Enerpac SFP Series User manual

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
L14004710 rev: preliminary F 03/07/14
1.0 SAFETY & GENERAL INFORMATION
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.
2.0 SAFETY PRECAUTIONS
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.
WARNING: Wear proper personal protective
gear when operating hydraulic equipment.
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.
CAUTION: 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.
OPERATING MANUAL
SFP SERIES
Index:
1.0 SAFETY & GENERAL INFORMATION............1
2.0 SAFETY PRECAUTIONS.................................1
3.0 SPECIFICATIONS............................................2
4.0 INSTALLATION................................................3
5.0 OPERATION.....................................................4
6.0 MAINTENANCE................................................5
7.0 TROUBLESHOOTING GUIDE.........................5
8.0 ATTACHED DOCUMENTATION TABLE.........6
1

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
CAUTION: Avoid damaging hydraulic hose.
A
void sharp bends and kinks when routing
hydraulic hoses. Using a bent or kinked hose
will cause severe backpressure. Sharp
bends and kinks will internally damage the
hose leading to premature hose failure.
CAUTION: 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 o
f
safe transport.
CAUTION: Keep hydraulic equipment away
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leaks. Heat also weakens hose materials
and packings. For optimum performance do
not expose equipment to temperatures o
f
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
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applicable, use a cylinder base for added
stability. Do not weld or otherwise modify the
cylinder to attach a base or other support.
CAUTION: 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.
3.0 SPECIFICATIONS
The system is composed by a powerpack which
commands 4 double acting cylinders.
There are different models of powerpack depending on
the number of outlets and flow. Check in the next table
the features of the powerpack concerning to the
equipment acquired
PUMP MODEL
SFP213SW SFP213MW SFP404SW SFP404MW SFP604SW SFP604MW SFP228SW SFP228MW SFP242SW SFP242MW SFP409SW SFP409MW SFP414SW SFP414MW SFP421SW SFP421MW
RESERVOIR CAPACITY (L) 40 150
OUTLETS (points) 2 4 6 2 4
FLOW (l/min) at 700 BAR 1,3 0,45 0,45 2,8 4,2 0,9 1,4 2,1
MOTOR POWER KW 5,5 7,5 11 5,5 7,5 11
WEIGHT (Kg) 240 488 526 475 488 526
CAUTION: Distribute the load evenly across
the entire saddle surface. Always use a
saddle to protect the plunger.
IMPORTANT: Hydraulic equipment mus
t
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technician. For repair service, contact the
A
uthorized ENERPAC Service Center in
your area.
WARNING: In case of leakage contact
ENERPAC parts. Standard grade parts will
break causing personal injury and propert
y
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properly and withstand high loads.
WARNING: Do not use electric pumps in an
explosive atmosphere. Adhere to all local
and national electrical codes. A qualified
electrician must do installation and
modification
WARNING: Start the pump with the valve in
the neutral position to prevent accidental
cylinder operation. Keep hands clear o
f
moving parts and pressurized hoses.
WARNING: These pumps have internal
factory adjusted relief valves, which must not
be repaired or adjusted except by an
A
uthorized Enerpac Service Center.
CAUTION: To prevent damage to pump
electric motor, check specifications. Use o
f
incorrect power source will damage the
motor.
CAUTION: Check motor rotation direction to
prevent damage to hydraulic pump (See 4.0
installation)
2

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
4.0 INSTALLATION
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.
Install or position the pump to ensure that air flow
around the motor and pump is unobstructed. Keep the
motor clean to ensure maximum cooling during
operation.
IMPORTANT: Eliminate the presence of side load
forces when using hydraulic cylinders. Side load can
occur through:
1. An eccentric load on the plunger.
2. A horizontal load on a structure.
3. A structure and/or cylinder misalignment.
4. Non synchronized lifting actions.
5. Non stable cylinder base support.
Always use a flat, hard surface as a cylinder support
plate. Use a low friction material on top of the saddle.
To reduce cylinder offset loading, optional CATG-
swivel saddles are available. Always use grease
underneath swivel saddles.
IMPORTANT: It is mandatory that the operator has a
full understanding of all instructions, safety regulations,
cautions and warnings, before starting to operate any
of this high force tool equipment. In case of doubt,
contact Enerpac.
4.1 Transportation
For transportation the frame has two forklift truck
pockets that make available for forklift lift, and four
hoisting certified eyes for lifting with cranes.
dwg 1
4.2 Electric connections
The pump is factory equipped with a 3
phase electrical plug for the given voltage,
altering the plug type should only be done by
a qualified electrician, adhering to all applicable local
and national codes.
The plug supplied is set as follow: 3+N+PE 380V 16 A
1. The disconnection and line circuit protection to be
provided by customer. Line circuit protection to be
115% of motor full load current at maximum pressure
of application.
IMPORTANT: The pumps with reservoir of 40 L. have
the motor rotation direction sense. When connect the
male plug to the electric main power, be sure that there
is in the correct phase. If not, change the phase of the
motor.
4.3 Hydraulic connections
WARNING: On double-acting cylinders be certain that
hoses are connected to BOTH couplers. Never attempt
to pressurize a double-acting cylinder if only one hose
is connected.
IMPORTANT: To decompress ports prior to connecting
hoses, move the manual valve several times in position
advance and retract with the motor switched off
(manual valves). For solenoid valves turn clockwise
completely the valve handler in every valve as showed
in the picture (previous unlock the locknut) and leave
finally valves deactivated.
Connect the hydraulic hoses using the following
diagram.
Port A to the advance side of the cylinder
Port B to the retract side of the cylinder (only for double
acting cylinders, for single acting cylinder leave it
disconnected).
Follow the next steps to correctly connect the hoses:
1. Keep cylinder connected to a hydraulic system with
a fluid cleanliness level minimum of NAS 1638 Class 6.
2. Remove dust covers/rubber plugs from oil ports
3. Inspect all threads and fittings for signs of wear or
damage and replace as needed.
4. Clean all threads and fittings.
5. Make hydraulic connections for double-acting
cylinders using two hoses.
6. Fully hand-tighten all couplers. Loose coupler
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and the cylinder.
7. Check for leaks in system and have repaired by
qualified personnel.
3

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
4.4 Flow level
Check the oil level of the pump prior to start-up, if
necessary add oil by removing the plug from the top of
the reservoir. The reservoir is full when the oil level
reaches the top of the sight glass.
IMPORTANT: Add oil only when all system
components are fully retracted, otherwise the system
will contain more oil than the reservoir can hold.
5.0 OPERATION
5.1 Manual valve Control
Some models have been designed to be operated 2, 4
or 6 manual valves, one per output (depend on the
model type:
To move the cylinder moves the handler of the valve
according to the desired movement. The movement
advance or retract is described in a label on the valve.
dwg 2
5.2 Pendant Control
Some machines (models with solenoid valves) have
been designed to be operated by a remote control
connected to the electric cabinet with a 10 m cable in
the connector Nr 6 (see dwg 3).
Through this device the operator can operate every
cylinder (2, 4 or 6 cylinders depending on model).
Therefore it is important to familiarize yourself with
every button. See the next explanation for it:
dwg 3
1. Cylinder 4 selector: This selector actives the
movement of cylinder 4
2. Cylinder 3 selector: This selector actives the
movement of cylinder 3
3. Cylinder 2 selector: This selector actives the
movement of cylinder 2
4. Cylinder 1 selector: This selector actives the
movement of cylinder 1
5. Retracting plunger: Pushing this button the flow of
the port A goes to tank, therefore in a general purpose
cylinder the plunger goes in.
6. Advancing plunger: Pushing this button the flow of
the port A goes to the cylinder, therefore in a general
purpose cylinder the plunger goes out.
7. Emergency button: Pushing this button the machine
stops all the movements.
5.3 Electric panel description
On the electric panel (models with solenoid valves)
there are the necessary controls to switch on the
machine.
dwg 4
1. Main electrical switch
2. Power on led
3. System Alarm Light
4. Reset Pushbutton
5. Start/Stop Motor Pushbutton
6. Decompress Pushbutton
7. Pendant Control Connector
8. Power supply connector
5.4 Turning the powerpack on
5.4.1 Pumps with manual valves
To turn the motor on following the next steps:
1. Turn the main switch to the right on the electrical
cabinet
2. Press the motor starter button for 3 seconds.
4

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
Now the machine is able to work. Use the manual
valves to move the cylinders as explained in the
paragraph 5.1.
5.4.2 Pumps with solenoid valves
To turn the motor on following the next steps:
1. Turn the main switch (Nr 1) to the right on the
electrical cabinet
2. Deactivate the emergency stop button (on the
pendant).
3. Press the reset button to reset the security system
after the emergency button have been activated (Nr 4)
4. Press the motor starter button for 3 seconds (Nr 3)
Now the machine is able to work with the pendant. Use
the pendant to move the cylinders as explained in the
paragraph 5.2.
5.5 Setting up the relief valve
The powerpack has been designed to set the
relief valves up by the operator. The maximum
pressure of the relief valve is between 10 and
700 bar. For this propose the operator needs
the next tools:
1. Plain slot screwdriver (1 unit)
2. Spanner of 13 mm (1 unit)
3. Manometer 0-1000 bar (for pressures up to 700 bar)
(4 units).
Manometers must be connected to the MP port (1/4”
NPT), in order to know the pressure in each line.
To set the relief valve up, follow the next steps:
1. Connect the output to one cylinder
2. Unblock the hexagonal nut of the relief valve.
3. Turn the bolt with the screwdriver totally (counter
clockwise)
4. Turn the bolt a quarter turn in order to open the relief
valve (clockwise)
5. Press the motor starter button for 3 seconds (Nr 3)
6. Extract the cylinder plunger up to final. (When the
plunger reaches the final of the stroke the pressure
gets up. See in the manometer the maximum pressure
reached).
7. Turn the bolt (counter clockwise to decrease the
pressure, or clockwise to increase the pressure) with
the screw driver to reach the desired pressure.
8. Block the nut with the spanner to block the relief
valve.
5.6 Decompressing system
With the motor switched off:
1. Select cylinders to decompress in the pendant
2. Push decompress button in the electric cabinet
3. Push at the same time the button up in the pendant
The solenoid valve will move to leave free way to the
pressurized line.
6.0 MAINTENANCE
6.1 Check Oil Level
Check the oil level of the pump prior to start-up, and
add oil, if necessary, by removing the fill port cap.
Always be sure cylinders are fully retracted before
adding fluid to the reservoir.
6.2 Change Oil and Clean Reservoir
Enerpac HF oil is a crisp blue color. Frequently check
oil condition for contamination by comparing pump oil
to new Enerpac oil. As a general rule, completely drain
and clean the reservoir every 250 hours, or more
frequently if used in dirty environments.
NOTE: This procedure requires that you remove the
pump from the reservoir. Work on a clean bench and
dispose of used oil according to local codes.
1. Unscrew the bolts holding the cover plate to the
reservoir and lift the pump unit out of the reservoir. Be
careful not to damage the filter screen.
2. Pour all oil out of the reservoir.
3. Thoroughly clean the reservoir and reservoir magnet
with a suitable cleaning agent.
4. Reassemble the pump and reservoir
5. Fill the reservoir with clean Enerpac hydraulic oil.
The reservoir is full when oil level is in middle of the
sight gauge
6.3 Changing the Filter Element
The filter element should be replaced every 250 hours,
or more frequently in dirty environments. The filter
manifold is equipped with a 25 psi (1,7 bar) bypass to
prevent over pressure rupture if filter plugging occurs
and with a small gauge that shows the pressure when
the filter is dirty (see in the hydraulic diagrams num 8).
7.0 TROUBLESHOOTING GUIDE
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.
Refer to the troubleshooting chart for a list of typical
cylinder problems and possible causes. The
troubleshooting chart is not all-inclusive, and should be
considered only as an aid to help diagnose the most
common problems. For repair service, contact your
local Authorized Enerpac Service Center.
5

Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
[phone]
[email protected]
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
www.hyquip.co.uk/web/index
7.1 Troubleshooting chart
8.0 ATTACHED DOCUMENTATION TABLE
In this manual other documents have been attached which are necessary to interpret this manual. In the next table
there is an index to facilitate finding these documents. Push on the paper icon to show them.
PROBLEM POSSIBLE CAUSE SOLUTION
Cylinder does not advance,
advances slowly or in spurts A. Oil level in pump reservoir is low. B. Release valve open.
C. Loose hydraulic coupler.
D. Air trapped in system.
E. Cylinder plunger binding
A. Add oil to pump.
B. Close pump release valve.
C. Check that all couplers are fully
tightened.
D. Remove air.
E. Check for damage to cylinder.
Have cylinder serviced by an
authorized Enerpac service center
Cylinder advances, but does not
hold pressure. A. Leaking oil connection.
B. Leaking seals.
C. Internal leakage in pump.
A. Check that all connections are
tightened.
B. Locate leak(s) and have
equipment serviced by an Enerpac
service center.
C. Have pump serviced by an
authorized Enerpac service center.
Cylinder does not retract A. Pump reservoir overfilled.
B. Loose hydraulic coupler.
C. Air trapped in system.
D. Oil flow to cylinder blocked.
E. Hose internal diameter too narrow.
F. No load on a load return cylinder
A. Drain oil level to full mark.
B. Check that coupler(s) are fully
tightened.
C. Remove air.
D. Check that coupler(s) are correctly
connected fully tightened and valving
is functioning properly.
E. Use a larger diameter hose.
F. CLL and CLS cylinders are load
return. Apply load force to completely
retract the cylinder
Wrong motor rotation direction A. The phase of the motor is wrong A change the phase of the motor
Alarm light switched on A. Thermic protection is down.
B. DC protection is down.
A. Open the electric cabinet and
switch up the thermic protection
B. Have pump serviced by an
authorized Enerpac service center.
150 L RESERVOIR 40 L RESERVOIR
MANUAL VALVES SOLENOID VALVES MAN. VALVES SOLEN. VALVES
PUMP MODEL
SFP228MW SFP242MW SFP409MW SFP414MW SFP421MW
SFP228SW SFP242SW SFP409SW SFP414SW SFP421SW
SFP213MW SFP404MW SFP604MW
SFP213SW SFP404SW SFP604SW
ASSEMBLY DRAWING 
HYDRAULIC SCHEME 
SPARE PARTS 
CE DECLARATION 
6