Enerpac ZC-Series, ZC3908J, ZC3308J, ZC3408J Instruction Sheet
Instruction Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE.
L4242 Rev. B 10/18
ZC-Series Cordless Electric Pumps
EN
ZC3308J
ZC3408J ZC3908J
TABLE OF CONTENTS:
1.0 SAFETY .........................................................................................3
1.1 Introduction ......................................................................3
1.2 General Hydraulic Safety Precautions ...........................3
1.3 Battery Operated Pump Safety Precautions .................4
2.0 MAJOR FEATURES AND COMPONENTS ..................................5
3.0 PRODUCT DATA ........................................................................... 6
3.1 Specifications ..................................................................6
3.2 Pressure and Flow Graphs ..............................................6
3.3 External Dimensions .......................................................7
4.0 PRODUCT DESCRIPTION ...........................................................8
4.1 Introduction ......................................................................8
4.2 Additional Information - Battery and Charger ..............8
4.3 Conformance to National and International Standards ..8
4.4 Electromagnetic Compatibility (EMC) ..........................8
5.0 IMPORTANT RECEIVING INSTRUCTIONS ................................8
5.1 Hydraulic Reservoir Breather .........................................8
6.0 HYDRAULIC CONNECTIONS......................................................8
7.0 BATTERY ......................................................................................9
7.1 Battery Capacity Indicator ..............................................9
7.2 Battery Installation ..........................................................9
7.3 Battery Removal ............................................................10
7.4 Battery Management System .......................................10
7.5 Additional Battery and Charger Information ...............10
8.0 OPERATION ................................................................................ 10
8.1 Before Start-up ..............................................................10
8.2 Starting the Pump Motor ..............................................10
8.3 Stopping the Pump Motor .............................................10
8.4 Operating Precautions ..................................................10
8.5 Manual Valve Operation ................................................10
8.5.1 VM33 Operation ..........................................................10
8.5.2 VM43 Operation ..........................................................11
8.5.3 VM43LPS Operation
(post-tensioning applications only) ...........................11
8.6 Air Removal ....................................................................11
8.7 Disconnecting Hydraulic Hoses ...................................12
8.8 Transporting the Pump ..................................................12
9.0 MAINTENANCE ..........................................................................12
9.1 Check Oil Level ..............................................................12
9.2 Hydraulic Oil Information ..............................................12
9.3 Adding Oil .......................................................................12
9.4 Oil Change ......................................................................12
10.0 PRESSURE RELIEF VALVE ADJUSTMENT ............................13
10.1 VM33 and VM43 Only ...................................................13
10.2 VM43LPS Only ..............................................................13
11.0 TROUBLESHOOTING ..............................................................14
Troubleshooting Guide .....................................................................14
1.0 SAFETY
WARNING
NOTICE
1.1 Introduction
Read all instructions carefully. Follow all recommended safety
precautions to avoid personal injury as well as damage to the
pump and/or damage to other property. Enerpac cannot be
responsible for any damage or injury from unsafe use, lack of
maintenance or incorrect operation. Do not remove warning
labels, tags, or decals. In the event any questions or concerns
arise, contact Enerpac or a local Enerpac distributor for
clarification.
If you have never been trained on high-pressure hydraulic safety,
consult your distributor or service center for information about an
Enerpac hydraulic safety course.
This manual follows a system of safety alert symbols, signal
words and safety messages to warn the user of specific hazards.
Failure to comply with these warnings could result in death or
serious personal injury, as well as damage to the equipment or
other property.
The Safety Alert Symbol appears throughout this
manual. It is used to alert you to potential physical
injury hazards. Pay close attention to Safety Alert
Symbols and obey all safety messages that follow this symbol to
avoid the possibility of death or serious personal injury.
Safety Alert Symbols are used in conjunction with certain Signal
Words that call attention to safety messages or property damage
messages and designate a degree or level of hazard seriousness.
The Signal Words used in this manual are WARNING, CAUTION
and NOTICE.
Indicates a hazardous situation that, if not
avoided, could result in death or serious
personal injury.
CAUTION
1.2 General Hydraulic Safety Precautions
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Do not remove or disable the pressure relief valve.
• Never set the pressure relief valve to a higher pressure than
the maximum rated pressure of the pump.
• Stay clear of loads supported by hydraulics. To avoid personal
injury, keep hands and feet away from cylinder and work piece
during operation.
• Do not handle pressurized hoses. Escaping oil under pressure
can penetrate the skin. If oil is injected under the skin, see a
doctor immediately.
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
personal injury.
Indicates information considered important,
but not hazard related (e.g. messages relating
to property damage). Please note that the
Safety Alert Symbol will not be used with this
signal word.
WARNING
• A cylinder when used as a load lifting device, should never be
used as a load holding device. After the load has been raised
or lowered, it always must be blocked mechanically.
• Do not pressurize disconnected couplers.
• Only use hydraulic cylinders in a coupled system. Never use
a cylinder with uncoupled couplers. If the cylinder becomes
extremely overloaded, components can fail catastrophically.
• Use only rigid pieces to hold loads. Carefully select steel or
wood blocks that are capable of supporting the load. Never
use a hydraulic cylinder as a shim or spacer in any lifting or
pressing application.
• Avoid situations where loads are not directly centered on the
cylinder plunger. O-center loads produce considerable strain
on cylinders and plungers. In addition, the load may slip or fall.
• The system operating pressure must not exceed the pressure
rating of the lowest rated component in the system. Install
pressure gauge(s) in the system to monitor operating pressure.
It is your window to see what is happening in the system.
• Do not exceed equipment ratings. Never attempt to lift a load
weighing more than the capacity of the cylinder. Overloading
causes equipment failure and possible personal injury.
• Wear personal protective equipment (P.P.E.) when operating
hydraulic equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hard
hat, or hearing protection used for appropriate conditions will
reduce personal injuries.
• Be sure setup is stable before lifting load. Cylinders should
be placed on a flat surface that can support the load. Where
applicable, use a cylinder base for added stability. Do not
weld or otherwise modify the cylinder to attach a base or other
support.
• Immediately replace worn or damaged parts with genuine
ENERPAC parts. Standard grade parts will break causing
personal injury and property damage.
CAUTION
Failure to observe and comply with the following precautions
could result in minor or moderate personal injury. Property
damage could also occur.
• Do not use or repair damaged hydraulic hose. Avoid sharp
bends and kinks when routing hydraulic hoses. Using a bent
or kinked hose will cause severe back-pressure. Sharp bends
and kinks will internally damage the hose, leading to premature
hose failure.
• Do not drop heavy objects on hose. A sharp impact may cause
internal damage to hose wire strands. Applying pressure to a
damaged hose may cause it to rupture.
• Distribute the load evenly across the entire saddle surface.
Always use a saddle to protect the plunger.
• Do not lift hydraulic equipment by the hoses or swivel couplers.
Use the carrying handle or strap.
• Keep hydraulic equipment away from flames and heat.
Excessive heat will soften packings and seals, resulting in
fluid leaks. Heat also weakens hose materials and packings.
For optimum performance, do not expose equipment to
temperatures of 150˚F [65˚C] or higher. Protect all hydraulic
equipment from weld spatter.
3
• Immediately replace worn or damaged parts with genuine
NOTICE
Enerpac parts. Enerpac parts are designed to fit properly and
to withstand high loads. Non-Enerpac parts may break or
cause the pump to malfunction.
Hydraulic equipment must only be serviced by a
qualified hydraulic technician. For repair service, contact the
Enerpac Authorized Service Center in your area.
1.3 Battery Operated Pump Safety Precautions
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Do not use the pump if the remote pendant rocker switch
cannot turn the pump on or o. Have the remote pendant
repaired before using the pump.
• Do not operate the pump near combustible materials, such as
flammable liquids, gases, or dust.
• Remove the battery from the pump before making any
adjustments, performing maintenance or storing the pump.
• Do not attempt to disable or modify the safety key interlock
feature.
• Remove safety key when pump is unattended to prevent
unauthorized persons from operating pump.
• Do not probe the battery or battery charger with conductive
materials.
• Do not allow metal items or material such as steel wool,
aluminium foil or other foreign objects into the battery or
battery charger cavity or charger terminals.
• Do not use the pump if the motor assembly is loose or
damaged. Have the motor assembly inspected and repaired
by an Enerpac Authorized Service Center before using the
pump.
• Do not attempt to charge non-specified batteries in the
charger.
• Do not expose the battery or battery charger to wet conditions
or excessive humidity.
• Do not immerse the battery or battery charger.
• Use the Enerpac ZC-Series pump only with the specified
Briggs & Stratton 82V LI-ION batteries. Refer to Section 3.1 for
approved battery model numbers.
• Recharge battery only with the charger specified by Briggs &
Stratton for the battery being used.
• Do not deliberately short circuit battery or battery charger.
• If battery liquid leaks and contact occurs, flush with water and
seek medical help.
• Do not attempt to disassemble, repair or modify the battery or
battery charger.
• Unplug battery charger when cleaning or not in use.
• Do not burn, crush or damage battery.
• Do not cover ventilation slots in the top of the charger or sides
of the battery.
• Do not place battery charger on a soft surface, such as a
blanket or pillow.
• Do not allow battery or battery charger to become too warm.
Allow these items to cool before attempting to charge the
battery.
• Store battery and battery charger in a cool, dry place. Keep
these items in a secured area, away from children and pets.
• Battery and battery charger may under no circumstances be
opened. If the cover is damaged, then these items should no
longer be used and must be replaced.
• Pump motor assembly (“powerhead”) is not serviceable and
should not be opened. Electric shock may result.
4
2.0 MAJOR FEATURES AND COMPONENTS
2
ZC-3308J
9
1
10
7
12
11
ZC-3408J
9
15
14
13
11
8
12
ZC-3908J
9
6
3
5
4
16
17
19
18
13
11
14
Key:
1. Remote Pendant
2. Carrying Handle/Roll Bar
3. Hydraulic Reservoir Sight Glass
4. Hydraulic Reservoir Drain Plug
5. Oil Fill Plug
6. Hydraulic Reservoir
7. Pump Motor
8. Directional Control Valve
9. Valve Handle
10. Advance/Retract Port
11. User-adjustable Relief Valve
12. Gauge Port
13. Advance Port
14. Retract Port
15. Auxiliary Tank Return Port
16. Battery Door
17. Battery Release Button
18. Battery
19. Safety Key
Figure 1, Major Features and Components, ZC-Series
5
3.0 PRODUCT DATA
3.1 Specifications
Pump
Model
Number
ZC3308J
ZC3408J
ZC3908J
Pump Model
Number
ZC3308J
ZC3408J
ZC3908J
Control Valve
Model Number and Function
Enerpac VM33
(Advance / Neutral / Retract)
Enerpac VM43
(Advance / Neutral / Retract)
Enerpac VM43LPS
(Advance / Neut. Hold / Retract)
Maximum Hydraulic
Pressure
psi bar
10,000
[+300 / -50]
10,000
[+300 / -50]
10,000
[+300 / -50]
700
[+20.7 / -3.4]
700
[+20.7 / -3.4]
700
[+20.7 / -3.4]
Operating Temp
˚ F ˚ C hp kW dBA
+40 to
+120
+40 to
+120
+40 to
+120
For Use With:
Single-acting
Cylinder
Double-acting
Cylinder
Power Seater
Post-Tensioning
Tools
Hydraulic
Connections
3/8" NPTF
3/8" NPTF
3/8" NPTF
Flow Rate (Refer to Section 3.2)
At
No Load
in³/
min
l/min
At 4,000 psi
[276 bar]
in³/
l/min
min
At 10,000 psi
[700 bar]
in³/
l/min gal l lb kg
min
310 5.0 80 1.3 32 0.52
Range
+4 to
+49
+4 to
+49
+4 to
+49
Reservoir
Size*
Motor Rating
1.4 1.0 75
1.4 1.0 75
1.4 1.0 75
Pump
Weight**
1.75 6.6 65.5 29.7 Enerpac HF
Sound
Pressure
Hydraulic Oil
Type
310 5.0 80 1.3 32 0.52 1.75 6.6 65.5 29.7 Enerpac HF
310 5.0 80 1.3 32 0.52 1.75 6.6 73.4 33.3 Enerpac HF
* Approximate usable capacity of oil reservoir.
** Approximate weight of pump with oil in reservoir and with battery installed.
Weight of battery is approximately 2.4 lb [1.1 kg].
Pump Series Item
Enerpac Briggs & Stratton
Battery Charger, 115V AC, 50/60 Hz Input NA ZC115VC 1760263
ZC-Series
Battery Charger, 230V AC, 50/60 Hz Input EU/AU ZC230VC 1760264
Battery, Lithium Ion, 82V, 4Ah, NA ZC82V4NA 1760265
Battery, Lithium Ion, 82V, 4Ah, EU/AU ZC82V4EUAU 1760515
Batteries and chargers can be purchased from an Enerpac distributor or Briggs & Stratton retailer.
*
3.2 Pressure and Flow Graphs
/min)
3
FLOW/RATE (in
400
350
300
250
200
150
100
FLOW VS. PRESSURE
50
6
5
4
3
FLOW/RATE (il/min)
2
1
FLOW VS. PRESSURE
Model Numbers
FLOW VS. PRESSUREFLOW VS. PRESSURE
*
0
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
PRESSURE (PSI) PRESSURE (BAR)
NOTE: All product data is subject to change without notice. Graphs in Section 3.2 show typical pump pressure/flow curves.
0
100 200 300 400 500 600 700 800
6
3.3 External Dimensions
B
A
F
E
H
G
D
C
I J K
ZC3308J ZC3408J ZC3908J
Item
A 25.48 647 G 16.28 414
B 14.00 356 H 10.92 277
C 9.69 246 I 11.74 298
D 8.09 205 J 11.74 298
E 4.22 107 K 10.43 265
F 5.66 144
Dimension
in mm in mm
Item
7
Dimension
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