ZAJ-065・ZAJ-123 シリーズ
Contents
1. http www apj ne jp 1 0 2 02. AN A A RE 1 2 ZA
3. A BAR 5 11 1 2 B 3 4 5
4. P 21 ENERPAC lS 7 POWERFUL SOLUTIONS GLOBAL FORCE 3 9 ZAJ I 7EB AER Yy CRAMER 0 1 0 7MPa 3 M3 S1 A1 4 M32 S2 A2 amy ye 4 M4 4 S2 A2 3 10 ZAJ IFE 0 1 0 7MPa V 152
5. 3 60 ENERPAC 2 9 POWERFUL SOLUTIONS GLOBAL FORCE 3 7 ZAJLILIEITEILI EID T TT M1 M3 M32 M4 S1 S2 C2 A1 2 52 T 12 2 065 1 65 123 1 123 B HAIT Ex No E En gna T i api qM MID u pn kg MPa MPa T T N 2 min re Be n 27 50 27 50 EH te
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7. F e en i isi pe re 3 Ka 1 s 1 iS 6 MIRE E ENERPAC 21 POWERFUL SOLUTIONS GLOBAL FORCE 5 9 1 2
8. P 18 P 28 P 28 P 18
9. d EUN 2 3 P 25 No 3 4 5 6 7 1 2 4 o 3
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12. ENERPAC 2 3 POWERFUL SOLUTIONS GLOBAL FORCE 3 ZAJ G D D BS 1 8 KHB06 010E KFZ16 6 1 4 FZ 1605 GP 50MG 60 660 ZAJ065 6 GP 100MG 60 60 ZAJ123 0 oo 96 IAR p TP llus c AN 3 2 ZA
13. P 22 P 28 ENERPACGC 2 POWERFUL SOLUTIONS GLOBAL FORCE 7 0 XI A Ban r 404 07MPa NPT1 A N EID j Ta Le L QU 1 6 GI 0 50000907 08 2 2 4 Q5 1 A EENI xx i RAMEE 6 KL 100A 1 8 ZEN 001 1 9 ZEN 002 CT695 885 11 kCT695 167 ENERPAC 2 25 POWERFUL SOLUTIONS GLOBAL FORCE 26 CT776 950B 70MPa CT698 950B 35MPa B QOS 2 DY 009 GD 09
14. 3 2 P ER 1 4 5 P 15 VCSW 130G VCSW 131G ZE WVP2 VCSW 130G A AC100V 50 60Hz oes VCSW 130G D AC200V 50 60Hz b a VCSW 130G C DC24V m CSW 131G A AC100V 50 60Hz ttl O SER ML VCSW 131G D AC200V 50 60Hz Es 2 ale VCSW 131G C DC24V 2 NPT3 8 XA DII TERR I3 SE tat V NPT1 4 VCSW 130G VCSW130K ZE WVP2 G178 6 vokas 3 8 4012010P9 1 10 9 759201P 2
15. ZAJ065 0 4MPa x65 26MPa ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 3 1 1 4PT 2 3 AN 0 7MPa AN 3 4 1
16. 6 0 1 0 2MPa C ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE ET ZZ Z A P f 9 L A amp 9 N 2 T 23 6 0 ZAJ AN
17. 7 8 AN 9 10 P 23 11 12
18. C 1 3 CT1098 190 CT1032 9500 F2Esbibcrr JvP27 CT102819000 9 Z27ULL F7 y RUT OAS 7 AN 400Z007P7 400Z008P7 ZAJ 06505K ZAJ 12305K ir H e mdas 0 4 a E
19. 11 V AN 1 2 1ISO VG 32 W O 3 1 600
20. 2 SAP03 000J e 0 1MPa AN 8 e e SAP03 000J 3 6 1 2
21. N V 152 E um DV4522 3 FZ 1620N FZ 1617 FZ 1612 un EU EVITER 1 B A O E Zee LIBRI T T P I s ec AN 3 4MPa ZAJ
22. 600 5 4 1 P 25 A No22 2 A No 13 15 No 2 No 1 No 11 3 18 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 4 P 26 B No8 5 P 25 A No 11 No 2 15 6 P 25 A No7 AN
23. 5 5 1 HELa Fo amx HEE T EDS d Ur AVE EAR La 2 AEBIRIGL TOS M fs 1 X 2 0 2 0 3 0 5 1 0 5 6 HF 100 14 ENERPAC 2 19 POWERFUL SOLUTIONS GLOBAL FORCE 5 7
24. 4 G T 2 V YG P iam ZE GAVM ER2 NPT3 8 pL NPT1 4 VC 20 No 1 A8076048 1 4 A8005071 4 1 4 5 B1006016 1 732 6 A8039110 1 B1401028 4 8 x B1126057 1 5 9 CB324001 1 SU LM 6 12 CB328281 1 13 CH536104 1 16 CH537950SR 1 17 B1109057 1 19 B1011564 6 20 B1006508 _ 3 0 2 22 CB28110 3 0 MEME B1111803 4 0 2
25. 4 3 0 3 1 1 2 I 2
26. ZAJ 12305K ZAJ 06505K ENERPAC 2 29 POWERFUL SOLUTIONS GLOBAL FORCE CT820 900 1 F CT820 900 1 No Bag 1 CT697 190 1 1 2 759202P5 1 3 A1006 245 1 FoF 4 40020077 2 O UvZ 5 CT2133245 1 oF re ee eee CT1032 950 30 G CT1032 950 2 k400Z008P7 5 OU 3 AcT805041 2 Eo odo LLL x ZAJ 12305K ZAJ 06505K ZAJ 12305K ZAJ 06505K ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 8 0
27. 6 1 U s Ij TES ER VO 2 3 5 3 1 600 600 n BE c wREmMERmRAQAR TI IRIE UOR O
28. R1 4 D 10 12 70221002T 1 RI4D 0 35 cmoo 1 5 13 CT696268 1 10 36 AOO9245 2 NPT3 8 14 CT695268 1 0 37 CT1O96646 1 4x 25xL0O D 10 38 CBS8 16 6 M8XL16 D 10 G1 8 18 CT698096 2 WNW 41 HFC4F 2 D 4 20 CT696646 1 10X 75XL360 43 SPEO1000 4 727 GUD 21 CT695646 1 va 7610x 75xte 22 CT698646 1 4x 25xtL220 fF ENERPAC 2 27 POWERFUL SOLUTIONS GLOBAL FORCE CT775 950 70MPa CT770 950 35MPa AS SS Tiss UZ J a a C 2AJ 123 ZAj065 6 creeeo40 creso 1 8 creetto cregstto 2
29. VCSW 130G VCSW130K ZE WVP1 P 10 P 15 ENERPAC 2 13 POWERFUL SOLUTIONS GLOBAL FORCE 4 6 ZAJ06505 S2 ZAJ12305 S2 3 X 2 1 3 2 AC100V AC200V DC24V 2 2 P ER 1 3 4 G T 2 G
30. ZE VM1 001 2 3 G T 2 AN Heese OCGBHEUBMSSRICAERU Z704629Z7 2 4 TNE FA e f FH ZAJ eG P S P NPT3 8 ZE VM1 I J Ll Rc1 4 gt LX ee E NPT3 8 z Ha IT aa a O H SOF dh TU R ij N NPT1 4 HN 4 maf a ZE VM1
31. 1 CT1028 190 1 2 2 3 1 2 N 0 opas Lt 1 29 2 CT1028 190 X 22 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 5 10
32. M8 35 G178 re wees 2 mvzrv79 TPE sfarzo 1 ons ofrezo 2 57270 LI a A ZE VM1 ENERPAC 2 9 POWERFUL SOLUTIONS GLOBAL FORCE 4 2 ZAJ06505 M3 ZAJ12305 M3 3 1 3 90 2 P ER 1 3 4 G T 2 Oo PP ER 1 VCMW 130 NPT3 8 SE Nem ZE WVP1 ae i PN Mal l NPT3
33. POWERFUL SOLUTIONS GLOBAL FORCE Japan Web http www apj ne jp 85 7331 0821 TEL 048 662 4911 FAX 048 662 4955 E Mail enerpac apj ne jp e lt ENERPAC 2 31 POWERFUL SOLUTIONS GLOBAL FORCE Instruction Sheet ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE Air hydraulic pumps Document Document Document Product Date Code Number Revision Revision Date Beginning With L4091 08 2014 32 ZAJ 065 ZAJ 123 Series INDEX PAGE 1 0 Important Receiving Instruction 33 2 0 Safety Information 33 34 3 0 Operation 34 39 3 1 Connection of Pipes and Pressure Gauge 34 35 3 2 Pressure Adjustment of the Pump 99 3 3 Connection of Air Supply Line 36 3 4 Inspection of Oil Quantity in the Reservoir 36 3 5 Releasing Air from the Hydraulic Circuit 36 3 6 Inspection Before Pump Activation 36 3 7 Pump Models and Specifications 37 3 8 Oil Flow Versus Pressure and Air Consumption 38 3 9 Basic System Set up The ZAJ type air hydraulic pumps 39 3 10 Valving Technology The ZAJ type air hydraulic pumps 39 4 0 Function and Operation of each model Air Hydra
34. eseeeeeeneeeee 67 Figure 3 Pump Subassembly eeeseeeeeeeeee 59 3 3 ZAJ06505 M32 ZAJ12305 M32 seeeeeeeeeeeees 68 Figure 4 Pump Subassembly eeeeeeeeeesss 60 3 4 ZAJ06505 M4 ZAJ12305 M4 eene 69 70 Figure 5 Intake Check Valve Assembly CT771 950 2 61 3 5 ZAJ06505 S1 ZAJ12305 81 seeeeeennm menn 70 Figure 6 Discharge Check Valve Assembly CT772 950 61 3 6 ZAJ06505 S2 ZAJ12305 S2 7 1 72 Figure 7 Valve Block Assembly CT820 900 1 62 3 7 ZAJ06505 C2 ZAJ12305 C2 eese nns 72 Figure 8 Sub Plate Assembly CT1032 950 62 3 8 ZAJ06505 A1 ZAJ12305 A1 73 Figure 9 Air Side Valve Parts on Pump Unit 63 3 9 ZAJ06505 A2 ZAJ12305 A2 c essen T3 Figure 10 Air Operated Valve een 64 Enerpac Worldwide Locations eee 74 ENERPAC 9 55 POWERFUL SOLUTIONS GLOBAL FORCE 1 0 Pump Models and Specifications BH Model Numbers ZAJLILILILILI ULILI T r at the end of the model numbers means Twin pump Valve type M1 A block for connecting remote valves with the pump M3 M32 M4 Manual valve S1 2 C2 Solenoid valve A1 A2 Air operated valve Oil capacity
35. 3 X 2 1 3 2 0 4MPa 0 7MP 2 2 P ER 1 3 4 G T 2 7 2 ENERPAC 2 17 POWERFUL SOLUTIONS GLOBAL FORCE 49 4 27 AP INE G1 4 VCAW 130 VCSW130K X ZE WVP2 P 14 5 0 5 1 1
36. 38 46 Nm 29 4 f A AUC SPOT VM4k3 DA9560041SR 12 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE ZE GAVM ER2 M8 35 6 759Z01P 2 R1 8 8 4012008P9 2 10 9 401Z010P9 1 oss 9 a ee ee A ZE GAVM ER2 WIL PF FOy 72H 4 5 ZAJ06505 S1 ZAJ12305 S1 3 1 3 AC100V AC200V DC24V 2 P ER 1 3 sJ UA 4 G T 2 LOYI YIRTTI G P ER 1 KA D4 TBM IS TCR
37. Glycerin filled pressure gauge Solenoid valve V V ds a VCSW 130G i m ON iv a ET 4 4 O Rin P b i The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket Refer to p 72 for wiring techniques of the solenoid valve Repair Kit for VCSW 130 MM A Solenoid valve Model No VCSW130K VCSW 130 Refer to p 67 for the repair parts list of ZE WVP1 valve mount block 70 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 6 ZAJ06505 S2 ZAJ12305 S2 The pump have two solenoid operated 3 way valves V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 S2G GP 50MG 60 ZAJ12305 S2G GP 100MG 60 V One cartridge style check valves ER 1 is installed in the P port of the each valve VCSW 130G by default to reinforce the pressure hold G option P port Glycerin filled pressure gauge Solenoid valve VCSW 130G ZE WVP2 Valve mount block Delivery port 2 NPT3 8 gt lt The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket X Refer to p 72 for wiring techniques of the solenoid valve A Solenoid valve VCSW 130 L4091 Drain port NPT1 4 Model No VCSW130K Repair Parts List for Figure 16 Figure 16 Valve Mount
38. R18 rs a rs ee eee A ZE WVP2 16 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 4 8 ZAJ06505 A1 ZAJ12305 A1 3 1 3 0 4MPa 0 7MP 2 P ER 1 3 Pr 4 G T 2 G P G1 4 NPT3 8 NPT1 4 VCAW 130 X ZE WVP1 VCAW 130 P 10 4 9 ZAJ06505 A2 ZAJ12305 A2
39. 20 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 5 8 1 2 1 3 4 2 N
40. 6 7 10 8 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 9 10 40C
41. 8 1 1 8 2 1 1 8 3 1 8 4 1 2 3 4 5 6 T 8 5 1 2 3
42. T 60min n 9 12 VCSW 1 G D 35C 2 A AC100V D AC200V C DC24V 20 30 40 50 60 70 80 90 100 ED 50C 1 5 70 1 6 1 2 PE NEN DC24V AC100V AC200V 50Hz 60Hz ENERPAC 2 15 POWERFUL SOLUTIONS GLOBAL FORCE 4 7 2AJ06505 C2 ZAJ12305 C2 3 X 2 1 3 AC100V AC200V DC24V 2
43. 2 ER 1 O Ring P A ZE WVP2 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE G P oO EU V NE VCMW 130 ZE WVP2 T E at 2 NPT3 8 NPT1 4 ZE WVP2 M68 35 G178 6 VDBK 15 3 0977 sfarzo 1 lousy ofrezo 2 57270 L dl 11 4 4 ZAJ06505 M4 ZAJ12305 M4 4 1 3 4 VC 20 A B 2 ER 2 P 3
44. A No 4 d bs 4 24 1 1 2 1 0 1MPa 0 7MPa P 21 LT ali P 18 P 28 P 28 P 23
45. Loosen the three cap bolts CD Remove the air operated spool type valve CT1098 190 3 and the subplate assembly CT1032 950 5 2 Loosen the two bolts at 6 and remove the air valves CT1028 190 from the subplate assembly AN CAUTION When dismantling the valve be careful not to lose the packing for 400Z007P7 and 7 400Z008P7 furthermore please be careful not to give the packing the damage Part list Lo SL Ul CAUTION It is provided at assembly CT1098 190 except No 2 No 7 of the part list When dismantling the valve please be careful not to give the packing the damage 6 MN NE ENERPAC 2 49 POWERFUL SOLUTIONS GLOBAL FORCE 5 8 Maintenance amp Disassembly Procedures for Air Operated Valve 1 Defects in the operation of the air operated valve are mainly caused by the internal spool getting stuck from accumulated dust etc 2 After stopping the air supply and before dismantling the air operated valve remove the sunken head plugs CD from both sides of the air operated valve As in Figure 1 below the end of the spool can be seen from the outside 3 Lightly push a thin long tool into the plug hole on the end of the spool from both sides in the direction of the arrow alternately being careful not to cause damage When the spool can be moved smoothly close the sunken head plug of both sides wrapped with seal tape D then provide air to the pump Work is complete when the pump is
46. 9 cre9e39 cre9s39 2 TI i T BHAU ZAJ 12305K ZAJ 06505K B sjt 1 slt amp 2 9 X 2 28 16 130210150 18 200210 8 19 120208020 8 re SN ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE CT771 950 2 CT771 950 2 D L4091 ZAJ 12305K ZAJ 06505K CT772 950 CT772 950 E L4091
47. Fm cei 6 Low head sorew MB LG H uM NN O Ring P30 NBR 70 ex plug 61 8 E B Filter kit H 59 Figure 4 Pump Subassembly CT775 950 70MPa CT770 950 35MPa Pump subassembly 7 EC CIEIEIBLLE LL el A i a Air pressure in out hh gt f 4 air operated valve V ee NEN T F4 creros cmosos 1 cyinder Ls creeeos0 ereeeoso 1 cyinder Ls cresce cmoso Pinger Ls creeefto creas t10 2 custion EE 2 as 10 520Z009019 x520ZX12022 Back up ring 11 5102009197 x5102X12227 1 1 1 2 creesos9 creesoso 2 Bush 2 2 Pilot pressure to air valve Exhaust port Pilot pressure to air valve 2009 4 I Air pressure in out air operated valve Shaded items are available only in Repair Kit ZAJ 12305K and ZAJ 06505K When ordering clearly indicate the product model number and serial number Caution Products may be changed without notice Indicate model number when ordering Panno Jay Description Lcreeso5f 1 Ars Figure above 1 EN EX EN 2 Le 5 Figure above f o Figure above 2 Jen t 120208020 5 Omsumw EN 1 1 1 1 2 Back up ring 60 RO a c 0 CT595 111 1 3 4 xFigure above 6 Bolt C Mounting stay ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Figure 5 Intake Che
48. 1200 E 60 1200 wS al SEEN 7 0 a MM tS AN EEE sl aoc S solu E E 600 8 ii 30 103 DOMINE 3 90 7 m TEM T ME H 200 10 200 0 0 0 0 TR 08 12 16 20 24 28 32 36 40 44 48 0 02 04 06 Q 0 8 1 0 TD TES 16 18 20 22 24 L min L min 0 1MPa 0 7MPa 0 1MPa 0 7MPa 1 1 CT1028 190
49. 54 Oil capacity of Twin pump 12 2 Increase ratio 065 1 65 Increase ratio 123 1 123 Air drive double acting booster hydraulic pump MSpecifications Air Supply Increase Pressure Useable Reservoir Air Weight T Model No Pressure Ratio Rating Oil Oil Consumption T MPa Air ae Capacity T Capacity T N 2 min kg ZAJ 065 500 1000 Apx 27 50 0 1 0 7 4 7 2 5 12 2 ZAJ 123 m nm mw 5401080 Apx 2750 E Models Equipped valves P R Port Solenoid X2 2 Air operated 3 Block 3 4 Mg 3 et 1 pi n 2 RP mansoni 31 1 ZAJ12305 M1 T ZAJ06505 M3 T ZAJ12305 M3 T ee NENNEN mas S S S AM908M82CD ANGST AMZO08SCD HANG of Pt zwan Pt C HAM2908MACO EH 1 31 1 1 CE ee ZAJ12305 S2 T 3X1 T at the end of the model numbers means Twin pump 2 The solenoid valve voltage current at 50 60Hz is A VAC100V 0 2A D VAC200V 0 1A CC VDC24V 0 83A Example in the case of ZAJxxx05 S2 the pump model that have solenoid valves of VAC200V with increased ratio of 65 is ZAJ06505 S2D 7X3 Air pilot pressure is 0 4MPa 0 7MPa 56 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 2 0 Repair Parts List Figure 1 Cover Subassembly and Tank Subassembly Hydraulic Circuit foi 0 1 0 7MPa N air source Fg 1 Port for pump relief valve adjustment NPT1 4 EID
50. The pump is equipped with one manual 3position 4way valve While the lever of the manual valve is in a neutral position the hydraulic oil discharged from the pump is returned to the reservoir through the manual valve Looking at the pump from the front when the lever of the valve was switched from the neutral position to the right position the hydraulic oil is discharged from A port of the valve or the hydraulic oil is discharged from B port when the lever was switched from the neutral position to the left position One cartridge style check valve ER 2 is installed in the valve P port by default to reinforce the pressure hold The plunger of the double acting hydraulic cylinder can be advanced or retracted by the 3position 4way manual valve and the plunger of the cylinder can stop in the middle of strokes 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 2 and double output flow Co N T L G opin Ppot QE Glycerin filled pressure gauge Manual valve 4 VC 20 V Description of lever position ZE GAVM ER2 Delivery port NPT3 8 Delivery port NPT3 8 Drain port NPT1 4 Neutral position 4 5 ZAJ06505 S1 ZAJ12305 S1 The pump have one solenoid operated 3 way valve 1 The pump is equipped with one solenoid operated 3 way valve The voltage of the solenoid operated valve is VAC100V VAC200V and VDC24V and u
51. ZAJ12305 S1 3 13 4 6 ZAJ06505 S2 ZAJ12305 S2 3 X 2 14 15 4 7 ZAJ06505 C2 ZAJ12305 C2 3 x 2 16 4 8 ZAJO6505 A1 ZAJ12305 A1 3 17 49 ZAJ06505 A2 ZAJ12305 A2 3 X2 17 18 5 0 18 23 5 1 18 5 2 18 5 3 18 5 4 18 19 5 5 19 5 6 19 57 0 5 8 21 5 9 22 5 10 23 5 11 23 60 ZAJ 24 7 0 ZAJ 25 30 8 0 31 ENERPAC 2 1 POWERFUL SOLUTIONS GLOBAL FORCE
52. 8 E A D n O EI i LL A LO 7 ii VCMW 130 NPT1 4 VCSW130K D ZE WVP1 M8 35 G178 6 VDBK 15 3 8 4012010P9 1 OUv7 J 9 759Z01P 1 R18 0 A ZE WVP1 10 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 4 3 ZAJ06505 M32 ZAJ12305 M32 3 1 3 90 2 P ER 1 3 4 G T
53. 9 ieu aA TOLD eS i eR C Ls Can Jy fe E ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE CT776 950B 70MPa CT698 950B 35MPa 23 000288 ADA I Boe HAE eee S A y y No LU UESE TODO EDS ZAJ 12305K ZAJ 06505K CT775 950 CT770 950 Pee pe ee a 2 CT21281901 1 25 W6S1 4 M6 M6 xL45 M8 xL20 5 00V90 1 28 rsozoip 2 RD 6 piste 2 0 M5 XL15 7 CT771950 2 2 30 CT2679167 1 8 DC9178118APJ 2 31 096P096 1 9 CT772950 2 10 70021002C 1 R14D 10 33 CT2675190 1
54. Eoo o Fill reservoir to proper level 2 air is breathed in the intake check valve assembly and the hydraulic pump cylinder from the suction port on that Conduct of priming of the pump referencing p 52 Pump operate but oil is not account hydraulic oil cannot be sucked in Change the position of the hydraulic directional control valve and check if the pump works Pump will not start discharged 3 There is an oil leak in the hydraulic manual valve the Shift the manual valve to the pressure position hydraulic solenoid valve or the hydraulic air operated Check the electrical power source of solenoid valve valve so all the discharge oil goes back to the reservoir Check the air source of the air operated valve R b bly f ir and wash th 4 The suction filter for the pump is clogged ene ave subassembly from reservoir and wash the suction filter 1 Air pressure is not sufficient Increase air pressure On input side Inspect hydraulic pipes and tighten the joints 2 0il is leaking from the hydraulic piping or cylinder R A P fth Pump works but hydraulic eplace the packing of the cylinder pressure does not reach the l l l l set pressure 3 Packing for pump cylinder or air cylinder is damaged Replace the packing Repl king for the val flush he val 4 0il is leaking in the hydraulic directional control valve id d peer ig IO vale ane iden Out le VOLO with air Or replace the valve body SS oe Increase the su
55. P ON ER 1 8B VCSW 130G S ZE WVP2 VCSW 130G A AC100V 50 60Hz VCSW 130G D AC200V 50 60Hz VCSW 130G C DC24V A D VCSW 130G VCSW130K ZE WVP2 M8 35 G178 6 VDBK 15 3 8 401Z 010 P9 9 759201P 2 R6 m E A ZE WVP2 14 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 5 2 6ED V 1 V 1 5mn T 30min 2 MPa 2 min D
56. POWERFUL SOLUTIONS GLOBAL FORCE 3 3 Connection of Air Supply Line 1 The air supply port for the air operated valve are Rc1 4 taper pipe thread 2 Wind the seal tape all around the male taper screw threads When tightening the taper screw threads of each size be careful not to over tighten it 3 Regulator Filter that provides clean air and allows of air pressure adjustment is recommended for use with all ZAJ air pumps and it lengthens the life time of the air pump AN CAUTION Adjust air pressure to supply the pumps with air below 0 7MPa by the regulator AN CAUTION To prevent accidents when using the pump remove the air supply line from the pump or shut off the air supply line 3 4 Inspection of Oil Quantity in the Reservoir 1 A defect may occur if there is not enough hydraulic oil in the reservoir Be sure to see the oil level gauge to check the quantity of hydraulic oil before operating the pump 2 While the cylinder is connecting with the pump fill the hydraulic oil up to the maximum level of the oil level gauge after retracting the plunger AN CAUTION To protect your Warranty use only ENERPAC hydraulic oil The case using the liquid different from a specification of the hydraulic oil which ENERPAC recommended is not guaran teed against the product While supplying the hydraulic oil be careful so that it is not contami nated with the dust 3 5 The methods to release air out of the hydraulic system 1 The hydraulic syste
57. back to the initial position with spring power 2 his pump is most suitable for holding the hydraulic pressure in the system during the long time in the case the position of the valve is changed rarely even if when the solenoid valves are not energized for power outage or when the pump is not supplied air pressure in the system will do not decrease immediately 3 The cartridge style check valves ER 1 is installed in two valves P port by default to reinforce the pressure hold 4 The plunger of the double acting hydraulic cylinder can be advanced or retracted by two solenoid operated 3 way valves or the plungers of the single acting hydraulic cylinders with spring return can be advanced or retracted by each of the 3 way valve on two circuits but both the plunger of the cylinder cannot stop in the middle of strokes G option P port Glycerin filled pressure gauge Solenoid valve VCSW 130G Solenoid valve VCSW 131G gt lt The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket X Refer to p 44 for weld times wiring techniques of the solenoid valve Valve mount block ZE WVP2 Delivery port 2 NPT3 8 EJ i o Ha N N Ho D co Drain port NPT1 4 A Solenoid valve 4 8 ZAJ06505 A1 ZAJ12305 A1 The pump have one air operated 3 way valve 1 The pump have one air operated 3 way valve The a
58. port by default to reinforce the pressure hold 3 The plunger of the double acting hydraulic cylinder can be advanced or retracted by two air operated 3 way valves or the plungers of the single acting hydraulic cylinders with spring return can be advanced or retracted by each of the 3 way valve on two circuits but both the plunger of the cylinder cannot stop in the middle of strokes 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow A Air operated valve VCAW 130 46 G option P port Air pilot port ucc amc CPU Air operated valve VCAW 130 ER 1 O Ring P E HfT H 2 NPT3 8 Drain port NPT1 4 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 5 0 Maintenance 5 1 Daily Inspection 1 Check whether the hydraulic oil is not leaking from the air hydraulic pump and the hydraulic system 2 If the air hydraulic pump and hydraulic equipments is used in an dusty environment all the equipments should be cleaned before using them 3 Check for any defects in the operation of the equipment pressure cylinder speed etc 5 2 Weekly Inspection 1 Check reservoir hydraulic oil level every 40 hours of operation Add oil when necessary to bring the level to an appropriate oil level at the sight of an oil level gauge Use only Enerpac hydraulic oil The use of other oils or fluids may damage
59. there is internal leakage in those valves therefore you cannot use a pump effectively G option P port Air vent and Oil feeding port Glycerin filled pressure gauge Tank port NPT3 8 Plate ZE VM1 Air supply port lt eat Po s Rc1 4 i 0 1 N Dod bo EP Delivery port u a c3 Tl VT ip a z A 7 h ft ott O H Sa ne LI T NB mim R A a O 60 300 45 257 m Lf 207 Drain port NPT1 4 4 11 LO P 140 190 40 212 4 2 ZAJ06505 M3 ZAJ12305 M3 The pump have one manual 3 way valve 1 The pump is equipped with one manual 3 way valve The knob to change a position of the valve provides reliable security against shock and vibration through 90 position detent mechanisms and you can turn the knob in both of rotate right and rotate left 2 One cartridge style check valve ER 1 is installed in the valve P port by default to reinforce the pressure hold 3 The plunger of the single acting cylinder with spring return can be advanced or retracted by the manual 3 way valve but the plunger of the cylinder cannot stop in the middle of move 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow 40 ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE Rotation knob ER 1 P A 3 way manua valve VCMW 130 G
60. to the initial position with spring power 2 The cartridge style check valves ER 1 is installed in two valves P port by default to reinforce the pressure hold 3 The plunger of the double acting hydraulic cylinder can be advanced or retracted by two solenoid operated 3 way valves or the plungers of the single acting cylinders with spring return can be advanced or retracted by each of the 3 way valve on two circuits but both the plunger of the cylinder cannot stop in the middle of strokes 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow G option P port Glycerin filled pressure gauge Solenoid valve VCSW 130G ER 1 SB Valve mount block ZE WVP2 SIRE ia Delivery port TB uoa Lb eben gt lt The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket Refer to p 44 for weld times wiring techniques of the solenoid valve Drain port NPT1 4 A Solenoid valve VCSW 130 ENERPAC 2 43 POWERFUL SOLUTIONS GLOBAL FORCE 5 Please refer to the following chart for the duty cycle 96ED of the solenoid valve CAUTION In case of bank arrangement of the valve and ambient temperatures above 40 C the layout should be designed in such a way that adjoining solenoids are not energized over prolonged
61. 1 12 16 20 24 28 TN Y 40 44 48 0 02 04 06 08 10 12 14 16 18 20 22 24 Oil Flow L min Oil Flow L min Oil flow of the case a pump is supplied with the air pressure 0 1MPa 0 7MPa Air consumption of the case a pump is driven at the air pressure 0 1MPa 0 7MPa W ZAJ type air hydraulic pumps can generate the hydraulic pressure by the air pressure you regulate and you can adjust the pressure of the pump with air pressure If the pressure of the pump reaches the pressure that you need using air pressure the pump will stop operation automatically because oil pressure balances with air pressure and if the pressure of the pump decrease the pump will be driven again The pump build the hydraulic pressure until it will get back balance status again In order to effectively use this function please do not stop the air supply to the pump BI Regulator Filter is recommended for use with all ZAJ type air hydraulic pumps but the lubricator is not necessary for these pump because releasing a large quantity of lubricant into the air pathway may cause the malfunction of the air valve CT1028 190 All the air devices which are used for a pump accommodate to non lubrication also you dismantle those air devices and must not treat it violently Doing so may cause a malfunction If you must repair a air valve which was contaminated in the oil be sure to read p 20 of the instruction manual before doing repair 38 ENERPAC 2 POWERFU
62. 10 AB Ede The Netherlands T 31 318 535 911 F 31 318 535 848 sales nl enerpac com Enerpac Integrated Solutions B V Opaalstraat 44 7554 TS Hengelo P O Box 421 7550 AK Hengelo The Netherlands T 31 74 242 20 45 F 31 74 243 03 38 integratedsolutions enerpac com South Africa and other English speaking African countries Enerpac Africa Pty Ltd Nod Bauhinia Avenue Cambridge Office Park Block E Highveld techno Park Centurion 0157 South Africa T 27 12 940 0656 sales za enerpac com United Kingdom and Ireland ENERPAC Ltd Bentley Road South Darlaston West Midlands WS10 8LQ England T 44 0 121 50 50 787 F 44 0 121 50 50 799 sales uk enerpac com USA Latin America and Caribbean ENERPAC P O Box 3241 Milwaukee WI 53201 USA T 1 262 293 1600 F 1 262 293 7036 User inquiries 1 800 433 2766 Distributor inquiries orders T 1 800 558 0530 F 1 800 628 0490 Technical inquiries techservices enerpac com sales us enerpac com ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE
63. 3Ba 717 Shihwa Industrial Complex Jungwang Dong Shihung Shi Kyunggi Do Republic of Korea 429 450 T 82 31 434 4506 F 82 31 434 4507 sales kr enerpac com Spain and Portugal ENERPAC SPAIN S L Avda Los Frailes 40 Nave C amp D Pol Ind Los Frailes 28814 Daganzo de Arriba Madrid Spain T 34 91 884 86 06 F 34 91 884 86 11 sales es enerpac com Sweden Denmark Norway Finland and Iceland Enerpac Scandinavia AB Fabriksgatan 7 412 50 Gothenburg Sweden T 46 0 31 799 0281 F 46 0 31 799 0010 scandinavianinquiries enerpac com The Netherlands Belgium Luxembourg Central and Eastern Europe Baltic States Greece Turkey and CIS countries ENERPAC B V Galvanistraat 115 6716 AE Ede P O Box 8097 6710 AB Ede The Netherlands T 31 318 535 911 F 31 318 535 848 sales nl enerpac com Enerpac Integrated Solutions B V Opaalstraat 44 7554 TS Hengelo P O Box 421 7550 AK Hengelo The Netherlands T 31 74 242 20 45 F 31 74 243 03 38 integratedsolutions enerpac com South Africa and other English speaking African countries Enerpac Africa Pty Ltd Nod Bauhinia Avenue Cambridge Office Park Block E Highveld techno Park Centurion 0157 South Africa T 27 12 940 0656 sales za enerpac com United Kingdom and Ireland ENERPAC Ltd Bentley Road South Darlaston West Midlands WS10 8LQ England T 44 0 121 50 50 787 F 44 0 121 50 50 799 sales uk enerpac com USA Latin Ameri
64. AC 2 47 POWERFUL SOLUTIONS GLOBAL FORCE V Air Hydraulic Pump Drawing D D Drain port NPT1 4 5 5 The Methods to Judge Degree of the Degradation of the Hydraulic Oil 1 Take a sample from the hydraulic oil being used for the purpose of comparing it with new hydraulic oil and judge degree of the degradation of the hydraulic oil by the following chart ee wl wae TEE Oxidation degradation X 1 Enerpac genuine hydraulic oil is colored a transparent blue Commercially available hydraulic oil are clear X 2 f the hydraulic oil are including water at only the rate of 0 2 0 396 the oil is normal If the hydraulic oil are including water at the rate of 0 5 1 0 it will turn milky white when it was stirred And the hydraulic oil have to be replaced then 5 6 Enerpac Genuine Hydraulic Oil Model Number Content Approx HF 100 1 litres HF 101 4 litres HF 102 19 litres 48 ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE 5 7 Disassembly Procedure for Air Side Valve Parts on Pump Unit Though air is supplied to a pump and the pump is not the balance status a pump is not run In such a case the major cause is the accumulation of dust or water in the air valve and the operation of the air valve are blocked by those factors Remove the air pipe and hose from the air supply port and remove the air valve from the pump unit in the region shown below then dismantle the air valve and remove dust and water from the inside
65. Block 6 VDBK 15 3 Backup washer 8 401Z010P9 1 ORing 9 759Z01P 2 Sunkhead plug R1 8 EE Ee rr ee eee A ZE WVP2 Valve mount block back side ENERPAC 2 71 POWERFUL SOLUTIONS GLOBAL FORCE V Connection scheme of the plugs Connect to the corresponding terminal numbers in the solenoid valve connector wiring diagram below 1 2 FE 1 2 BE Lo VDC24V VAC100V VAC200V Note There is no polarity 50Hz 60Hz 3 7 ZAJ06505 C2 ZAJ12305 C2 The pump have two solenoid operated 3 way valves V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 C2G GP 50MG 60 ZAJ12305 C2G GP 100MG 60 V One cartridge style check valves ER 1 is installed in the P port of the each valve VCSW 130G VCSW 131G by default to reinforce the pressure hold ER 1 G option P port Glycerin filled pressure gauge Solenoid valve Vi VCSW 130G O Ring P d Solenoid valve H VCSW 131G is X The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket Refer to p 18 for wiring techniques of the solenoid valve Repair Kit for VCSW 130 VCSW 131 BEI A Solenoid valve Model No VCSW130K Refer to p 17 for the repair parts list of ZE WVP2 valve mount block ZE WVP2 Valve mount block Delivery port 2 NPT3 8 Drain port NPT1 4 72 ENERPAC 2 PO
66. C 20 ZE GAVM ER2 Delivery port NPT3 8 Delivery port NPT3 8 Drain port NPT1 4 Neutral position V Figure 14 Manual Valve VC 20 Repair Parts List for Figure 14 7 32 Bal 6 A8039110 1 Spring O 8 kB126057 1 Ropn 9 CB324001 1 VaveCap 1 0 5 rin Oo CH537950SR Disk Assembly B1109057 Roll pin lt Oo No RO RO RO C1 Co in 9 B1011564 6 Back Up Washer 20 B1006503 2 CB28110 CH539190 B1111803 8 O Ring for locking valve 26 X lt 1 Apply Loctite 222 Items included in and available only as part of Repair Kit VM4K3 2 Torque item 7 to 38 46 Nm 28 34 ft Items included in and available only as part of Repair Kit DA9560041SR DA9560041SR ENERPAC 69 POWERFUL SOLUTIONS GLOBAL FORCE Repair Parts List for Figure 15 5 15 Valve Mount Block Fe 759zo1P 2 Smkwaipug RVD sfarzo 2 orn LL LI A ZE GAVM ER2 Valve mount block back side 3 5 ZAJ06505 S1 ZAJ12305 S1 The pump have one solenoid operated 3 way valve V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 S1G GP 50MG 60 ZAJ12305 S1G GP 100MG 60 V One cartridge style check valve ER 1 is installed in the P port of the valve VCSW 130G by default to reinforce the pressure hold G option P por
67. G 60 V One cartridge style check valve ER 2 is installed in the P port of the Plate ZE VM1 by default to reinforce the pressure hold Air vent and Oil feeding port G option P port Glycerin filled pressure gauge Tank port NPT3 8 Plate ZE VM1 Air supply port a A Rc1 4 i la i i a 2 b 4 f Delivery port E dn NPT3 8 s3 N YT i Re S Drain port NPT1 4 Ji peo O O O Repair Parts List for Figure 12 6 VDBK 15_ 2 Backup washer 8 4012010P9 1 ORmm i 9 759Z01P 2 Sunkhead plug R1 8 pp A ZE VM1 Plate back side 66 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 2 ZAJ06505 M3 ZAJ12305 M3 The pump have one manual 3 way valve V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 M36C GP 50MG 60 ZAJ12305 M3G GP 100MG 60 V One cartridge style check valve ER 1 is installed in the P port of the valve VCMW 130 by default to reinforce the pressure hold G option P port Glycerin filled pressure gauge ER 1 I Tank port VCMW 130 3 way manua valve ZE WVP1 Valve mount block Delivery port NPT3 8 t Repair Kit for VCMW 130 BEI Model No VCSW130K Drain port NPT1 4 Repair Parts List for Figure 13 BEW 6 VDBK15 3 Backup washer 8 4012010P9 1 ORing 9 759201P 1 Sunkheadplug R1 8 eee A ZE WVP1
68. J065 35MPa 37MPa ep 3 ZAJ123 70MPa 72MPa 4 35MPa ZAJ065 70MPa ZAJ123 P 4 5
69. JL PR M1 R P R P 1 ZAJ06505 M1 T ZAJ12305 M1 T ZAJ06505 M3 T ZAJ12305 M3 T ZAJ06505 M32 T ZAJ12305 M32 T ZAJ06505 S1 T ZAJ12305 S1 T ZAJ06505 A1 T ZAJ12305 A1 T ZAJ06505 M4 CT ZAJ12305 M4 CT ZAJ06505 S2 T ZAJ12305 S2 T ZAJ06505 A2 T ZAJ12315 A2 T ZAJ06505 C2 T ZAJ12305 C2 T 1 T 2 A AC100V 50 60Hz D AC200V 50 60Hz C DC24V A D C ZAJ06505 S2 AC200V 65 ZAJ06505 S2D 3 0 4MPa 0 7MPa CT 6 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 8 V ZAJ 1 65 Y ZA 1 123 ent MPa MPa e E g E 9002 gt R 400 ti R tip H H i 300 E E a 200 amp H 00 B E s EI ESS n 0 2 04 0 06 08 10 12 14 UN TE 20 22 24 0 0 102 03 04 05 06 07 08 09 10 11 12 HH e L min L min v 2AJ 1 65 4 D T V ZAJ 1 123 DAT MPa MPa 80
70. L Fig A CD Hydraulic pump cylinder 2 Intake check valve assembly 3 Suction filter 4 Air port plug for priming 5 Air vent oil filler plug Air jet nozzle gun C Air quick coupling Hydraulic fluid Q Air pressure direction 10 Hydraulic fluid flow direction Fig C ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 6 0 Troubleshooting Chart AN CAUTION If the issue is not resolved with the following steps contact your dealer or Enerpac customer service as an overhaul parts replacement or other repairs may be necessary Pueden Jut 1 Air is not being supplied to the pump Supply air to the pump 2 Supplied air pressure is too low Supply pumps with air pressure 0 1MPa 0 7MPa 3 Air is supplied to the pump but pumps do not operate Adjust the air operated valves with the procedure on due to air operated valve defect p 950 4 Pressure is already rising the pump is balancing air pressures against oil pressures But pump is stopped because the pressure is maintained 5 Air is leaking from the air pipe in the reservoir and air Remove the cover subassembly from the reservoir and comes out of the vent repair the spot leaking 6 Packing In the pump cylinder is damaged causing the Replace the packing pump cylinder not to stroke Pd9KI06 In the air cylinder is damaged causing air to Replace the packing eject from the air muffler 1 Hydraulic oil level is too low Hydraulic oil level is
71. L SOLUTIONS GLOBAL FORCE 3 9 Basic System Set up The ZAJ type air hydraulic pumps A single acting cylinders 3 way directional control valves M3 S1 A1 Air source A A double acting cylinder 4 way manual directional control valves M4 Air source U RV lt o D PPA NNV PPA LVV AM LA T M UR gt db E X ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE AAA VV Multiple single acting cylinders 4 way directional control valves M32 S2 A2 A double acting cylinder 4 way directional control valves S2 A2 Air source air pressure 0 1 0 MPa Description This hydraulic circuit is most suitable for holding the hydraulic pressure in the system during the long time in the case the position of the valve is changed rarely Though the solenoid valves are not energized for power outage or the pump is not supplied air pressure in the system will not decrease immediately V 152 relief valve 3 is a safety valve for when a defect occurs in valves D or The air operated valves 4 can be used in the same manner For details please consult with Enerpac customer service Secondary circuit Description RDV 50R reducing relief valve can adjust the hydraulic pressure of the secondary circuit to lower than the hydraulic pressure of the primary side in the hydraulic system Moreover pressure holding of the secondary circuit can be maintained withou
72. S 1 16 OW AD ODD O 2 4 Q5 1 Drain port NPT1 4 Repair Parts List for Figure 1 REV Shaded items are available only in Repair Kit ZAJ 12305K and No Qty Description 2 i indi 7AJ 123 7AJ 065 y p ZAJ 06505K When ordering clearly indicate the product model number and serial number CT776 950B CT698 950B Cover subassembly Fe w ww 1 Oilevel gauge re zenoot 31 vavemountpiate ess 4 ORig o enoo 1 Vaie mount gaset ENERPAC 2 57 POWERFUL SOLUTIONS GLOBAL FORCE Figure 2 Pump Subassembly QOS 82 DAD 1 49 GD 4 GE CT776 950B 70MPa CT698 950B 35MPa Cover Subassembly dS TULL T q is lt P Please refer to next page for the parts list of Figure 2 58 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Figure 3 Pump Subassembly CT776 950B 70MPa CT698 950B 35MPa Cover Subassembly Repair Parts List for Figure 2 3 fey No Qty Description CT776 950B CT698 950B Q3 WDO y 7 PEHA me ird ZA FA 4 a gt Shaded items are available only in Repair Kit ZAJ 12305K and ZAJ 06505K When ordering clearly indicate the product model number and serial number CT775 950 CT770 950 Pump subassembly ls keep 2 Gasket s poserg 2 suotonfiter Le omms 2 Advance check assembly ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE
73. Valve mount block back side ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Backup washer 67 3 3 ZAJ06505 M32 ZAJ12305 M32 The pump have two manual 3 way valves V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 M36C GP 50MG 60 ZAJ12305 M3G GP 100MG 60 V One cartridge style check valves ER 1 is installed in the P port of the each valve VCMW 130G by default to reinforce the pressure hold 43 Rotation knob G option P port Glycerin filled pressure gauge ER 1 VCMW 130 y MB MA 3 way manua valve P f ZE WVP2 Valve mount block UA o Delivery port 2 NPT3 8 Drain port NPT1 4 Repair Kit for VCMW 130 as Model No VCSW130K A 3 way manua valve VCMW 130 Refer to p 71 for the parts list of ZE WVP2 valve mount block 68 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 4 ZAJ06505 M4 ZAJ12305 M4 The pump have one manual 4 way valve V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 M4G GP 50MG 60 ZAJ12305 M4G GP 100MG 60 V One cartridge style check valve ER 2 is installed in the P port of the Valve mounting block ZE GAVM ER2 by default to reinforce the pressure hold V Description of lever position G option P port Leber Glycerin filled pressure gauge a Manual valve V
74. WERFUL SOLUTIONS GLOBAL FORCE 3 8 ZAJ06505 A1 ZAJ12305 A1 The pump have one air operated 3 way valve V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 A16G GP 50MG 60 ZAJ12305 A1G GP 100MG 60 V One cartridge style check valve ER 1 is installed in the P port of the valve VCAW 130G by default to reinforce the pressure hold G option P port Air pilot port O32 G1 4 Air operated valve VCAW 130 Repair Kit for VCAW 130 BEP Model No VCSW130K A Air operated valve VCAW 130 Refer to p 67 for the parts list of ZE WVP1 valve mount block 3 9 ZAJ06505 A2 ZAJ12305 A2 The pump have two air operated 3 way valves V G at the end of the model means that a pressure gauge is equipped Refer to 3 7 of the above V One cartridge style check valves ER 1 is installed in the P port of the each valve VCAW 130G by default to reinforce the pressure hold G option P port Air pilot port Air operated valve VCAW 130 Repair Kit for VCAW 130 EUM Model No VCSW130K Refer to p 71 for the parts list of ZE WVP2 valve mount block ENERPAC 73 POWERFUL SOLUTIONS GLOBAL FORCE Enerpac Worldwide Locations Australia and New Zealand Actuant Australia Ltd Block V Unit 3 Regents Park Estate 391 Park R
75. X2 2 Air operated 3 Block 3 4 Mg 3 et 1 pi n 2 RP mansoni 31 1 ZAJ12305 M1 T ZAJ06505 M3 T ZAJ12305 M3 T ee NENNEN mas S S S AM908M82CD ANGST AMZO08SCD HANG of Pt zwan Pt C HAM2908MACO EH 1 31 1 1 CE ee ZAJ12305 S2 T 3X1 T at the end of the model numbers means Twin pump 2 The solenoid valve voltage current at 50 60Hz is A VAC100V 0 2A D VAC200V 0 1A CC VDC24V 0 83A Example in the case of ZAJxxx05 S2 the pump model that have solenoid valves of VAC200V with increased ratio of 65 is ZAJ06505 S2D 7X3 Air pilot pressure is 0 4MPa 0 7MPa ENERPAC 2 37 POWERFUL SOLUTIONS GLOBAL FORCE 3 8 Oil Flow Versus Pressure and Air Consumption W ZAJ model pump increase ratio 1 65 spt W ZAJ model pump increase ratio 1 123 spt Air pressure MPa Air pressure MPa 2 z 60 3 5 Z Z 9 500 _ D E 400 amp E m 30 2 c 3 Q D 200 V e gt a T 100 r 0 0 02 04 06 08 10 12 14 16 18 20 22 24 0 0 1 02 0 3 0 4 05 0 6 0 7 08 09 10 1 1 12 Oil Flow L min Oil Flow L min W ZAJ model twin pump increase ratio 1 65 ti W ZAJ model twin pump increase ratio 1 123 DART Air pressure MPa Air pressure MPa c z 5 5 Z z B E T S z S a 3 E s o o o 3 5 5 O E gt c gt 0 04 08
76. c com Japan Applied Power Japan LTD KK Besshocho 85 7 Kita ku Saitama shi 331 0821 Japan T 81 48 662 4911 F 81 48 662 4955 sales jp enerpac com Middle East Egypt and Libya ENERPAC Middle East FZE Office 423 LOB 15 P O Box 18004 Jebel Ali Dubai United Arab Emirates T 971 0 4 8872686 F 971 0 4 8872687 sales ua enerpac com Russia Rep office Enerpac Russian Federation Admirala Makarova Street 8 125212 Moscow Russia T 7 495 98090 91 F 7 495 98090 92 sales ru enerpac com Singapore Actuant Asia Pte Ltd 83 Joo Koon Circle Singapore 629109 T 65 68 63 0611 F 65 64 84 5669 Toll Free 1800 363 7722 sales sg enerpac com South Korea Actuant Korea Ltd 3Ba 717 Shihwa Industrial Complex Jungwang Dong Shihung Shi Kyunggi Do Republic of Korea 429 450 T 82 31 434 4506 F 82 31 434 4507 sales kr enerpac com Spain and Portugal ENERPAC SPAIN S L Avda Los Frailes 40 Nave C amp D Pol Ind Los Frailes 28814 Daganzo de Arriba Madrid Spain T 34 91 884 86 06 F 34 91 884 86 11 sales es enerpac com Sweden Denmark Norway Finland and Iceland Enerpac Scandinavia AB Fabriksgatan 7 412 50 Gothenburg Sweden T 46 0 31 799 0281 F 46 0 31 799 0010 scandinavianinquiries enerpac com The Netherlands Belgium Luxembourg Central and Eastern Europe Baltic States Greece Turkey and CIS countries ENERPAC B V Galvanistraat 115 6716 AE Ede P O Box 8097 67
77. ca and Caribbean ENERPAC P O Box 3241 Milwaukee WI 53201 USA T 1 262 293 1600 F 1 262 293 7036 User inquiries 1 800 433 2766 Distributor inquiries orders T 1 800 558 0530 F 1 800 628 0490 Technical inquiries techservices enerpac com sales us enerpac com ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Repair Parts Sheet ENERPAGC 2 Air hydraulic pumps ZAJ 065 ZAJ 123 Series POWERFUL SOLUTIONS GLOBAL FORCE Document Document Document Product Date Code Number Revision Revision Date Beginning With L4091 08 2014 To Protect Your Warranty Use Only ENERPAC Hydraulic Oil Enerpac recommends that all kit components be installed to insure optimum performance of the repaired unit ZAJ06505 M1 ZAJ06505 M3 ZAJ06505 M32 ZAJ06505 M4 ZAJ12305 M1 ZAJ12305 M3 ZAJ12305 M32 ZAJ12305 M4 ZAJ06505 A1 ZAJ06505 A2 ZAJ06505 S1 ZAJ06505 S2 C2 ZAJ12305 A1 ZAJ12305 A2 ZAJ12305 S1 ZAJ12305 S2 C2 Table of Contents Page Page 1 0 Pump Models and Specifications 56 Figure 11 Air Valve ceeeeeeeeereennnenmnnn enn 65 2 0 Repair 8 c 57 65 3 0 Repair Parts List for each model Air Hydraulic Pumps 66 73 Figure 1 Cover Subassembly and Tank Subassembly 57 3 1 ZAJ06505 M1 ZAJ12305 M1 eene 66 Figure 2 Pump Subassembly eeeeeeeeeees 58 3 2 ZAJ06505 M3 ZAJ12305 M3
78. ck Valve Assembly CT771 950 2 Repair Parts List for Figure 5 L4091 Check valve 2 CT696 096 1 Joint Items available only in Repair Kit are included in Repair Kit ZAJ 12305K ZAJ 06505K When ordering clearly indicate the product model number and serial number Figure 6 Discharge Check Valve Assembly CT772 950 an Repair Parts List for Figure 6 L4091 1 crei 1 checkvane ie 0016 eal S Items available only in Repair Kit are included in Repair Kit ZAJ 12305K ZAJ 06505K When ordering clearly indicate the product model number and serial number ENERPAC 2 61 POWERFUL SOLUTIONS GLOBAL FORCE Figure 7 Valve Block Assembly CT820 900 1 Repair Parts List for Figure 7 Items available only in Repair Kit are included in CT697 190 1 Valve block Repair Kit ZAJ 12305K ZAJ 06505K When ordering clearly indicate the product model number and serial A1006 245 4 400007P7 Figure 8 Sub Plate Assembly CT1032 950 Repair Parts List for Figure 8 Items available only in Repair Kit are included in CT1027 190 Sub plate Repair Kit ZAJ 12309K ZAJ 06505K When ordering clearly indicate the product model number and serial Eoo ee I 62 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Figure 9 Air Side Valve Parts on Pump Unit Air supply opening Repair Parts List for Figure 9 HO o Geb e ism AN CAUTION It is provi
79. ded at assembly except No 2 No 7 of the part list When dismantling the valve please be careful not to give the packing the damage ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 63 Figure 10 Air Operated Valve Air operated valve Exploded view Repair Parts List for Figure 10 BEUR m Hr le 8 8 9e EE z p slslpsweg 1 ty 1 1 1 1 EN EN paste ing bac 1 12 Side pae EN Pr teapot sl AN CAUTION The parts of the air operated valve is provided at assembly CT1098 190 When dismantling the valve please be careful not to give the packing the damage 64 ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE Figure 11 Air Valve Ww Output indicator red Input indicator green Fig Air valve CT1028 190 Repair Parts List for Figure 11 re soing o s Tapping screw dC s Pon 1 Lp I For disassembly remove this screw AN CAUTION The parts of the air valves is provided at assembly CT1028 190 When dismantling the valve please be careful not to give the packing the damage ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 65 3 0 Repair Parts List for each model Air Hydraulic Pumps 3 1 ZAJ06505 M1 ZAJ12305 M1 The pump have one P R ports block V G at the end of the model means that a pressure gauge is equipped Pressure gauge model for G option ZAJ06505 M1G GP 50MG 60 ZAJ12305 M1G GP 100M
80. driven normally 4 f the spool does not move smoothly even after the above steps are taken dismantle the valve and clean the contaminant out Please refer to the following exploded view for work AN CAUTION The parts of the air operated valve is provided at assembly CT1098 190 When dismantling the valve please be careful not to give the packing the damage Air operated valve Exploded view Part list ree elslsem 5 er zlelpemwewg 1 EA slvaesew 1 7lemse sl 1 50 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 5 9 Maintenance amp Disassembly Procedures for Air Valve DZAJ type air hydraulic pumps can generate the hydraulic pressure by the air pressure And hydraulic pressure of the pump can be adjusted with the air pressure If hydraulic pressure rise to pressure adjusted with the air pressure the pump stop operation Then the pump automatically is balancing the air pressure and the hydraulic pressure If the stopped the air hydraulic pumps does not activate even when the hydraulic system pressure drops there may be the defects in the air operated valve When the pump is balanced and stopped a very small amount of air may continuously leak from the exhaust muffler on the air valve This is caused by a defective diaphragm on the air valve 1 Defects with the air valve CT1028 190 are mainly caused by the accumulation of water and lubricant from the internal air supply line Two air valves are
81. es are not in a condition of the vacuum Therefore it is necessary to eject the air from the intake check valve assemblies And its work is called priming See fig A 5 11 How to Do Priming 1 Before working be sure to see the oil level gauge to check the quantity of hydraulic oil If the oil level is low add oil to the reservoir 2 Prepare another air line so the air jet nozzle gun 6 can be used See fig B 3 Close the air vent oil filler plug 4 Pull the air port plug for priming out while pushing the head of the air quick coupling C2 down 5 Connect the hydraulic cylinder etc to confirm whether hydraulic fluid is discharged by the pump AN CAUTION Be sure never to inject high pressure air into the reservoir because it is not a pressure container 6 While the nozzle of the air jet nozzle gun continues to be inserted into the opening of the air quick coupling please inject air into the reservoir by the air jet nozzle gun with the air pressure 0 1 0 2MPa And while the air is injected into the reservoir be running the pump W when air is injected into the reservoir the oil surface is pressed down by air pressure and the air in the intake check valve assembly is pushed off its valve assembly to the hydraulic pump cylinders CD with the oil Then the pump can discharge oil as normal See fig C 52 SSK Sr Z XN f l Z d 2 E a II 5 Q 4 6 6 FF gt E
82. ir pressure of 0 4MPa 0 7MPa is necessary to operate the air operated 3 way valve If the air is exhausted from the air operated 3 way valve the valve revert back to the initial position with spring power 2 The cartridge style check valves ER 1 is installed in the valves P port by default to reinforce the pressure hold 3 The plunger of the single acting cylinder with spring return can be advanced or retracted by the air operated 3 way valve but the plunger of the cylinder cannot stop in the middle of strokes 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow ENERPAC 2 45 POWERFUL SOLUTIONS GLOBAL FORCE A Air operated valve VCAW 130 O Ring P G option P port Air pilot port G1 4 Air operated valve VCAW 130 Valve mount block ER 1 I2 4 9 ZAJ06505 A2 ZAJ12305 A2 The pump have two air operated 3 way valves 1 The pump have two air operated 3 way valves The air pressure of 0 4MPa 0 7MPa is necessary to operate the air operated 3 way valve If the air is exhausted from the air operated 3 way valve the valve revert back to the initial position with spring power 2 The cartridge style check valves ER 1 is installed in two valves P
83. m including air cause irregular moves for the plungers of the cylinders In such a case release air from the hydraulic system that include hydraulic hose When releasing air from the hoses connect the discharge port with the return port with the hydraulic hose Change the directional control valve from the neutral position into the discharge position and cycle the hydraulic oil Do not build pump pressure then Release air from all the hydraulic hoses with the hydraulic system 2 When the hydraulic system is connected with high pressure piping attach air release valve SAP03 000J to the terminal part of the piping Cap screw e Loosen the cap screw of the air removal valve one rotation e Change the directional control valve from the neutral position to the discharge position Inch the pump operation with pressure lower than air pressure is 0 1MPa AN CAUTION the air including the oil is exhausted from the air release valve For such a reason do not stand in front of the exhaust port Then cover the exhaust port in a cloth etc so that oil is not scattered from a port e When the air without including the oil is discharged from the exhaust port the work that release air is complete e When the cap screw on the air release valve is completely screwed and shut the exhaust port the work is completed 66 SAP03 000J Air release valve 3 6 Instructions before use 1 Activate the pump with no building hydraulic pressure and check for
84. may cause damage to enter the check valve or the directional control valves screwing torque is 79 98 Nm 8 10kgf m at a diameter of 3 8 X Winding direction of the seal tape screwing direction of hose fitting Wind the seal tape two times while pulling it to firmly stick it on the ridge If taped poorly the seal tape will revert back to its original shape when screwed in losing its effectiveness 34 ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE 3 A pressure gauge is incorporated into the pump when G is added to the end of the ZAJ type pump models D BS 1 8 Bonded seal 2 KHB06 010E Parallel screw adapter 3 KFZ16 6 1 4 Bite type tube fitting 4 FZ 1605 Socket GP 50MG 60 Pressure gauge 60 ZAJ065 6 GP 100MG 60 Pressure gauge 60 ZAJ123 D Directional control valve Hydraulic Circuit B A LI 99 LLL Figure D T P ee J AN CAUTION When tightening the taper screw threads of each size be careful not to over tighten it 3 2 Pressure Adjustment of the Pump A relief valve safety valve is built in to the reservoir of the ZAJ model air drive hydraulic pump for adjusting the maximum discharge pressure on the pump However the check valve is installed to reinforce the pressure hold between the safety valve and the directional control valve So when the pressure is higher than rated pressure of the cylinder the relief valve cannot function as the safety valve AN CAUTION Whe
85. n there is a risk of overload from the exterior pressure in the hydraulic system may suddenly rise and lead to personal injury Attach relief valve V 152 to the discharge port exterior and adjust the pressure while checking the pressure gauge See figure E D V 152 Relief valve 2 To increase setting turn the handle clockwise px N 2 FZ 1620N Long nipple FZ 1617 Nipple re Decrease FZ 1612 Tee ho D L 5 Directional control valve qudm I cM E E 1 2 Hydraulic Circuit y I a r7 gt H Ln 1 9 PT y 1 9 T T P l Figure E AN CAUTION If the set pressure for the relief valve is not set around 3 4MPa higher than the necessary pressure the relief valve will always be working while the pump is in operation Because the hydraulic pump that is supplied air cannot stop lifespan of the hydraulic equipment shorten by reason of the oil temperature rise Normally adjust air pressure with the air reducing valve on the air supply side For ZAJ model pumps the air side pressure and hydraulic side pressure will be balanced in the range of the increased pressure ratio and the pump operations will stop allowing for setup of the discharge hydraulic power with the air pressure Do not touch the relief valve built in to the reservoir Pressure Setting Example model ZAJ065 0 4MPa input air pressure x 65 increased pressure ratio 26MPa discharge hydraulic power theoretical value ENERPAC 2 35
86. nder a non excited state the solenoid valve will revert back to the initial position with spring power 2 One cartridge style check valve ER 1 is installed in the valve P port by default to reinforce the pressure hold 3 The plunger of the single acting cylinder with spring return can be advanced or retracted by the solenoid 3 way valve but the plunger of the cylinder cannot stop in the middle of strokes 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow 42 ENERPAC g POWERFUL SOLUTIONS GLOBAL FORCE G option P port Glycerin filled pressure gauge ER 1 Solenoid valve VCSW 130G 7 47 O Ring P A Solenoid valve model Voltage current at 50 60 Hz 1 S e VCSW 130G A VAC100V 0 2A ue VCSW 130G D VAC200V 0 1A VCSW 130G C VDC24V 0 83A gt lt The A D type of the valve have an adapter and a bridge rectifier socket and the bridge rectifier is incorporated into the socket Refer to p 44 for weld times wiring techniques of the solenoid valve Drain port NPT1 4 A Solenoid valve VCSW 130 4 6 ZAJ06505 S2 ZAJ12305 S2 The pump have two solenoid operated 3 way valves 1 The pump is equipped with two solenoid operated 3 way valves The voltage of the solenoid valve is VAC100V VAC200V and VDC24V and under a non excited state the solenoid valve will revert back
87. ndicate correct operating or maintenance procedures and practices to prevent damage to or destruction of equipment or other property AN A WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury AN A DANGER is only used when your action or lack of action may cause serious injury or even death N WARNING 1 When hydraulic oil has been dispersed usage is not allowed at a location where serious damage might occur In particular do not use the product near open flame as doing so may lead to injury or fire etc 2 Maximum working pressure for model ZAJ065 is 35MPa Since the relief valve safety valve in the pump is adjusted to 37MPa upon shipment do not adjust the pressure to higher than that 3 Maximum working pressure for model ZAJ123 is 70MPa Since the relief valve safety valve in the pump is adjusted to 72MPa upon shipment do not adjust the pressure higher to than that 4 When using hydraulic equipment below the maximum working pressure with pumps of maximum working pressures of 35MPa ZAJ065 and 70MPa ZAJ123 set the pressure of the relief valve below the lowest working pressure of the hydraulic equipment used Using the equipment exceed ing the range of working pressure will cause damage to the equipment For details on pressure setting see p 4 5 If for some reason the hydraulic equipment is damaged do not touch or go near any place where high pressure oil is spouti
88. ng The oil may penetrate your skin and cause serious injury Promptly stop usage of the hydraulic equipment and replace the damaged parts with new ones before using the equipment again 6 Do not hold the high pressure hose with your hands during pressurization Holding the high pres sure hose in the event of rupture may cause the high pressure hydraulic oil to instantly shoot out penetrating your body and hands 7 High pressure hoses are the consumable Replace the hose after using it for 100 000 cycles even If no defects are visible 8 Do not pressurize with the pump the high pressure hoses that connected the male or the female half of couplers To prevent danger when the coupler is pressurized do not bring a hand and a body to the direction of the coupler connection ENERPAC 33 POWERFUL SOLUTIONS GLOBAL FORCE 9 Alteration of hydraulic equipment is extremely dangerous and may cause loss of safety or opera bility resulting in a serious accident Do not under any circum stances make any alterations etc 10 Keep hydraulic equipment away from flames and heat otherwise a hydraulic fluid leak and cause igniting hydraulic oil Excessive heat will soften packings and seals resulting in fluid leaks Heat also weakens hose materials and packings For optimum perfor mance do not expose equipment to temperatures of 40 C 104 F or higher 11 When operating hydraulic machinery wear protective gear such as work clothes safe
89. oad Regents Park NSW 2143 P O Box 261 Australia T 61 297 438 988 F 61 297 438 648 sales au enerpac com Brazil Power Packer do Brasil Ltda Rua dos Inocentes 587 04764 050 Sao Paulo SP T 55 11 5687 2211 F 55 11 5686 5583 Toll Free 0800 891 5770 vendasbrasil enerpac com Canada Actuant Canada Corporation 6615 Ordan Drive Unit 14 15 Mississauga Ontario L5T 1X2 T 1 905 564 5749 F 1905 564 0305 Toll Free T 1 800 268 4987 F 1 800 461 2456 customer service actuant com China Actuant China Industries Co Ltd No 6 Nanjing Road Taicang Economic Dep Zone Jiangsu China T 86 0512 5328 7500 F 86 0512 5335 9690 Toll Free 86 400 885 0369 sales cn enerpac com France Switzerland North Africa and French speaking African countries ENERPAC Une division d ACTUANT France S A S ZA de Courtaboeuf 32 avenue de la Baltique 91140 VILLEBON YVETTE France T 33 1 60 13 68 68 F 33 1 69 20 37 50 sales fr enerpac com Germany and Austria ENERPAC GmbH P O Box 300113 D 40401 Dusseldorf Willstatterstrasse 13 D 40549 Dusseldorf Germany T 49 211 471 490 F 49 211 471 49 28 sales de enerpac com India ENERPAC Hydraulics Pvt Ltd No 1A Peenya Industrial Area IInd Phase Bangalore 560 058 India T 91 80 40 792 777 F 91 80 40 792 792 sales in enerpac com Italy ENERPAC S p A Via Canova 4 20094 Corsico Milano T 39 02 4861 111 F 39 02 4860 1288 sales it enerpa
90. ons before using the product Follow all safety precautions to avoid personal injury or property damage during system operation If you have any questions about the product or instructions please contact the distributor or ENERPAC Customer Service In addition take care of the instruction manual warning labels etc and in the event of loss damage or defacement promptly purchase and properly attach the stored documents Repair sheets can be found at the Enerpac website http www apj ne jp 1 0 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 replace ment costs resulting from damage in shipment 2 0 Safety Precautions Read all instructions cautions warnings and dangers carefully Follow all safety precautions to avoid personal injury or property damage during system operation ENERPAC cannot be responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact ENERPAC when in doubt as to the safety precautions and operations If you have never been trained on high pressure hydraulic safety consult your distribution service center or ENERPAC Customer Service Failure to comply with the following dangers cautions and warnings could cause equipment damage and personal injury AN A CAUTION is used to i
91. option P port Glycerin filled pressure gauge Tank port VCMW 1 NPT3 8 a 3 way manua valve ZE WVP1 Valve mount block Delivery port NPT3 8 BERG pom Drain port NPT1 4 4 3 2AJ06505 M32 ZAJ12305 M32 The pump have two manual 3 way valves 1 The pump is equipped with two manual 3 way valves The knob to change a position of the valve provides reliable security against shock and vibration through 90 position detent mechanisms and you can turn the knob in both of rotate right and rotate left 2 One cartridge style check valve ER 1 is installed in P port of each valve by default to reinforce the pressure hold 3 The plunger of the single acting cylinder with spring return can be advanced or retracted by the each manual 3 way valve which have independent oil pressure system but the plunger of the cylinder cannot stop in the middle of move 4 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 and double output flow Rotation knob ER 1 A 3 way manua valve VCMW 130 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE G option P port j Glycerin filled pressure gauge VCMW 130 3 way manua valve ZE WVP2 Valve mount block Delivery port 2 NPT3 8 Drain port NPT1 4 41 4 4 ZAJ06505 M4 ZAJ12305 M4 The pump have one manual 4 way valve 1
92. periods because the damage of the valve is caused by the duty cycle and heat generation in the solenoid Please refer to the following chart for finding the duty cycle ED of the solenoid valve V id cycle chart 1 Teycetine V Duty cycle during operation O XN Model Max operating Max flow Duty cycle amet 9 pressure ature 2 EN ES ED 3 Under nur X2 Solenoid valve voltage E end of model A AC100V D AC200V C DC24V 44 20 20 30 40 50 60 70 80 90 100 Rel duty cycle ED Continuous operation Exp In the case of ambient temperatures 50 C of the solenoid valves its valves can be energized within 70 of duty cycle X1 The chart mentioned above is applied in the case of the only solenoid valve installed in the place where there is not the adjoining solenoid valves If the valves are installed in a cabinet it should be always equipped with louvers 6 Connection scheme of the plugs Connect to the corresponding terminal numbers in the solenoid valve connector wiring diagram below 1 2 PE VDC24V VAC100V VAC200V Note There is no polarity 50Hz 60Hz ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 4 7 ZAJ06505 C2 ZAJ12305 C2 The pump have two solenoid operated 3 way valves 1 The pump is equipped with two solenoid operated 3 way valves The voltage of the solenoid valve is VAC100V VAC200V and VDC24V and under a non excited state the solenoid valve will revert
93. pply air pressure until it reaches the set hydraulic pressure Inspect hydraulic piping and tighten joints 2 0il is leaking from the hydraulic piping or the cylinder Replace packing for the cylinder MTM SSR II Repl king for th nd flush out the valve balance and stop It keeps 3 0il is leaking in the hydraulic directional control valve zr jd Padi pM A with air Or replace the valve body working 4 Packing for pump cylinder or air cylinder is damaged Replace the packing 5 Air is leaking from the air pipe in the reservoir and Remove cover subassembly from reservoir and repair air air comes out from the air vent leaks 1 Air is not being provided Supply the air 2 Electricity and air is not provided to hydraulic solenoid Check if electricity and air are supplied to the hydraulic Pump balances air pressure valve or air pilot operated valve selector valve and hydraulic pressure and stops but pump does not restart even when hydraulic 3 Air valve on p 51 is not functioning Wash the air valve referencing p 51 pressure drops 4 Packing in pump cylinder is damaged and will not Replace packing stroke 53 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE o4 7 0 Warranty D A one year warranty from the date of purchase 2 Free of charge repair or replacement will be made the defective parts under normal usage 3 Exception of warranty Q Damage or injury resulting from natural disaster and inevi
94. rpac com France Switzerland North Africa and French speaking African countries ENERPAC Une division d ACTUANT France S A S ZA de Courtaboeuf 32 avenue de la Baltique 91140 VILLEBON YVETTE France T 33 1 60 13 68 68 F 33 1692037 50 sales fr enerpac com Germany and Austria ENERPAC GmbH P O Box 300113 D 40401 D sseldorf Willst tterstrasse 13 D 40549 D sseldorf Germany T 49 211 471 490 F 49 211 471 49 28 sales de enerpac com India ENERPAC Hydraulics Pvt Ltd No 1A Peenya Industrial Area IInd Phase Bangalore 560 058 India T 91 80 40 792 777 F 91 80 40 792 792 sales in enerpac com Italy ENERPAC S p A Via Canova 4 20094 Corsico Milano T 39 02 4861 111 F 39 02 4860 1288 sales it enerpac com Japan Applied Power Japan LTD KK Besshocho 85 7 Kita ku Saitama shi 331 0821 Japan T 81 48 662 4911 F 81 48 662 4955 sales jp enerpac com Middle East Egypt and Libya ENERPAC Middle East FZE Office 423 LOB 15 P O Box 18004 Jebel Ali Dubai United Arab Emirates T 971 0 4 8872686 F 971 0 4 8872687 sales ua enerpac com Russia Rep office Enerpac Russian Federation Admirala Makarova Street 8 125212 Moscow Russia T 7 495 98090 91 F 7 495 98090 92 sales ru enerpac com Singapore Actuant Asia Pte Ltd 83 Joo Koon Circle Singapore 629109 T 65 68 63 0611 F 65 64 84 5669 Toll Free 1800 363 7722 sales sg enerpac com South Korea Actuant Korea Ltd
95. ssembly with No 4 15 bolts 6 Remove No 2 the air vent tank oil filler plug from the pump then fill the hydraulic oil up to the maximum level of the oil level gauge AN CAUTION While supplying the hydraulic oil be careful so that it is not contaminated with the dust Dust and other foreign objects are a major cause of malfunctions in the hydraulic equipment T Remove the pipe connecting to the hydraulic cylinder loosen the joint at the lowest position and drain the dirty hydraulic fluid from the pipes 8 Also loosen the joint at the oil port of the hydraulic cylinder and drain the dirty hydraulic fluid from the cylinder as well AN CAUTION In the case the hydraulic fluid is especially dirty flush out the pipes and hydraulic cylinder with flushing liquid Thoroughly clean out the flushing liquid from the hydraulic system afterwards 9 Restore the pipings or the hydraulic hoses that were removed from the hydraulic system 10 Run the pump and remove the air from within the pipings and the hydraulic cylinder AN CAUTION After replacing the hydraulic fluid the pump may not discharge the hydraulic fluid In such a case refer to p 21 and perform priming 11 After air removal is completed inspect the amount of oil again and adjust the amount of hydraulic oil 12 Regarding the hydraulic valves and hydraulic cylinders being used read the instruction manual each the hydraulic equipments have as well as this instruction manual ENERP
96. t being affected by a change in the pressure of the primary side The pressure maintenance of the secondary circuit is possible in the range of the pressure of 1 8MPa 38MPa lower than the hydraulic pressure of the primary side in the system Air operated valves can be used in the same manner For details please consult with Enerpac customer service 39 Air source air pressure 0 1 0 MPa 4 0 Function and Operation of each model Air Hydraulic Pumps 4 1 ZAJ06505 M1 ZAJ12305 M1 The pump have one P R ports block 1 The pump is equipped with the block having the delivery ports and the tank ports and the plate ZE VM 001 which substitutes for the directional control valve 2 he pump can connect the remote directional control valve through the high pressure hose or the pressure piping and you can use it as the hydraulic power source of the hydraulic systems 3 G at the end of the model means that a pressure gauge is equipped and T at the end of the model means the twin pump that have the effective oil 7 Z and double output flow AN CAUTION Do not use the spool type directional control valves because internal leakage in those valves is typically equal to the total amount of flow required for a workholding circuit ZAJ models control the consumption of air by balancing the air pressure with the hydraulic power and automatically stopping the pump drive while the hydraulic system is holding pressure The pump cannot be balanced when
97. tability by fires Damage or injury resulting from unsafe product usage lack of maintenance or incorrect product and system application Q Damage or injury resulting from the modification or change without E N s approval In the case of receiving warranty at the nation except the nation which purchased products Q In the case of exporting from the nation which purchased products For standard products our overseas branch can repair with pay For special products a maintenance contract can be necessary beforehand 4 In the case of lapse of guarantee period Contact ENERPAC when product is repairable with pay Enerpac Worldwide Locations Australia and New Zealand Actuant Australia Ltd Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 2143 P O Box 261 Australia T 61 297 438 988 F 61 297 438 648 sales au enerpac com Brazil Power Packer do Brasil Ltda Rua dos Inocentes 587 04764 050 Sao Paulo SP T 55 11 5687 221 F 55 11 5686 5583 Toll Free 0800 891 5770 vendasbrasil enerpac com Canada Actuant Canada Corporation 6615 Ordan Drive Unit 14 15 Mississauga Ontario L5T 1X2 T 1 905 564 5749 F 1905 564 0305 Toll Free T 1 800 268 4987 F 1 800 461 2456 customer service actuant com China Actuant China Industries Co Ltd No 6 Nanjing Road Taicang Economic Dep Zone Jiangsu China T 86 0512 5328 7500 F 86 0512 5335 9690 Toll Free 86 400 885 0369 sales cn ene
98. ty goggles helmets etc keep the moving things or sharp objects chemicals corrosives and other dangerous objects away Such objects may cause a serious accident for an trouble or error when operating the hydraulic equipment N CAUTION 1 Carry out protective measures against rain mud dust and humidity when using the pump outdoors 2 Use only genuine Enerpac Hydraulic Oil The use of any other fluid will render your Enerpac warranty null and void Please contact Enerpac Customer Service if it is the environment that Enerpac Hydraulic Oil cannot use 3 Replace the hydraulic oil once per year or after around 600 hours of continuous use Please discard the waste oil that was replaced according to the domestic law 4 The pump body have two handles Be sure to use the handle when moving or raising it 3 0 Operation 3 1 Connection of Pipes and Pressure Gauge 1 Remove the plug from the valve advance port AN CAUTION Check that a chip of the seal tape was not left to the port Chips of the seal tape that are remaining in the thread of pipes hoses may cause damage to enter the check valves or the directional control valves 2 Wind the seal tape all around the male taper screw threads AN CAUTION Leave one pitch or two pitch of the ridge from the tip of the screw thread Refer to the following figures and wind seal tape one or two times around the screw Because chips of the seal tape that are remaining in the thread of pipe hose
99. ulic Pumps 40 46 4 1 ZAJ06505 M1 ZAJ12305 M1 The pump have one P R ports block 40 4 2 ZAJ06505 M3 ZAJ12305 M3 The pump have one manual 3 way valve 40 41 4 3 ZAJ06505 M32 ZAJ12305 M32 The pump have two manual 3 way valves 41 4 4 Z2AJ06505 M4 ZAJ12305 M4 The pump have one manual 4 way valve 42 4 5 ZAJO6505 S1 ZAJ12305 S1 The pump have one solenoid operated 3 way valve 42 43 4 6 ZAJO6505 S2 ZAJ12305 S2 The pump have two solenoid operated 3 way valves 43 44 4 7 ZAJ06505 C2 ZAJ12305 C2 The pump have two solenoid operated 3 way valves 45 4 8 ZAJO6505 A1 ZAJ12305 A1 The pump have one air operated 3 way valve 45 46 4 9 ZAJO6505 A2 ZAJ12305 A2 The pump have two air operated 3 way valves 46 5 0 Maintenance 47 52 5 1 Daily Inspection 47 5 2 Weekly Inspection 47 5 3 Monthly Inspection 47 5 4 How to Replace the Hydraulic Fluid 47 48 5 5 The Methods to Judge Degree of the Degradation of the Hydraulic Oil 48 5 6 Enerpac Genuine Hydraulic Oil 48 5 7 Disassembly Procedure for Air Side Valve Parts on Pump Unit 49 5 8 Maintenance amp Disassembly Procedures for Air Operated Valve 50 5 9 Maintenance amp Disassembly Procedures for Air Valve 51 5 10 Priming the Pump 52 5 11 How to Do Priming 52 6 0 Troubleshooting Chart 53 7 0 Warranty 54 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE Before Using Thank you for choosing Enerpac products Make sure to carefully read and clearly understand these instructi
100. used for the air operated valve on the pump 2 After stopping the supply of air refer to the exploded view below to dismantle the air valve Clean the dismantled parts carefully to prevent damage 3 Clean the dismantled parts carefully to prevent damage And please confirm whether what is listed in CD and does not happen with the pump AN CAUTION The parts of the air valves is provided at assembly CT1028 190 When dismantling the valve please be careful not to give the packing the damage W Quo Exploded view Part list Output indicator red Input indicator green efs SS s raong sre 3 o Powtawe 1 Fig Air valve CT1028 190 E X For disassembly remove this screw ENERPAC e 51 POWERFUL SOLUTIONS GLOBAL FORCE 5 10 Priming the Pump When a level oil is lower than an suction port of the pump air is breathed in the pump from the suction port And when oil was replaced with new oil or a pump was repaired air is breathed in the pump sometimes similarly In such a case the pump continues operating but may not discharge the oil Then mainly the cause why the pump does not discharge the oil is caused by air entering the intake check valve assembly Even if the hydraulic plunger of the pump strokes the oil cannot be breathed Its cause is because the inside of the intake check valve assembli
101. whether there is any irregular sounds or vibrations etc of it Check for the overall hydraulic system 2 Check for leakage of the hydraulic oil from the piping or hydraulic equipment In the case of an oil leak stop the supplying air and completely stop the pump before repairing the place of the leak oee the pressure gauge to make sure that there is not any pressure in the hydraulic circuit 3 Confirm whether a valve and pump functions and make sure the temperature of hydraulic oil is not rapidly increasing to over 60 C 104 F If there is abnormity please stop a pump promptly and repair it 36 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE 3 7 Pump Models and Specifications BH Model Numbers ZAJLILILIELILI ULILI T r at the end of the model numbers means Twin pump Valve type M1 A block for connecting remote valves with the pump M3 M32 M4 Manual valve S1 2 C2 Solenoid valve A1 A2 Air operated valve Oil capacity 54 Oil capacity of Twin pump 12 2 Increase ratio 065 1 65 Increase ratio 123 1 123 Air drive double acting booster hydraulic pump MSpecifications Air Supply Increase Pressure Useable Reservoir Air Weight T Model No Pressure Ratio Rating Oil Oil Consumption T MPa Air ae Capacity T Capacity T N 2 min kg ZAJ 065 500 1000 Apx 27 50 0 1 0 7 4 7 L 5 12 2 ZAJ 123 m nm mw 5401080 Apx 27 50 E Models Equipped valves P R Port Solenoid
102. your system and will void your Enerpac warranty N CAUTION While the cylinder is connecting with the pump fill the hydraulic oil up to the maximum level of the oil level gauge after retracting the plunger While supplying the hydraulic oil be careful so that it is not contaminated with the dust 2 Keep all the equipment clean and check for defects in each part 3 Tighten a screw fixing a pump and a part also Especially securely tighten the hydraulic couplers and tighten the screws fixing the hydraulic valve also 5 3 Monthly Inspection 1 Replace the hydraulic oil after around 600 hours plus hours of load running and non load running of continuous use If the air hydraulic pump and hydraulic equipments is used in an dusty environment replace the hydraulic oil early 5 4 How to Replace the Hydraulic Fluid 1 Please refer to Air hydraulic pump drawing of P17 To drain the hydraulic oil remove No 7 drain plug 2 Remove bolts 15 bolts of No 4 of Air hydraulic pump drawing from the reservoir lift the No 3 cover subassembly and remove from the No 1 tank subassembly 3 Wash the inside of the reservoir with the treated oil and attach No 7 drain plug to the reservoir 4 Remove No 6 two suction filters from the No 3 cover subassembly and attach those after clean up the suction filters 5 After attach No 5 gasket to No 1 tank subassembly lay No 3 cover subassembly on the tank subassembly and fix the cover suba
103. z ENERPAC T POWERFUL SOLUTIONS GLOBAL FORCE T y EK gt H HE J A snas amar ma 4091 08 2014 ZAJ 065 ZAJ 123 INDEX PAGE 1 31 English Instruction Sheet 32 54 English Repair Parts Sheet 55 74 ENERPAC 2 POWERFUL SOLUTIONS GLOBAL FORCE ENERPAC POWERFUL SOLUTIONS GLOBAL FORCE T j EL L4091 08 2014 ZAJ 065 ZAJ 123 INDEX PAGE 1 0 2 2 0 2 3 3 0 3 8 3 1 3 4 32 4 33 5 34 5 3 5 5 3 6 5 37 6 3 8 7 3 9 ZAJ 8 3 10 ZAJ 8 4 0 9 18 4 1 ZAJ06505 M1 ZAJ12305 M1 P R 9 4 2 ZAJO6505 M3 ZAJ12305 M3 3 10 4 3 ZAJO6505 M32 ZAJ12305 M32 3 11 44 ZAJ06505 M4 ZAJ12305 M4 4 12 13 4 5 ZAJ06505 S1
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