Enerpac HPT-1500 Use and care manual

Repair Parts Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE.
To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.
Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product.
HPT-1500 and HPN-2000
Hydraulic Hand Pumps
L2742 Rev. D 06/15 For Date Codes Beginning with the Letter “A”
Index:
English. . . . . . . . . . . . . . . . . . . . . . . .1-9
Français . . . . . . . . . . . . . . . . . . . . . . N/A
Deutsch . . . . . . . . . . . . . . . . . . . . . . N/A
Italiano. . . . . . . . . . . . . . . . . . . . . . . N/A
Español . . . . . . . . . . . . . . . . . . . . . . N/A
Nederlands . . . . . . . . . . . . . . . . . . . N/A
Portuguese . . . . . . . . . . . . . . . . . . . N/A
Finnish . . . . . . . . . . . . . . . . . . . . . . . N/A
Norwegian . . . . . . . . . . . . . . . . . . . . N/A
Swedish. . . . . . . . . . . . . . . . . . . . . . N/A
. . . . . . . . . . . . . . . . . . . . . . . . . N/A
. . . . . . . . . . . . . . . . . . . . . . . . N/A

2
Repair Parts List (Refer to figures 1 through 8)
Item Part Number Qty. Description Item Part Number Qty. Description
1 (not available) 1 Pump Base 40 DA1177349 2 Retaining Ring
6 ★ DA4416290 1 Valve Seat 41 CR581061 1 Cross Pin
7 ★ A8050110 1 Spring 42 CR339040 1 Clip
8 ★ B1011016 1 Check Ball, 3/8" 43 CL918900SR 1 Beam and Handle Assembly
11 DA4345107 1 Tie Rod 44 CM927061 1 Locking Pin
12 DC7688071 1 Valve Disc 45 ★ CM928044 1 Push-on Ring
13 ★ B1135517 1 Gasket, Square Ring 46 Y267110 1 Spring
14
★ DA3729900SR 1 Filter Assembly 47 ★✝DA6944110 1 Spring
15A ♦DC1057025 1 Reservoir 48 ★✝B1003016 1 Check Ball, 1/8"
15B ♦B1047121 2 Nut 49 DA5255026 1 Decal, Model No.
15C ♦DC663338 1 Foot 50 CR59026 1 Decal, Enerpac
15D ♦F866028 2 Machine Screw 53 CN780026 1 Decal, Vent/fill cap
16 DA4528040 1 Plunger 54 DC7812026 1 Decal, “Warning, 1500
Bar”
17 ★ DA4529566 1 Backup Ring DC7811026 1 Decal, “Warning, 2000
Bar”
18 DA4530186 1 Spacer 60 DC7831900SR 1
Safety Relief Valve, 1500 Bar
19 DA4344039 1 Bushing DC7483900SR 1 Safety Relief Valve, 2000 Bar
20 ★ DA4531249 1 Retaining Ring 61 ★DC7687108 1 Gasket
21 DA4532186 1 Gasket, Nylon 63 CR210900W 1 Bypass Valve Assy
22 ★✝DC4308059 1Pin 64
★ S3037 1 Gasket
23 ★ B1009803 1 O-Ring 65 ★ A8044110 1 Spring
24 CB180040 1 Piston 66 ★ B1005016 1 Check Ball, 3/16"
25 ★ B1257503 1 O-Ring 67
❚ ◗ (not available) 1 Block
26 ★✝F100016-6 1 Check Ball, 6 mm 71
❚ ◗ F73232 2 Sleeve
27 ★✝B1007503 1 O-Ring 72
❚ ◗ F157021 2 Gland Nut
28 ★✝DA4534628 1 Setscrew 73
❚ ◗ DC7825223SR 1 Gauge
29 ★✝DA4535167 1 Gasket 74
❚ ◗ DA6686268 1 Tube
30 ✝DC4383900SR 1
Release Housing (incl. item 31) 75
❚ ◗ ▲ DC7806689 1 Guard
31 ✝DC4452900 1 Release Spindle/Knob 76
❚ ◗ ▲ DC7807689 1 Guard Cover
33 ★♦ CU293167 1 Gasket 78
❚ ◗ CBE425028-1A
3 SHCS
34 ★♦ CL341055 1 Acorn Nut 79
❚ ◗ CBE1040120-1D
3 NUT, Hex M4
35 CN823020 1 End Cap 80
❚ ◗ DC7808038 1 Adapter
36 ★♦ B1291503 1 O-Ring 81
❚ DC7495034 1 Coupler, Female (1500 bar)
37 CN766950SR 1 Vent/Fill Cap Assembly ◗DC7708034 1 Coupler, Female (2000 bar)
39 CR214061 1 Beam Pin
★ Items included in Pump Repair Kit, P2282K1. ▲ Items included in Gauge Guard Kit, DC7806689SR.
♦Items included in Reservoir Assembly Kit, DA8384900SR. ❚ Items included in 1500 Bar Gauge Assy, DC7809900SR.
✝ Items included in Release Housing and Spindle Kit, ◗ Items included in 2000 Bar Gauge Assy, DC7810900SR.
DC4383900SR.

3
Figure 1, Exploded View, Pump Assembly
39
42
25
19
17, 18, 23
16, 20, 21, 24
65 66 6 8 61 12 13
33,
34
37,
53 36 35
60 11636444 45
41
40
46
14 15A 49 50 54
7
15B
15D
15C
40
Notes:
Torque to 60-70 in-lbs [6.8-7.9 Nm].
Torque to 25-30 ft-lbs [34-40 Nm].
Torque to 30-35 ft-lbs [40-47 Nm].
Torque to 15-19 ft-lbs [20-26 Nm].
Apply grease (roller bearing quality) to contact surfaces
of pin (item 41) and piston clip (item 42).
Remove adhesive backing from item 61 and
align holes to item 12. Then, press onto item 12.
1
2
3
5
8
9
8
3
8
1 3
5
92
1
43
Notes:
Apply Loctite 242MS to
threads before assembly.
Torque to 6-10 ft-lbs
[8-13 Nm].
Apply Loctite 242 to
threads before assembly.
Torque to 25-30 ft-lbs
[34-40 Nm].
1
2
78
76
75
73
7979
71 72 74 72 71
2
1
2
67
8081
Figure 2, Release Valve Assembly Figure 3, Gauge and Coupler Assembly
4748 26 22 29 30 27 31
28
Notes:
Apply Loctite 222MS before assembly.
Torque to 25-30 ft-lbs [34-40 Nm].
1
2
1
2

4
INSPECTION AND OVERHAUL INSTRUCTIONS – HPN AND HPT SERIES HYDRAULIC HAND PUMPS
BEFORE YOU BEGIN
1. Avoid sharp edges. Cover threaded areas as required.
2. Unless specified, do not use sharp-edged tools.
3. Ensure that the work area is clean and dry.
4. Before repairing the pump, see troubleshooting guide at
the end of this document to help identify possible pump
malfunctions.
5. Be sure the proper tools and supplies before beginning
any disassembly procedures. See the Tools and Supplies
section of this procedure.
WARNING: Be certain that hydraulic pressure is
completely relieved (0 psi/bar) and that all hoses are
removed from the pump. Never attempt to service the
pump while it is pressurized.
CAUTION: Standard safety procedures are to be
followed during disassembly and reassembly procedures
to minimize any possibility of injury.
TOOLS AND SUPPLIES
Be sure that the following tools and supplies are available
BEFORE beginning disassembly or reassembly procedures:
• Calibrated torque wrenches
• Allen wrenches
• O-ring pick
• Rubber mallet
• Small hammer and punch
• 5 ton [44 kN] press
• Diamond hone tools (See Figure 9 for fabrication instructions)
• Roller bearing grease
• Loctite 222MS, 242 and 242MS thread locking compound
• Enerpac hydraulic oil
REPLACEMENT PARTS
To ensure optimum performance, it is recommended that
the following items be replaced with new parts during
reassembly: 3/8" check ball (item 8), backup ring (item 17),
spacer (item 18), O-ring (item 23), O-ring (item 25), 6 mm check
ball (item 26), O-ring (item 27), gasket (item 29), 1/8" check ball
(item 48), gasket (item 64) and 3/16" check ball (item 66).
Replace other parts as required if worn or damaged, or if
troubleshooting procedures indicate that replacement is
necessary. See page 2 for parts list. If parts are included in a kit,
it is strongly recommended that all kit parts applicable to your
pump model be installed.
DISASSEMBLY
Disassemble the pump as described in the following steps.
Refer to Figures 1, 2 and 3 for numbered callouts in parenthesis
(item . . .).
1. Fully open the pump release valve to relieve any trapped
pressure. Be sure that pressure gauge indicates zero (0)
psi/bar.
2. Open the vent/fill cap (item 37). Drain all oil into a suitable
container. Dispose of used oil in accordance with applicable
laws and regulations.
3. Remove acorn nut (item 34), gasket (item 33) and end cap
(item 35) from reservoir (item 15A).
4. Remove the reservoir (item 15A) and square ring gasket
(item 13) from the pump base (item 1). The vent/fill cap (item
37) will be removed with the reservoir.
5. Unscrew tie rod (item 11) from the pump base (item 1).
6. Remove retaining rings (item 40) from beam pin (item 39)
and cross pin (item 41).
7. Remove cross pin (item 41) from handle assembly (item 43)
and clip (item 42). Remove clip (item 42) from plunger (item
16).
8. Remove beam pin (item 39) from handle assembly (item
43). Remove handle assembly (item 43) from pump base
(item 1).
Important: In the following steps, handle machined parts with
care so that they are not damaged during disassembly.
9. Remove plunger, (item 16), piston (item 24), retaining ring
(item 20) and nylon gasket (item 21) as an assembly.
10. Remove O-ring (item 25).
11. Unscrew bushing (item 19). Remove backup ring (item 17),
spacer (item 18) and O-ring (item 23) from the bore.
12. Remove the filter assembly (item 14) by pulling it straight out
of the valve disc (item 12). Remove any debris from the filter
screen. Replace if damaged or clogged.
13. If necessary, remove the bypass valve assembly (item 63)
and gasket (item 64) from the valve disc (item 12).
14. Remove the square ring gasket (item 13) from around the
valve disc (item 12).
Note: Check ball (item 8) and spring (item 7) may drop out when
valve disc (item 12) is removed in the next step.
15. Remove the valve disc (item 12), gasket (item 61), 3/8"
check ball (item 8) and spring (item 7) from the pump base
(item 1).
16. If necessary, remove the safety relief valve (item 60) from the
pump base (item 1).
17. Remove the valve seat (item 6), 3/16" check ball (item 66)
and spring (item 65) from the pump base (item 1).
18. Remove setscrew (item 28) from release housing (item 30).
Remove release spindle (item 31) and O-ring (item 27) as an
assembly.
19. Remove release housing (item 30) and O-ring (item 29) from
pump base (item 1).
20. Remove pin (item 22), spring (item 47) and 6 mm check ball
(item 26) from the release spindle hole. Note: an oil film may
retain these parts.
21. If necessary, remove gauge and coupler assembly
components (items 67-81) from the pump base (item 1).
22. If necessary, remove push-on ring (item 45), spring (item 46)
and locking pin (item 44).
23. If necessary, remove machine screws (item 15D), foot (item
15C) and nuts (item 15B).

5
b. Remove adhesive backing from new gasket (item 61).
c. Align holes. Place the gasket - glue side down - onto the
valve disc (item 12).
Note: During the following step, align matching holes in valve
disc (item 12) with safety relief valve (item 60) and valve seat
(item 6). Be sure that 3/8" check ball (item 8) and spring (item 7)
remain in place as valve disc (item 12) is installed.
10. Place the valve disc (item 12) into the pump base main
opening with the gasket side down. Using a rubber mallet,
lightly tap the valve disc (item 12) into the opening until it is
fully seated.
11. Install new gasket (item 64) and bypass valve (item 63) on
the valve disc (Location “D”, Figure 6) Torque to 60-70 in-lbs
[6.8-7.9 Nm].
Important: The bypass valve (item 63) is factory set at 200-250
psi [13.8-17.2 bar]. DO NOT attempt to readjust the setting.
12. Using a rubber mallet, lightly tap the filter assembly (item
14) into the oil inlet port (Location “C”, Figure 6) on the valve
disc (item 12). Important: Before installation, be sure the
filter assembly is clean and free of debris.
REASSEMBLY
Reassemble the pump as described in the following steps. Refer
to Figures 1 through 4 for numbered callouts in parenthesis
(item . . .). Refer to other figures as indicated.
Important: Lubricate all components with Enerpac hydraulic oil
before assembly.
1. Flush the interior of the pump base (1). This area must be
clean and free of dirt, chips, shavings or debris.
2. Using a 5 ton [44 kN] press, use check balls (items 8 and 66)
to coin the ball seats:
a. Using a new 3/8" check ball (item 8), coin the ball seat
located on valve disc (item 12). Apply a coining force of 410-
430 psi [28-29 bar].
b. Using a new 3/16" check ball (item 66), coin the ball seat
located on the valve seat (item 6). Apply a coining force of
410-430 psi [28-29 bar].
3. Position the pump base (item 1) so that the main (reservoir)
opening is facing up.
4. Place spring (item 65) large end down into hole (Location
“B”, Figure 5). Place the 3/16" check ball (item 66) onto end
of spring (item 65).
5. Thread the valve seat (6) into hole (Location “B”, Figure 5).
Be sure that spring (65) and 3/16" check ball (66) remain in
place. Torque to 25-30 ft-lbs [34-40 Nm].
6. If it requires replacement, install a new safety relief valve
(item 60) into tapped hole (Location A, Figure 5). Torque to
30-35 ft-lbs [40-47 Nm].
WARNING: The safety relief valve is factory set to
prevent over pressurization of the pump. Do not
attempt to readjust or disable the safety relief valve.
Serious personal injury and/or equipment damage could result.
Important: The safety relief valve (item 60) is color coded with
BLACK ink for HPT-1500 models and with RED ink for HPN-
2000 models. Be certain to use the correct valve for your pump
model. Refer to parts list on page 2 for part numbers.
7. Place spring (item 7) inside valve seat (6).
8. Place 3/8" check ball (item 8) on top of spring (item 7).
9. Inspect the valve disc gasket (item 61). If nicks, cuts or other
damage is present, replace the gasket as described in steps
a through c:
a. Remove the old valve disc gasket (item 61) from the valve
disc (item 12). Be sure the valve disc surface is clean and
free of any adhesive residue.
AB
Figure 5, End View of Pump with Valve Disc Removed
Figure 6, End View of Pump with Valve Disc InstalledFigure 4, Inlet Check Valve and Valve Disc
65 66 6
78
61
12
13
NOTE: Torque to
25 - 30 ft-lbs.
[34-40 Nm]
Key:
A - Safety Relief Valve (item 60)
B - Inlet Check Valve Assy. (see Fig. 4)
(Viewed from rear of pump)
Valve Disc
(item 12)
D
C
Key:
C - Filter Assy. (item 14)
D - Bypass Valve and Gasket (items 63, 64)
(Viewed from rear of pump)

6
13. Place square ring gasket (item 13) into the groove between
the valve disc (item 12) and the pump base main opening.
14. Slide tie rod (item 11) through the center hole of the valve
disc (item 12) and into the tapped center hole of the pump
base (item 1). Tighten hand tight.
15. If removed, secure foot (item 15C) to reservoir (item 15A)
with machine screws (item 15D) and nuts (item 15B).
16. Place reservoir (item 15A) onto pump base (item 1). While
installing reservoir, position chain of vent/fill cap (item 37)
around tie rod (item 11). Tap reservoir into place using a
rubber mallet.
17. Install O-ring (item 36) in groove on end cap (item 35).
18. Place end cap (item 35) on reservoir (item 15A). Secure with
gasket (item 33) and acorn nut (item 34).
19. Position pump flat on table, so that the plunger bore is
facing up.
20. If removed, insert locking pin (item 44) through hole in pump
base (item 1). Assemble spring (item 46) and push-on ring
(item 45) onto locking pin (item 44).
21. Place new O-ring (item 25) into the groove at the top of the
plunger bore.
22. Place new spacer (item 18), new O-ring (item 23) and new
backup ring (item 17) into the hole at the bottom of the
plunger bore.
23. Thread bushing (item 19) into the hole at the bottom of
the plunger bore. Using a hand torque wrench, tighten the
bushing to 30-35 ft-lbs [40-47 Nm].
24. Assemble piston (item 24), plunger (item 16) nylon gasket
(item 21) and retaining ring (item 20). See Figure 7.
25. Apply hydraulic oil to the plunger bore. Grease the piston
end and place the plunger assembly (items 16, 20, 21 and
24) into the bore.
26. Place clip (item 42) onto top of plunger (item 16).
27. Place cross pin (item 41) through holes in handle assembly
(item 43).
28. Apply grease (roller bearing quality) to contact surfaces of
cross pin (item 41) and clip (item 42). Slide handle assembly
(item 43) into place on pump, ensuring that cross pin
engages with clip.
29. Place beam pin (item 39) through holes in handle assembly
and pump base (item 1).
30. Secure beam pin (item 39) and cross pin (item 41) with
retaining rings (item 40).
31. Tip the pump on its side, so that the release spindle hole is
facing up.
Note: Steps 32 and 33: If using a new pump base (item 1), coin
the ball seats using a hammer and punch (as described in step
32) and a press (as described in step 33).
If the old pump base is being re-used, re-coining of ball seats
is not necessary. Instead, clean-up each seat using the correct
diamond hone tool. See Figure 9 for diamond hone tool sizes
and fabrication details.
Important: To prevent damage to ball seat in the following step,
do not strike the check ball (item 48) with great force.
32. Place a new 1/8" check ball (item 48) into the release spindle
hole. Using a small hammer and punch, lightly tap the check
ball (item 48) to coin the ball seat. Or, use diamond hone tool
DT-1560-1 to clean-up seat.
33. Using a new 6 mm check ball (item 26), coin the release
spindle ball seat. Apply a coining force of 800-820 psi [55-
56 bar] using a 5 ton [44 kN] press. Or, use diamond hone
tool DT-1560-5 to clean-up seat.
16
25
24
21
20
19
17
23
18
NOTE: Torque to
30 - 35 ft-lbs.
[40-47 Nm]
Figure 7, Plunger Assembly Components
30 - NOTE: Torque to 25 - 30 ft-Lbs.
[34-40 Nm]
28
29
31 27 22 26 47 48
NOTE: Apply
Loctite 222MS
Figure 8, Release Valve Components

7
2.50 [63.50]
2
1
0.03 [0.76] x 45°
(see ø Dim A)
2.62 [66.54]
120°
(see ø Dim B)
34. Place spring (item 47) and new 6 mm check ball (item 26)
into the release spindle hole. Install new gasket (item 29) flat
side down.
35. Thread the release housing (item 30) into the release spindle
hole. Torque to 25-30 ft-lbs [34-40 Nm].
36. Place pin (item 22) into release housing (item 30). Install
new O-ring (item 27) on release spindle (item 31). Thread
the release spindle (item 31) into the release housing (item
30) but do not tighten.
37. Apply Loctite 222MS to threads of setscrew (item 28). Install
and hand tighten setscrew.
38. Position pump flat on table, so that the pump reservoir is
horizontal and the handle is facing up.
39. If removed, assemble gauge and coupler components as
described in steps a through d:
a. Slip gland nuts (item 72) over tube (item 74). Thread
sleeves (item 71) onto both ends of tube, leaving two or
three threads exposed at each end.
b. Apply Loctite 242 to threads on gland nuts (item 72).
Thread the gland nuts into ports on pump base (item 1) and
gauge block (item 67). Torque to 25-30 ft-lbs [34-40 Nm].
c. Install gauge (item 73), adapter (item 80) and coupler (item
81) to gauge block (item 67).
d. If removed, install guard (item 75) and guard cover (item
76). Secure with capscrews (item 78) and hex nuts (item
79). Apply Loctite 242MS to threads of capscrews (item 78)
before installing. Torque to 6-10 ft-lbs [8-13 Nm].
40. Fill the pump reservoir with Enerpac hydraulic oil. Note: The
HPN and HPT Series pumps have a usable oil capacity of 155
cu. in [2540 cm3]. Oil level should be up to the indicator mark
on the end cap. DO NOT overfill.
DIAMOND HONE TOOLS
Diamond hone tools are used to smooth and deburr the ball seat
surfaces during pump reassembly procedures. There are four
dierent diamond hone tool sizes:
• DT-1560-1 - Used on ball seat for 1/8" check ball (item 48).
• DT-1560-3 - Used on ball seat for 3/16" check ball (item 66).
• DT-1560-5 - Used on ball seat for 6 mm check ball (item 26).
• DT-1560-9 - Used on ball seat for 3/8" check ball (item 8).
These tools can be purchased from Continental Diamond Tool
Corporation or may be fabricated by a qualified source, Refer to
Figure 9 for additional information.
Use each diamond hone tool as described in the following steps:
1. Clean the ball seat surface. Remove any oil or debris.
2. Be sure that the mating surface of the diamond hone tool is
clean.
3. Gently apply diamond hone tool to seat, rotating it back and
forth. At first, there will be a “rough” feel. Continue to apply
gentle pressure and rotation until the roughness is gone.
4. Clean the ball seat surface after using the diamond hone
tool.
Important: Always install a new check ball of the proper size
after using the diamond hone tool. DO NOT reuse an old check
ball.
Figure 9, Fabrication Details - Diamond Hone Tools
All dimensions in inches [mm] unless otherwise noted.
FABRICATION INSTRUCTIONS:
1. Make stem as shown.
2. Place ball in countersink seat and braze in place.
3. Clean up excess braze. Do not damage ball.
4. Electroplate front half of ball with diamond grit
400, 0.0012 inch, +0.0005/-0.0000 inch [0.03048
mm, +0.0127/-0.0000 mm] on the side.
5. Remove all burrs and sharp edges.
Braze all around
Material: hardened steel ball
Material: A-2 drill rod
DETAIL A
SCALE 4:1
Item 1 - Ball
Item 2 - Stem
Diamond coat this half
of ball (see note 4)
Tool Size ø Dim. A (Item 1)
inch [mm]
ø Dim. B (Item 2)
inch [mm]
DT-1560-1 0.125 [3.175] 0.09 [2.286]
DT-1560-3 0.1875 [4.7625] 0.156 [3.9624]
DT-1560-5 0.250 [6.35] 0.218 [5.5372]
DT-1560-9 0.375 [9.525] 0.343 [8.7122]
If desired, tools may be purchased from:
Continental Diamond Tool Corporation
P.O. Box 126
1221 Hartzell Street
New Haven, Indiana USA 46674-0126
www.cdtusa.net

8
Problem Probable Cause Remedy
1. Pump does not hold pressure. a. Release spindle knob not tight. Check that release spindle knob is tight. When the
knob is firmly tightened by hand, the valve is closed.
DO NOT use tools!
b. Low or no oil in reservoir. Fill reservoir with Enerpac oil.
c. Leakage from hose, fittings, coupler or
gauge assembly.
Check for leaks. Tighten and/or replace fittings.
Note: Refer to Figure 3 for Loctite locations.
d. Leakage at release valve check ball (item 26). Replace check ball (item 26) and use diamond hone
tool DT-1560-5 to clean-up seat. See Figure 9 for
tool fabrication details.
2. Pump loses pressure and the handle
rises.
a. Leakage at outlet check ball (item 48). Inspect spring (item 47), check ball (item 48) and ball
seat for obvious wear, corrosion or damage.
Replace check ball (item 48) and use diamond hone
tool DT-1560-1 to clean-up seat. See Figure 9 for
tool fabrication details.
Note: Refer to parts list on page 2 for numbered items in parenthesis (item . . .). Also see figures 1 through 8.
TROUBLESHOOTING
TESTING
1. Verify that the gauge and coupler assembly is installed on
the pump (items 67 through 81). This assembly must be
installed before pump testing begins.
2. Open reservoir vent/fill cap and check the oil level. If oil level
is low, add oil until the oil level is up to the indicator mark on
the end cap. DO NOT overfill. Use only Enerpac oil.
3. Reinstall the vent/fill cap and turn it to the VENT position.
4. Attach a hose with one open end to the pump coupler. Place
the open end in a container. The container will be used to
catch purged oil in step 6.
5. Close the release valve by turning the release spindle knob
clockwise.
Important: The release valve is designed to close with hand
pressure only. Use of tools to close valve can result in damage
to the valve and/or valve seat.
6. Operate the pump handle (using full strokes) six or more
times as necessary to purge any contaminants from the
pump mechanism.
7. Remove hose from pump coupler. Dispose of used oil in
accordance with applicable laws and regulations.
8. Recheck oil level as described in step 2. Add oil if low.
Reinstall the vent/fill cap and turn it to the VENT position.
WARNING: Do not stand directly over the pump
handle. It is possible for the pump handle to “kick
back.” Keep your body to the side of the pump and
away from the line of force of the handle.
WARNING: Keep away from opening of coupler (item
81) during pump testing. A high pressure oil stream
can penetrate the skin. Serious personal injury could
result if leakage of coupler occurs while the pump is under
pressure.
9. While watching the pressure gauge, operate the pump handle
to build pressure. Continue until the gauge indicates 10,000
psi [689 bar].
10. Check for drift. The maximum allowable drift (pressure drop)
is 250 psi [17.2 bar] in 10 seconds, from a steady state
pressure condition.
Note: if pressure drop is within allowable limits, continue on to
steps 11 through 14.
11. While watching the pressure gauge, operate the pump handle
to build additional pressure:
• Model HPT-1500 - pressurize pump to 21,600 psi
[1489 bar].
• Model HPN-2000 - pressurize pump to 27,000 psi
[1861 bar].
12. Visually inspect pump for leakage or other obvious problems
while it is under pressure.
13. Continuously monitor the pressure gauge. The maximum
allowable drift (pressure drop) is 250 psi [17.2 bar] in 10
seconds.
14. If pump fails to hold pressure, refer to Step 1 of the
Troubleshooting section for possible causes.

9
Problem Probable Cause Remedy
3. Pump does not build pressure. a. Low or no oil in reservoir. Fill reservoir with Enerpac oil.
b. Oil filter screen clogged with debris. Flush pump. Replace filter assembly (item 14).
Drain old oil from reservoir and refill with Enerpac oil.
c. Damaged sealing components on the pump
plunger assembly.
Inspect and replace sealing components (items 17,
18, 21, 23 and 25) as required.
d. Leakage at small inlet check ball (item 66). Inspect spring (item 65), check ball (item 66) and
valve seat (item 6) for obvious wear corrosion or
damage.
Replace check ball (item 66) and use diamond hone
tool DT-1560-3 to clean-up seat. See Figure 9 for
tool fabrication details.
e. Leakage at large inlet check ball (item 8). Inspect spring (item 7), check ball (item 8) and
ball seat on valve disc (item 12) for obvious wear,
corrosion or damage.
Replace check ball (item 8) and use diamond hone
tool DT-1560-9 to clean-up seat. See Figure 9 for
tool fabrication details.
f. Gasket (item 64) leaking. Inspect gasket (item 64). Replace if worn or
damaged.
g. Bypass valve (item 63) damaged. Replace bypass valve (item 63).
Important: Bypass valve on HPN and HPT series
pumps is factory set. DO NOT attempt to readjust.
h. Safety relief valve (item 60) damaged. Replace safety relief valve (item 60).
Important: Safety relief valve on HPN and HPT
series pumps is factory set. DO NOT attempt to
readjust.
4. Pump does not create flow. a. Low or no oil in reservoir. Fill reservoir with Enerpac oil.
b. Pump not vented. Open vent/fill cap.
c. Couplers not properly connected. Correctly connect the couplers.
d. Oil filter screen clogged with debris. Flush pump. Replace filter assembly (item 14).
Drain old oil from reservoir and refill with Enerpac oil.
e. Debris in pump. Inspect all components for contamination, then
flush.
Note: Refer to parts list on page 2 for numbered items in parenthesis (item . . .). Also see figures 1 through 8.
TROUBLESHOOTING (Continued)

Australia and New Zealand
Actuant Australia Ltd.
Block V Unit 3
Regents Park Estate
391 Park Road
Regents Park NSW 2143
(P.O. Box 261) Australia
T [phone]
F [phone]
[email protected]
Brazil
Power Packer do Brasil Ltda.
Rua
Luiz Lawrie Reid, 548
09930-760
- Diadema (SP) - Brazil
T [phone]
Toll Free: 0800 891 5770
[email protected]
China
Actuant (China) Industries Co. Ltd.
No. 6 Nanjing East Road,
Taicang Economic Dep Zone
Jiangsu, China
T [phone]
F [phone]
Toll Free: [phone]
[email protected]
France, Switzerland, North Africa
and French speaking African
countries
ENERPAC
Une division d’ACTUANT France S.A.S.
ZA de Courtaboeuf
32, avenue de la Baltique
91140 VILLEBON /YVETTE
France
T [phone]
F [phone]
[email protected]
Germany and Austria
ENERPAC GmbH
P.O. Box 300113
D-40401 Düsseldorf
Willstätterstrasse 13
D-40549 Düsseldorf, Germany
T [phone]
F [phone]
[email protected]
India
ENERPAC Hydraulics (India) Pvt. Ltd.
No. 10, Bellary Road,
Sadashivanagar,
Bangalore,
Karnataka 560 080
India
T
[email protected]
www.enerpac.com
Italy
ENERPAC S.p.A.
Via Canova 4
20094 Corsico (Milano)
T [phone]
F [phone]
[email protected]
Japan
Applied Power Japan LTD KK
Besshocho 85-7
Kita-ku, Saitama-shi 331-0821, Japan
T [phone]
F [phone]
[email protected]
Middle East, Egypt and Libya
ENERPAC Middle East FZE
Oce 423, LOB 15
P.O. Box 18004, Jebel Ali, Dubai
United Arab Emirates
T [phone]
F [phone]
[email protected]
Russia
Rep. oce Enerpac
Russian Federation
Admirala Makarova Street 8
125212 Moscow, Russia
T [phone]
F [phone]
[email protected]
Southeast Asia, Hong Kong
and Taiwan
Actuant Asia Pte Ltd.
83 Joo Koon Circle
Singapore 629109
T [phone]
F [phone]
[email protected]
South Korea
Actuant Korea Ltd.
3Ba 717, Shihwa Industrial Complex
Jungwang-Dong, Shihung-Shi,
Kyunggi-Do
Republic of Korea 429-450
T [phone]
F [phone]
[email protected]
Spain and Portugal
ENERPAC SPAIN, S.L.
Avda. Los Frailes, 40 – Nave C & D
Pol. Ind. Los Frailes
28814 Daganzo de Arriba
(Madrid) Spain
T [phone]
F [phone]
[email protected]
Sweden, Denmark, Norway,
Finland and Iceland
Enerpac Scandinavia AB
Kopparlundsvägen 14,
721 30 Västerås
Sweden
T [phone]
[email protected]
The Netherlands, Belgium,
Luxembourg,
Central and Eastern Europe,
Baltic States, Greece, Turkey
and CIS countries
ENERPAC B.V.
Galvanistraat 115, 6716 AE Ede
P.O. Box 8097, 6710 AB Ede
The Netherlands
T [phone]
F [phone]
[email protected]
Enerpac Integrated Solutions B.V.
Opaalstraat 44, 7554 TS Hengelo
P.O. Box 421, 7550 AK Hengelo
The Netherlands
T [phone]
F [phone]
integr[email protected]
South Africa and other English
speaking African countries
Enerpac Africa Pty Ltd.
No. 5 Bauhinia Avenue
Cambridge Oce Park
Block E
Highveld Techno Park
Centurion 0157
Republic of South Africa
T: [phone]
[email protected]
United Kingdom and Ireland
ENERPAC UK Ltd.
5 Coopies Field
Morpeth, Northumberland
NE61 6JR, England
T +44 (0)
1670 5016 50
F [phone]
[email protected]
USA, Latin America and Caribbean
ENERPAC World Headquarters
P.O. Box 3241
Milwaukee WI 53201-3241 USA
T [phone]
F [phone]
User inquiries:
T [phone]
Distributor inquiries/orders:
T [phone]
F [phone]
Technical inquiries:
[email protected]
[email protected]
Enerpac Worldwide Locations e-mail: [email protected] internet: www.enerpac.com
011415
50 00
N86 W12500 Westbrook Crossing
Menomonee Falls, Wisconsin 53051
Toll Free: [phone]
(Taicang)
[phone]
All Enerpac products are
guaranteed against defects
in workmanship and materials
for as long as you own them.
For the location of your nearest
authorized Enerpac Service Center,
visit us at www.enerpac.com