Enerpac PowaPak ZA4208TX-QR0P, Instruction Sheet

Page 1: ...ZA4T Series PowaPak Bolting Pump Instruction Sheet Model ZA4208TX QR0P EN L4463 REV C 07 20 ...

Page 2: ...AGE 1 0 INTRODUCTION 3 2 0 SAFETY 3 3 0 PRODUCT DATA 5 4 0 MAJOR FEATURES AND COMPONENTS 7 5 0 PRODUCT DESCRIPTION 8 6 0 PREPARATION FOR USE 8 7 0 LIFTING AND TRANSPORTING 11 8 0 OPERATION 11 9 0 MAINTENANCE 13 10 0 TROUBLESHOOTING 19 ...

Page 3: ...f maintenance or incorrect operation Do not remove warning labels tags or decals In the event that any questions or concerns arise contact Enerpac or a local Enerpac distributor for clarification Save these instructions for future use If you have never been trained on high pressure hydraulic safety consult your distributor or service center for information about Enerpac hydraulic safety courses Th...

Page 4: ...reservoir Dispose of oil in accordance with all applicable laws and regulations 5 Take the pump to an approved industrial recycling facility for disposal Ensure all hydraulic components torque wrench hoses fittings couplers etc are rated to a safe working pressure of 10 000 psi 690 bar Do not overload equipment Never attempt to remove or readjust the pump s internal safety pressure relief valve Va...

Page 5: ... 10 0 psi 0 6 bar Hyd pressure At 10 000 psi 690 bar Hyd pressure psi bar in min l min in min l min psi bar 2 Stage 10 000 690 350 5 7 60 1 0 2000 10 000 138 690 Maximum pressure setting of pump advance A port is limited to approximately 10 300 10 800 psi 710 745 bar by an internal safety relief valve Air Motor Rating Dynamic Air Pressure Range at air inlet connection Air Consumption max Operating...

Page 6: ...6 L4463 rev c 3 3 External Dimensions Model ZA4208TX QR0P D A B C Item Dimension inch mm A 20 5 521 B 19 7 500 C 12 5 318 ft m D pendant cable length 20 0 6 0 ...

Page 7: ...alve Manifold 10 Reservoir Oil Drain Plug magnetic 11 Reservoir Oil Sight Glass 12 Hydraulic Hose Port B retract 13 Hydraulic Hose Port A advance 14 Hydraulic Control Valve 15 Hydraulic Pressure Gauge 16 Roll Cage 17 Remote Pendant and Cable 18 Reservoir Oil Fill Plug 19 Air Logic Control Valve 20 Air Lubricator 21 Air Filter Regulator 22 Air Pressure Adj Knob 4 0 MAJOR FEATURES AND COMPONENTS Fig...

Page 8: ...revent damage A B C Figure 2 Air Breather Installation 6 2 Hydraulic Reservoir Oil Level The hydraulic reservoir is pre filled with oil at the factory However the oil level should always be checked as a precaution before running the pump See Figure 3 and refer to the following steps 1 If compressed air hose was previously connected to pump Be certain that compressed air supply is shut off and that...

Page 9: ...fully engaged and threaded together There should be no threads visible at the couplers Partial coupler engagement can prevent proper wrench operation and may result in high pressure oil leakage and or detachment of the hose under pressure Skin penetration and serious personal injury could occur 7 When a torque wrench is first connected to the pump air may be trapped in the hydraulic circuit Refer ...

Page 10: ...ty at 100 F 38 C and an aniline point greater than 200 F 93 C Do not use alcohol or ethanol based lubricants as these may cause damage to lubricator components Add oil to the air lubricator as described in the following steps 1 Shut off compressed air supply Disconnect air supply line from air inlet connection on pump 2 Remove the fill plug at the top of the air lubricator 3 Slowly add air lubrica...

Page 11: ...e oil in the reservoir Refer to Section 3 1 for weights Lift the pump using only the built in lifting eye See Figure 7 for location DO NOT use the roll cage hydraulic reservoir or air motor housing as a lifting point Before lifting check that pump lifting eye lifting eye support bracket and associated mounting hardware are tightly installed and in good condition CAUTION If bracket lifting eye or f...

Page 12: ...elease green button several times 3 Verify that hydraulic pressure is completely relieved 0 psi bar ON ADV OFF 1 Press and hold red button Figure 9 Relieving Hydraulic Pressure 8 4 Removing Air from Hydraulic System When the torque wrench is first connected to the pump or after a different torque wrench is connected air may become trapped in the hoses and components To ensure smooth and safe opera...

Page 13: ...zero 0 psi bar 3 At pump hydraulic ports A and B loosen the threaded collars on the female couplers Disconnect hoses from pump 4 To prevent contamination install dust covers over pump and hose couplers 9 0 MAINTENANCE 9 1 Oil Change and Hydraulic Reservoir Change the oil in the hydraulic reservoir after every 250 hours of operation If pump is operated in very dusty areas or at high temperatures oi...

Page 14: ... bottom of the sight glass 9 2 Hydraulic Reservoir Cleaning Inspection It is recommended that the hydraulic reservoir be cleaned when the oil is changed At this time the oil intake filter can also be cleaned and the pump element can be externally checked for loose parts or obvious signs of wear or damage This procedure is mandatory if it is suspected that the oil is contaminated or if pump perform...

Page 15: ... Filter Regulator Lubricator Air Logic Control Valve and Mounting Hardware 3 2 6 6 5 8 7 1 4 Key 1 Air Logic Control Valve 2 Capscrew long 3 Capscrew short 4 Filter Regulator Lubricator Assembly 5 Support Bracket 6 Hex Nut 7 Flat Washer 8 Roll Cage 2 1 3 Key 1 Intake Hose 2 Hose Clamp 3 Elbow Figure 15 Air Motor Intake Hose ...

Page 16: ... 2 Gasket 3 Pump Assy 4 Reservoir Gasket 5 Hyd Reservoir Figure 18 Pump Assembly and Hyd Reservoir NOTICE Refer to Figure 19 during steps 12 through 15 12 Inspect the reservoir interior Using a clean lint free cloth remove any dirt or sludge from interior surfaces 13 Inspect the pump element for obvious signs of wear or damage Verify that there are no loose components Remove any dirt or sludge fro...

Page 17: ...the roll cage with two screws flat washers and hex nuts Apply Loctite 243 to screw threads and torque to 55 65 in lbs 6 2 7 3 Nm See Figure 16 22 Secure the support bracket to the roll cage with two screws and hex nuts Apply Loctite 243 to screw threads and torque to 55 65 in lbs 6 2 7 3 Nm See Figure 16 23 Reconnect the pump air tubes at locations A B C and D See Figure 13 and Figure 14 24 Refill...

Page 18: ...intenance and replacement parts information Air Filter Bowl 1 2 7 6 3 5 4 8 MIN MAX MAX Condensate Drain Port with G1 8 connection auto draining Figure 21 Air Filter Bowl Details 9 5 Air Lubricator Maintenance CAUTION Always shut off compressed air supply and disconnect air supply hose from pump before removing the air lubricator bowl for any reason Failure to follow this instruction will result i...

Page 19: ...ulic system Perform air removal procedure Refer to Section 8 4 c External leak in the hydraulic system Check entire hydraulic system for leaks Tighten repair or replace components as required d Oil needs changing Pump oil intake filter clogged Drain clean and inspect the hydraulic reservoir per instructions in Sections 9 1 and 9 2 Remove any dirt or sludge Clean or replace the oil intake filter e ...

Page 20: ...ed pressure and flow Refer to Section 3 1 c External leak in hydraulic system Check entire hydraulic system for leaks Tighten repair or replace components as required d Torque wrench internal leakage Worn or damaged internal components Troubleshoot torque wrench Tighten repair or replace components as required Refer to torque wrench manufacturer s repair and overhaul instructions e Internal leak i...

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