Enerpac ZUTP1500-S Series User manual

ZUTP1500-S Series
Electric Tensioning Pumps
21,750 psi [1500 bar]
Instruction Sheet
To protect your warranty, use only ENERPAC hydraulic oil.
L4279 Rev. D 08/20 EN

2
1.0 RECEIVING INSTRUCTIONS...........................3
2.0 IMPORTANT SAFETY INSTRUCTIONS ..........3
2.1 Introduction.............................................3
2.2 General Hydraulic Safety Precautions..3
2.3 Hydraulic Tensioning Safety ..................4
2.4 Electrical Safety......................................4
2.4.1 Electrical Safety Precautions .............4
2.4.2 Use and Care........................................4
2.4.3 Disconnecting Power ..........................4
2.4.4 Grounding Instructions .......................5
2.4.5 Use Of Extension Cords......................5
2.5 Additional Precautions...........................5
3.0 MAJOR FEATURES AND COMPONENTS......6
4.0 PRODUCT DATA...............................................7
4.1 External Dimensions ..............................7
4.2 Specifications .........................................7
4.3 Recommended Enerpac Ultra High
Pressure Hoses and Hydraulic
Components (sold separately) ..............7
4.4 Pressure, Flow and Current Draw.........8
5.0 PRODUCT DESCRIPTION...............................8
5.1 Introduction.............................................8
5.2 Conformance to National &
International Standards .........................8
5.3 Electromagnetic Compatibility (EMC) ..8
6.0 HYDRAULIC RESERVOIR BREATHER ...........8
7.0 HYDRAULIC CONNECTIONS .........................9
8.0 POWER REQUIREMENTS...............................9
9.0 OPERATION......................................................9
9.1 Pendant Controls....................................9
9.2 Depressurizing the System..................10
9.3 Setting the Pump Pressure Relief
Valve ......................................................10
9.4 Transporting the Pump.........................11
9.5 Pump Location......................................11
9.6 Preparation for Use ..............................11
9.7 Operating Precautions .........................11
9.8 Operation...............................................11
9.9 Hourmeter .............................................11
9.10 Circuit Breaker....................................11
10.0 MAINTENANCE............................................12
10.1 Hydraulic Oil Information ...................12
10.2 Checking Oil Level..............................12
10.3 Adding Oil............................................12
10.4 Oil Change...........................................12
10.5 Heat Exchanger Maintenance
(pumps equipped with optional
heat exchanger) ..................................12
10.6 Hydraulic Filter Element Cleaning
and Replacement................................13
11.0 TROUBLESHOOTING ..................................14
Troubleshooting Guide................................14
Table of Contents:

3
1.0 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.
2.0 IMPORTANT SAFETY INSTRUCTIONS
2.1 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 DANGER, WARNING,
CAUTION and NOTICE.
DANGER
Indicates a hazardous situation that, if not
avoided, will result in death or serious personal
injury.
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.
2.2 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 items being tensioned. To avoid personal injury,
keep hands and feet away from tensioner pinch point areas.
• 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. Install properly rated
blanking couplers in any unused couplers.
• Do not exceed equipment ratings. Overloading may cause
equipment failure, possibly result in death or serious personal
injury.
• Do not adjust, bypass or tamper with safety relief valves.
• 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.

4
2.3 Hydraulic Tensioning Safety
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Never exceed the maximum working pressure of the hydraulic
tensioner (21,750 psi or 1500 bar unless otherwise specified).
Maximum working pressure is stamped on the tensioner body.
• Never stand in-line with the bolt axis while tensioning or
detensioning is in progress. If the bolt should fail, serious
personal injury or death could result if loose or broken
parts become projectiles. All personnel must be aware of
this potential hazard at all times. High pressure hydraulic
equipment can be very dangerous if misused.
• Keep away from oil leakages at high pressure. Liquid escaping
from highly pressurized equipment has sucient power to
penetrate the skin, which can cause blood poisoning. In the
case of such an accident, seek IMMEDIATE medical attention.
• Do not exceed the maximum allowable piston movement
(stroke) of the hydraulic tensioner. An indicator will appear
when the tensioner is near maximum extension. Refer to the
maximum stroke dimension stamped on the tensioner body.
• Never attempt to repair leaks while the system is pressurized.
Be sure system pressure gauge indicates zero (0) psi/bar
before making repairs.
• Check that the bolt material is capable of taking the initial load
to be applied. Hydraulic tensioners are powerful tools and
are capable of yielding or breaking studs/bolts if tensile/yield
properties are not sucient to support the load applied.
• Use caution when pressurizing a system. Pressure can rise
faster than anticipated. Continuously monitor the pressure
gauge during pressurization. Be prepared to stop the pump
immediately at any time.
• Be sure that the relief valve is adjusted to the appropriate
setting, so the hydraulic tensioners do not apply excessive
force for the application. The hydraulic working pressure must
not exceed 1500 bar [21,750 psi].
• Never leave a pressurized system unattended. If you must
leave the area, stop the pump, fully open the pressure release
valve and ensure that hydraulic pressure gauge indicates
zero (0) psi/ bar.
• Any maintenance or repairs to the hydraulic tensioner(s), the
pump or related components must be performed with the
equipment in the unpressurized state (0 psi/bar).
• Refer to the tensioner instruction manual for important
operation, safety and maintenance information specific to the
tensioner(s) being used. Read, understand and follow tension
manufacturer's instructions and safety precautions.
2.4 Electrical Safety
2.4.1 Electrical Safety Precautions
DANGER
Failure to observe the following instructions and precautions
may result in serious personal injury or death.
• High voltage is present inside the pump even when motor
is o. Before opening the pump housing or performing any
maintenance or repairs, be sure that the pump power cord
is disconnected from the electrical outlet or other electrical
power source.
• Always be certain that the pump is stopped and disconnected
from AC power supply before performing any inspection,
maintenance or repair procedures.
• Do not leave the pump unattended in the workplace when
connected to AC power supply. Take all reasonable precautions
to avoid unauthorized use.
• Take precautions so that the pump is not switched on
accidentally.
• If it is not possible to unplug the pump power cord from the AC
power outlet, the power must be turned o and locked out at
the AC power supply.
• Always disconnect the pump from AC power before
transporting it.
• Do not use the pump if it cannot be switched on and o using
the pendant. Pump must be repaired before use.
• Make sure the pump cooling vents and heat exchanger fan
openings (units equipped with heat exchanger only) are
unobstructed and free of dirt or dust.
• Do not service or clean the hydraulic tensioner(s) while the
pump is operating and/or if pump is connected to AC power
supply.
• Keep electric tools out of the reach of children. Do not
allow inexperienced users or users who have not read the
instructions to operate them.
2.4.2 Use and Care
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Store the pump indoors. Keep in a secured area to prevent use
by unauthorized personnel.
• Do not clean the pump with a water spray or the like.
• Do not operate the pump with a damaged cord or plug, or
after the pump malfunctions or is dropped or damaged
in any manner. Return the pump to the nearest Enerpac
authorized service center for examination, repair, or electrical
or mechanical adjustment.
2.4.3 Disconnecting Power
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Be sure that the pump is o before removing plug from
electrical outlet.
• Do not unplug the pump by pulling on the cord. To unplug,
grasp the plug, not the cord.
• Remove plug from electrical outlet when the pump is not in
use and before servicing or cleaning the pump.

5
2.4.4 Grounding Instructions
DANGER
Failure to observe the following instructions and precautions
may result in serious personal injury or death.
• The pump must be properly grounded. In the event of
malfunction or breakdown, grounding provides a path of least
resistance for electric current to reduce the risk of electric
shock. The pump is equipped with a cord having an equipment
grounding conductor.
• A grounding plug is included with the cord. The plug must be
plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
• Improper connection of the pump grounding conductor can
result in electric shock. The conductor with insulation having
an outer surface that is green with or without yellow stripes is
the pump grounding conductor.
• If the cord and/or plug are damaged, do not connect the pump
to a live electrical outlet. Repair or replace the damaged items
as required and be sure the grounding conductor is properly
wired before reconnecting the pump to the outlet. Consult a
qualified electrician if grounding conductor wiring procedures
are not completely understood or if there is any doubt as to
whether the pump is properly grounded.
• Do not modify the plug provided with the pump. If the plug will
not fit in the outlet, have a proper outlet installed by a qualified
electrician.
• A qualified electrician should be consulted if there is any doubt
as to whether an outlet box is properly grounded.
• This pump is equipped with an electric power cord and plug
specific to its rated single-phase voltage. No adapter should
be used with the plug
• If the pump must be reconnected for use on a dierent type of
electric circuit, the reconnection should be made by a qualified
electrician. After the reconnection, the pump should comply
with all local codes and ordinances.
2.4.5 Use Of Extension Cords
DANGER
Failure to observe the following instructions and precautions
may result in serious personal injury or death.
• Use the proper size extension cord with the pump power
cord when use of an extension cord is necessary. A qualified
electrician should be consulted to help specify and select the
proper size extension cord. The marked electrical rating of the
extension cord should be at least as great as the electrical
rating of the pump.
• The extension cord should be a grounding-type 3-wire cord for
single-phase power.
• A long extension cord should be arranged so that it will not
drape over any working area where it can be tripped over,
snagged, or pulled on unintentionally.
• If the pump is to be operated outdoors and an extension
cord is needed, use only an outdoor-use extension cord. An
outdoor-use extension cord will be clearly marked with the
sux letter “W” and the statement “Suitable for Use with
Outdoor Appliances.”
2.5 Additional Precautions
WARNING Do not use electric pumps in an explosive
atmosphere. Sparks and electrical arcing could ignite
combustible vapors or airborne dust.
WARNING Do not expose the pump to rain, water, or
moisture. Though the pump can be operated outdoors, in
case of rain, the pump needs to
be taken indoors. Failure to
observe this precaution could
result in an electric shock. Death
or serious personal injury could
occur.
CAUTION The pump is designed for a 33% duty cycle
(10 minutes ON, 20 minutes OFF). Please allow time for
the pump to cool before continuing with cycles. Failure to
observe this precaution may result in motor damage.
CAUTION To prevent damage to the pump electric
motor, check power specifications on pump data plate. Use
of incorrect outlet will damage the motor.

6
3.0 MAJOR FEATURES AND COMPONENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
Key
1. Heat Exchanger (optional)
2. Power Cord
3. Pendant
4. Oil Outlet Coupler
5. Hydraulic Reservoir Breather
6. Pressure Gauge
7. Manual Pressure Release Valve
8. User Adjustable Relief Valve Knob
9. User Adjustable Relief Valve Locknut
10. Oil Level Sight Glass
11. Drain Plug
12. Manifold
13. Control Valve (solenoid operated)
14. Hydraulic Reservoir
15. Shroud Air Vents
16. Hourmeter
17. Carrying Handle

7
4.0 PRODUCT DATA
Motor Size Motor
Duty Cycle
Output Flow Rate
(approximate)
Sound
Level Usable Oil Capacity
hp kW 0 psi
[0 bar]
10,000 psi
[700 bar]
15,000 psi
[1000 bar]
21,750 psi
[1500 bar] dBA gallons liters
1.7 1.25
33%
(10 min. ON,
20 min. OFF)
230 in³/min
[3.80 l/min]
32 in³/min
[0.52 l/min]
27 in³/min
[0.44 l/min]
20 in³/min
[0.33 l/min] 89 1 3.8
NOTICE
Output flow rates shown are based on 60 Hz operation. Flow rates at 50 Hz will be approximately 5/6 of these values
Temperature Range Hydraulic Oil Type Seal Materials Max. Hydraulic
Working Pressure Electric Current Draw
-20°F to 140°F
[-29°F to 50°C]
Enerpac HF (ISO 32) or
ISO 64 Synthetic
Buna, Viton and
Polyurethane
21,750 psi
[1500 bar]
(Refer to graphs in
Section 4.4)
Item Dimension
inch mm
A19.00 483
B18.75 476
C20.64 524
D12.75 324
BC
D
A
Pump Model Number Rated Voltage Plug Type Heat Exchanger Weight with Oil (approximate)
lbs kg
ZUTP1500SB 115 VAC, 1-ph NEMA 5-15 No 65 29.5
ZUTP1500SB-H 115 VAC, 1-ph NEMA 5-15 Yes 75 34.0
ZUTP1500SI 230 VAC, 1-ph NEMA 6-15 No 65 29.5
ZUTP1500SI-H 230 VAC, 1-ph NEMA 6-15 Yes 75 34.0
ZUTP1500SE 230 VAC, 1-ph Schuko No 65 29.5
ZUTP1500SE-H 230 VAC, 1-ph Schuko Yes 75 34.0
Description Model Number Length Connections
ft m End 1 End 2
Hydraulic Tensioner Hose HT1503 3.28 1.00 G ¼ 120° Cone G ¼ 120° Cone
Hydraulic Tensioner Hose HT1510 9.84 3.00 G ¼ 120° Cone G ¼ 120° Cone
Hydraulic Tensioner Hose QHT1503HR 3.28 1.00 BH150 Coupler BR150 Coupler
Hydraulic Tensioner Hose QHT1510HR 9.84 3.00 BH150 Coupler BR150 Coupler
Description Model Number
Complete Set Female Half Male Half
Quick Disconnect Coupler QB150 QBR150 QBH150
Quick Disconnect Coupler And Adaptor Kit QBW150AW - - - - - -
Quick Disconnect Blanking Coupler Set QB150B - - - - - -
QIncludes dust caps.
NOTICE
Model numbers of ultra high pressure hydraulic hoses and components are subject to change without notice.
Refer to Enerpac catalog for latest information and additional product details.
4.2 Specifications
4.3 Recommended Enerpac Ultra High Pressure Hoses and Hydraulic Components (sold separately)
4.1 External Dimensions

8
5.0 PRODUCT DESCRIPTION
5.1 Introduction
The ZUTP1500-S Series electric tensioning pumps are designed
to operate ultra high pressure hydraulic tensioners rated at
21,750 psi [1500 bar] working pressure.
A 20 foot [6 m] pendant and electric solenoid valve are included
on all pump models, allowing the operator to easily pressurize
and depressurize the system as required.
Major features include:
• 1.7 hp [1.25 kW] heavy-duty universal motor.
• Remote control 2 button pendant.
• Electric solenoid operated control valve.
• Manual pressure release valve.
• Replaceable 10 micron oil filter.
• Two-stage pump design for fast system fills and controlled
flow at high pressures.
• Panel mounted 6" [152 mm] pressure gauge.
5.2 Conformance to National & International Standards
Enerpac declares that the ZUTP1500-S Series pumps have been
tested and conform to applicable standards and are approved to
carry the CE, TÜV C and US, and FCC certification marks. An EU
declaration of conformity is enclosed separately.
5.3 Electromagnetic Compatibility (EMC)
The ZUTP1500-S Series pumps have been tested and certified
to conform to CE-EMC Emission and Immunity standards and to
FCC Emission standards.
6.0 HYDRAULIC RESERVOIR BREATHER
A shipping plug is installed in the breather port on the top of the
reservoir. Before using the pump, remove the shipping plug and
install the adapter fitting and breather. These parts are included
loose in the shipment. Refer to Figure 1.
1
23
Figure 1, Hydraulic Reservoir Breather
Key
1. Hydraulic Reservoir
Breather
2. Adapter Fitting
3. Shipping Plug
4
8
12
16
20
0
115V
230V
115V & 230V, 60 Hz
0
0.8
1.6
2.4
3.2
4.0
350 700 1050 14000
Oil Flow and Current vs. Pressure
Oil Flow (l/min)
Pressure (bar) ▶
Current (Amps) ▶
Flow (l/min)
Current (amps)
▶
4
8
12
16
20
0
115V
230V
115V & 230V, 60 Hz
Oil Flow and Current vs. Pressure
Oil Flow (in3/min)
▶
Pressure (psi) ▶
Current (Amps) ▶
Flow (in3/min)
Current (amps)
0
50
100
150
200
250
500010,00015,00020,000
0
NOTE: Output flow rates shown are for 60 Hz operation.
Flow rates at 50 Hz will be approximately 5/6 of these values.
METRICIMPERIAL
4.4 Pressure, Flow and Current Draw
Oil Flow (l/min)
Current (Amps)
Oil Flow (l/min)
Current (Amps)
Pressure [psi]
Flow (in3/min)
Current (amps)
Flow (l/min)
Current (amps)
Oil Flow and Current vs. Pressure Oil Flow and Current vs. Pressure
Pressure [bar]

9
7.0 HYDRAULIC CONNECTIONS
WARNING
Failure to observe and comply with the follow precautions
could result in death or serious personal injury. Property
damage could also occur.
• To prevent accidental startup of the pump, be certain that the
pump is disconnected from electrical power before connecting
or disconnecting hydraulic hoses.
• The ZUTP1500-S Series pumps must be operated only with
hydraulic hoses and fittings rated to operate at 21,750 psi
[1500 bar] working pressure. Hoses and fittings of a lower
pressure rating will rupture or burst.
NOTICE
Enerpac recommends the use of Enerpac HT1500
Series thermoplastic hoses with the ZUTP1500-S Series
pumps. These hoses are rated at 21,750 psi [1500 bar]. Refer to
Section 4.3 and the Enerpac catalog for additional information.
The ZUTP1500-S Series pumps are equipped with a female
quick-disconnect hydraulic coupler for the oil outlet. This coupler
is rated at 21,750 psi [1500 bar]. Refer to Figure 2.
Before connecting a hose to the oil outlet coupler, verify that
the pressure gauge indicates zero (0) psi/bar. Be certain that
all hydraulic pressure is fully relieved before continuing. If
any pressure remains, then relieve pressure as described in
Section 9.2.
Figure 2, Oil Outlet Coupler
8.0 POWER REQUIREMENTS
The ZUTP1500-S Series pumps are available in three dierent
versions to suit dierent electrical power requirements:
• Models ZUTP1500SB and ZUTP1500SB-H are designed for
115 VAC, single-phase, 50-60 Hz power. These models have a
USA style NEMA 5-15 power plug.
• Models ZUTP1500SI and ZUTP1500SI-H are designed for
230 VAC, single-phase 50-60 Hz power. These models have
a NEMA 6-15 power plug.
• Models ZUTP1500SE and ZUTP15000SE-H are designed for
230 VAC, single-phase 50-60 Hz power. These models have a
European style “Schuko” power plug.
Before connecting electrical power to the pump, be certain that
the power supply is the proper voltage and Hz for the pump
version that you are using. Refer to the pump data plate. Also
refer to Section 2.4 for important electrical safety information and
precautions.
WARNING
Failure to follow the electrical safety precautions contained
in Section 2.4 of this manual could result in electric shock.
Death or serious personal injury could occur.
9.0 OPERATION
9.1 Pendant Controls
Refer to Figure 3.
NOTICE
The user adjustable pressure relief valve setting must
be set high enough for pressure to build when the motor is
started. Refer to Section 9.3 for user adjustable pressure relief
valve setting instructions.
• The motor jog button starts and stops the motor. When the
motor jog button is pressed the motor starts. This builds
system pressure and the hydraulic tensioner(s) is actuated for
as long as the button is depressed. Releasing the button will
stop the motor, but a check valve will hold system pressure.
• When the pressure dump button is pressed, system pressure is
relieved and flow is directed to the reservoir. Flow will continue
to be directed to the reservoir until the motor jog button is
pressed.
• The active indicator light will illuminate when the motor jog
button is pressed. It will remain illuminated until the pressure
dump button is pressed or the power cord is disconnected.
CAUTION
The pump is designed for a 33% duty cycle (10 minutes
ON, 20 minutes OFF). Please allow time for the pump to
cool before continuing with cycles. Failure to observe this
precaution may result in motor damage.
M
O
T
O
R
J
O
G
A
C
T
I
V
E
P
R
E
S
S
U
R
E
D
U
M
P
3
1
2
Figure 3, Pendant
Key
1. Pressure Dump Button
2. Active Indicator Light
3. Motor Jog Button

10
9.2 Depressurizing the System
To relieve system pressure:
1. If not already connected, connect the pump to an electrical
power source.
2. Press the pressure dump button. Refer to Figure 3.
3. Check that the pressure gauge indicates zero (0) psi/bar.
If electrical power fails, or if the control valve solenoid or pendant
malfunctions, system pressure may be trapped. To manually
relieve pressure under these conditions:
1. Rotate the manual pressure release valve handle
counterclockwise to the open position to release pressure.
Refer to Figure 4.
2. Verify that the pressure gauge indicates zero (0) psi/bar.
3. Rotate the handle on the manual pressure release valve
clockwise to the closed position to close the valve. Tighten
until hand tight. To prevent damaging the valve, DO NOT use
excessive force.
Figure 4, Manual Pressure Release Valve
CLOSE
OPEN
9.3 Setting the Pump Pressure Relief Valve
NOTICE
The relief valve pressure setting must be adjusted
before the pump is placed into operation.
Set the pump pressure relief valve as described in the following
steps:
1. Verify that the pressure gauge indicates zero (0) psi/bar.
Be certain that all hydraulic pressure is fully relieved before
continuing this procedure. If any pressure remains, then
relieve pressure as described in Section 9.2.
2. Disconnect hose (if connected) from the oil outlet coupler.
Refer to Figure 2.
3. Install a male blanking coupler in the oil outlet coupler.
WARNING Use of a compatible male blanking coupler
rated at 21,750 psi [1500 bar] is mandatory. Refer to
Section 4.3 of this manual for blanking coupler set information.
Use of an incompatible blanking coupler may result in high
pressure oil leakage and/or catastrophic failure (projectile
hazard). Death or serious personal injury could result.
1
2
Figure 5, Pressure Relief Valve (user adjustable)
Key
1. Pressure Relief Valve Knob
2. Pressure Relief Valve Locknut
4. Loosen the pressure relief valve locknut to allow for pressure
adjustment. Refer to Figure 5.
5. Turn the pressure relief valve knob several turns
counterclockwise so that the relief valve is set lower than the
desired setting. Refer to Figure 5.
NOTICE
When adjusting the relief valve pressure, always start
at a low setting. Then slowly increase the pressure to the desired
setting.
6. Press and hold the motor jog button. The pump motor will
start and pressure will begin building immediately.
WARNING
Pump maximum working pressure is 21,750 psi
[1500 bar]. Do not set the relief valve pressure above 21,750 psi
[1500 bar]. Failure to observe and comply with this instruction,
may result in excessive hydraulic working pressures. High
pressure oil leakage and/or component failures may occur.
Death or serious personal injury could result.
7. While continuing to press and hold the motor jog button,
slowly turn the user adjustable pressure relief valve knob
clockwise (as required) until the desired pressure reading is
shown on the pressure gauge.
8. When the desired reading is shown on the pressure gauge,
release the motor jog button. The pump motor will stop.
9. After verifying that the pressure setting is correct, push the
dump pressure button, to relieve pressure. Verify that the
pressure gauge indicates zero (0) psi/bar.
WARNING
The pump contains an internal safety relief valve that is
factory set to approximately 22,550 psi [1554 bar].
The safety relief valve is NOT user-adjustable. Never tamper
with or attempt to readjust or disable the safety relief valve.
The safety relief valve should be serviced and adjusted only
by an Enerpac Authorized Service Center.

11
9.4 Transporting the Pump
Always transport the pump using the handle at the top of the roll
cage.
To prevent possible damage, never attempt to transport or
reposition the pump by dragging it by the hose, power cord or
pendant.
9.5 Pump Location
Place the pump in a location where airflow around the pump
shroud vents are free and unobstructed.
On pumps equipped with the optional heat exchanger, be sure
that the fan vents are not blocked by walls or other objects.
9.6 Preparation for Use
Before use, set the pump pressure relief valve and connect the
hydraulic tensioner(s) and hose(s) as described in the following
steps:
1. Set the pump pressure relief valve to the desired setting.
Refer to Section 9.3.
2. After setting the pressure relief valve, press the pressure
dump button to relieve any trapped pressure in the pump
element and manifold. Refer to Section 9.2.
3. Release the pressure dump button. Check that the pressure
gauge indicates zero (0) psi/bar. Be sure there is no pressure
shown.
4. Connect hydraulic tensioner(s) and hose(s). Refer to the
tensioner manufacturer's instructions for detailed tensioner
setup and installation instructions. Also refer to instructions
and precautions in Section 7.0 of this manual.
9.7 Operating Precautions
WARNING
Failure to observe and comply with the following instructions
and precautions could result in catastrophic tensioner failure
and/or high pressure oil leakage. Death or serious personal
injury could occur.
• Do not continue pressurizing hydraulic tensioner(s) after they
reach maximum stroke length or operating pressure.
• Before pressurizing the system, read and understand all
instructions and safety precautions applicable to the hydraulic
tensioner(s) being used. Refer to the tensioner manufacturer's
instructions for detailed tensioner operation and safety
information.
• Follow safe work practices in accordance with all applicable
laws, regulations and industry standards.
• Continuously monitor the pressure gauge while the pump is
running.
• Stop the pump immediately if the tensioner maximum stroke
length is reached or if oil leakage occurs. Pressures can rise
faster than anticipated.
9.8 Operation
Operate the pump as described in the following steps. Refer to
Figure 3 for a diagram of the pendant controls.
1. Press and hold the motor jog button to start the pump
motor. The active indicator light will illuminate and pressure
will begin building immediately. Continuously observe the
pressure gauge while the pump is running.
NOTICE
The amount of time required to pressurize a hydraulic
circuit will vary depending on the quantity and type of hydraulic
tensioner(s) connected, hydraulic hose lengths and other factors.
2. When the desired operating pressure is reached, release the
motor jog button. The pump will stop and the active indicator
light will remain lit.
3. Press the pressure dump button to relieve pressure. The
active indicator light will turn o. The pressure gauge should
indicate zero (0) psi/bar.
NOTICE
For some systems, it may be necessary to manually
retract the tensioner(s) after the hydraulic pressure is relieved.
9.9 Hourmeter
The pump is equipped with a digital hourmeter that displays the
motor's elapsed running time. It should be used as a guide to help
determine when oil changes and other scheduled maintenance
procedures should be performed. The hourmeter operates only
when the motor is running. It is not resettable.
Figure 6, Hourmeter
9.10 Circuit Breaker
The pump circuit breaker is located at the front of the pump
shroud. In the event of an electrical overload the circuit breaker
will trip and the pump will stop. After investigating and correcting
the source of the overload, push the circuit breaker button to
reset. Refer to Figure 7.
CIRCUIT BREAKER
Press to Reset
Figure 7, Circuit Breaker
CIRCUIT BREAKER
Press to Reset

12
10.0 MAINTENANCE
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• To avoid accidental starting, the pump must be disconnected
from electrical power before maintenance is performed.
• Fully relieve all system pressure before performing any
maintenance.
10.1 Hydraulic Oil Information
The pump reservoir is filled with Enerpac HF hydraulic oil
(ISO Grade 32) prior to shipment. This oil is suitable for most
applications and working environments.
For applications where unusually high ambient temperatures
and/or extended duty cycles cause the oil temperature to exceed
130°F [54°C], the use of ISO Grade 64 synthetic hydraulic
oil is recommended. This will help maintain maximum pump
performance.
NOTICE
Never mix oils of dierent viscosities. Mixing oil
viscosities may result in damage to pump hydraulic components
and will void the product warranty.
10.2 Checking Oil Level
1. Be sure hydraulic tensioner(s) is fully retracted.
2. Verify that the pressure gauge indicates zero (0) psi/bar.
Be certain that all hydraulic pressure is fully relieved before
continuing this procedure. If any pressure remains, then
relieve pressure as described in Section 9.2.
3. Disconnect the power cord from the electrical outlet.
4. Be sure that the pump is placed on a level surface.
5. Visually check the oil level by looking through the oil level
sight glass. Reservoir is FULL when oil level is about halfway
between the top and bottom of the slight glass. Refer to
Figure 8.
If oil level is low:
Add oil as described in Section 10.3. Refer to Section 10.1
for oil specifications.
NOTICE
Be sure that the oil is clean. If the oil has a milky,
cloudy or dark appearance, it should be changed immediately as
described in Section 10.4.
10.3 Adding Oil
NOTICE
Never mix oils of dierent viscosities. Mixing oil
viscosities may result in damage to pump hydraulic components
and will void the product warranty.
1. Be sure hydraulic tensioner(s) is fully retracted.
2. Verify that the pressure gauge indicates zero (0) psi/bar.
Be certain that all hydraulic pressure is fully relieved before
continuing this procedure. If any pressure remains, then
relieve pressure as described in Section 9.2.
3. Disconnect the power cord from the electrical outlet.
4. Disconnect hydraulic hose from oil outlet coupler.
5. Remove hydraulic reservoir breather. Refer to Section 6.0.
6. Slowly pour new oil into the reservoir through the breather
port. Refer to Section 10.1 for oil specifications. Refer to
Section 10.2 for oil level check instructions.
1
2
Key
1. Oil Level Sight Glass
2. Oil Drain Plug
Figure 8, Sight Glass and Drain Plug
Full
NOTICE
Remove and dispose of any spilled oil in accordance
with all applicable laws and regulations. Use only new oil poured
from a clean container.
7. Reinstall hydraulic reservoir breather.
10.4 Oil Change
1. Be sure hydraulic tensioner(s) is fully retracted.
2. Verify that the pressure gauge indicates zero (0) psi/bar.
Be certain that all hydraulic pressure is fully relieved before
continuing this procedure. If any pressure remains, then
relieve pressure as described in Section 9.2.
3. Disconnect the power cord from the electrical outlet.
4. Disconnect hydraulic hose from oil outlet coupler.
NOTICE
The pump is equipped with a 1 gallon [3.8 liter]
hydraulic reservoir. Be sure the pan or container 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. Refer to Figure 8.
6. Remove hydraulic reservoir drain plug.
NOTICE
Remove and dispose of any used oil in accordance
with all applicable laws and regulations.
7. Allow used oil to drain completely from the hydraulic
reservoir.
8. Clean hydraulic reservoir drain plug and remove any metal
shavings (plug is magnetic).
9. Reinstall hydraulic reservoir drain plug.
10. Clean or replace the hydraulic filter element. Refer to Section
10.6 for procedure.
11. Refill the reservoir with new hydraulic oil as described in
Section 10.3
NOTICE
It is recommended that the hydraulic reservoir breather
be replaced at every oil change. Refer to Figure 1 for assembly
details.
10.5 Heat Exchanger Maintenance
(pumps equipped with optional heat exchanger)
• Check that the heat exchanger fan openings are unobstructed
and free of dirt or dust.
• Check for loose or missing fasteners and components. Tighten
or replace as required.
• Check the heat exchanger core and lines for oil leaks. If leaks
are found, make repairs as required.
• Verify that heat exchanger fan starts when pump motor starts.

13
10.6 Hydraulic Filter Element Cleaning and Replacement
NOTICE
To ensure optimal performance, always clean or
replace the hydraulic filter element at every oil change.
To properly inspect, clean and replace the hydraulic filter, refer to
the following steps:
1. Verify that the pressure gauge indicates zero (0) psi/bar.
Be certain that all hydraulic pressure is fully relieved before
continuing this procedure. If any pressure remains, then
relieve pressure as described in Section 9.2.
2. Disconnect the power cord from the electrical outlet.
3. Loosen the user adjustable pressure relief valve locknut.
Turn the relief valve knob counterclockwise until the shaft
disengages from the threaded fitting on the valve manifold.
Refer to Figure 5.
4. Remove the six M4 capscrews securing the front panel to
the roll cage. Remove the front panel to provide access.
Refer to Figure 9.
1
2
Key
1. Front Panel
2. M4 Capscrew
Figure 9, Front Access Panel
WARNING
Be certain that hydraulic pressure is fully relieved before
loosening the gland plug in the next step. Failure to observe
this instruction may result in the uncontrolled release of
pressurized hydraulic oil when gland plug is loosened. Skin
penetration and serious personal injury may result.
5. Using a 1" wrench or socket, loosen and remove the gland
plug from the valve manifold. Refer to Figure 10.
NOTICE
After the gland plug is removed, the filter spacer, filter
element and anti-extrusion disc can be removed with a pick or by
carefully tipping the pump forward until the parts drop out.
6. Remove the filter spacer, filter element and anti-extrusion
disc.
7. Remove any loose debris that may have accumulated on the
filter spacer, filter element and anti-extrusion disc. Flush and
clean the filter element.
123456
Key
1. Gland Plug
2. Washer
3. O-ring
4. Filter Spacer
5. Filter Element
6. Anti-Extrusion Disc
Figure 10, Filter Element
NOTICE
The filter element should not be reused if it is very
dirty. If embedded particles cannot be removed from the mesh
by flushing, replace the old filter element with a new one. Refer to
the pump repair parts sheet for replacement filter element part
number.
8. Install the anti-extrusion disc. Be sure that the mesh side of
the disc faces outward, toward the manifold opening.
9. Install the filter element. It can be installed with either side
toward the manifold opening.
10. Install the filter spacer into the filter element.
11. Inspect the gland plug, O-ring and backup ring. Replace
these parts if worn or damaged.
12. Thread the gland plug into the valve manifold using a 1"
wrench or socket. Torque to 60-65 ft-lbs [81-88 Nm].
13. Reinstall the front panel on the roll cage with six M4
capscrews.
14. Thread the shaft of the user adjustable pressure relief valve
knob into the threaded fitting on the valve manifold. After
threads are engaged, rotate the user adjustable pressure
relief valve knob clockwise several turns.
15. Readjust the relief pressure. Refer to Section 9.3.

14
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 disconnect the pump from electrical power sources
before performing any maintenance or repair procedures.
Troubleshooting Guide
Problem Possible Cause Action
1. Pump will not start. a. No power. Be sure that the pump power plug is
connected to AC power supply. Be sure that
the voltage is correct for the pump model.
b. Pump circuit breaker tripped. Push pump circuit breaker button to reset.
c. Low voltage. Turn o other electric loads.
Use heavier gauge extension cord.
d. Motor brushes worn to end of life. Contact Enerpac Authorized Service Center.
e. Pendant cable wires loose or broken.
Pendant jog switch worn of defective.
Repair wiring and/or replace switch as
required.
Contact authorized service center.
2. Motor stops under load. Low voltage. Turn o other electric loads.
Use heavier gauge extension cord.
3. Pump fails to build
pressure or builds less
than full pressure.
a. Pressure dump button is depressed. Release pressure dump button.
b. Low oil in reservoir. Add oil to reservoir. Refer to Section 10.3.
c. Manual pressure release valve is not fully
closed (or cannot be fully closed due to
internal wear).
Close valve hand tight. If wear is suspected,
contact Enerpac Authorized Service Center.
d. Relief valve setting too low. Adjust relief valve pressure. Refer to
Section 9.3.
e. External system leak. Repair or replace components as required.
f. Pump hydraulic filter element clogged. Replace pump hydraulic filter element. Refer to
Section 10.6.
Change hydraulic oil. Refer to Section 10.4.
g. Pump hydraulic oil intake screen is dirty. Clean or replace hydraulic intake screen.
Change hydraulic oil and filter element. Refer
to Sections 10.4 and 10.6.
h. Internal leak in pump control valve. Contact Enerpac Authorized Service Center.
i. Internal leak in system component. Contact Enerpac Authorized Service Center.
4. Pump takes an
excessively long time to
build pressure.
a. Cold hydraulic oil. Warm the hydraulic oil to approximately 60°F
[15°C] by running the pump and allowing the
oil to flow over the user-adjustable relief valve
(set to 1000 psi [68 bar] ).
b. Manual pressure release valve is not fully
closed (or cannot be fully closed due to
internal wear).
Close valve hand tight. If wear is suspected,
contact Enerpac Authorized Service Center.
(continued on next page)

15
Troubleshooting Guide (continued)
Problem Possible Cause Action
4. Pump takes an
excessively long time to
build pressure.
(continued)
c. Pump hydraulic filter element clogged. Replace pump hydraulic filter element. Refer to
Section 10.6.
Change hydraulic oil. Refer to Section 10.4.
d. Higher oil viscosity needed. Change to ISO Grade 64 synthetic oil.
Completely drain and refill reservoir per
instructions in Section 10.4.
NOTICE
To prevent damage to pump, do not
combine dierent oil grades.
e. Install a heat exchanger. Contact Enerpac Authorized Service Center.
5. Pump builds to full
pressure, but hydraulic
tensioner does not move.
a. Load greater than hydraulic tensioner
capacity at full pressure.
Reduce load or increase hydraulic tensioner
capacity.
b. Flow to hydraulic tensioner is blocked. Check hydraulic couplers for full engagement.
Check hose for blockage or kinks.
6. Pressure is not relieved
when pressure dump
button is pressed.
a. Low voltage. Check for proper voltage. Dump function may
not operate if voltage is low.
b. Pendant cable wires loose or broken. Contact Enerpac Authorized Service Center.
NOTICE
If indicator light on valve solenoid
illuminates when pressure dump button is
pressed and released, pressure dump switch
and pendant wiring are probably OK. Check
for defective solenoid coil.
c. Pump control valve needs cleaning
or is not opening.
Contact Enerpac Authorized Service Center.
d. Loose connections and/or damaged
electrical components inside pump shroud.
Contact Enerpac Authorized Service Center.
7. Low oil flow. a. Low oil level in hydraulic reservoir. Check oil level and add oil to hydraulic
reservoir if needed. Refer to Sections 10.2 and
10.3.
b. Pump hydraulic filter element clogged. Replace pump hydraulic filter element. Refer to
Section 10.6.
Change hydraulic oil. Refer to Section 10.4.
c. Pump hydraulic intake screen dirty. Clean or replace hydraulic intake screen.
Change hydraulic oil. Refer to Section 10.4.
8. Hydraulic tensioner
drifts back on its own
when motor jog button is
released.
a. External system leak. Inspect all hydraulic connection. Tighten,
repair or replace components as required.
b. Pump check valve malfunctioning. Contact Enerpac Authorized Service Center.
c. Pump control valve needs repair. Contact Enerpac Authorized Service Center.
9. Hydraulic tensioner will
not return (or cannot be
manually returned) when
pressure is relieved.
a. Flow is restricted or blocked. Check hydraulic couplers for full engagement.
Check hose for blockage or kinks.
b. Pump control valve malfunction. Contact Enerpac Authorized Service Center.
10. Pump runs hot. a. Flow restricted. Check hydraulic couplers for full engagement.
Check hose for blockage or kinks.
b. Oil flowing over the relief valve for long
periods of time.
Reduce the amount of motor running time
while oil is flowing over the relief valve.
c. Heat exchanger not working (pumps
equipped with heat exchanger only).
Check for proper operation of heat exchanger.
Repair or replace heat exchanger as required.

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