Enerpac PTE-3404B 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.
A CAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction of
equipment or other property.
A WARNING indicates a potential danger that requires correct
procedures or practices to avoid personal injury.
A DANGER 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 700 bar [10,000 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.
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.
®
L2085 Rev. B 06/01
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Instruction Sheet
PTE-3404B, PTE-3404E, PTE-3404M,
PTE-3404T, PTE-3404W Torque Wrench Pump

2
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.
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.
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 table below)
4.0 INSTALLATION
4.1 Wiring Motor
On single phase units, “B” and "E" voltage suffix, a proper plug is
already installed and rotation is factory set.
On three-phase models, an electrical plug must be installed in
accordance with local electrical codes. Be sure to verify rotation
of the motor prior to operation, by observing the direction arrows
(A) on the rear of the pump. (See photo 1).
4.2 Connect Hydraulic Hoses
Be sure to use hose marked “ENERPAC THC-700 SERIES - 800
Bar/11,600 psi max.” Connect hoses as shown in Figure 1 and
photo 2. The hoses are “polarized” to ensure correct wrench
operation. Hand tighten coupler lock rings. No tools are required.
Pump will not operate without hoses and wrench attached.
4.3 Connect Control Pendant
Connect the remote pendant by turning screw coupler to male
connector (B) on pump, next to hoses, see photo 3. Pump WILL
NOT operate without pendant installed.
Specifications
Operating Pressure
Electrical Power
Source
Motor Rating
Sound Level
Oil Flow Rate
Unloading (or bypass)
Pressure
Operating Oil
Temperature
Reservoir Capacity
Useable Reservoir
Capacity
Shipping Weight
PTE-3404W
0-11,600 psi (800 bar) max.
5 Amp max. / 380 Volt
3-phase, 50 Hz
2.0 HP, 1.5 kW Motor,
5 Amp max.@11,600 psi
(800 bar) and 3000 RPM
70-80 dBA
430 in3/min (7 l/min)
@0 psi (0 bar)
55 in3/min (0,90 l/min)
@11,600 psi (800 bar)
2200 psi (150 bar)
150° F (65.5° C) maximum
1.0 gallon (3,8 liter)
.4 gallon (1,7 liter)
70 lbs (31,8 kg)
PTE-3404M, PTE-3404T
0-11,600 psi (800 bar) max.
PTE-3404T–7 Amp max. /220V 3-ph, 50-60 Hz
PTE-3404M–7.5 Amp max. /200V 3-ph, 50-60 Hz
2.0 HP, 1.5 kW Motor,
7.5 Amp max@11,600 psi
(800 bar) and 3000 RPM
70-80 dBA
300 in3/min (5 l/min) @0 psi (0 bar)@50 Hz
50 in3/min (0,80 l/min) @11,600 psi (800
bar)@50Hz
2200 psi (150 bar)
150° F (65.5° C) maximum
1.0 gallon (3,8 liter)
.4 gallon (1,7 liter)
70 lbs (31,8 kg)
PTE-3404B
0-11,600 psi (800 bar) max.
24 Amp max. / 115 Volt
1-phase, 60 Hz
2.4 HP, 1.8 kW Motor,
24 Amp max.@11,600 psi
(800 bar) and 3600 RPM
70-80 dBA
366 in3/min (6 l/min)
@0 psi (0 bar)
55 in3/min (0,90 l/min)
@11,600 psi (800 bar)
2200 psi (150 bar)
150° F (65.5° C) max.
1.0 gallon (3,8 liter)
.4 gallon (1,7 liter)
70 lbs (31,8 kg)
PTE-3404E
0-11,600 psi (800 bar) max.
14 Amp max. / 220 Volt
1-phase, 50 Hz
2.4 HP, 1.8 kW Motor,
13 Amp max.@11,600 psi
(800 bar) and 3600 RPM
70-80 dBA
300 in3/min (5 l/min)
@0 psi (0 bar)
50 in3/min (0,8 l/min)
@11,600 psi (800 bar)
2200 psi (150 bar)
150° F (65.5° C) max.
1.0 gallon (3,8 liter)
.4 gallon (1,7 liter)
70 lbs (31,8 kg)

3
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 Check Oil Level, using Sight Gauge/Adding Oil
Check the oil level prior to start-up by viewing clear sight gauge
(C) on pump housing. Unit is at correct level when oil level is near
top mark, see photo 4 and Figure 2. If level is low, add Enerpac
hydraulic oil as necessary. To add oil, remove fill cap/breather and
add oil through the opening until sight gauge level has reached
“Full.”
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.
5.2 Operating the Pump
1. Connect single or double-acting torque wrench. Do not operate
pump without torque wrench. See Section 4.2.
2. Plug power cord into outlet with appropriate voltage rating.
3. Turn pump on by turning power switch to the “on” position (see
photo 5). The pump on-off switch (D) is located on the back of
the pump shroud. In this position the pump will run when you
operate the pendant switch.
5.3 Operating Pendant Switch
The pendant has two push buttons. When starting the pump, fully
activate the "ADV/START" push button (E) for a minimum of one
second before releasing (do not jog). When you release the button,
Photo 1
(A)
Photo 2
Photo 3
(B)
Photo 4
Full
Low
Operating
Figure 2
Figure 1
(C)

4
the valve shifts to retract and the motor stops
running after 60 seconds. Use the “STOP” (F)
pushbutton only if you need to turn off the unit
manually otherwise, let the built in timer
automatically shut the pump off. This will
assist in keeping the pump cool.You must
turn the power switch to the “OFF”
position to cut off all power to unit.
5.4 Removing Air from 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.
5.5 Setting Pump to Torque Value
Pressure and torque are set by adjusting the relief valve. The
external relief valve is located on the side of the pump. It is
adjustable from 11,600 psi (800 bar) down to 0 psi (0 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 setting.
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 (see photo 6).
2. Loosen the locknut on the relief valve adjustment screw. Turn
the adjustment screw counter-clockwise to decrease
pressure setting. (See photo 7.)
3. Turn the pump on, and press and hold “ADV START.”
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.
NOTE: To read torque instead of pressure, install the correct
torque gauge overlay into the slot found in the shroud in
front of the pressure gauge face by removing clip and face.
The torque gauge overlay is designed to be used with
specific wrenches. The overlay is calibrated in metric units
on one side and imperial units on the other side. (See
photo 8.)
NOTE: The pump has a built in temperature switch designed to
protect the motor from overheating. The temperature
switch will turn the motor off when 212°F (100 °C) is
reached and will not allow pump operation until winding
temperature drops to 170°F (77 ° C).
Figure 3
E
F
Photo 6
Photo 7
Photo 8
Photo 5
(D)

5
6.0 MAINTENANCE
Completely drain and clean the reservoirs after every 100 hours
of operation. There are two drain plugs on the pump. The first
plug is found on the bottom of the front yellow cast reservoir and
the second plug is found on the bottom of the aluminum pump
manifold located between the yellow reservoir and the finned
motor housing. Remember to replace the drain plugs and torque
to 20-25 ft-lbs (27-34 Nm) before refilling with new Enerpac
hydraulic oil. If pump is used infrequently, clean the reservoir once a
year. Clean off surfaces of electrical components. Clean out cooling
fins of reservoir, cooling fan’s shroud, and cooling fan.
6.1 Fuse Replacement
If pump fails to start when ADV/Start button is pushed and power
is available to pump, the main fuse may need to be replaced. The
fuse is located in the rear of the pump, under the main power
cord.
6.2 Removal of Torque Wrench
To remove the torque wrench from the pump, the pressure
contained in the hydraulic hoses must be relieved to 0 psi (0 bar).
To accomplish this, follow these steps in the order given.
1. Fully back off the relief valve (red knob) by turning it in a
counterclockwise direction.
2, Depress and hold in the adv/start button.
3. While depressing the adv/start button, turn the power to the
pump off by the on/off switch found on the back of the pump.
4. After the motor stops rotating, release the adv/start button.
5. Disconnect the hoses from the pump.
Remember to reset the operating pressure of the system to the
recommended safe operating pressure, as found in the
instruction sheet, for the size of the torque wrench being used.
7.0 TROUBLESHOOTING
Only qualified hydraulic technicians should service the pump or
system components. A system failure may or may not be the
result of a pump malfunction. To determine the cause of the
problem, the complete system must be included in any
diagnostic procedure.
The following information is intended to be used only as an aid
in determining if a problem exists. For repair service, contact you
authorized Enerpac Service Center.
Symptom
Pump will not start
Motor will not start 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
Hoses can not be
disconnected from pump.
Possible Cause
1. No power
2. Wrong voltage
3. Yemperature switch open
4. Hydraulic hoses and wrench not attached.
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 malfunction
1. Pressure trapped in hoses.
Solution
1. Check electrical power source
2. See voltage specifications, Section 3.0
3. Replace fuse No. AGC3
4. Power switch is not on
5. Pendant connection not fully engaged
6. Allow motor to cool down to reset temperature switch
7. Attach hoses and wernch to pump.
1. Check electrical power source, see voltage specifications, Section 3.0
2. Use shorter power cord, 50’ of #10 AWG wire, minimum
3. Reset relief valve, Section 5.5.
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, Section 5.5
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.
1. See Section 6.2 Removal of Torque Wrench.