Enerpac ZC Series User manual

L4267 Rev. B 04/20 EN
ZC-Series Cordless Electric Rail Puller Pumps
Models ZC3404JB-RS and ZC3404JE-RS
Instruction Sheet

1.0 SAFETY.............................................................2
1.1 Introduction.............................................2
1.2 General Hydraulic Safety
Precautions .............................................3
1.3 Battery Operated Pump Safety
Precautions .............................................3
1.4 Battery First Aid Instructions.................3
1.5 Battery and Battery Charger
Safety Precautions .................................4
1.6 General Rail Puller Safety
Precautions .............................................4
2.0 MAJOR FEATURES AND COMPONENTS......5
3.0 PRODUCT DATA...............................................6
3.1 Specifications .........................................6
3.2 Performance Curves - Flow Rate vs.
Pressure ..................................................6
3.3 External Dimensions ..............................7
4.0 PRODUCT DESCRIPTION...............................8
4.1 Introduction.............................................8
4.2 Additional Information - Battery and
Charger....................................................8
4.3 Conformance to National and
International Standards .........................8
4.4 Electromagnetic Compatibility
(EMC) ......................................................8
5.0 SETUP...............................................................8
5.1 Important Receiving Instructions..........8
5.2 Hydraulic Reservoir Air Breather ..........8
5.3 Oil Level (new pumps) ............................8
6.0 HYDRAULIC CONNECTIONS .........................9
7.0 BATTERY ........................................................10
7.1 Battery Capacity Indicator...................10
7.2 Battery Installation ...............................10
7.3 Battery Removal ...................................10
7.4 Battery Management System ..............10
7.5 Additional Battery and Charger
Information............................................10
8.0 OPERATION....................................................11
8.1 Before Start-up .....................................11
8.2 Transporting and Positioning
the Pump ...............................................11
8.3 Starting and Stopping the
Pump Motor ..........................................11
8.4 Operating Precautions .........................11
8.5 Control Valve Operation .......................11
8.6 Air Removal...........................................12
8.7 Relieving Trapped Pressure.................12
8.8 Emergency Pressure Release Valve ...12
8.9 Disconnecting Hydraulic Hoses ..........12
9.0 MAINTENANCE..............................................12
9.1 Check Oil Level .....................................12
9.2 Hydraulic Oil Information .....................12
9.3 Oil Level Sight Gauge...........................13
9.4 Adding Oil..............................................13
9.5 Oil Change.............................................13
10.0 PRESSURE RELIEF VALVE
ADJUSTMENT..............................................13
11.0 TROUBLESHOOTING ..................................14
12.0 SAFE DISPOSAL PROCEDURE ..................15
TABLE OF CONTENTS:
1.0 SAFETY
1.1 Introduction
Read all instructions carefully. Follow all recommended safety
precautions to avoid personal injury as well as damage to the pump
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.
SAVE THIS INSTRUCTION SHEET FOR FUTURE USE
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.

3
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.
1.2 General Hydraulic Safety Precautions
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Do not remove or disable the pressure relief valve.
• Never set the pressure relief valve to a higher pressure than the
maximum rated pressure of the pump.
• Stay clear of loads supported by hydraulics. To avoid
personal injury, keep hands and feet away from rail puller and
surrounding area during operation.
• 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.
• The system operating pressure must not exceed the pressure
rating of the lowest rated component in the system. Install
pressure gauge(s) in the system to monitor operating pressure.
It is your window to see what is happening in the system.
• Do not exceed equipment ratings. Overloading can result in
equipment failure and possible personal injury.
• Wear personal protective equipment (P.P.E.) when operating
hydraulic equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hard
hat, or hearing protection used for appropriate conditions will
reduce personal injuries.
• Immediately replace worn or damaged parts with genuine
ENERPAC parts. Standard grade parts will break causing
personal injury and property damage.
CAUTION
Failure to observe and comply with the following precautions
could result in minor or moderate personal injury. Property
damage could also occur.
• Do not use or repair damaged 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.
• Do not lift hydraulic equipment by the hoses or swivel couplers.
Use the carrying handle or strap.
• 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 150˚F [65˚C] or higher. Protect all hydraulic
equipment from weld spatter.
• 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 pump 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.
1.3 Battery Operated Pump Safety Precautions
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Do not use the pump if the remote pendant button will not start
or stop the pump. Make repairs before resuming use.
• Do not operate the pump near combustible materials, such as
flammable liquids, gases, or dust.
• Remove the battery from the pump before cleaning, making
adjustments, performing maintenance or repair procedures,
or storing the pump.
• Do not attempt to disable or modify the safety key interlock
feature.
• Remove safety key when pump is unattended to prevent
unauthorized persons from operating pump.
• Use the pump only with the specified Briggs & Stratton 82V
lithium-ion batteries. Refer to Section 3.1 for model numbers
of compatible batteries.
• Pump motor assembly (“powerhead”) is not serviceable and
should not be opened. Electric shock may result.
• Do not use the pump if the powerhead is loose or damaged.
Have the powerhead inspected and repaired by an Enerpac
Authorized Service Center before using the pump.
1.4 Battery First Aid Instructions
WARNING
Failure to observe and comply with the following instructions
and precautions could result in serious personal injury.
• If battery fluid leaks and gets into your eyes or contacts your
skin, flush immediately with clean water for at least 15 minutes.
Get immediate medical attention! Do not rub the eyes.

4
1.5 Battery and Battery Charger Safety Precautions
WARNING
Failure to observe and comply with the following instructions
and precautions could result in death or serious personal
injury. Property damage could also occur.
• Recharge battery only with the charger model(s) specified by
Briggs & Stratton for the battery being used.
• Do not allow metal items or material such as steel wool,
aluminium foil or other foreign objects to contact the battery or
charger terminals. Do not allow these items to enter the battery
cavity of the powerhead or charger.
• Handle the battery carefully. Do not knock, strike, step-on
crush, or burn the battery.
• Do not attempt to short circuit any terminals on the battery or charger.
• Do not allow liquid or debris to enter the battery or charger.
• Do not expose the battery or charger to wet conditions or
excessive humidity. Do not charge the battery in rain or in wet
conditions.
• Do not use a damp cloth or detergent on the battery or battery
charger
• Do not immerse the pump, battery or charger in water or in
any other liquid.
• Do not insert battery into pump or charger if battery case is
cracked or damaged. Replace with a new battery.
• Do not attempt to modify the battery or charger.
• Do not solder onto the battery or pierce the battery with nails
or other objects.
• Do not probe the battery or charger with conductive materials.
• Do not cover the ventilation slots in battery or charger.
• Do not place battery or charger on a soft surface, such as a
blanket or pillow.
• Do not place the battery in high temperature locations, such as
near fire or a heater. Avoid placing the battery in direct sunlight.
• Do not allow the battery or charger to overheat. If battery and/
or charger are warm, allow time for them to cool down before
charging.
• Discontinue use of the battery if it emits an unusual smell, feels
hot, changes color, changes shape or appears abnormal in
any other way.
• Unplug the charger when it is being cleaned or not in use.
• Store the battery and charger in a cool, dry place. Keep these
items in a secured location, away from children and pets.
• Battery and charger may under no circumstances be opened.
These items contain no user-serviceable components.
• If battery housing cracks or breaks, with or without fluid leaks,
do not recharge or use the battery. Dispose of it and replace it
with a new battery.
• For damaged or worn out batteries, follow safe disposal
procedures as described in the battery manufacturer's manual.
• Do not attempt to repair a damaged battery. Do not attempt to
open or disassemble the battery. Do not attempt to remove or
destroy any of the battery's components.
NOTICE
Battery and charger are manufactured by Briggs &
Stratton Corporation. For complete operation, maintenance and
safe disposal information, refer to the Briggs & Stratton user's
manual provided with the battery or charger. If this manual
is missing, go to the Briggs & Stratton website to obtain an
electronic version of the manual.
All personnel should read and understand the information
contained in the Briggs & Stratton user's manual before operating
the pump.
1.6 General Rail Puller Safety Precautions
WARNING
Failure to observe and comply with the following instructions
and precautions could result in death or serious personal
injury. Property damage could also occur.
• Never exceed the rail puller's rated maximum input pressure.
• Always inspect all system parts before each use for wear,
distortion, cracks or improper fit.
• Never use the rail puller if it is leaking oil. Replace any leaking
components and make required repairs before use.
• Be sure that non-operating personnel stand clear of the
direction of force (directly in front of or behind the rail puller)
during the pull.
• Always be aware of pulling force and system pressure during
the pull by monitoring the tonnage (pressure) gauge while
operating the system.
• Always re-install dust caps to couplers when not in use.
• Always release any trapped pressure from rail puller by shifting
the control valve on the pump before connecting or disconnecting
hydraulic hoses. Never disconnect any other hydraulic
connections on the rail puller to release trapped pressure.
• Refer to instructions in Section 8.7 of this manual for correct
procedure to release trapped pressure in the rail puller
hydraulic circuit.
• Always review and understand proper use of all safety
equipment before attempting to operate the rail puller.
• During transit and while using the pump, use care to keep the
rail puller away from all electrified lines.
• Always ensure that all hydraulic components and couplers are
clean. Retract the rail puller cylinders and reinstall all dust caps
after use.
• Lift the rail puller evenly, in accordance with the instructions in
the puller manual.
• Always use a hydraulic pump that is fully compatible with the
rail puller.
• Always consult the operation manual supplied with the rail
puller for additional information.
• Be sure that the pump reservoir is filled with new Enerpac HF
hydraulic oil.
• Be sure that the pump and rail puller are properly maintained
and that they do not contain contaminated oil. No liability will
be accepted for failure or malfunction of the equipment if this
condition is not met.

5
2.0 MAJOR FEATURES AND COMPONENTS
1
3
2
4
10
8
11
12
3F
3E
3B
3A
3D
7
15
14
13
3G
5
6
9
3C
Figure 1, Major Features and Components, ZC-Series Rail Puller Pumps
Key:
1. Air Breather
2. Powerhead
3. Control Valve Assembly
3A. Pressure Gauge
3B. Directional Control Valve
3C. Check Valve (pilot-operated)
3D. Emergency Pressure Release Valve
3E. Hydraulic Connection, Port “A” (open)
3F. Relief Valve (User Adjustable)
3G. Hydraulic Connection, Port “B” (close)
4. Hydraulic Reservoir Sight Glass
5. Hydraulic Reservoir Drain Plug
6. Hydraulic Reservoir
7. Cord Storage Bracket
8. Roll Cage
9. Battery Access Door
10. Battery Release Button
11. Battery
12. Safety Key
13. Pendant
14. Oil Fill Plug
15. Hydraulic Reservoir Sight Gauge
1
3
2
4
10
8
11
12
3F
3E
3B
3A
3D
7
15
14
13
3G
5
6
9
3C
CONTROL VALVE DETAILS

6
Pump Model
Number
Control Valve
Model Number and Function For Use With: Hydraulic Connections*
Operating Temp
Range
Motor
Rating
Sound
Level
˚F ˚C hp kW dBA
ZC3404JB-RS
and
ZC3404JE-RS
Enerpac VM43
Special Rail Puller Version
(Open - Neutral/Hold - Close)**
Rail Puller
Applications
(double-
acting)
3/8" NPTF +40 to
+120
+4 to
+49 1.4 1.0 75
*Enerpac FH604 coupler installed in A port, Enerpac FR400 coupler installed in B port.
** For most systems, the open side of the valve = advance and the close side of the valve = retract.
Pump Model
Number Item*Model Numbers**
Enerpac Briggs & Stratton
ZC3404JB-RS
and
ZC3404JE-RS
Battery Charger, 115V AC, 50/60 Hz Input NA ZC115VC 1760263
Battery Charger, 230V AC, 50/60 Hz Input EU/AU ZC230VC 1760264
Battery, Lithium Ion, 82V, 4Ah, NA ZC82V4NA 1760265
Battery, Lithium Ion, 82V, 4Ah, EU/AU ZC82V4EUAU 1760515
* Maximum initial battery voltage (measured without a workload) is 82 volts. Nominal voltage is 72.
** Batteries and chargers can be purchased from an Enerpac distributor or Briggs & Stratton retailer.
Battery nomenclature may vary depending on country and/or region.
3.0 PRODUCT DATA
Pump Model
Number
Maximum Hydraulic
Pressure
Flow Rate (Refer to Section 3.2) Reservoir
Size*Pump Weight** Hydraulic
Oil Type
At
No Load
At 4,000 psi
[276 bar]
At 10,000 psi
[700 bar]
psi bar in³/
min l/min in³/ min l/min in³/ min l/min gal l lb kg
ZC3404JB-RS
and
ZC3404JE-RS
10,000
[+300 / -50]
700
[+20.7 / -3.4] 310 5.0 80 1.3 32 0.52 1.0 4.0 85.7 38.9 Enerpac
HF
*Approximate usable capacity of oil reservoir.
** Approximate weight of pump with oil in reservoir and with battery installed.
Weight of battery is approximately 5.7 lb [2.6 kg].
NOTE: All product data is subject to change without notice. Graphs in Section 3.2 show typical pump flow/pressure curves.
3.2 Performance Curves - Flow Rate vs. Pressure
3.1 Specifications
0
50
100
150
200
250
300
350
400
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
FLOW VS. PRESSURE
0
1
2
3
4
5
6
100 200 300 400 500 600 700 800
FLOW VS. PRESSURE
(METRIC)(IMPERIAL)
FLOW RATE (in3/min)
FLOW RATE (l/min)
PRESSURE (psi) PRESSURE (bar)

7
A
C
D
E
F
B
G
3.3 External Dimensions
Item Dimension
in mm
A12.50 318
B6.02 153
C4.24 108
D22.75 578
E11.97 304
F6.06 154
G20.50 521

8
4.0 PRODUCT DESCRIPTION
4.1 Introduction
The Enerpac ZC-Series rail puller pump combines the high
performance of an electric AC-powered pump with the
convenience of a cordless, battery powered pump. It is an ideal
solution for remote rail maintenance locations, where electrical
or pneumatic power sources are either inconvenient to use or
unavailable.
Major features include a brushless DC electric motor, three-stage
pump element and 1.0 gallon [4.0 liter] hydraulic reservoir. Three
dierent control valves are available.
Power is supplied by a rechargeable 82V lithium-ion battery,
manufactured by Briggs & Stratton Corporation. See Figure 2.
The lithium-ion battery is capable of providing impressive run
times, even under extreme job site conditions.
Figure 2, Battery and Charger
4.2 Additional Information - Battery and Charger
• The Briggs & Stratton logo is trademarked and intellectual
property of Briggs & Stratton.
• Portions of this publication are subject to copyright of Briggs
& Stratton Corporation.
4.3 Conformance to National and International Standards
Enerpac declares that the ZC-Series rail puller pump has been
tested and conforms to applicable standards and is approved
to carry the CE, TUV C and US certification marks. An EU
Declaration of Conformity is enclosed separately.
4.4 Electromagnetic Compatibility (EMC)
The ZC-Series rail puller pump has been tested and certified to
conform to CE-EMC emission and immunity standards.
5.0 SETUP
5.1 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.
5.2 Hydraulic Reservoir Air Breather
A shipping plug is installed in the breather port on the top of the
reservoir. Before using the pump, replace the shipping plug with
the adapter fitting and breather. See Figure 3.
1
2
2
3
1
1
2
2
3
1
1. Shipping Plug
2. Breather
3. Adapter Fitting
Figure 3, Hydraulic Reservoir Air Breather
5.3 Oil Level (new pumps)
For most shipping destinations, the reservoir is filled with Enerpac
HF oil at the factory, prior to shipment. However, as a precaution,
always check the oil level to verify that the reservoir is filled. Refer
to Section 9.1 for additional instructions.

9
6.0 HYDRAULIC CONNECTIONS
WARNING To ensure proper operation, avoid kinking or
tightly bending hydraulic hoses. If a hose becomes kinked or
otherwise damaged, it must be replaced. Damaged hoses
may rupture at high pressure. Serious personal injury may
result.
The pump is equipped with an Enerpac 4-way, 3-position control
valve specifically engineered for hydraulic rail puller use.
The control valve manifold is equipped with Enerpac FR Series
“flat face” quick-disconnect couplers. Other hoses, fittings
and couplers must be user-supplied. Refer to Figure 4 for a
connection diagram of a typical setup.
NOTICE
Use of a load lock valve (user-supplied) is strongly
recommended. All hoses, couplers and fittings must be rated to
at least 10,000 psi [700 bar].
Make hydraulic connections as described in the following steps.
1. To prevent the pump from starting, be sure that the battery is
removed from the pump.
2. Remove the plugs from the couplings on pump ports “A” and
“B”.
3. Connect the hydraulic hoses:
• Connect the hose from pump port “A” to the open port on
each rail puller cylinder.
• Connect the hose from pump port “B” to the close port on
each rail puller cylinder.
• Be certain that coupling halves are fully engaged and that
each threaded collar is fully threaded onto the male coupling
half.
Figure 4, Hydraulic Hose Arrangement (typical)
Rail Puller
Cylinders
OPEN (push)
CLOSE (pull)
B Port
(close)
A Port
(open)
Load Lock
Valve
Note: Connections shown are
typical for most rail pullers but
may vary depending on model
and manufacturer. Refer to rail
puller operation manual for
hookup instructions specific
to your puller.

10
7.0 BATTERY
7.1 Battery Capacity Indicator
New batteries should be charged before use. Each battery
contains four indicator lights. The battery capacity indicator
lights show the approximate battery capacity level.
Press the battery capacity indicator button to display the lights.
The battery capacity indicator lights will stay lit for two seconds
after the button is pressed. Refer to Figure 5 to determine the
level of charge.
NOTICE
Run time between battery charges is dependent on the
application, pump run time, pressure setting and other factors.
NOTICE
If none of the battery capacity indicator lights illuminate
when the battery capacity indicator is pressed, place the battery
on the charger and charge as needed.
1
2
When Battery Capacity Indicator
Button is pressed:
Percent Charge:
(approximate)
4 Lights ON 80 - 100%
3 Lights ON 60 - 80%
2 Lights ON 40 - 60%
1 Lights ON 25 - 40%
0 Lights ON < 25%
Figure 5, Battery Capacity Indicator
1. Battery Capacity Indicator Button
2. Indicator Lights
7.2 Battery Installation
1. Be sure that pump motor is not running.
2. Lift battery door and hold it open. See Figure 6.
3. Align ribs on battery and battery bracket. Then, slide the
battery fully into the battery compartment until it stops.
4. Ensure battery release button snaps in place and that
the battery is fully seated and secured before beginning
operation.
5. Close the battery door.
NOTICE
To ensure compatibility and proper operation, use only
Briggs & Stratton 82V lithium-ion batteries with the pump. Refer
to Section 3.1 for battery model number information.
7.3 Battery Removal
1. Ensure pump motor is switched o.
2. Lift the battery door and hold it open.
3. Press the battery release button located above battery.
4. Slide the battery outwards and remove it from the battery
compartment. See Figure 6.
Figure 6, Battery Installation
1
2
4
3
1. Battery Door
2. Battery
3. Battery Release Button
4. Safety Key
7.4 Battery Management System
The battery management system monitors and controls battery
operation:
• A low voltage cut-o feature will shut down the battery when
the battery voltage drops to below acceptable limits.
• A high temperature shut down feature will shut down the
battery if its internal temperature rises to above acceptable
limits.
• If the low voltage cut-o or high temperature shut down feature
is activated while the pump is operating, the pump motor will
emit a beeping sound and the pump will stop.
• If the high temperature shut down feature is activated, the
battery must cool down to an acceptable internal temperature
before the pump can be restarted.
7.5 Additional Battery and Charger Information
• It is recommended that battery be fully charged before first use
to ensure maximum run time can be achieved.
• The battery should be charged at normal room temperature
whenever possible. If the surrounding air temperature is not
normal room temperature, move the battery and charger to a
location with a temperature of between 43°F [6°C] and 104°F
[40°C].
• The battery is a lithium-ion device. It will not develop a memory
and may be charged at any time.
• If the battery charger light glows green and blinks when the
battery is placed in the battery charger, this indicates that the
battery is being charged. A solid green light indicates that
the battery is fully charged. A blinking red light indicates a
charging fault.
• If the battery charger light glows solid red when the battery is
placed in the battery charger, this indicates that the battery
temperature is above acceptable limits. Remove the battery
from the charger and allow time (up to 30 minutes) for the
battery to cool. Charging should resume after the battery has
cooled and been inserted into the charger.

11
• If the battery has been stored with little to no charge for a long
period of time, the charger will go into recovery mode, which
will take 20 hours to fully charge the battery. This will enhance
the life of the battery. Once the battery is fully charged, the
next charge will return to standard charging.
8.0 OPERATION
8.1 Before Start-up
1. Check all hydraulic fittings and connections to be sure they
are tight and leak free.
2. Install hydraulic reservoir breather. Refer to Section 5.1.
3. Check the hydraulic oil level. Add oil if necessary. Refer to
sections 9.1 through 9.4.
4. Install a fully charged battery on the pump. Refer to
Section 7.2.
5. Verify safety key is installed.
6. Connect hydraulic hoses to pump as described in Section
6.0. Remove air from system before placing pump into
operation. Refer to instructions in Section 8.6.
8.2 Transporting and Positioning the Pump
To prevent damage, always use the roll cage when transporting
or positioning the pump. Never attempt to transport or position
the pump by dragging it by the hoses or by the pendant cable.
Never attempt to lift the pump using the powerhead. Serious
damage to the pump, hoses and/or pendant cable may result.
8.3 Starting and Stopping the Pump Motor
1. Before starting the pump motor:
• Place control valve lever in the neutral/hold position (“3”).
Refer to Section 8.5 for control valve positions.
• Be sure that the emergency pressure release valve is fully
closed. Refer to Section 8.8 for additional information.
2. Use the on-o button on the remote pendant:
• To start the pump motor, press and hold the motor on-o
button.
• To stop the pump motor, release the motor on-o button.
NOTICE
A motor start delay of up to 5 seconds (safety feature)
is built into the pump motor circuitry. For this reason, the pump
motor cannot be rapidly jogged on and o. The ZC-Series rail
puller pump is not intended for use as a jog pump.
NOTICE
In an emergency, the pump motor can also be stopped
by removing either the safety key or the battery.
Figure 7, Remote Pendant
Motor On-O Button
• push = start
• release = stop
8.4 Operating Precautions
WARNING
Failure to observe the following precautions and instructions
could allow load to drop on persons working in the area.
Death or serious personal injury could result.
• Be sure that persons remain outside of the rail puller structure
and away from the direction of force area (directly in front of or
behind the rail puller) during the pull.
• ZC-Series rail puller pumps are designed exclusively for use
with compatible rail pullers. To prevent serious personal injury,
do not use the ZC-Series rail puller pumps for lifting tasks or
for any other non-rail puller applications.
8.5 Control Valve Operation
The pump control valve is operated by a rotary lever located at
the front of the pump. Refer to Figure 8 for control valve positions.
To open the rail puller:
1. Be sure that the control valve lever is in the neutral/hold (“3”)
position.
2. Push and hold the motor on-o button to start the pump.
3. Move control valve lever to the open (“1”) position. The puller
cylinders will advance.
4. To stop cylinder movement, release the motor on-o button
or move the control valve lever to the neutral/hold (“3”)
position.
To close the rail puller:
1. Be sure that the control valve lever is in the neutral/hold (“3”)
position.
2. Press and hold the motor on-o button. Pump must be on to
retract cylinders.
3. Move control valve lever to the close (“2”) position. The
puller cylinders will retract.
4. To stop cylinder movement, release the motor on-o button
or move the control valve lever to the neutral/hold (“3”)
position.
2
3
1
Figure 8, Control Valve Positions
1. Open
2. Close
3. Neutral/Hold
NOTICE
The control valve will block hydraulic flow in the cylinder
hoses when the lever is moved to the neutral/hold position (“3”).
However, use of a separate load lock valve in the pulling (close)
circuit is strongly recommended, as shown in Figure 4.

12
8.6 Air Removal
When hydraulic components are connected for the first time,
air will be trapped in the components. To ensure smooth, safe
operation, run the cylinder through several complete advance-
retract cycles before placing the pump into service. Do this with
no load on the cylinder and with the pump positioned higher than
the cylinder.
When the cylinders advance and retract smoothly and without
hesitation, the air has been vented from the system.
NOTICE
Trapped air purged from system components will return
to reservoir. Oil level may drop. Add additional oil (if required) to
reservoir after purging air. Refer to Section 9.4.
8.7 Relieving Trapped Pressure
To relieve trapped pressure in the circuit
1. Be sure that pump is o and that puller is not under load.
2. Rapidly move the control valve lever back and forth through
all three positions.
3. Be certain that pressure gauge(s) indicates zero (0) psi/bar.
Be sure there are no indications of any remaining pressure
being trapped in the system, such as a sti hose.
8.8 Emergency Pressure Release Valve
In the event of a pump malfunction or other condition that
prevents pressure from being relieved in the normal way (see
Section 8.7), the emergency pressure release valve can be used.
See Figure 9.
To relieve pressure, turn the valve knob counter clockwise until
pressure is relieved and gauge indicates zero psi/bar.
After relieving pressure, turn the knob clockwise until it is firmly
closed. Use hand force only. DO NOT USE TOOLS!
NOTICE
The emergency pressure release valve is intended for
emergency use only and should not be used to relieve pressure
during routine pump operation.
Figure 9, Emergency Pressure Release Valve
OPEN
CLOSE
8.9 Disconnecting Hydraulic Hoses
Disconnect hydraulic hoses after use as described in the
following steps:
1. Fully retract the rail puller cylinders. Be sure that the load is
completely removed from the device.
2. Move the control valve lever back and forth between the
open (“1”) and close (“2”) positions several times to relieve
any trapped pressure.
3. Verify that the hydraulic pressure gauge indicates zero (0)
psi/bar.
4. Disconnect hydraulic hoses from rail puller.
5. To prevent contamination, cap or plug all open hydraulic
couplings and ports.
9.0 MAINTENANCE
9.1 Check Oil Level
1. Be sure rail puller hydraulic cylinders are fully retracted.
2. Rotate the control valve lever back and forth several times
between the open and close positions (“1” and “2”) to
remove any trapped pressure.
3. Remove the battery from the pump. Refer to Section 7.2.
4. Place the pump on a level surface.
5. Visually check the oil level by looking through the hydraulic
reservoir sight glass. Reservoir is FULL when oil level is
about halfway between the top and bottom of the sight
glass. Refer to Figure 10.
If oil level is low:
Add oil as described in Section 9.4. Refer to Section 9.2 for
oil requirements.
9.2 Hydraulic Oil Information
Use only Enerpac HF hydraulic oil when adding additional oil
or when performing an oil change. Enerpac HF hydraulic oil is
available from Enerpac distributors and Enerpac authorized
service centers.
NOTICE
Use of other oils may result in damage to pump
components. Such damage is not covered under the Enerpac
product warranty.
1
2
Figure 10, Hydraulic Reservoir
Full
Key:
1. Oil Level Sight Glass
2. Drain Plug
3. Fill Plug
3

13
9.3 Oil Level Sight Gauge
An oil level sight gauge is located on one side of the reservoir.
See Figure 11. The sight gauge allows the operator to view the
reservoir oil level at a glance. For most rail puller applications if
the oil level is 1/4 to 1/2 inch [6.4 to 13.0 mm] below the top of the
sight gauge, the amount of oil in the reservoir will be sucient.
Note that larger rail pullers may require that the reservoir be filled
to its full capacity, as described in Section 9.4 (and shown in
Figure 10).
Figure 11, Oil Level Sight Gauge
9.4 Adding Oil
1. Be sure that rail puller cylinders are fully retracted.
2. Rotate the control valve lever back and forth several times
between the open and close positions (“1” and “2”) to
remove any trapped pressure.
3. Disconnect hydraulic hoses.
4. Remove the battery from the pump. Refer to Section 7.3.
5. Place the pump on a level work surface.
6. Remove the oil fill plug from cover plate. Refer to Figure 10.
7. Slowly fill the reservoir with new oil until level is about halfway
between the top and bottom of the hydraulic reservoir sight
glass, as shown in Figure 10. Refer to Section 9.2 for oil
requirements.
NOTICE
Do NOT overfill. Be certain that puller hydraulic
cylinders are fully retracted before adding any oil. Over filling the
hydraulic reservoir may cause damage to the pump.
9.5 Oil Change
Change the hydraulic oil in the pump reservoir at least once a
year. Oil should be changed immediately it is suspected that the
oil has become contaminated.
To properly drain and refill the reservoir, change the oil as
described in the following steps. Refer to Figure 10.
1. Be sure that rail puller cylinders are fully retracted.
2. With the pump o, rotate the control valve lever back and
forth several times between the open and close positions
(“1” and “2”) to remove any trapped pressure.
3. Remove the battery from pump.
4. Disconnect hydraulic hoses from pump.
NOTICE
The pump is equipped with a 1.0 gallon [4.0 liter]
hydraulic reservoir. Be sure the pan or container used in the next
step is large enough to hold all the drained oil.
5. Place a suitable pan or container of appropriate capacity
under the hydraulic reservoir drain plug.
6. Remove hydraulic reservoir drain plug. Allow used oil to
drain completely from reservoir.
7. Clean hydraulic reservoir drain plug and remove any metal
shavings (plug is magnetic).
8. Reinstall hydraulic reservoir drain plug.
NOTICE
Dispose of used oil in accordance with all applicable
laws and regulations.
10. Refill hydraulic reservoir with new oil. Refer to Section 9.4.
10.0 PRESSURE RELIEF VALVE ADJUSTMENT
WARNING
Never adjust the pressure relief valve setting above 10,000 psi
[700 bar]. Be certain that the pressure setting does not exceed
the maximum rated pressure of rail puller being used. Failure to
observe these precautions may result in catastrophic failure of
rail puller and related components. Death or serious personal
injury could occur.
Adjust the relief valve setting as described in the following steps.
Refer to Figure 11 for relief valve and manifold details. Refer to
Figure 8 for valve lever positions.
1. Install a 0-15,000 psi [0-1000 bar] gauge in the “B” port.
2. Install a 3/8" pipe plug in the “A” port and torque to 25 ft-lbs
[33 Nm].
3. Loosen the relief valve locknut to permit adjustment of set
screw.
4. Rotate the control valve lever to the neutral/hold position (“3”).
5. Start the pump and allow the oil to warm.
6. Rotate the control valve lever to the close position (“2”). Allow
pressure to build.
7. To increase pressure: SLOWLY turn the relief valve set screw
clockwise until pressure increases to the desired setting.
NOTICE
An internal check valve in the manifold will prevent the
pressure from dropping when the set screw is turned counter-
clockwise. To lower the pressure setting, follow steps 8a through
8e.
8. To decrease pressure:
a. Be sure the pump is running.
b. Rotate the control valve lever to the open position (“1”) to
relieve pressure on the “B” port.
c. Turn the relief valve set screw counter-clockwise one
turn.
d. Rotate the control valve lever to the close position (“2”).
e. SLOWLY turn the relief valve set screw clockwise until
“B” port pressure increases to the desired setting.
AB
Figure 12, Relief Valve
Relief Valve Body (DO NOT TURN)
Set screw
Locknut “A” Port
(open)
“B” Port
(close)

14
9. When the desired pressure setting is reached, lock the set
screw with the locknut. DO NOT overtighten.
10. Before turning o pump, rotate the control valve lever
momentarily to the open position (“1”) to relieve pressure at
the “A” port. Then, rotate the lever to the neutral/hold position
(“3”). Check that gauge indicates zero (0) psi/bar.
11. Shut o the pump.
11.0 TROUBLESHOOTING
The information in the Troubleshooting Guide is intended as an
aid to help diagnose and correct various possible problems that
may occur.
For repair service, contact your nearest Enerpac Authorized
Service Center. Only an Enerpac Authorized Service Center
should be permitted to service the pump and its components.
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Never tighten or loosen hydraulic fittings while the pump
hydraulic system or connected components are pressurized.
Escaping oil under pressure can penetrate the skin, causing
serious personal injury.
• Keep hands, fingers and other body parts clear of pinch
points and moving parts when observing operation during
troubleshooting.
• To prevent accidental start-up of pump during servicing,
always remove battery from pump before performing any
maintenance or repair procedures.
TROUBLESHOOTING GUIDE
Symptom Possible Cause Solution
1. Pump will not start. a. Battery is not installed. Install battery.
b. Safety key is not inserted. Insert safety key.
c. Battery is discharged. Charge battery.
d. Safety time delay activated. The motor circuitry contains a safety time delay feature
that briefly delays motor start-up after the pendant switch
is placed in the ON position. This delay may last up to 5
seconds.
Wait at least 5 seconds before restarting the pump motor
after stopping it. Do not attempt to rapidly jog the pump
motor on and o.
e. Electrical contacts are dirty or
corroded.
Clean contacts on the battery, pump and charger.
2. Pump clicks when
remote pendant switch
is on, but does not
start.
a. Battery is discharged. Charge battery.
b. Battery is damaged or not
functioning.
Replace battery.
c. Electrical contacts are dirty or
corroded.
Clean contacts on the battery, pump and charger.
d. Pump is jammed due to
obstruction. Possible internal
damage to pump.
Contact Enerpac Authorized Service Center.
3. Low fluid output. a. Pump needs priming. To prime the pump, be sure that the pump reservoir is filled
with oil. Then, run the pump with the control valve in the
neutral/hold position (“3”) while gently rocking the pump
from side-to-side.
b. Bypass valve malfunction. Contact Enerpac Authorized Service Center.
c. Oil intake screen is clogged with
debris.
Contact Enerpac Authorized Service Center.
d. Internal damage to pump. Contact Enerpac Authorized Service Center.
4. Pump does not build
pressure.
Pressure relief valve setting too
low.
Adjust pressure relief valve setting. Refer to Section 10.
(continued on next page)

15
TROUBLESHOOTING GUIDE (continued)
Symptom Possible Cause Solution
5. Noisy and/or vibrating
pump operation.
a. Pump element piston is sticking. Contact Enerpac Authorized Service Center.
b. Motor is damaged. Contact Enerpac Authorized Service Center.
6. Battery charge is
reduced after more than
one month of use.
The battery has automatically
performed self-maintenance to
extend its life.
Fully recharge battery before use.
7. Puller cylinders will not
advance or retract when
pump is started.
a. Control valve lever is in neutral/
hold (“3”) position.
Move valve lever to the open (“1”) or close (“2”) position
as required. Pump motor must be running to advance or
retract cylinders.
b. Low oil level. Add oil as required.
c. Pump needs priming. To prime the pump, be sure that the pump reservoir is filled
with oil. Then, run the pump with the control valve in the
neutral/hold position (“3”) while gently rocking the pump
from side-to-side.
d. Oil intake screens clogged with
debris.
Contact Enerpac Authorized Service Center.
e. Internal damage to control valve
or pump.
Contact Enerpac Authorized Service Center.
8. Pump slows down and
stops.
Battery is discharged. Charge battery.
9. Puller cylinders advance
and retract erratically.
a. Air in the system. Advance and retract the puller cylinders until operation is
smooth.
b. External hydraulic leak. Tighten connections. Replace damaged components.
c. Internal leakage in valve. Contact Enerpac Authorized Service Center.
d. Internal damage to valve. Contact Enerpac Authorized Service Center.
e. Internal damage to pump. Contact Enerpac Authorized Service Center.
12.0 SAFE DISPOSAL PROCEDURE
When the pump has reached the end of its useful life, dispose of
it as described in the following steps:
1. Be certain that all hydraulic pressure is completely relieved.
2. Disconnect hydraulic hoses from pump.
3. Remove battery from pump. Dispose of battery in accordance
with battery manufacturer's instructions. Refer to Briggs &
Stratton battery user's manual.
4. Drain all hydraulic oil from pump reservoir. Dispose of oil in
accordance with all applicable laws and regulations.
5. Take the pump to an approved industrial recycling facility for
disposal.

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