Enerpac PMU-30457 User manual

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.
SAFETY FIRST
2.0 SAFETY ISSUES
Read all instructions, warnings and cautions
carefully. Follow all safety precautions to avoid
personal injury or property damage during system
operation. Enerpac cannot be responsible for damage or injury
resulting from unsafe product use, lack of maintenance or incorrect
product and/or system operation. Contact Enerpac when in doubt
as to the safety precautions and operations. If you have never been
trained on high-pressure hydraulic safety, consult your distribution
or service center for a free Enerpac Hydraulic safety course.
Failure to comply with the following cautions and warnings could
cause equipment damage and personal injury.
ACAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction of
equipment or other property.
AWARNING indicates a potential danger that requires correct
procedures or practices to avoid personal injury.
ADANGER is only used when your action or lack of action may
cause serious injury or even death.
WARNING: Wear proper personal protective gear
when operating hydraulic equipment.
WARNING: Stay clear of loads supported by
hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device.
After the load has been raised or lowered, it must always be
blocked mechanically.
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS.
Carefully select steel or wood blocks that are capable
of supporting the load. Never use a hydraulic cylinder
as a shim or spacer in any lifting or pressing application
.DANGER: To avoid personal injury keep hands
and feet away from cylinder and workpiece
during operation.
WARNING: Do not exceed equipment ratings. Never
attempt to lift a load weighing more than the capacity
of the cylinder. Overloading causes equipment failure
and possible personal injury. The cylinders are designed for a
max. pressure of 800 bar [11,600 psi]. Do not connect a jack or
cylinder to a pump with a higher pressure rating.
Never set the relief valve to a higher pressure than the
maximum rated pressure of the pump. Higher settings
may result in equipment damage and/or personal
injury.
WARNING: The system operating pressure must not
exceed the pressure rating of the lowest rated
component in the system. Install pressure gauges in
the system to monitor operating pressure. It is your window to
what is happening in the system.
CAUTION: Avoid damaging hydraulic hose. Avoid
sharp bends and kinks when routing hydraulic hoses.
Using a bent or kinked hose will cause severe back-
pressure. Sharp bends and kinks will internally damage the
hose leading to premature hose failure.
Do not drop heavy objects on hose. A sharp impact
may cause internal damage to hose wire strands.
Applying pressure to a damaged hose may cause it
to rupture.
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Instruction Sheet
11/8HP Titan Torque Wrench Pumps
L1843 Rev. A 10/01
®
Genesis Series

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IMPORTANT: Do not lift hydraulic equipment by the
hoses or swivel couplers. Use the carrying handle or
other means of safe transport.
CAUTION: Keep hydraulic equipment away from
flames and heat. Excessive heat will soften packings
and seals, resulting in fluid leaks. Heat also weakens
hose materials and packings. For optimum performance do
not expose equipment to temperatures of 65°C [150°F] or
higher. Protect hoses and cylinders from weld spatter.
DANGER: Do not handle pressurized hoses. Escaping
oil under pressure can penetrate the skin, causing
serious injury. If oil is injected under the skin, see a
doctor immediately.
WARNING: Only use hydraulic cylinders in a coupled
system. Never use a cylinder with unconnected
couplers. If the cylinder becomes extremely
overloaded, components can fail catastrophically causing
severe personal injury.
WARNING: BE SURE SETUP IS STABLE BEFORE
LIFTING LOAD. Cylinders should be placed on a flat
surface that can support the load. Where applicable,
use a cylinder base for added stability. Do not weld or otherwise
modify the cylinder to attach a base or other support.
Avoid situations where loads are not directly centered
on the cylinder plunger. Off-center loads produce
considerable strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
dangerous results.
Distribute the load evenly across the entire saddle
surface. Always use a saddle to protect the plunger.
IMPORTANT: Hydraulic equipment must only be
serviced by a qualified hydraulic technician. For repair
service, contact the Authorized ENERPAC Service
Center in your area. To protect your warranty, use only
ENERPAC oil.
WARNING: Immediately replace worn or damaged
parts by genuine ENERPAC parts. Standard grade
parts will break causing personal injury and property
damage. ENERPAC parts are designed to fit properly and
withstand high loads.
To avoid personal injury, do not use electric pumps in
an explosive atmosphere. Adhere to all local and
national electrical codes.
Do not use hoses, fittings, or couplers with pressure
ratings below 11,600 psi (800 bar). Equipment with
inadequate pressure ratings can fail and cause
personal injury or equipment damage.
Titan pumps have an internal relief valve installed
under the pump cover. This relief valve is factory
adjusted and must not be repaired or adjusted except
by qualified hydraulic technicians.
To help prevent pump failure, check hydraulic
reservoir fluid level prior to pump operation. When
gauge reads low, add oil. Always be sure tools are
fully retracted before adding fluid to the reservoir.
To prevent damage to pump electric motor, check
specifications.
3.0 SPECIFICATIONS (see Specification Table below)
4.0 INSTALLATION
4.1 Install Oil Level Gauge
For shipping purposes, a plug is installed in the fill port on the top
of the reservoir. Remove this plug and install the oil level gauge
that was shipped with the pump. (See Fig. 1).
NEVER RUN THE PUMP WITH THE SHIPPING PLUG
INSTALLED. THIS WILL CAUSE DAMAGE TO THE
PUMPING MECHANISM.
4.2 Connect Hydraulic Hoses
Be sure to use hose marked "ENERPAC 800 SERIES–800
BAR/11,600 PSI MAX". Connect hoses as shown in Figure 2. Hand
tighten coupler lock rings. No tools are required.
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Specification PMU-30457 PMU-30457R PMU-30452 PMU-30452R
Operating Pressure 0 – 11,600 psi (800 bar) Maximum
Electrical Power 30 Amp / 115 Volt Grounded 15 Amp / 230 Volt
Source Single-phase 50-60 Hz Single-phase, 50-60 Hz
11/8Universal Motor 0.84 kW Universal Motor
Motor Rating
25 Amp @ 10,000 psi (700 bar) and 12,000 RPM 12.5 Amp @ 10,000 psi (700 bar) and 12,000 RPM
operates at 60-125 Volts operates at 115-240 Volts
Sound Level 83 – 88 dBA
Flow Rate 640 in3/min (10,5 l/min) @ 0 psi (0 bar)
55 in3/min (0,90 l/min @ 11,600 psi (800 bar)
Unloading (or Bypass) 1600 psi (110 bar)
Pressure
Operating Oil 150 °F (65 °C) Maximum
Temperature
Reservoir Capacity 1.3 gallons (5 liter)
Shipping Weight 77 lbs. (35 kg) 89 lbs. (40 kg) 77 lbs. (35 kg) 89 lbs (40 kg)

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Figure 1
Warning: To ensure proper operation, avoid kinking
or tightly bending hoses. If a hose becomes kinked or
otherwise damaged, it MUST be replaced. Damaged
hoses may rupture at high pressure causing personal injury.
4.3 Check Oil Level
Check the oil level prior to start-up and add Enerpac hydraulic oil,
if necessary (see figure 3). Remove the oil level gauge and add oil
through the opening in the top of the reservoir.
IMPORTANT: Add oil only when all system components are in the
fully retracted position. If oil is added when plungers are advanced,
there will be more oil in the system than the pump can hold.
Figure 3
Warning: Attempting to couple a hose to the pump or
torque wrench while coupler is under pressure can
result in personal injury or fluid leakage.
5.0 OPERATION
When possible, a single user should operate both the torque
wrench and the pump. This prevents accidental activation of the
pump while another person is positioning the wrench.
5.1 Operating the Pump
1. Plug power cord into outlet with appropriate voltage rating.
2. Turn pump on by pressing "I" on the switch (see Fig. 4). The
pump on-off switch is located on the side of the pump shroud.
The pump will run when you operate the pendant switch.
Figure 4
3. Operate the pendant switch. Pendants have a 3-position,
momentary switch. Press the bottom of the pushbutton for
"Advance". When you release the button, the valve shifts to
retract and the motor stops running after 10 seconds. Use the
"Retract" pushbutton if you need to start the unit in the retract
mode. Again, the motor stops running 10 seconds after you
release the switch (see Fig. 5).
Figure 5
Remove shipping plug
ENERPAC 800 SERIES - 800 BAR/11,600 PSI MAX.
ENERPAC 800 SERIES - 800 BAR/11,600 PSI MAX.
B
A
ENERPAC 800 SERIES - 800 BAR/11,600 PSI MAX.
B
A
Figure 2
Empty
Add Oil
Full
In Use
Oil Level Gauge Press to retract
Press to advance
Tool
Pump

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5.2 Removing Air From the System
When the wrench is first connected to the pump, air will be trapped
in the components. To ensure smooth operation, remove air by
cycling the wrench several times without load. Cycle until wrench
advances and retracts without hesitation.
5.3 Gauge and Overlay
Operating Procedure
The pump is supplied with a
pressure gauge installed. A torque
overlay fits over the pressure
gauge dial face which easily
converts pressure readings to
torque readings (see Fig. 6).
The overlay has imperial units
(Ft.lbs) on one side and metric
units (Nm) on the other. To change
scales simply flip overlay over.
WARNING: Each overlay is sized for a specific Enerpac
torque wrench ONLY. Do not use with other
wrenches.
5.4 Changing the Overlay
1. Remove the three black wing
knobs which hold the front
gauge flange in place (see
Fig. 7).
2. Remove the front flange and
overlay (see Fig. 8).
3. Insert new overlay (remember
to verify correct overlay to the
Enerpac torque wrench being
used) onto the flange,
aligning the overlay with the
dimples on the back of the
flange (see Fig. 9).
4. While holding the overlay
behind the flange (see Fig. 8.)
insert the flange onto the knob
studs, repositioning the
overlay as needed, and
secure knobs finger tight (see
Fig. 7).
The flange will press the
overlay onto the gauge and
secure it in place. See torque
wrench instructions for
amount of pressure required
to produce desired torque.
Note that the maximum
pressure varies for different
wrenches and accessories.
5.5 Setting Pump to Torque Value
Pressure and torque are set by adjusting the relief valve. The
external relief valve is located on top of the pump. It is adjustable
from 11,600 psi (800 bar) down to 2000 psi (140 bar). Operating
pressure cannot be adjusted to above 11,600 psi (800 bar). To get
the most accurate relief valve setting, start at a lower pressure and
adjust up to the desired relief valve.
Warning: Make these adjustments BEFORE putting
torque wrench on nut or bolt head. The pump
pressure setting may be above the pressure needed
to provide the required torque for your application. Exceeding
required torque will cause equipment damage and may lead
to serious personal injury.
1. The pump is supplied with a pressure gauge installed. See the
torque wrench instructions for the amount of pressure needed
to produce the required torque. Note that the maximum
pressure varies for the different wrenches and accessories.
2. Loosen the locknut on the relief valve adjustment screw. Using
the knurled knob, turn the adjustment screw counter-
clockwise to decrease pressure setting (see Fig. 10).
3. Turn the pump on, and press and hold "ADV". Observe the
pressure gauge reading. Adjust the relief setting up to the
desired pressure.
4. Verify the setting by running the pump several times.
5. Tighten lock nut to secure setting on relief valve.
Figure 10
6.0 MAINTENANCE
6.1 Change Oil and Clean Reservoir
IMPORTANT: You will need a new reservoir gasket to reassemble
the pump after changing the oil.
1. Completely drain and clean the reservoir after every 100
hours of operation. Refill with new Enerpac hydraulic oil. If
pump is used infrequently, clean the reservoir once a year.
NOTE: This procedure requires that you remove the pump
from the reservoir. Work on a clean bench and use proper oil
disposal methods.
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Relief Valve

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1. No power
2. Wrong voltage
1. Low voltage
2. Power cord too long
3. Relief valve setting too high
1. No power or wrong voltage
2. Valve out of adjustment
1.External leak in system
2. Internal leak in pump or valve
3. Internal leak in system component
1. Relief valve setting too low
2. External leak in system
3. Internal leak in pump or valve
4. Internal leak in system component
1. Job exceeds wrench rating
2. Flow to wrench blocked
1. Return flow restricted or blocked
2. Internal spring damaged or broken
3. Valve malfunction
1. Return flow restricted or blocked
2. Valve misfunction
1. Check electrical power source
2. See voltage specification table
1. Check electrical power source / see voltage
specification table
2. Use shorter power cord
3. Reset relief valve (see section 5.3)
1. Check valve power connection to pump
2. Contact your local authorized Enerpac Service
Center
1. Trace circuit checking all connections and
components
2. Contact your local authorized Enerpac Service
Center
3. Repair or replace leaking system component
1. Reset relief valve (see section 5.3)
2. Trace circuit checking all connections and
components
3. Contact your local authorized Enerpac Service
Center
4. Repair or replace leaking system component
1. Use higher capacity wrench
2. Check for loose coupler connection
1. Loose coupler connection
2. Test circuit using another wrench
3. Contact your local authorized Enerpac Service
Center
1. Loose coupler connection
2. Contact your local authorized Enerpac Service
Center
Pump will not start
Motor stalls under load
Valve will not operate
Pump fails to build pressure
Pump does not reach full pressure
Pressure builds but wrench does not
turn
Single-acting wrench will not retract
Double-acting wrench will not retract
TROUBLE-SHOOTING GUIDE
Problem Possible Cause Solution
2. Remove heat exchanger tubing.
3. Remove heat exchanger and set it to the side.
4. Remove the 10 screws holding the pump to the reservoir.
After these screws are removed, one of the shroud brackets
will be loose, so it is best to lift the pump off of the reservoir
by holding the coverplate.
5. Carefully set the pump down without damaging filter screens.
6. Remove the reservoir gasket and discard it.
7. Pour all oil out of reservoir. Thoroughly clean the reservoir by
wiping and rinsing with a suitable solvent.
8. Use a soft bristle brush and solvent to clean the 3 intake
screens.
9. Reassemble the pump and reservoir, installing a new gasket.
10. Clean the heat exchanger before reinstalling.Use compressed
air to blow dirt out of the heat exchanger.
11. Fill the reservoir with new Enerpac hydraulic oil.

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Enerpac Worldwide Locations ✦ e-mail: [email protected] ✦ internet: www.enerpac.com
All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com
Australia
ENERPAC, Applied Power Australia Ltd.
Block V Unit 3
Regents Park Estate
391 Park Road
Regents Park NSW 2143
(P.O. Box 261) Australia
Tel: [phone]
Fax: [phone]
Canada
Actuant Canada Corporation
6615 Ordan Drive, Unit 14-15
Mississauga, Ontario L5T 1X2
Tel: [phone]
Fax: [phone]
Toll Free:
Tel: [phone]
Fax: [phone]
China
Applied Power China Ltd.
1F, 269 Fute N. Road
Waigaoqiao Free Trade Zone
Pudong New District
Shanghai, 200 131
China
Tel: [phone]
Fax: [phone]
France, Turkey, Greece,
Africa, Middle East
ENERPAC S.A.
B.P. 200
Parc d’Activités
du Moulin de Massy
F-91882 Massy CEDEX (Paris) France
Tel: [phone]
Fax: [phone]
Germany, Switzerland,
Austria, Eastern Europe
ENERPAC
Applied Power GmbH
P. O. Box 300113
D-40401 Düsseldorf
Germany
Tel: [phone]
Fax: [phone]
Hong Kong
ENERPAC
Room 907 Workingberg
Commercial Building
41-47 Marble Road
North Point
Tel: [phone]
Fax: [phone]
India
ENERPAC
Hydraulics (India) Pvt Ltd
Plot No. A-571
MIDC, TTC Industrial Area
Mahape-400 701
Navi Mumbai, India
Tel: [phone]
Fax: [phone]
Italy
ENERPAC
Applied Power Italiana S.p.A.
Via Canova 4
20094 Corsico (Milano)
Tel: [phone]
Fax: [phone]
Japan
Applied Power Japan Ltd.
1-1-11, Shimomae
Toda-shi
Saitama Pref.
Japan 335-0016
Tel: [phone]
Fax: [phone]
Mexico
ENERPAC Applied Power
Mexico S.A. de C.V.
Avenida Principal
La Paz #100
Fracc. Industrial La Paz
42092 Pachuca, Hidalgo
Tel: [phone]
Fax: [phone]
The Netherlands, Belgium,
Luxembourg, Sweden, Denmark,
Norway, Finland, United Kingdom,
Ireland
ENERPAC B.V.
Storkstraat 25
P. O. Box 269, 3900 AG Veenendaal
The Netherlands
Tel: [phone]
Fax: [phone]
[phone]
UK, Ireland
Tel: [phone]
Fax: [phone]
Singapore
Applied Power Asia Pte Ltd
No. 8, Ang Mo Kio,
Industrial Park 2
#01-00
Singapore 569500
Thomson Road, P.O. Box 114
Singapore 915704
Tel: [phone]
Fax: [phone]
South Korea
ENERPAC
Applied Power Korea Ltd.
163-12 Dodang-Dong
Wonmi-Ku, Buchun-shi
Kyunggi-Do
Republic of Korea
Tel: [phone]
Fax: [phone]
Spain, Portugal
ENERPAC
Applied Power International S.A.
Avda. Camino de lo Cortao
21 - Nave 3
San Sebastian de los Reyes
28709 Madrid
Spain
Tel: [phone]
Fax: [phone]
USA, Latin America
and Caribbean
ENERPAC
P. O. Box 3241
6101 N. Baker Road
Milwaukee, WI 53209 USA
Tel: [phone]
Fax: [phone]
User inquiries:
[phone]
Distributor inquiries/orders:
[phone]
092501