air must be removed from the hydraulic cylinder(s)
and hoses before the pump is placed into operation.
1. Move the air on-o control to the ON position.
2. Under no load, repeatedly cycle the cylinders (or other
hydraulic actuators) from the fully extended to fully retracted
position until operation is smooth. Repeat this procedure
for each valve station.
Smooth operation indicates that air has successfully been
removed from the system.
3. Move the air on-o control to the OFF position.
4. Check the oil level in the pump hydraulic reservoir. If oil level
has dropped, add additional oil to the reservoir as required.
NOTICE
Refer to Section 5.3 of this manual for hydraulic oil
requirements and reservoir filling instructions.
5. Check the air pressure setting after performing air
removal procedures. The air pressure setting (and the
corresponding hydraulic pressure setting) may drop
slightly after the pump has been operated for the first
time. If readjustment is required, refer to the instructions
in Section 5.9.
6.0 OPERATION
Specific pump operation procedures will vary, depending on
control valve type and configuration, workholding devices
used and other factors. For detailed operating instructions and
related information, refer to the instruction sheet included with
your hydraulic valve(s), cylinder(s) or other actuator(s). Refer
to Section 6.1 for a general overview of pump operation. Also
follow the additional instructions and precautions contained in
sections 6.2 and 6.3 of this manual.

9
6.1 Overview of Operation
Typical operation - with standard closed center or float center
control valves (pressure holding type):
• The pump will start immediately if the air on-o control is
moved to the ON position while the control valve is in the
neutral position. The pump will stop automatically (and
remain idle) when pressure reaches the user-adjustable
pressure setting.
• If the pump is idle, and the control valve is moved from the
neutral position to either the advance or retract position,
the pump will start immediately. The pump will stop
automatically when pressure reaches the user-adjustable
pressure setting.
Typical operation - with spool type closed center or float center
control valves (non-sealed type):
• When the air on-o control is in the ON position and the
control valve is in the neutral position: The pump will start
and stop as needed to maintain the user-adjusted pressure.
This feature helps compensate for the normal internal oil
leakage present in a spool type control valve.
• Operation is otherwise the same as described for the
standard (pressure holding type) control valves.
NOTICE
It is mandatory that the operator has a full
understanding of all instructions, safety precautions and
applicable safety regulations before operating any high force
hydraulic equipment. If any questions or concerns, contact
your local Enerpac Distributor or Authorized Service Center.
6.2 Maximum Hydraulic Working Pressure
Rated maximum hydraulic working pressure varies, depending
on the pump model:
• WAP07 Series: 1920 psi [132 bar].
• WAP15 Series: 2760 psi [190 bar].
• WAP30 Series: 5280 psi [364 bar].
WARNING
Maximum hydraulic system pressure is limited by an
internal safety relief valve that is set slightly higher than
the pump's maximum rated hydraulic working pressure.
Do not attempt to adjust, bypass or alter this valve. It is
factory set and is not user-adjustable.
Be certain that all hydraulic hoses, hydraulic cylinders
and any other connected hydraulic devices are rated at or
above the maximum hydraulic working pressure for your
pump model.
Serious personal injury or death could occur if these
instructions and precautions are not followed.
6.3 Relieving Pneumatic and Hydraulic Pressure
WARNING
Failure to observe the following instructions and
precautions could result in dangerous high pressure oil
leakage and possible skin penetration. Death or serious
personal injury could result.
Perform the following procedure before disconnecting any
hydraulic hoses or lines from either the pump manifold or a
connected device, before loosening any hydraulic fittings or
before servicing the pump or any connected devices:
1. Move the pump air on-off control to the OFF position. See Figure 9.
2. Disconnect the air supply hose from the pump air inlet
connection. Be certain that the pump air pressure gauge
indicates zero (0) psi/bar. See Figure 10.
3. Cycle the hydraulic control valve(s) to relieve residual
pressure in the pump hydraulic system (this will also
remove residual pressure in the pump pneumatic system).
Figure 11 - Pump Hydraulic Pressure Gauge
4. Verify that all hydraulic pressure is completely relieved:
-Check that the pump hydraulic pressure gauge indicates
zero (0) psi/bar. See Figure 11.
-Verify that other hydraulic pressure gauges in the system
(if present) also indicate zero (0) psi/bar.
-Be sure that no hydraulic hoses are sti, which may
indicate trapped pressure.
5. If any hydraulic pressure remains, cycle the control valve(s)
again to relieve pressure. Then, re-check the hydraulic
pressure gauge(s) to be sure that no pressure is indicated.
7.0 INSPECTION, MAINTENANCE & STORAGE
• Periodically check the pump for loose hydraulic connections
leaks and obvious problems. Replace any damaged
components immediately.
• Monitor the pump oil temperature during operation. Do not
exceed oil temperatures above 150°F [65°C].
• Install dust caps and plugs on all hydraulic couplings after
the hydraulic hoses are disconnected from the pump.
• Keep the pump and all hydraulic components clean.
• Change the hydraulic oil at the recommended interval shown
in Section 8.2 of this manual. Change the oil immediately if
dirty, or if contamination is suspected.
• Store the pump in a clean, dry and secure location. Keep the
stored pump and hoses away from heat and direct sunlight.
• If repair parts are required, refer to the Enerpac website
(www.enerpac.com) for the repair parts sheet applicable to
your pump model.
NOTICE
Hydraulic equipment must only be serviced by a
qualified hydraulic technician. For repair service, contact the
Enerpac Authorized Service Center in your area.
8.0 ROUTINE MAINTENANCE PROCEDURES
8.1 Preparation
Always perform the following steps before beginning any
maintenance or repair procedures contained in Section 8:
1. Disconnect the air supply hose and fully relieve pneumatic
and hydraulic pressure. Follow the steps in Section 6.3.
2. Disconnect hydraulic hoses from hydraulic manifold.
Install plugs in open ports.
3. Position the pump on a workbench or other substantial
work surface.
NOTICE
Pump dry weight is approximately 71 lb [32.2 Kg]. This
figure does NOT include the weight of the hydraulic oil or the
control valves. Actual weight will vary, depending on amount of
oil in reservoir and number of control valves installed on manifold.
4. Remove the two screws located on either side of the pump
shroud. Remove the pump shroud and position it behind
the pump on the work surface. Be careful not to damage
the flexible air tubing, which must remain connected. See
Figure 12.

10
Figure 12 - Pump Shroud Removal
(Note: air tubing removed for illustrative purposes)
8.2 Oil Change
Change the hydraulic oil every 12 months. If the oil is dirty
or contaminated, change the oil immediately. Refer to the
following steps:
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Refer to maintenance
preparation procedures in Section 8.1 of this manual. Also
refer to pressure relief procedures in section 6.3.
2. Place the pump on a workbench or other substantial work
surface. To allow draining in the next step, position the
pump so that the side with the oil drain plug is even with
the edge of the workbench.
3. Place a suitable container under the pump oil drain plug.
The container capacity must be 1.8 gallon [6.8 liter] or
larger.
4. Slowly unscrew the oil drain plug and remove it. See
Figure 13. Allow the old oil to flow into the container.
NOTICE
Dispose of used oil in accordance with all applicable
laws and regulations.
5. Clean and reinstall the oil drain plug.
6. Remove the oil fill plug. See Figure 4.
NOTICE
Use of Enerpac HF hydraulic oil is strongly
recommended. Refer to Section 5.3 for additional information.
7. Slowly pour new oil through the oil fill opening while
watching the oil sight gauge. Continue until reservoir is
1/2 to 3/4 full. DO NOT OVERFILL.
8. Reinstall the oil fill plug.
Figure 13 - Drain Plug
Drain Plug
9. Reconnect hoses and test pump operation without load
before placing the pump back into service. Cycle the
hydraulic cylinders (or other hydraulic actuators) until all
air is removed and operation is smooth.
8.3 Suction Strainer Replacement
Two suction strainer filters are located inside the pump oil
reservoir. Replace these strainers if there is a noticeable drop in
oil flow or if it is suspected that the oil is dirty or contaminated.
Refer to the following steps:
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Remove pump shroud. Refer
to maintenance preparation procedures in Section 8.1 of
this manual. Also refer to pressure relief procedures in
Section 6.3.
2. Place the pump on a workbench or other substantial work
surface.
3. Fully drain all oil from the hydraulic reservoir. Refer to the
steps in Section 8.2.
NOTICE
To ensure cleanliness, the hydraulic oil MUST be
changed whenever the suction strainers are replaced.
4. Check that the pump hydraulic pressure gauge indicates
zero (0) psi/bar. Hydraulic pressure must be completely
relieved before loosening hydraulic fittings in the following
step.
5. Loosen the connectors located on each end of the
hydraulic manifold. Refer to Figure 14.
Figure 14 - Connectors
(Located on each end of manifold)

11
11. Install two new oil suction strainers. Be sure that each
new suction strainer is oriented as shown in Figure 16.
Hydraulic fittings must be assembled so that flat side of
suction strainer is parallel with reservoir floor. Refer to the
pump repair parts sheet for part number.
12. Clean the mating surfaces of the reservoir and the
hydraulic manifold cover plate.
13. Check the condition of the reservoir gasket. If the gasket
is worn or deteriorated, install a new reservoir gasket.
Refer to the pump repair parts sheet for part number.
14. Remove caps and plugs installed in step 8.
15. Carefully lift the manifold and cover plate assembly and
position it directly over the hydraulic reservoir opening.
Note the locating tabs on either side of the reservoir
flange.
16. Slowly lower the assembly until the manifold cover plate
is supported by the hydraulic reservoir flange. Align bolt
holes.
17. Apply PTFE pipe thread sealing tape to the threads of the
two hydraulic tubes. Engage threads of connectors and
hydraulic tubes. Tighten each connector until finger tight.
DO NOT final tighten at this time.
18. Secure the manifold cover plate to the hydraulic reservoir
with twelve bolts and sealing washers. Torque each bolt to
20-22 in-lbs [2.26-2.49 Nm].
19. Tighten both connectors an additional 2-3 full turns
beyond finger tight.
20. Refill the hydraulic reservoir. Refer to the steps in Section
8.2 of this manual.
21. Reconnect hoses and test pump operation without load
before placing the pump back into service. Cycle the
hydraulic cylinders (or other hydraulic actuators) until all
air is removed and operation is smooth.
8.4 Air Filter/Regulator
The air filter/regulator contains a removable filter bowl and
cleanable air filter. Periodically check the filter bowl for
accumulated water and clean the filter. Refer to the following
procedure:
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Remove pump shroud. Refer
to maintenance preparation procedures in Section 8.1 of
this manual. Also refer to pressure relief procedures in
Section 6.3.
2. Locate the air filter/regulator. It is mounted inside the
pump shroud.
3. Grasp the filter bowl and depress the release button.
Pull straight down and remove the filter bowl from the air
regulator. See Figure 17.
4. Drain any accumulated water from the filter bowl. Remove
any dirt or debris. Wipe the filter bowl clean.
5. A filter element is located inside the air regulator housing.
Using a clean rag, wipe o any loose dirt or dust from the
filter element.
NOTICE
If the filter element is very dirty, or if the filter bowl is
damaged, replace the entire filter/regulator. Replacement parts
are not available from Enerpac for this device. Order complete
filter/regulator unit. Refer to pump repair parts sheet for filter/
regulator part number.
6. Reinstall the filter bowl in the air regulator. Be sure it locks
into place.
7. Reconnect the air supply hose to the pump air inlet
connection. Test pump operation without load before
placing the pump back into service.
Figure 15 - Manifold Assembly
6. Remove the bolts and sealing washers securing the
hydraulic manifold and cover plate to the hydraulic
reservoir. See Figure 15.
NOTICE
Hydraulic manifold and cover plate assembly
weighs approximately 20 lb. [9 kg]. Manifold mounted control
valves will add additional weight.
7. Carefully lift the manifold and cover plate assembly
straight up until it is removed from the hydraulic reservoir.
See Figure 15. Set this assembly aside, in a clean and dry
location.
8. Install caps or plugs over all open fittings to prevent dirt
entry.
9. Inspect the hydraulic reservoir. Remove any sludge or
debris from the reservoir interior.
10. Unscrew and remove each oil suction strainer. Discard
both used suction strainers. See Figure 16.
Figure 16 - Suction Strainer
1
2
3
Key:
1. Connector
2. Adapter
3. Suction Strainer

12
Filter Bowl
Figure 17 - Air Regulator and Filter Bowl
Air Regulator
8.5 Air Shuttle Valve Routine Maintenance
The pump air shuttle valve is located on the right-hand side of
the pump element (when the pump is viewed from the rear).
The valve end cap and piston must be inspected, cleaned
and lubricated at the recommended time interval to ensure
optimum pump operation.
NOTICE
Disassemble and inspect the pump air shuttle valve
at least every 100,000 cycles.
Refer to Figure 18 during the following procedures.
8.5.1 Disassembly
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Remove pump shroud. Refer
to maintenance preparation procedures in Section 8.1 of
this manual. Also refer to pressure relief procedures in
Section 6.3.
2. To aid end cap removal, install an M5 bolt (user supplied)
in the tapped center hole of the end cap.
WARNING A small amount of pressurized trapped air
may be present under the end cap. End cap may eject
suddenly as it is being removed, even if the pump air
pressure gauge indicates zero (0) psi/bar. To prevent
possible eye injury, wear safety goggles during disassembly
procedures.
3. Using a snap ring pliers, remove the snap ring.
4. Using a suitable needle nose pliers, grasp the head of the
M5 bolt. Pull straight up and remove the end cap from the
bore of the shuttle valve assembly.
5. Remove the M5 bolt from the end cap and reinstall it in the
tapped center hole of the piston.
6. Using a suitable needle nose pliers, grasp the head of the
M5 bolt. Pull straight up and remove the piston from the
bore of the shuttle valve assembly.
8.5.2 Inspection
1. Using a clean, lint free rag, remove the old grease lubricant
from piston, end cap, and from the valve assembly bore.
2. Inspect piston and end-cap for excessive wear, nicks,
scratches, corrosion or other problems.
2
3
4
1
*
Figure 18 - Air Shuttle Valve Components
1. Snap Ring
2. End Cap
3. Piston
4. Housing
*M5 Bolt
(user-supplied)
3. Check the condition of all piston seals. Replace entire
piston assembly if seals are worn or damaged.
NOTICE
If obvious wear or damage is indicated, replace the
entire air shuttle valve assembly. Individual components and
seals are not sold separately.
8.5.3 Reassembly
1. Using a small brush, lubricate the O-rings and seals on the
piston with lithium grease.
2. If removed, re-install the M5 bolt in the tapped center hole
of the piston.
3. Align the piston with the bore opening and carefully
reinstall it in the bore.
4. Using a suitable needle nose pliers, apply firm pressure to
the head of the M5 bolt until the piston has bottomed out
in the bore of the housing. Then, unscrew and remove the
M5 bolt.
5. Align the end cap with the bore opening and position it in
the bore.
6. Using a suitable needle nose pliers, apply firm pressure to
the end cap until it has bottomed-out, and is located just
below the snap ring groove.
7. Using a snap ring pliers, reinstall the snap ring.
8.6 Pump Element Air Switch Maintenance
The pump element contains two air switches, one located
on each side of the pump element. The air switches must be
inspected, cleaned and lubricated at the recommended time
interval to ensure optimum pump performance.
NOTICE
Disassemble and inspect the pump air switches at
least every 100,000 cycles.

13
8.6.3 Reassembly
1. Using a small brush, lubricate the piston surface, O-rings
and seals with lithium grease.
2. Place the coil spring around the piston.
3. Carefully place the piston and coil spring into the air switch
bore.
4. Engage the threads on the cap nut with the threads in the
air switch bore. Using a wrench, tighten the end cap snug
tight.
8.7 Air Exhaust Muer
The pump air shuttle valve contains a muer assembly. The
muer felt must be replaced at the recommended time interval
to ensure optimum pump performance.
NOTICE
Replace the muer felt at least every 100,000
cycles.
Replace the air exhaust muer felt as described in the following
steps:
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Remove pump shroud. Refer
to maintenance preparation procedures in Section 8.1 of
this manual. Also refer to pressure relief procedures in
Section 6.3.
2. Loosen and remove the four screws securing the cover to
the air shuttle valve. See Figure 21.
3. Remove the cover. Remove and discard the old muer
felt.
NOTICE
Exhaust muer felt is not purchasable from Enerpac,
but is available from many pneumatic maintenance supply
distributors.
4. Place the new muer felt inside the cover.
5. Position the cover plate against the air shuttle valve and
secure it with four screws.
123
4
Figure 21 - Air Exhaust Muffler
1. Screw
2. Cover
3. Muer Felt
4. Air Shuttle Valve
Key:
Figure 19 - Air Switches
(viewed with shroud removed)
123
Figure 20 - Air Switch - Exploded View
1. Cap Nut
2. Coil Spring
3. Piston
Key:
Always perform maintenance procedures for BOTH air
switches. Follow the instructions in sections 8.6.1 through
8.6.3 for each air switch. Refer to Figures 19 and 20.
8.6.1 Disassembly
1. Fully relieve pressure in the pneumatic and hydraulic
circuits. Disconnect hoses. Remove pump shroud. Refer
to maintenance preparation procedures in Section 8.1 of
this manual. Also refer to pressure relief procedures in
Section 6.3.
2. Using an adjustable wrench, loosen and remove the air
switch cap nut.
3. Using a right-angle needle nose pliers, grasp the end of
the air switch piston and carefully pull it straight out of the
air switch bore.
4. If it was not removed with the piston, remove the coil
spring.
8.6.2 Inspection
1. Using a clean, lint free rag, remove old grease lubricant
from the air switch bore, the piston and the coil spring.
2. Inspect piston for obvious wear, nicks, scratches,
corrosion or other problems. Recondition or replace
piston as required.
3. Check the condition of both piston seals. Replace entire
piston assembly if seals are worn or damaged.
NOTICE
If obvious wear or damage is indicated, replace the
entire air switch assembly. Individual components and seals
are not sold separately.
4. Inspect the coil spring. Replace if broken, bent or obviously
worn. Refer to pump repair parts list for part number.

14
TROUBLESHOOTING GUIDE
Problem Possible Cause Action
Pump does not cycle. No air pressure at supply. Check air supply.
Pump air-shuto valve closed. Open pump air-shuto valve.
Pump air pressure regulator set too low. Check pressure regulator setting.
Pump air exhaust muer dirty. Clean or replace the muer felt. Refer to Section 8.7
of this manual.
Pump air shuttle valve needs cleaning and
lubrication.
Refer to procedure in Section 8.5 of this manual.
Pump air motor worn or damaged. Contact Enerpac Authorized Service Center.
Pump element jammed. Contact Enerpac Authorized Service Center.
Pump fails to build hydraulic
pressure or builds less than
desired pressure.
Low air pressure or volume at air supply. Check air supply.
Pump air pressure regulator set too low. Check regulator setting.
Pump air exhaust muer dirty. Clean or replace the muer felt. Refer to Section 8.7
of this manual.
Control valve returning oil to reservoir. Change position of control valve.
Low oil level in reservoir. Check oil level. Add oil as required.
Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to
Section 8.3 of this manual.
Oil leakage at hydraulic hoses, fittings or connected
devices.
Replace leaking components as required.
Internal leakage in control valve or valve manifold. Repair or replace components as required.
Internal leakage in pump element. Pump element
worn or damaged.
Contact Enerpac Authorized Service Center.
Jerky or erratic pump operation. Low air pressure or volume at plant air supply. Check plant air supply.
Air in hydraulic lines. Remove air as described in Section 5.10 of this
manual.
Hydraulic oil dirty. Change hydraulic oil. Use Enerpac HF oil. Refer to
Section 8.2 of this manual.
Low oil level in reservoir. Check oil level. Add oil as required. Refer to sections
5.3 and 5.4 of this manual.
Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to
Section 8.3 of this manual.
Internal leakage in pump element. Pump element
worn or damaged.
Contact Enerpac Authorized Service Center.
Pump Noise. Low air pressure or volume at air supply. Check air supply.
Pump air pressure regulator set too low. Check regulator setting. Refer to Section 5.9 of this
manual.
Pump air exhaust muer dirty. Clean or replace the muer felt. Refer to Section 8.7
of this manual.
Oil leakage Loose connections. Tighten loose connections. Replace any worn or
damaged connectors.
Worn or damaged components. Repair or replace components as required.
(continued on next page)
9.0 TROUBLESHOOTING
Refer to the troubleshooting guide when diagnosing pump operational problems. Please note that the troubleshooting guide is
not all-inclusive, and should be considered only as an aid to help diagnose the most common possible problems.
For repair service, contact your nearest Enerpac Authorized Service Center. As required, also refer to the troubleshooting
information provided with your hydraulic control valves and other system components.

15
TROUBLESHOOTING GUIDE (continued)
Problem Possible Cause Action
Excessive moisture in pump
exhaust.
Excessive water and/or lubricant in supply air. Reduce moisture in air. Install water separator.
Note: Pump components are self-lubricating.
Lubricated air is permitted, but not required.
Pump air filter bowl needs draining. Check bowl for water. Drain as required. Refer to
Section 8.4 of this manual.
Pump air filter dirty. Clean air filter element. Refer to Section 8.4 of this
manual.
Internal leakage in pump element. Pump element
damaged or worn.
Contact Enerpac Authorized Service Center.
Low oil flow rate. Reservoir not vented. Open vent screw on reservoir. Refer to Section 5.7 of
this manual.
Pump air filter bowl needs draining. Check bowl for water. Drain as required. Refer to
Section 8.4 of this manual.
Pump air filter dirty. Clean air filter element. Refer to Section 8.4 of this
manual.
Internal leakage in pump element. Pump element
worn or damaged.
Contact Enerpac Authorized Service Center.
Low air pressure or volume at air supply. Check air supply.
Pump air pressure regulator set too low. Check regulator setting. Refer to Section 5.9 of this
manual.
Pump suction strainer elements dirty. Replace pump suction strainer elements. Refer to
Section 8.3 of this manual.
Cylinder drift. External system leak. Repair or replace leaking components as required.
Internal leak in system component. Repair or replace leaking components as required.
Cylinder will not return. Return flow blocked or restricted. Check system for blockages and make repairs
as required. Be sure that all couplers are fully
connected.
Control valve malfunction. Repair or replace control valve as required.
Air leakage. Loose air system connections. Tighten connections as required.
Worn or damaged air system components. Repair or replace components as required.

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