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Enerpac

PRO Series Pumps

PRO115E-A

Summary of Contents for 76501-02000

Page 1: ...Enerpac PRO Series Pumps PRO115E A...

Page 2: ...Pump AV Tool Operator Guide Original Instruction Enerpac PRO Series Pump Hydraulic Power Unit...

Page 3: ...age resulting from activities carried out by third parties The working names trade names registered trademarks etc used by STANLEY Engineered Fastening should not be considered as being free pursuant...

Page 4: ...t always be followed to reduce the risk of personal injury IMPORTANT READ THE SAFETY RULES PROVIDED IN THE ENERPAC PUMP INSTRICTION MANUAL AND IN THE PLACING TOOL INSTRUCTION MANUAL CAREFULLY BEFORE P...

Page 5: ...the hydraulic supply Use only lubricants recommended by the manufacturer Contact with hydraulic fluid should be avoided To minimise the possibility of rashes care should be taken to wash thoroughly if...

Page 6: ...ent and the implementation of appropriate controls for these hazards are essential Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpieces from ring...

Page 7: ...by the hose or electrical cable Always use the placing tool handle DO NOT pull or move the hydraulic pump unit using the hoses Always use the pump unit handle or roll cage Keep dirt and foreign matter...

Page 8: ...tached it can then be used to install a range of Avbolt Avdelok Avseal II Avdelok XT and Neobolt fasteners in industrial environments The tool is fitted with two Hydraulic Hoses and an electrical Cont...

Page 9: ...60 50 60 Phase 1 1 1 1 Current Full Load Amps A 18 0 18 0 6 8 6 8 Output Flow Rate l min at 7 bar 8 9 8 9 8 9 8 9 l min at 50 bar 8 2 8 2 8 2 8 2 l min at 350 bar 0 8 0 8 0 8 0 8 l min at 600 bar 0 8...

Page 10: ...60 Phase 3 3 3 3 Current Full Load Amps A 6 8 6 8 3 0 3 0 Output Flow Rate l min at 7 bar 8 9 8 9 8 9 8 9 l min at 50 bar 8 2 8 2 8 2 8 2 l min at 350 bar 0 8 0 8 0 8 0 8 l min at 600 bar 0 8 0 8 0 8...

Page 11: ...60 Phase 3 3 1 1 Current Full Load Amps A 2 4 2 4 21 0 11 0 Output Flow Rate l min at 7 bar 8 9 8 9 11 5 11 5 l min at 50 bar 8 2 8 2 8 8 8 8 l min at 350 bar 0 8 0 8 1 2 1 2 l min at 600 bar 0 8 0 8...

Page 12: ...60 Phase 1 1 3 3 Current Full Load Amps A 21 0 11 0 16 8 16 8 Output Flow Rate l min at 7 bar 11 5 11 5 12 3 12 3 l min at 50 bar 8 8 8 8 12 2 12 2 l min at 350 bar 1 2 1 2 2 9 2 9 l min at 600 bar 1...

Page 13: ...0 60 Phase 3 3 3 3 Current Full Load Amps A 10 2 10 2 8 4 8 4 Output Flow Rate l min at 7 bar 12 3 12 3 12 3 12 3 l min at 50 bar 12 2 12 2 12 2 12 2 l min at 350 bar 2 9 2 9 2 9 2 9 l min at 600 bar...

Page 14: ...00 76503 02000 76504 02000 76505 02000 76508 02000 76510 02000 76511 02000 b Pump Models 76501 02500 76503 02500 76504 02500 76505 02500 76508 02500 76510 02500 76511 02500 c Pump Models 76506 02000 7...

Page 15: ...14 2 3 PUMP UNIT DIMENSIONS d Pump Models 76506 02300 76507 02300 All dimensions are shown in millimetres...

Page 16: ...ivate a preset Return Timer This controls the time that the pump motor will continue run before switching to the idle mode The timer can be manually set between 5 and 20 seconds to ensure that the pla...

Page 17: ...1 Litre 5 Litres 20 Litres Viscosity 32 mm2 s 32 mm2 s 32 mm2 s IMPORTANT Add oil only when the placing tool piston is in the fully forward position or the system will contain more oil than the reser...

Page 18: ...TTON FAULT in this instance Reset by switching off the power supply for 10 seconds In addition to the tool trigger switch which is used to operate the basic function of the pump the pump control unit...

Page 19: ...the pump Set the pressure units to PSI MPa BAR by pressing the Down or Up Arrow buttons BAR is the default setting Save the setting and step forward using the MENU button SCREEN 3 SET PSI BAR MPa UNI...

Page 20: ...ined as an operating condition with the main power supply at or below 80 of nominal voltage This screen allows the operator to read the number of hours the pump has been operated in a low voltage cond...

Page 21: ...roud buttons replace the placing tool trigger button as the method to operate the pump In LOCAL mode the Up Arrow switches the solenoid valve between the two positions and the MOTOR On Off will start...

Page 22: ...alue between 5 and 20 seconds but must be adjusted to allow the placing tool piston sufficient time to fully return before switching the motor off The following timer settings are recommended for the...

Page 23: ...MENU button for 2 seconds Turn on the pump by pressing the MOTOR On Off button Press and hold the Up Arrow This will switch the valve solenoid to the pull advance position and the relief valve pressur...

Page 24: ...t hand side of the valve block manifold Refer to the illustration below Connect the unit to the power supply and switch on as described on page 13 and 14 RETURN PRESSURE RELIEF VALVE JAM NUT ADJUSTMEN...

Page 25: ...on Button pressed Motor turns ON Tool piston ADVANCES for as long as button is held down Button released Tool piston RETRACTS and returns to fully forward position Motor continues running for up to 20...

Page 26: ...pler on one end to the female quick coupler on pump valve port A Then take the female quick coupler on the other end of the hose and connect this to the male quick coupler on pump valve port B Connect...

Page 27: ...mbilical sleeve trigger control cable and hydraulic hoses Check for leakage and or wear and tear on hydraulic quick connectors Check tightness of hydraulic fittings and fasteners on the pump unit Chec...

Page 28: ...cause nausea and diarrhea If contamination of the mouth occurs wash out thoroughly with water Except as a deliberate act the ingestion of large amounts of product is unlikely If it should occur do not...

Page 29: ...o Diagnose Menu 19 Trigger control cable or connector damaged Refer to placing tool Instruction manual for repair replacement Motor running but placing tool does not function Hydraulic Hoses not conne...

Page 30: ...w restricted or blocked Check couplers for full engagement and or fault Hydraulic hoses not connected Check for correct connections at pump and placing tool Valve malfunction See authorized service ce...

Page 31: ...than 3 seconds Motor Overload Display MTR OVLD Motor Overload The Motor Overload fault is displayed when the electric current drawn by the motor exceeds the pre set limit of the internal circuit brea...

Page 32: ...s warranted by ENERPAC in accordance to the warranty terms as provided on their website at http www enerpac com en warranty Seller agrees to co operate with Buyer and to render assistance in enforcing...

Page 33: ...tered trademarks of Avdel UK Limited AV is a trademark of Avdel UK Limited The names and logos of other companies mentioned herein may be trademarks of their respective owners This document is for inf...

Page 34: ...ce 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...

Page 35: ...fications Use of incorrect power source will damage the motor 3 0 SPECIFICATIONS 3 1 Performance Chart see bottom of page 3 2 Flow Chart see Figure 1 Flow and current vs Pressure Current Amps Flow in3...

Page 36: ...rvoir is full when oil level is here Figure 5 Sight Glass IMPORTANT Add oil only when all system components are fully retracted or the system will contain more oil than the reservoir can hold 4 5 Conn...

Page 37: ...to power Move the pump on off switch to ON See Figure 7 WARNING In the following step the pump motor will start and the valve will shift automatically retracting the torque wrench Verify torque wrenc...

Page 38: ...que wrench on nut or bolt head The pump pressure setting may not be above the pressure needed to provide the required torque for your application Exceeding required torque will cause equipment damage...

Page 39: ...ve the pick up filter screen for cleaning Do not pull on the screen or the bottom of the intake to avoid possible damage Clean the screen with solvent and a soft brush Reinstall 5 Reassemble the pump...

Page 40: ...ment See authorized service center Pump fails to build pressure or less than full pressure Low oil level Add oil per section 4 4 Relief valve set too low Adjust per section 5 7 External system leak In...

Page 41: ......

Page 42: ...This repair sheet is applicable to Stanley Avdel pumps and supplements standard Z class repair part sheets Determining Pump Configuration Review the product spec decal located on the reservoir to dete...

Page 43: ......

Page 44: ...or Date Codes Beginning with the Letter B Figure 1 Reservoir Assembly Repair Parts List for Figure 1 Item Part Number Qty Description Item Part Number Qty Description 31 DC9379025SR 1 Reservoir 4L inc...

Page 45: ...Nm 57 56 55 66 65 6 64 69 54 52 62 51 68 107 69 67 4 50 45 102 4 7 65 65 66 6 106 2 7 109 Notes 2 Torqueto 16 19 ft lbs 21 7 25 8 Nm 4 Torque to 84 108in lbs 9 5 12 2 Nm 6 Torqueto 18 26 in lbs 2 0 2...

Page 46: ...4 1 Assembly Middle Bracket 105 CBE415028 1A 4 SHCS M4 59 DC9444960 1 Power Cord 115V 15 Amp 106 DC9740969 1 Ferrite 107 DC9661066 1 Washer Wavy DC9445960 1 Power Cord 230V w NEMA 5 15 plug 108 DC9653...

Page 47: ...418646 1 Return Hose Heat Exc 19A B1006006 2 Plug SAE 8 Std Pump 126 DC9639299 2 Clamp Heat Exc Pump 19B DC9273097 2 Fitting Heat Exc Pump 301 DC8250006 1 Breather Assembly 20 B1908503 2 O Ring Heat E...

Page 48: ...oltage 150 DC8237026 1 Decal CB Reset 87 DD1273960 1 Cable Solenoid 260 DC8317960 1 Wire Contactor to timer 88 DD5790960 1 Pendant Assy 261 DD1263960 1 Power Cable Solenoid 89 DA3639028 2 Self Tapping...

Page 49: ...6 LEFT BLANK INTENTIONALLY...

Page 50: ...er Qty Description 85 E1001352 4 Flag Connector 1 4 146 DC9583960 1 Ground Earth Wire 101 DC9580380 1 RF In line lter 147 DD1590960 1 RF Filter Cable brown 102 DC8290111 1 CE Bracket 148 DD1591960 2 R...

Page 51: ...900 1 Heat Exch Assy 230 VAC 126 DC9639299 2 Hose Clamp 3 8 7 8 127 DC9537021 1 Locking Nut 16 mm Items included as part of Heat Exchanger Kit ZHE U115 115V Items included as part of Heat Exchanger Ki...

Page 52: ...h Cap ZU4 Items included as part of DC8244259SR Motor Kit 115V Items included as part of DC8245259SR Motor Kit 230V Repair Parts List for Figure 9 Item Part Number Qty Description 241 CBE817028 1E 4 B...

Page 53: ...10 WARNING Disconnect power cord from outlet before removing pump shroud or beginning any repairs Figure 10 Electrical Diagram ZU4 Classic Torque Wrench Pump View 1 of 2...

Page 54: ...OFF OFF STOP OFF ON released released ON OFF OFF STOP OFF C M1 and M2 will be off after the time delay ON released pressed and released ON ON ON RUN ON ON pressed released OFF OFF OFF STOP OFF Figure...

Page 55: ...tor C defective k Do the contactor C contacts close when the ON ADV button b2 is depressed k No Replace the contactor C l Pump element mechanically blocked l Does the motor M1 try to start but not rot...

Page 56: ...if necessary Refer to Enerpac Repair Parts Sheet L2596 for additional information 4 Wrench will not retract when ON ADV button is released a Return ow line restricted or blocked a Is a restriction in...

Page 57: ...ir or replace if necessary Refer to Enerpac Repair Parts Sheet L2596 for additional information 7 Pump runs hot a Advance or retract ow restricted a Is a restriction in ow suspected a Yes Check couple...

Page 58: ...NOTES 15...

Page 59: ...Makarova Street 8 125212 Moscow Russia T 7 495 98090 91 F 7 495 98090 92 sales ru enerpac com Southeast Asia Hong Kong and Taiwan Actuant Asia Pte Ltd 83 Joo Koon Circle Singapore 629109 T 65 68 63 0...

Page 60: ...and 24 VDC 2 Figure 2 Relief Valve B Port Retract Circuit 3 Figure 3 Valve Mounting Components and Oil Return Tube 4 Figure 4 Slider Valve Assembly Electric Models 5 Figure 5 Main Relief Valve Assembl...

Page 61: ...raved on valve manifold 15 Torque to 32 ft lbs MINIMUM 3 Apply Teflon tape to NPTF threads 16 Orient fitting as shown 5 Refer to Table 1 for relief valve settings 17 Torque to 44 53 ft lbs 60 70 Nm 9...

Page 62: ...1 Tube Assembly 43 F100094 7 1 90 Elbow F100095 7 1 Street Elbow 1 4 NPTF 44 DD1235186 4 Spacer 45 See Fig 4 1 Slider Valve Electric 115 VAC See Fig 4 1 Slider Valve Electric 208 VAC See Fig 4 1 Slide...

Page 63: ...e 3 Valve Mounting Components and Oil Return Tube Repair Parts List for Figure 3 Item Part Number Qty Description 1 CBE843028 1A 3 Capscrew Socket Hd 80mm 2 CBE831028 1A 1 Capscrew Socket Hd 45mm 3 DC...

Page 64: ...s solenoid core retainer nut O Ring and coil item 12 DD4286900SR 1 Solenoid Assembly 208 VAC DD1665900SR 1 Solenoid Assembly 230 VAC DD1666900SR 1 Solenoid Assembly 24 VDC Indicates items included in...

Page 65: ...asket 21 B1011203 1 O Ring 31 DC6383190 1 Body 22 DC8331013 2 Spring Guide 32 DC6792245 2 1 16 Pipe Plug 23 CS357110 1 Spring 49 B1012803 2 O Rings Notes Components of subassembly item 28 are availabl...

Page 66: ...additional information 6 Press and hold the pendant advance button Pressure will begin building in the advance A Port circuit and a pressure value will be displayed on the LCD screen 7 While continuin...

Page 67: ...Y rotate relief valve handle clockwise to increase pressure or counter clockwise to reduce pressure as required Note To obtain an accurate setting always decrease the pressure to a point below the fin...

Page 68: ...TTING A Port RETRACT PRESSURE SETTING B Port Electric 115 208 and 230 VAC Used on Enerpac ZU4 Classic series pumps DATE CODE B VE42TQ 115 7 900 200 0 PSI 545 14 0 BAR 2 900 100 PSI 200 7 BAR VE42TQ 20...

Page 69: ...www enerpac com...

Page 70: ...nen 69 76 Serviceinstrukser Norsk 77 84 Serviceinstruktioner Svensk 85 92 Japanese 93 100 Chinese 101 107 Figure 1 Pump Element Assembly typical Item Figure Description 1 2A 2B Top Plate Assembly 2 3A...

Page 71: ...7x25x4SC 4 A1006245 4 1 16 Flush Plug 5 DA5999900SR 1 1 8 NPT Relief Valve Items included in Repair Kit DC9280900SR Item 1 Notes Old style 3 piston top plate DC9223101 used on ZU Series pumps made bef...

Page 72: ...Repair Kit DC9279900SR use for 2 3 or 6 piston Items included in Repair Kit DC9281900SR 2 piston Items included in Repair Kit DD1121900SR 3 piston Items included in Repair Kit DC9278900SR 6 piston A 4...

Page 73: ...lled on all ZE ZG and ZW Series pump elements that are being updated from aluminum to steel top plate assemblies Note Locating washer item 7 is larger in diameter than rings item 4 Be sure to install...

Page 74: ...DC9238900SR Items available as part of Eccentric Assembly kit DC9215900SR Note Locating washer item 7 is used on all ZE ZG and ZW pumps with date code D Locating washer item 7 is NOT USED on ZA Serie...

Page 75: ...9D 6 Spring 7 BSS5356D 6 Retaining Ring 17 DC9293016 2 Ball Nylon 3 16 8 DC9292051 1 Piston Bypass Items included in and available only as a part of Piston Check Kit ZRKS Each kit includes three sets...

Page 76: ...date codes A and B Figure 5A Specifications Settings and Repair Kits Pump Model Pump Element Replacement Kit Gear Pump Replacement Kit Piston Ring Replacement Kit By Pass Setting PSI By Pass End Cap H...

Page 77: ...outed through the high pressure pistons inlet and outlet checks up to six sets and then out the pressure port Low Pressure High Flow Intake Oil Pressure port Safety relief valve Low pressure by pass v...

Page 78: ...pump oil returns to tank via the by pass valve Eccentric driven piston reciprocates to build high pressure High Pressure Low Flow Low Pressure High Flow Intake Oil Pressure port Safety relief valve R...

Page 79: ......

Page 80: ...d adjust the bypass valve Replace or rebuild if required d Remove and inspect the gear pump Replace if necessary e Replace or repair as necessary Pump runs and delivers flow but will not build pressur...

Page 81: ...the bore With the piston ring assembly Fig 1 item 3 in your hands install one piston item 15 and spring item 16 into a piston bore While covering the outlet O ring item 13 with your thumb slowly push...

Page 82: ...ring Fig 4 item 1 5 Place check ball Fig 4 item 4 on outlet seat Fig 4 item 6 and apply 1500 lbs of force by using tool DC9505816 and a hydraulic press Note This will install and coin the outlet seat...

Page 83: ...section of the hex cam 7 Install piston ring assembly with the o rings on the bottom onto the top plate assembly being careful to slide hex cam over eccentric bearing The by pass end cap needs to be o...

Page 84: ...a 0 15 000 psi pressure gauge to the VM 2 outlet Fully close the VM 2 valve 4 Operate the hand pump and monitor the pressure gauge Note the pressure at which the pump safety valve begins to relieve a...

Page 85: ...nce position for 30 seconds 5 Stop the pump motor and unplug the pump from its electrical power supply 6 Calculate the flow rate by dividing the amount of oil collected in the cylinder or beaker and d...

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