AGPU-ENG-LNE-CYN-LT-PP-001

LÍNEA DE TRANSMISION AGUAYTÍA – Rev. 00 Date 12/23/2019

PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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SCREW PILE LOAD TEST OUTLINE

Pile Type 1:

180mm ODx9mm wt, 7.6m long with single 500mm dia x

12mm thk helix
per IEC61773-1996
Overhead Lines - Testing of Foundations for Structures

Revision 0

Client: Terna Plus S.r.L.

Project:
OP0000064
Terna 138kV Transmission Line
Aguaytia – Pucallpa, Peru

December 23rd, 2019

 AGPU-ENG-LNE-CYN-LT-PP-001
LÍNEA DE TRANSMISION AGUAYTÍA – Rev. 00 Date 12/23/2019
PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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TABLE OF CONTENTS

1.0 METHOD FOR TESTING HELICAL PILES UNDER STATIC AXIAL

COMPRESSIVE LOAD per IEC61773-1996

1.1 Introduction (pg.3)

1.2 Objective (pg.4)
1.3 Work Scope (pg.4)
1.4 Test Setup (pg.4)
1.5 Test Procedure (pg.5)
1.6 Recording Test Readings (pg.6)
1.7 Test Report (pg.7)

2.0 METHOD FOR TESTING HELICAL PILES UNDER STATIC AXIAL TENSILE
LOAD per IEC61773-1996

2.1 Introduction (pg.8)

2.2 Objective (pg.9)
2.3 Work Scope (pg.9)
2.4 Test Setup (pg.9)
2.5 Test Procedure (pg.10)
2.6 Recording Test Readings (pg.11)
2.7 Test Report (pg.12)

3.0 TESTING EQUIPMENT MECHANICAL SPECIFICATIONS

3.1 Introduction (pg.13)

3.2 Equipment (pg.13)

APPENDIX A Compressive Load Test Data Sheet (pg.14)

APPENDIX B Tensile Load Test Data Sheet (pg.15)
APPENDIX C Load Test Apparatus Set Up (pg.16)
APPENDIX D IEC61773-1996 Standard Test Methods (pg.17)
APPENDIX E Certification & Equipment (pg.18)
 AGPU-ENG-LNE-CYN-LT-PP-001
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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1.0 METHOD FOR TESTING HELICAL PILES UNDER STATIC AXIAL

COMPRESSIVE LOAD per IEC61773-1996

1.1 Introduction

1.1.1 Pile load tests will be executed on site. Pile load testing areas
will be defined based upon suitable access location along the
line. The purpose of load testing is to test ‘production’ piles, or
piles closely resembling actual situations encountered during
construction.

1.1.2 Helical Pile foundations have been designed for the proposed
138kV transmission line located between city of Aguaytia to
the city of Pucallpa in Peru. The proposed line will consist of a
series of transmission towers (T228 – T297) connecting the
Aguaytia-Pucallpa substations.

1.1.3 Test procedures chosen follow all local safety standards and
norms.

1.1.4 The test will be overseen by a Peruvian licensed professional

engineer who will review and sign off on the final report.

1.1.5 Pile will be load tested to a maximum load of 190kN. The

piles will be installed to the required torque as per the design.
The test procedure will follow IEC61773-1996 Section 8.3
Loading Procedure. Each test pile will be loaded to 190kN, or
50mm settlement (failure), whichever occurs first. For
additional information of maximum load, please refer to
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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Section 3 Helical Pile Axial Calculations of the Helical Pile

Design Report for Tower Type S.

1.1.6 The scope of the compression test on foundation, is to

determine the compressive limit capacity of the
pile/foundation and/or to control its suitability for the ultimate
load and validation of design methodology.

1.2 Objective

1.2.1 To acquire the load-settlement compression data for two

‘production’ piles.

1.2.2 To verify the pile design at vertical axial loads.

1.2.3 To verify the acceptable pile shaft behavior.

1.2.4 To verify torque vs. capacity relationships.

1.3 Work Scope

1.3.1 The compression tests will be carried out on the proposed pile
to verify the pile behavior and performance at vertical axial
loads up to 190kN or 50mm settlement (failure), whichever
occurs first.

1.3.2 Upon completion of the load tests a report will be prepared

analyzing the test results with a conclusion and
recommendations for actual installation. If the pile behavior
does not confirm the design parameters, recommendations
with any modifications will be also addressed in the final
report.

1.3.3 After testing, reaction piles would be used for its original
purpose in production. Test piles will be discarded.

1.4 Test Setup

1.4.1 If necessary, excavate or fill the test area to the final grade
elevation within a radius of 6 m from the test pile or group
using the same material and backfilling methods for
production piles.

1.4.2 The test pile and the reaction piles will be installed at
minimum spacing of 2.0 m or 3 times the helix diameter,
whichever is greater as per IEC61773-1996. The test pile and
reaction piles will be installed to the required elevations or cut
off at the required elevation.
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1.4.3 Pile caps will be installed on top of the reaction piles either by
utilizing the drive pin holes in the pile to bolt the pile cap to the
pile, or by burning new holes into the pile if the pile has been
cut off to the required elevation. A pile cap will also be
installed on top of the compression test pile.

1.4.4 A Hydraulic jack will be placed on top of the test pile.

1.4.5 A test beam will be placed on the reaction pile caps. Dywidag
bars will be used to transfer the uplift forces from the test
beam to reaction pile caps.

1.4.6 Two reference bars will be placed one on each side of the
tested pile. The bars will be used to support dial gauges,
which will record displacement as the pile is loaded. Two dial
gauges will be used to measure the test pile movement during
the load test. The hydraulic jack and pump will be used to
measure the load using pressure gauges. Hydraulic pressure
shown on the pump will be transferred to loads based on the
manufacturers published information. A chart will be
generated showing this relationship. Refer to the appropriate
sections of this submittal for reference drawings.

1.4.7 If necessary, provide a tarp or shelter to prevent direct

sunlight or precipitation from affecting the measuring and
reference systems.

1.4.8 The piles to be tested are executed to the dimensions and

with characteristics of the materials exactly as shown on the
construction drawing # AGPU-ENG-LNE-CYN-LT-PP-018; in
order to facilitate the applying of the compression and uplift
test load the foundations will be installed vertically.

1.5 Test Procedure

1.5.1 Apply the test load in loading steps in % of target maximum

load according to test condition of 25, 50, 70, 80, 90, 100, 0
percent of the maximum load of 190kN or 50mm settlement
(failure). Add each load increment in a continuous fashion and
immediately following the completion of movement readings
for the previous load interval. Maintain loading steps for
minimum 10 minutes. The design load should be maintained
for minimum 30minutes. See IEC61773-1996 Section 8.3
Table 1 for additional information.

1.5.2 Add load increments until reaching 190kN or 50mm deflection

(failure), whichever occurs first, keeping the load constant for
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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a time interval of 10 minutes for each load increment except

for the load increments of 95 kN and 190 kN at which the load
should be kept constant for a time interval of 30 minutes.
Time intervals and load increments are shown in the Pile
Load Test Tables provided in Appendix A.

1.5.3 Remove the load once maximum design load has been
achieved and maintained for 30min. Record final result at 0
load.

1.5.4 The foundation will be considered to have passed the test if

the total movement doesn’t exceed 50mm during this first
stage.

1.5.5 The residual movement, once all load has been removed,
must be recorded at the end of the test.

1.6 Recording Test Readings

1.6.1 Test readings will be recorded at 5 and 10 minutes after

completing load increments.

1.6.2 Test reading will be recorded at 5 and 10 minutes after all

load has been removed.

1.6.3 Immediately after the application of each load increment;

1.6.4 At the end of the pause, immediately before the application of

new load.

1.6.5 All displacements readings will be recorded in special form,

containing the following additional information:
• Tower type;
• Type of test (compression or tension);
• Type of foundation (single or double helix);
• Type of ground (soil 1 , 2 or 3);
• Test location (peg number);
• Meteorological and seasonal conditions during the test,
average daily temperature;
• Date of the test;
• Start and finish time of the test;
• Recording of the pressure exerted by the jack in atm (or
equivalent) and corresponding loads in KN, (or equivalent) as
well as the times of application and pauses;
• Initial and final gauge readings;
• Eventual remarks.
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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1.7 Test Report

A final report will be drawn up which gives the results of

the test carried out, consisting of:
• Foundation Test Data Sheet;
• Test Results;
• A dimensioned sketch of the foundation;
• Data recording form.
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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2.0 METHOD FOR TESTING HELICAL PILES UNDER STATIC AXIAL TENSILE
LOAD per IEC61773-1996

2.1 Introduction

2.1.1 Pile load tests will be executed on site. These load tests are
to test ‘production’ piles, or piles closely resembling actual
situations encountered during construction.
2.1.2 Helical Pile foundations have been designed for the proposed
138kV transmission line located between city of Aguaytia to
the city of Pucallpa in Peru. The proposed line will consist of a
series of transmission towers (T228 – T297) connecting the
Aguaytia-Pucallpa substations.

2.1.3 The test procedure follows all local safety standards and
norms.

2.1.4 The test will be overseen by Peruvian licensed professional

engineer who will review and sign off on the final report.

2.1.5 Piles will be load tested to a maximum load of 190kN. The

piles will be installed to the required torque as per the design.
The test procedure will follow IEC61773-1996 Section 8.3
Loading Procedure. Each test pile will be loaded to 190kN or
50mm settlement (failure), whichever occurs first.

2.1.6 The scope of the uplift test on foundation, is to determine the

uplift limit capacity of the pile/foundation and/or to control its
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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suitability for the ultimate load and validation of design

methodology.

2.2 Objective

2.2.1 To acquire the load-settlement tensile data for two

‘production’ piles.

2.2.2 To verify the pile design at vertical axial loads.

2.2.3 To verify the acceptable pile shaft behavior.

2.2.4 To verify torque vs. capacity relationships.

2.3 Work Scope

2.3.1 The tension tests will be carried out on the proposed pile to
verify the pile behavior and performance at vertical axial loads
up to 190kN or 50mm settlement (failure), whichever occurs
first.

2.3.2 Upon completion of the load tests a report will be prepared

analyzing the test results with a conclusion and
recommendations for actual installation. If the pile behavior
does not confirm the design parameters, recommendations
with any modifications will be also addressed in the final
report.

2.3.3 After testing, any production pile used as either a test pile or
reaction pile, would be used for its original purpose.

2.4 Test Setup

2.4.1 If necessary, excavate or fill the test area to the final grade
elevation within a radius of 6 m from the test pile or group
using the same material and backfilling methods for
production piles.

2.4.2 The test pile and the reaction piles will be installed at
minimum spacing of 2.0 m or 3 times the helix diameter,
whichever is greater as per IEC61773-1996. The test pile and
reaction piles will be installed to the required elevations or cut
off at the required elevation.

2.4.3 Pile caps will be installed on top of the reaction piles either by
utilizing the drive pin holes in the pile to bolt the pile cap to the
pile, or by burning new holes into the pile if the pile has been
 AGPU-ENG-LNE-CYN-LT-PP-001
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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cut off to the required elevation. A pile cap will also be

installed on top of the compression test pile.

2.4.4 A Hydraulic jack will be placed on top of the test pile.

2.4.5 A test beam will be placed on the reaction pile caps. Dywidag
bars will be used to transfer the uplift forces from the test
beam to reaction pile caps.

2.4.6 Two reference bars will be placed one on each side of the
tested pile. The bars will be used to support dial gauges,
which will record displacement as the pile is loaded. Two dial
gauges will be used to measure the test pile movement during
the load test. The hydraulic jack and pump will be used to
measure the load using pressure gauges. Hydraulic pressure
shown on the pump will be transferred to loads based on the
manufacturers published information. A chart will be
generated showing this relationship. Refer to the appropriate
sections of this submittal for reference drawings.

2.4.7 If necessary, provide a tarp or shelter to prevent direct

sunlight or precipitation from affecting the measuring and
reference systems.

2.4.8 The piles to be tested are executed to the dimensions and

with characteristics of the materials exactly as shown on the
construction drawing # AGPU-ENG-LNE-CYN-LT-PP-018; in
order to facilitate the applying of the compression and uplift
test load the foundations will be installed vertically.

2.5 Test Procedure

2.5.1 Apply the test load in loading steps in % of target maximum

load according to test condition of 25, 50, 70, 80, 90, 100, 0
percent of the maximum load of 190kN or 50mm settlement
(failure). Add each load increment in a continuous fashion and
immediately following the completion of movement readings
for the previous load interval. Maintain loading steps for
minimum 10 minutes. The design load should be maintained
for minimum 30minutes. See IEC61773-1996 Section 8.3
Table 1 for additional information.

2.5.2 Add load increments until reaching 190kN or 50mm deflection

(failure), whichever occurs first, keeping the load constant for
a time interval of 10 minutes for each load increment except
for the load increments of 95 kN and 190 kN at which the load
should be kept constant for a time interval of 30 minutes.
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Time intervals and load increments are shown in the Pile

Load Test Tables provided in Appendix B.

2.5.3 Remove the load once maximum design load has been
achieved and maintained for 30min. Record final result at 0
load.

2.5.4 The foundation will be considered to have passed the test if

the total movement doesn’t exceed 50mm during this first
stage.

2.5.5 The residual movement, once all load has been removed,
must be recorded at the end of the test.

2.6 Recording Test Readings

2.6.1 Test readings will be recorded at 5 and 10 minutes after

completing load increments.

2.6.2 Test reading will be recorded at 5 and 10 minutes after all

load has been removed.

2.6.3 Immediately after the application of each load increment;

2.6.4 At the end of the pause, immediately before the application of

new load.

2.6.5 All displacements readings will be recorded in special form,

containing the following additional information:
• Tower type;
• Type of test (compression or tension);
• Type of foundation (single or double helix);
• Type of ground (soil 1, 2 or 3);
• Test location (peg number);
• Meteorological and seasonal conditions during the test,
average daily temperature;
• Date of the test;
• Start and finish time of the test;
• Recording of the pressure exerted by the jack in atm (or
equivalent) and corresponding loads in KN, (or equivalent) as
well as the times of application and pauses;
• Initial and final gauge readings;
• Eventual remarks.
 AGPU-ENG-LNE-CYN-LT-PP-001
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PUCALLPA 138 kV (SEGUNDO CIRCUITO)
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2.7 Test Report

A final report will be drawn up which gives the results of

the test carried out, consisting of:
• Foundation Test Data Sheet;
• Test Results;
• A dimensioned sketch of the foundation;
• Data recording form.
 AGPU-ENG-LNE-CYN-LT-PP-001
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3.0 TESTING EQUIPMENT MECHANICAL SPECIFICATIONS

3.1 Introduction

3.1.1 Pile load test requirements are not to exceed the testing
equipment capacity.

3.1.2 All equipment should be handled and used in the manner it

was designed for as per the product instruction sheet.

3.2 Equipment

3.2.1 The equipment required for the pile testing procedure can be
found in Appendix F.

3.2.2 All instruction manuals for the specified mechanical

equipment can be found in Appendix F.

3.2.3 No pressure should exceed that of 10,000 psi (700 bar), as

these values are stated in the equipment instructions
manuals.

3.2.4 Test beam calculations can be found in Appendix C.

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APPENDIX A Compressive Load Test Data Sheet

Compression Test, minimum 14.2 kN-m or 10,400 ft-lbs installation torque.
Pile Type 1

Date Tested: Hollow Aluminum Cylinder Specs (ENE-RACH306)

3
Hydraulic Jack Used: 100T Simplex Hollow Jack 6in Stroke Cylinder Capacity 996kN Oil Capacity 2028.1 cm

Hydraulic Pump Used: Electric Pump or 2-speed hand pump Stroke 150 mm Center Hole Diameter 80mm

2
Description of Testing: One compression test pile connected to two similar reaction piles Cylinder Effective Area 133.1 cm Weight 80 kg

Tower type:
Type of Test Tension
Date Installed:
Type of Foundation - Pile Type 1 Description: 180mm OD x 9mm wt, 10m long with single 500mm dia x 12mm thk helixes
Type of Ground (Soil Type 1, 2 or 3):
Test Location (peg number):
Meteorological and seasonal conditions during the test, average daily temperature:
Date of the test:
Start and finish time of the test:
Installation Depth:
Specified Mininum Installation Torque: 14.2kN-m
Actual Installation Torque:
Maximum Test Load: 190kN
Compression Increments/Decrements *** All Measured Dimensions in mm***
Actual Calculated Load Time (Minutes)
Measured Pressure Increment 0.5 5 10 30
Pressure (kPa) Increment (kPa) (N) Gauge 1 Gauge 2 Gauge 1 Gauge 2 Gauge 1 Gauge 2 Gauge 1 Gauge 2
0 0 x x x x x x x x
AL* x x x x x x
3571 47500 x x
7143 95000
10000 133000 x x
11429 152000 x x
12857 171000 x x
14286 190000
0 0
*Note: AL - alignment load.
Tested:
Name
Position
Company
Signature

Witnessed By:
Name
Position
Company
Signature
 AGPU-ENG-LNE-CYN-LT-PP-001
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APPENDIX B Tensile Load Test Data Sheet

Tension Test, minimum 17.8 kN-m or 13,140 ft-lbs installation torque.
Pile Type 1

Date Tested\ Hollow Aluminum Cylinder Specs (ENE-RACH306)

3
Hydraulic Jack Used\ 100T Simplex Hollow Jack 6in Stroke Cylinder Capacity 996kN Oil Capacity 2028.1 cm

Hydraulic Pump Used\ Electric Pump or 2-speed hand pump Stroke 150 mm Center Hole Diameter 80mm

2
Description of Testing\ One tension test pile connected to two similar reaction piles Cylinder Effective Area 133.1 cm Weight 80 kg

Tower type:
Type of Test Tension
Date Installed:
Type of Foundation - Pile Type 1 Description: 180mm OD x 9mm wt, 10m long with single 500mm dia x 12mm thk helixes
Type of Ground (Soil Type 1, 2 or 3):
Test Location (peg number):
Meteorological and seasonal conditions during the test, average daily temperature:
Date of the test:
Start and finish time of the test:
Installation Depth:
Specified Mininum Installation Torque: 17.8kN-m
Actual Installation Torque:
Maximum Test Load: 190kN
Tension Increments/Decrements *** All Measured Dimensions in mm***
Actual Calculated Load Time (Minutes)
Measured Pressure Increment 0.5 5 10 30
Pressure (kPa) Increment (kPa) (N) Gauge 1 Gauge 2 Gauge 1 Gauge 2 Gauge 1 Gauge 2 Gauge 1 Gauge 2
0 0 x x x x x x x x
AL* x x x x x x
3571 47500 x x
7143 95000
10000 133000 x x
11429 152000 x x
12857 171000 x x
14286 190000
0 0
*Note: AL - alignment load.
Eventual remarks:

Tested:
Name
Position
Company
Signature

Witnessed By:
Name
Position
Company
Signature
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APPENDIX C Load Test Apparatus Set Up

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APPENDIX D IEC61773-1996 Standard Test Method

 AGPU-ENG-LNE-CYN-LT-PP-001
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APPENDIX E Certification & Equipment

 Instruction Sheet

ULTIMA Series Hand Pumps

POWERFUL SOLUTIONS. GLOBAL FORCE.
P-18, P-39, P-77, P-80, P-801 and P-84
L3070 Rev. E 05/12
Index:
English ............................................................... 1-9
Français ......................................................... 10-18
Deutsch ........................................................ 19-27
Italiano .......................................................... 28-36
Español......................................................... 37-45
Nederlands ................................................... 46-54
Portuguese ................................................... 55-63
........................................................... 64-71
.......................................................... 72-79
Finnish ........................................................... 80-88
Norwegian ..................................................... 89-97
Svenska ....................................................... 98-106
Russian ...................................................... 107-115
Greek ......................................................... 116-125
Repair Parts Sheets for this product are available WARNING: Wear proper personal
from the Enerpac web site at www.enerpac.com, or protective gear when operating hydraulic
from your nearest Enerpac Authorized Service Center equipment.
or Enerpac Sales office.
WARNING: Stay clear of loads supported
1.0 IMPORTANT RECEIVING by hydraulics. A cylinder, when used as a
INSTRUCTIONS load lifting device, should never be used
as a load holding device. After the load
Visually inspect all components for shipping damage.
has been raised or lowered, it must always be
Shipping damage is not covered by warranty. If
blocked mechanically.
shipping damage is found, notify carrier at once. The
carrier is responsible for all repair and replacement WARNING: USE ONLY RIGID PIECES
costs resulting from damage in shipment. TO HOLD LOADS. Carefully select steel
SAFETY FIRST or wood blocks that are capable of
supporting the load. Never use a hydraulic cylinder
2.0 SAFETY ISSUES as a shim or spacer in any lifting or pressing
application.
Read all instructions,
warnings and cautions DANGER: To avoid personal injury
carefully. Follow all safety keep hands and feet away from cylinder
precautions to avoid personal injury or property and workpiece during operation.
damage during system operation. Enerpac cannot be
responsible for damage or injury resulting from unsafe WARNING: Do not exceed equipment
product use, lack of maintenance or incorrect product ratings. Never attempt to lift a load
and/or system operation. Contact Enerpac when in weighing more than the capacity of the
doubt as to the safety precautions and operations. If cylinder. Overloading causes equipment
you have never been trained on high-pressure failure and possible personal injury. The cylinders are
hydraulic safety, consult your distribution or service designed for a max. pressure of 700 bar [10,000 psi].
center for a free Enerpac Hydraulic safety course. Do not connect a jack or cylinder to a pump with a
higher pressure rating.
Failure to comply with the following cautions and
warnings could cause equipment damage and WARNING: Never set the relief valve
personal injury. pressure above 10,500 psi [725 bar].
Serious personal injury could result if this
A CAUTION is used to indicate correct operating or
maximum limit is exceeded. Damage to pump and
maintenance procedures and practices to prevent
components may also occur.
damage to, or destruction of equipment or other
property. WARNING: The system operating
pressure must not exceed the pressure
A WARNING indicates a potential danger that
rating of the lowest rated component in
requires correct procedures or practices to avoid
the system. Install pressure gauges in the
personal injury.
system to monitor operating pressure. It is your
A DANGER is only used when your action or lack of window to what is happening in the system.
action may cause serious injury or even death.
 CAUTION: Avoid damaging 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.
IMPORTANT: Do not lift hydraulic
equipment by the hoses or swivel
couplers. Use the pump lifting/transport
handle or other means of safe transport.
CAUTION: 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 hoses and cylinders from
weld spatter.
DANGER: Do not handle pressurized
hoses. Escaping oil under pressure can
penetrate the skin, causing serious injury.
If oil is injected under the skin, see a doctor
immediately.
WARNING: Only use hydraulic cylinders in
a coupled system. Never use a cylinder
with unconnected couplers. If the cylinder
becomes extremely overloaded,
components can fail catastrophically causing severe
personal injury.
WARNING: 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.
Avoid situations where loads are not
directly centered on the cylinder plunger.
Off-center loads produce considerable
strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
dangerous results.
Distribute the load evenly across the
entire saddle surface. Always use a saddle
to protect the plunger.
IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
technician. For repair service, contact the
Authorized ENERPAC Service Center in
your area. To protect your warranty, use only
ENERPAC oil.
WARNING: Immediately replace worn or
damaged parts with genuine ENERPAC
parts. Standard grade parts will break
causing personal injury and property
damage. ENERPAC parts are designed to fit properly
and withstand high loads.
CAUTION: Always use the pump lifting/
transport handle to carry the pump.
Carrying the pump by the hose may
damage the hose and/or the pump.

3.0 PRODUCT INFORMATION

Table 1, Specifications - ULTIMA Series Hand Pumps
Pump Pump Max. Pressure Rating Oil Volume Per Stroke Usable Oil Weight Max. Handle
Model Type psi [bar] in3 [cm3] Capacity With Oil Effort
(Speed) in3 [cm3] lbs [kg] lbs [kg]
Stage 1 Stage 2 Stage 1 Stage 2
P-18 1 — 2850 [200] — 0.15 [2,46] 22 [360] 11.0 [5,2] 34 [16]
P-39 1 — 10,000 [700] — 0.15 [2,46] 47 [769] 13.6 [6,2] 85 [38]
P-77 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 47 [769] 15.6 [7,1] 88 [40]
P-80 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 134 [2195] 23.6 [10,7] 77 [35]
P-801 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 250 [4095] 31.0 [14,0] 77 [35]
P-84 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 134 [2195] 26.0 [11,7] 77 [35]

Table 2, Features and Major Components - ULTIMA Series Hand Pumps

Item Pump Model
(See figures 1 thru 4
for item locations) P-18 P-39 P-77 P-80 P-801 P-84

4-Way, 3-Position
A Release Valve Release Valve Release Valve Release Valve Release Valve
Control Valve
One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF Two 3/8" NPTF
B Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Ports

C Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug

Mounting Mounting Mounting Mounting Mounting Mounting

D
Slots Slots Slots Slots Slots Slots
User-Adjustable User-Adjustable User-Adjustable User-Adjustable User-Adjustable User-Adjustable
E
Relief Valve Relief Valve Relief Valve Relief Valve Relief Valve Relief Valve
3/8" NPTF Return 3/8" NPTF Return
F — — — —
to Tank Port to Tank Port

G — — Bypass Valve Bypass Valve Bypass Valve Bypass Valve

2
3.1 Pump Features and Major Components
See figures 1 through 4 for the locations of pump
features and major components. Refer to Table 2 for
descriptions of items A through G.

E
A
A

B B

G
E

C C

D D D D

Figure 1, Models P-18 and P-39 Figure 3, Models, P-80 and P-801

E E
A
B
B

G A G

C
C

D D D D

Figure 2, Model P-77 Figure 4, Model P-84

3
 8 10 7

P-18, P-39, P-77, P-80, P-801

3 9 5 6 1

8 10 5 6 7

P-84

4 9 5 6 11 2

Key:
1. Cylinder (single-acting) 7. Female Coupler
2. Cylinder (double-acting) 8. Pressure Gauge
3. Hand Pump w/Release Valve 9. Gauge Adapter
4. Hand Pump w/4-Way Valve 10. Swivel Connector
5. Hose 11. Safety Holding Valve
6. Male Coupler
Figure 5, Hydraulic Connections (typical)

4.0 INSTALLATION • For double-acting cylinders, connect two hoses.

Connect one hose from port (A) of the pump to
4.1 Connecting the Pump the advance port of the cylinder. Connect another
1. Remove shipping plug(s) hose from port (B) of the pump to the retract port
from pump outlet port(s). of the cylinder.
2. Adjust the relief Models P-80 and P-801 only: If an external
valve to the desired pressure reducing valve is being used in the
hydraulic pressure limit. circuit, connect the tank port of the valve to the
See Section 7.0 for return-to-tank port on the pump.
instructions. Note: Cylinders, hoses and accessories shown
3. Connect hose(s) to in Figure 5 are sold separately and not included
pump. To seal threads, with pump. Refer to the Enerpac catalog for a
Figure 6
use anaerobic thread sealer, complete description of available components and
Teflon® paste or Teflon® accessories. The exact components required for
tape. your system will vary, depending on application and
other factors.
IMPORTANT: When using Teflon® tape, apply the
tape one thread back from the end of the fitting to
prevent pieces of tape from entering the hydraulic 4.2 Pump Venting
system. See Figure 6. The ULTIMA series hand pumps are designed
4. Install a pressure gauge in-line from the pump for for non-vented operation. The oil fill plug can be
added safety and better control. loosened if needed to vent air from the system but
should be fully installed before using the pump.
5. Connect the hose(s) to your cylinder or tool.
• For single-acting cylinders, connect one hose IMPORTANT: To prevent contaminants from entering
from the pump to the cylinder. the hydraulic system, do not operate pump with oil fill
plug loosened or removed.

4
4.3 Pump Position
The pump may be operated in either the horizontal or
vertical position. See Figure 7.
When operated in the vertical position, hose end of
pump must be pointed down, or the pump will pick
up air and will not properly build pressure.
Note: The pump is not designed for use in the
inverted (upside-down) position.
OK
5.2 Two Stage Flow
Models P-77, P-80, P-801 and P-84
Two-speed pumps provide two stage flow. Under
no-load, the pump operates in the high flow first
stage for rapid advance. When the load is contacted,
the pump automatically shifts to the second stage
for building pressure. After the pump shifts, pumping
takes less effort.
Note: For best performance, operate pump handle
at moderate speed during the high flow first stage.
Rapid handle speed in the first stage will prevent the
pump from delivering full volume of oil.

5.3 Pump Operation

OK

Models P-18, P-39, P-77, P-80 and P-801

All pump models except the P-84 are designed for
use with single-acting cylinders and are equipped
with an integral release valve.
1. Close the release valve by turning knob clockwise
Figure 7, Pump Orientation until it stops. See Figure 8.
CAUTION: Close release valve finger tight
5.0 OPERATION ONLY. Using tools on release valve can
damage it and cause the pump to
5.1 Before Using the Pump malfunction.
1. Check all system fittings and connections to be
2. Operate pump handle to deliver hydraulic power
sure they are tight and leak free.
to system. Pressure will be maintained until
2. Check oil level in reservoir and add oil if required. release valve is opened.
Refer to instructions in Section 9.1.
3. Open the release valve by turning knob counter-
3. Read and understand the following precautions clockwise. Pressure will be released, allowing oil
before operating pump: to flow back to the reservoir.
WARNING: In certain situations the pump
handle can “kick back”. Always keep your
body to the side of the pump, away from
the line of force of the handle.
WARNING: When operating the pump
handle, keep hands and fingers away from
pinch point area between pump handle OPEN CLOSE
and lifting/transport handle.
CAUTION: Always remove shipping
plug(s) from pump outlet port(s) and
replace with proper hydraulic fitting(s)
before operating pump handle. If pump handle is
operated with shipping plug(s) installed, plug(s) could
eject from port(s) with great force, resulting in Figure 8, Release Valve (all except P-84)
possible personal injury.
CAUTION: Never add extensions to pump CAUTION: If release valve knob is difficult
handle. Extensions cause unstable pump to turn or becomes stuck, immediately
operation. discontinue using pump. Have pump
inspected and repaired by an Enerpac Authorized
CAUTION: To prevent mechanical Service Center.
damage, do not pull on pump handle after
it has reached the end of its travel. Do not
apply side force to pump handle.
IMPORTANT: To reduce handle effort at high
pressure, take short strokes. Maximum leverage is
obtained in the last 5 degrees of stroke.

5
5.4 Pump Operation - Model P-84
The model P-84 is equipped with a 4-way, 3-position
control valve. It is designed for use with double-
acting cylinders. See figures 9 and 10.
1. Position lever on 4-way valve to select function as
follows:
(A) Flow directed to port “A”; port “B” returns flow
to the reservoir.
(N) Neutral - ports “A” and “B” open to the reservoir.
(B) Flow directed to port “B”; port “A” returns flow
to the reservoir.
WARNING: Valve contains no load holding
device. Be sure load is supported by
blocking, mechanical stands or other
appropriate supports before moving valve lever to the
neutral (N) position.
A B A B A B
(A) (N)
Figure 9, 4-Way Valve Diagram (P-84)
2. Operate pump to perform work.
3. Change valve positions as needed.
WARNING: Operate double-acting
cylinder only when both hoses are
connected to the pump. If one coupler is
left unconnected, high pressure will build behind the
coupler which could cause personal injury and/or
equipment damage.
6.0 AIR REMOVAL
Removing air from the hydraulic system will help the
cylinder to advance and retract smoothly.
6.1 Pump With Single-Acting Cylinder
1. Loosen and remove oil fill plug to provide reservoir
venting during the following steps.
2. Fully close release valve.
3. Position pump in the horizontal position at higher
elevation than cylinder. See Figure 11.
4. Position cylinder with the plunger end down (up if
using pull cylinder).
5. Operate pump to fully extend the cylinder (retract
if using pull cylinder).
(B) 6. Open release valve to retract cylinder (extend if
using pull cylinder). This will force the trapped air
to move up to the pump reservoir.
7. Repeat steps 2 through 6 as needed, until cylinder
operation is smooth.
8. Add oil if necessary. See Section 9.1.
9. Reinstall oil fill plug.

6.2 Pump With Double-Acting Cylinder

1. Loosen oil fill plug several turns to allow reservoir
(B) (A) venting during the following steps.
2. Position pump in the horizontal position at higher
(N) elevation than cylinder. See Figure 11.
3. Put cylinder in horizontal position with ports up.
4. Fully advance and retract the cylinder 2 to 3 times.
5. Repeat steps 2 through 4 as needed, until cylinder
operation is smooth.
6. Add oil if necessary. See Section 9.1.
7. Reinstall oil fill plug.

7.0 RELIEF VALVE ADJUSTMENT

Port Port 1. All models except P-84: Install a 0-15,000 psi
“B” “A” [0-1000 bar] pressure gauge in the pump oil
outlet port. Close the release valve (turn knob fully
Figure 10, Control Valve Lever Positions clockwise until it stops).
and Hose Connections (P-84)

air

air Double-acting
Cylinder
Single-acting
Cylinder

Figure 11, Air Removal

6
2. Model P-84 only: install a 0-15,000 psi [0-1000
bar] pressure gauge in the pump “A” port. Install
a pipe plug in the pump “B” port. Move the control
valve lever to the (A) position.
3. Using a 1/4" Allen wrench, remove the dust plug Dust
over the relief valve adjustment screw. Plug
• On models P-18 and P-39, the relief valve is
located on the top surface of the pump head. See
Figure 12.
• On models, P-77, P-80, P-801 and P-84, the
relief valve is located on the side of the pump
head. See Figure 13.
Figure 13, Relief Valve (P-77, P-80, P-801 and P-84)
Note: To obtain an accurate setting during the
following steps, always decrease the pressure to a
point below the desired final setting and then slowly
increase the pressure until the final setting is reached.
4. Using a 7/32" Allen wrench, loosen the relief valve
adjustment screw about 2 turns. See Figure 14.
5. While operating the pump handle, slowly turn
the relief valve adjustment screw clockwise until
pressure increases to the desired setting. The
pressure setting is indicated when additional Decrease Increase
pumping does not result in a higher pressure
reading on the gauge.
Figure 14, Relief Valve Adjustment Screw
WARNING: Never set the relief valve
pressure above 10,500 psi [725 bar].
8.0 BYPASS VALVE ADJUSTMENT
Serious personal injury could result if this
maximum limit is exceeded. Damage to pump and
MODELS P-77, P-80, P-801 and P-84
components may also occur. The bypass valve controls the pressure at which a
6. All models except P-84: After the desired two-speed pump shifts from the first to the second
setting is obtained, turn the release valve counter stage. See Figure 15.
clockwise to relieve system pressure. Check that The bypass valve is factory set and should not
pressure gauge indicates zero (0) psi/bar. require readjustment unless the pump is overhauled
7. Model P-84 only: After the desired setting is or repaired. If needed, readjustment should be
obtained, move the valve handle to the (N) neutral performed only by an Enerpac Authorized Service
position to relieve system pressure. Check that Center.
pressure gauge indicates zero (0) psi/bar.
8. All models except P-84: Remove pressure gauge
from pump oil outlet port. Reinstall dust plug over Bypass
Valve
relief valve adjustment screw.
9. Model P-84 only: Remove pressure gauge from
pump “A” port. Remove pipe plug from pump
“B” port. Reinstall dust plug over relief valve
adjustment screw.

Dust
Plug

Figure 15, Bypass Valve

(P-77, P-80, P-801 and P-84)

Figure 12, Relief Valve (P-18 and P-39)

7
9.0 MAINTENANCE
Use only Enerpac hydraulic oil with the pump to
promote long pump life and to protect your warranty.
Viton and EPR seal kits are available for some hand
pump models. Contact your Enerpac representative
for more information on these products and their
applications.
9.1 Adding Oil to the Pump
WARNING: Always add oil with cylinders
fully retracted (extended if pull cylinders)
or the system will contain more oil than the
reservoir can hold.
Check oil level regularly and add oil if needed. Refer
to the following steps:
1. Place pump in the horizontal position on a level
surface.
2. Remove oil fill plug from reservoir.
3. Check oil level. See Figure 16. If oil level is low,
add additional oil until oil level is up to the bottom
thread of the oil fill plug opening.
IMPORTANT: Do not overfill! Some air space must
be present in reservoir to allow proper operation. If
the reservoir contains too much oil, a vacuum will
form, preventing oil flow when pump is operated.
4. Reinstall oil fill plug after adding oil. Be sure that
plug is fully installed (not loose).
5. Remove air from system if necessary. See Section
6.0. Recheck oil level after removing air.
Oil Fill Plug
Fill Line
FILL TO
BOTTOM
OF THREADS
Figure 16, Reservoir Oil Level
WARNING: The oil fill plug contains an
integral pressure relief passage, a safety
feature that prevents over-pressurization
of the reservoir. Use only the oil fill plug supplied with
the pump or a genuine Enerpac replacement plug of
identical specifications.
CAUTION:. Never attempt to return more
oil to the reservoir than it is capable of
holding.
8
9.2 Changing the Oil
Drain all oil from reservoir and refill with clean
Enerpac oil every 12 months. If pump is used in dirty
environments, change the oil more frequently.
1. Remove oil fill plug from reservoir.
2. Tilt pump to drain out old oil.
IMPORTANT: Dispose of used oil in accordance with
all applicable laws and regulations.
3. Fill reservoir with new Enerpac oil. Refer to
Section 9.1 for additional information.
4. Reinstall oil fill plug.
9.3 Lubrication
To extend pump life and improve performance,
lubricate the three pump handle pins regularly, using
roller bearing grease. See Figure 17.
Pin 2 Pin 3
Pin 1
Figure 17, Lubrication Points
9.4 Keeping Oil Lines Clean
Always install dust caps when coupler halves are
disconnected. To help prevent failure of pump and
other components, use every precaution to guard
the system against entrance of dirt and other foreign
matter.
10.0 TROUBLESHOOTING GUIDE
The information in the troubleshooting guide (see
Table 3) is intended only as an aid to help diagnose
and correct selected problems that may occur.
A system failure may or may not be the result of a
pump malfunction. To determine the cause of the
problem, the complete system must be included in
any diagnostic procedure.
For repair service, contact your local Enerpac
Authorized Service Center. Only an Enerpac
Authorized Service Center should service the pump
or system components.
 Table 3, Troubleshooting Guide - ULTIMA Series Hand Pumps
Problem Possible Cause Solution

Cylinder does 1. Low oil level in pump reservoir.
not advance, 2. Release valve open or not fully
advances slowly, closed.
or advances
3. Relief valve setting too low.
erratically.
4. Hydraulic coupler not properly
connected.
5. Load is too heavy.
6. Air trapped in system.
7. Reservoir overfilled.
8. Cylinder plunger binding.
1. Add oil according to the instructions in Section 9.1.
2. Close the release valve.
3. Set the relief valve pressure according to
instructions in Section 7.0.
4. Check that all couplers are fully tightened.
5. Do not attempt to lift more than rated tonnage.
6. Remove air according to the instructions in
Section 6.0.
7. Remove excess oil from reservoir.
Note: If cylinder operates normally when pump oil fill
plug is loosened, reservoir may be overfilled with oil.
8. Check for damage to cylinder. Have cylinder
serviced by an Enerpac Authorized Service Center.

Cylinder 1. Leaking connection. 1. Check that all connections are tight and leak free.
advances, but 2. Leaking seals. 2. Locate leak(s) and have equipment serviced by an
does not hold Enerpac Authorized Service Center.
3. Internal leakage in pump.
pressure.
4. Bypass valve setting too low. 3. Have pump serviced by an Enerpac Authorized
(Models P-77, P-80, P-801 and Service Center.
P-84) 4. Have an Enerpac Authorized Service Center adjust
the bypass valve setting.

Cylinder does 1. Release valve closed. 1. Open the release valve.

not retract, 2. Reservoir overfilled. 2. Remove excess oil from reservoir.
retracts part
3. Hydraulic coupler not properly Note: If cylinder operates normally when pump oil fill
way, or retracts
connected. plug is loosened, reservoir may be overfilled with oil.
more slowly than
normal. 4. Air trapped in system. 3. Check that all couplers are fully tightened.
5. Hose inside diameter too 4. Remove air according to the instructions in
narrow. Section 6.0.
6. Cylinder retraction spring 5. Use larger diameter hydraulic hose.
broken or other cylinder 6. Have cylinder serviced by an Enerpac Authorized
damage. Service Center.
7. In-line valve closed. 7. Ensure that in-line valves (if used) are correctly
set.

Note: For the location of your nearest Enerpac Authorized Service Center go to www.enerpac.com

9
 Instruction Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE.
Hydraulic Hose / Fittings
L2255 Rev. B 11/11
Index:
English:........................................................................... 1-4 Español: ..................................................................... 13-16
Deutsch: ..........................................................................5-8 Italiano:........................................................................17-20
Français:........................................................................9-12 Nederlands: .................................................................21-24

IMPORTANT RECEIVING INSTRUCTIONS

Visually inspect all components for shipping damage. If any shipping
damage is found, notify carrier at once. Shipping damage is NOT
covered by warranty. The carrier is responsible for all repair or
replacement cost resulting from damage in shipment.

DESCRIPTION
Enerpac supplies two different types of hydraulic hoses: thermoplastic
and heavy duty rubber. The thermoplastic hose has four layers, including
two high strength steel wire braids. The rubber hose is reinforced with
two layers of braided steel webbing.

WARNING
Do not use Enerpac hoses in systems exceeding 10,000 psi [700 bar].

HOSE COMPARISON
Hose 700 Series Thermoplastic 900 Series Rubber

Design Factor 4 to 1 2 to 1

Expansion Low May expand under pressure

Less flexible Most flexible at low temperatures, but

Flexibility
tight bends can lead to damage

Less tolerant to different types

Tolerance to Fluids Inert to most fluids
of fluid

Tolerance to Heat Sensitive to heat More tolerant to heat

Durability of Outer
Abrasion-resistant Easily abused
Covering

Tolerance to High
Very tolerant Less tolerant
Pressure Cycling

(1)
SAFETY INFORMATION

To avoid personal injury during system operation, read and follow all
CAUTIONS, WARNINGS, and INSTRUCTIONS included with or attached
to each product. ENERPAC CANNOT BE RESPONSIBLE FOR DAMAGE
RESULTING FROM UNSAFE USE OF PRODUCT, LACK OF
MAINTENANCE, OR INCORRECT PRODUCT OR SYSTEM
APPLICATION. Contact Enerpac when in doubt about applications and
safety precautions.

WARNING
Be certain that ALL system components, including couplers, fittings, pipes,
and tubing, are rated for the maximum operating pressure of the system. The
system operating pressure must not exceed the pressure rating of the lowest
rated component in the system or system failure may occur, resulting in serious
personal injury or equipment damage.

WARNING
Always wear proper personal protective gear, when operating hydraulic
equipment.

WARNING
Make sure that all system components are protected from
external sources of damage, such as excessive heat, flame, weld
spatter, moving machine parts, sharp edges, and corrosive
chemicals. Do not expose hoses to temperatures of 150°F [65°C]
or higher.

WARNING
NEVER make or break hydraulic connections while the
system is under pressure.

WARNING
Wear proper personal protective gear when operating
hydraulic equipment.

WARNING
Do not handle hoses under pressure. Replace damaged
hoses immediately. Hydraulic fluid escaping through a small
hole can penetrate the skin, causing serious injury. If oil is
injected under the skin, see a doctor immediately.

CAUTION
Do not use hydraulic hose to carry hydraulic components
such as pumps or cylinders.

CAUTION
Use only the manufacturer's recommended fluid. Do not mix fluids in a
system. Use only fluids that are compatible with system components, or seals and
hoses will be damaged. Synthetic and fireproof fluids require special seals and
hoses. Contact the nearest authorized service center or the manufacturer for
recommendation.

(2)
INSTALLATION
Hydraulic Hoses
1. Before operating, visually inspect the system.
2. Check to be sure there are no cracks, kinks, cuts, or other damage
which might cause the hose to leak. Rubber guards protect crimped
areas at each end of the hose.
3. Make sure all hose ends, couplers, or union ends are R=4Ω in.
clean and threads are in good condition. R=11,4 cm
4. Hose should not be twisted or bent too sharply. The
bend radius should always be at least 4.5 inches
(11,4 cm). Always use as few bends as possible.
5. 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.
6. Make sure all hose connections between pump and
cylinder are tight and leak free. Do not over-tighten connections or
use tools to tighten connections. Excessive torque may cause
premature thread failure and may cause high pressure fittings to split
at pressure lower than rated capacity. When using quick disconnect
fittings, make sure the fittings are correctly and completely fastened
together.

Fittings and Tubing

The following guidelines should be used whenever fittings are used in
hydraulic systems.
1. Care must be taken that threaded fittings are not cross-threaded.
2. Be sure connections are sealed using high grade pipe thread sealer.
3. Tape or sealing compound should be confined to threaded areas only.
Keep first thread free of tape to avoid pieces of tape getting into the
system.

CAUTION
Use care to ensure that pieces of tape do not enter the hydraulic system.
Pieces of tape in the fluid impairs fluid flow, causing system malfunctions.

4. Vibration and system shock-loads are the primary cause of

fitting/tubing leaks. Use commercially available tube supports to
extend the life of your system. The most critical area to use a tube
support is 4-7 inches behind a fitting.
5. Tubing is not rigid. Long runs must be supported. Unsupported
sections can lead to premature fitting failure. Always hard mount
valves and gauges. Never allow tubing to be their sole support!

(3)
MAINTENANCE
This section refers to components commonly found in a hydraulic system.

General
1. Keep the components clean at all times. Many hydraulic service
problems are caused by dirt and/or metallic particles in the hydraulic
system. To avoid these problems, the use of proper maintenance
including rust prevention and cleanliness will help extend the life of
your hydraulic system.
2. Use only an approved clean hydraulic fluid and change fluid as
recommended by the manufacturer. Change fluids more often if unit is
used under extreme conditions.
3. Change or clean the filter in the system periodically if one is used.

Hydraulic Hoses
1. Hydraulic hoses should be left in carton until needed.
2. Store hoses at a temperature between 50º to 75ºF [10º to 24ºC ] and
at a humidity between 20 and 70 percent.
3. Never store hoses in a hot, damp room, in direct sunlight or near heat
sources.
4. Do not stack hoses. The weight of the pile will tend to flatten the hose
on the bottom. Hanging in a rack is preferred.
5. Do not carry or drag hydraulic assemblies by pulling or pushing on
couplings or hoses.

Fittings and Couplers

1. All coupler threads, either male or female, must be kept clean and
lubricated regularly. Cover couplers with dust caps when not
connected to system. Do not remove covers or plugs until component
is ready to be used.
2. Keep dust caps on couplers when not in use. Make certain that all
unused couplers are sealed with dust caps/thread protectors.
3. Be sure all hose connections are free of grit and grime.

(4)
 Instruction Sheet

ULTIMA Series Hand Pumps

POWERFUL SOLUTIONS. GLOBAL FORCE.
P-18, P-39, P-77, P-80, P-801 and P-84
L3070 Rev. E 05/12
Index:
English ............................................................... 1-9
Français ......................................................... 10-18
Deutsch ........................................................ 19-27
Italiano .......................................................... 28-36
Español......................................................... 37-45
Nederlands ................................................... 46-54
Portuguese ................................................... 55-63
........................................................... 64-71
.......................................................... 72-79
Finnish ........................................................... 80-88
Norwegian ..................................................... 89-97
Svenska ....................................................... 98-106
Russian ...................................................... 107-115
Greek ......................................................... 116-125
Repair Parts Sheets for this product are available WARNING: Wear proper personal
from the Enerpac web site at www.enerpac.com, or protective gear when operating hydraulic
from your nearest Enerpac Authorized Service Center equipment.
or Enerpac Sales office.
WARNING: Stay clear of loads supported
1.0 IMPORTANT RECEIVING by hydraulics. A cylinder, when used as a
INSTRUCTIONS load lifting device, should never be used
as a load holding device. After the load
Visually inspect all components for shipping damage.
has been raised or lowered, it must always be
Shipping damage is not covered by warranty. If
blocked mechanically.
shipping damage is found, notify carrier at once. The
carrier is responsible for all repair and replacement WARNING: USE ONLY RIGID PIECES
costs resulting from damage in shipment. TO HOLD LOADS. Carefully select steel
SAFETY FIRST or wood blocks that are capable of
supporting the load. Never use a hydraulic cylinder
2.0 SAFETY ISSUES as a shim or spacer in any lifting or pressing
application.
Read all instructions,
warnings and cautions DANGER: To avoid personal injury
carefully. Follow all safety keep hands and feet away from cylinder
precautions to avoid personal injury or property and workpiece during operation.
damage during system operation. Enerpac cannot be
responsible for damage or injury resulting from unsafe WARNING: Do not exceed equipment
product use, lack of maintenance or incorrect product ratings. Never attempt to lift a load
and/or system operation. Contact Enerpac when in weighing more than the capacity of the
doubt as to the safety precautions and operations. If cylinder. Overloading causes equipment
you have never been trained on high-pressure failure and possible personal injury. The cylinders are
hydraulic safety, consult your distribution or service designed for a max. pressure of 700 bar [10,000 psi].
center for a free Enerpac Hydraulic safety course. Do not connect a jack or cylinder to a pump with a
higher pressure rating.
Failure to comply with the following cautions and
warnings could cause equipment damage and WARNING: Never set the relief valve
personal injury. pressure above 10,500 psi [725 bar].
Serious personal injury could result if this
A CAUTION is used to indicate correct operating or
maximum limit is exceeded. Damage to pump and
maintenance procedures and practices to prevent
components may also occur.
damage to, or destruction of equipment or other
property. WARNING: The system operating
pressure must not exceed the pressure
A WARNING indicates a potential danger that
rating of the lowest rated component in
requires correct procedures or practices to avoid
the system. Install pressure gauges in the
personal injury.
system to monitor operating pressure. It is your
A DANGER is only used when your action or lack of window to what is happening in the system.
action may cause serious injury or even death.
 CAUTION: Avoid damaging 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.
IMPORTANT: Do not lift hydraulic
equipment by the hoses or swivel
couplers. Use the pump lifting/transport
handle or other means of safe transport.
CAUTION: 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 hoses and cylinders from
weld spatter.
DANGER: Do not handle pressurized
hoses. Escaping oil under pressure can
penetrate the skin, causing serious injury.
If oil is injected under the skin, see a doctor
immediately.
WARNING: Only use hydraulic cylinders in
a coupled system. Never use a cylinder
with unconnected couplers. If the cylinder
becomes extremely overloaded,
components can fail catastrophically causing severe
personal injury.
WARNING: 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.
Avoid situations where loads are not
directly centered on the cylinder plunger.
Off-center loads produce considerable
strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
dangerous results.
Distribute the load evenly across the
entire saddle surface. Always use a saddle
to protect the plunger.
IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
technician. For repair service, contact the
Authorized ENERPAC Service Center in
your area. To protect your warranty, use only
ENERPAC oil.
WARNING: Immediately replace worn or
damaged parts with genuine ENERPAC
parts. Standard grade parts will break
causing personal injury and property
damage. ENERPAC parts are designed to fit properly
and withstand high loads.
CAUTION: Always use the pump lifting/
transport handle to carry the pump.
Carrying the pump by the hose may
damage the hose and/or the pump.

3.0 PRODUCT INFORMATION

Table 1, Specifications - ULTIMA Series Hand Pumps
Pump Pump Max. Pressure Rating Oil Volume Per Stroke Usable Oil Weight Max. Handle
Model Type psi [bar] in3 [cm3] Capacity With Oil Effort
(Speed) in3 [cm3] lbs [kg] lbs [kg]
Stage 1 Stage 2 Stage 1 Stage 2
P-18 1 — 2850 [200] — 0.15 [2,46] 22 [360] 11.0 [5,2] 34 [16]
P-39 1 — 10,000 [700] — 0.15 [2,46] 47 [769] 13.6 [6,2] 85 [38]
P-77 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 47 [769] 15.6 [7,1] 88 [40]
P-80 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 134 [2195] 23.6 [10,7] 77 [35]
P-801 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 250 [4095] 31.0 [14,0] 77 [35]
P-84 2 500 [34] 10,000 [700] 1.00 [16.38] 0.15 [2,46] 134 [2195] 26.0 [11,7] 77 [35]

Table 2, Features and Major Components - ULTIMA Series Hand Pumps

Item Pump Model
(See figures 1 thru 4
for item locations) P-18 P-39 P-77 P-80 P-801 P-84

4-Way, 3-Position
A Release Valve Release Valve Release Valve Release Valve Release Valve
Control Valve
One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF One 3/8" NPTF Two 3/8" NPTF
B Outlet Port Outlet Port Outlet Port Outlet Port Outlet Port Outlet Ports

C Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug Oil Fill Plug

Mounting Mounting Mounting Mounting Mounting Mounting

D
Slots Slots Slots Slots Slots Slots
User-Adjustable User-Adjustable User-Adjustable User-Adjustable User-Adjustable User-Adjustable
E
Relief Valve Relief Valve Relief Valve Relief Valve Relief Valve Relief Valve
3/8" NPTF Return 3/8" NPTF Return
F — — — —
to Tank Port to Tank Port

G — — Bypass Valve Bypass Valve Bypass Valve Bypass Valve

2
3.1 Pump Features and Major Components
See figures 1 through 4 for the locations of pump
features and major components. Refer to Table 2 for
descriptions of items A through G.

E
A
A

B B

G
E

C C

D D D D

Figure 1, Models P-18 and P-39 Figure 3, Models, P-80 and P-801

E E
A
B
B

G A G

C
C

D D D D

Figure 2, Model P-77 Figure 4, Model P-84

3
 8 10 7

P-18, P-39, P-77, P-80, P-801

3 9 5 6 1

8 10 5 6 7

P-84

4 9 5 6 11 2

Key:
1. Cylinder (single-acting) 7. Female Coupler
2. Cylinder (double-acting) 8. Pressure Gauge
3. Hand Pump w/Release Valve 9. Gauge Adapter
4. Hand Pump w/4-Way Valve 10. Swivel Connector
5. Hose 11. Safety Holding Valve
6. Male Coupler
Figure 5, Hydraulic Connections (typical)

4.0 INSTALLATION • For double-acting cylinders, connect two hoses.

Connect one hose from port (A) of the pump to
4.1 Connecting the Pump the advance port of the cylinder. Connect another
1. Remove shipping plug(s) hose from port (B) of the pump to the retract port
from pump outlet port(s). of the cylinder.
2. Adjust the relief Models P-80 and P-801 only: If an external
valve to the desired pressure reducing valve is being used in the
hydraulic pressure limit. circuit, connect the tank port of the valve to the
See Section 7.0 for return-to-tank port on the pump.
instructions. Note: Cylinders, hoses and accessories shown
3. Connect hose(s) to in Figure 5 are sold separately and not included
pump. To seal threads, with pump. Refer to the Enerpac catalog for a
Figure 6
use anaerobic thread sealer, complete description of available components and
Teflon® paste or Teflon® accessories. The exact components required for
tape. your system will vary, depending on application and
other factors.
IMPORTANT: When using Teflon® tape, apply the
tape one thread back from the end of the fitting to
prevent pieces of tape from entering the hydraulic 4.2 Pump Venting
system. See Figure 6. The ULTIMA series hand pumps are designed
4. Install a pressure gauge in-line from the pump for for non-vented operation. The oil fill plug can be
added safety and better control. loosened if needed to vent air from the system but
should be fully installed before using the pump.
5. Connect the hose(s) to your cylinder or tool.
• For single-acting cylinders, connect one hose IMPORTANT: To prevent contaminants from entering
from the pump to the cylinder. the hydraulic system, do not operate pump with oil fill
plug loosened or removed.

4
4.3 Pump Position
The pump may be operated in either the horizontal or
vertical position. See Figure 7.
When operated in the vertical position, hose end of
pump must be pointed down, or the pump will pick
up air and will not properly build pressure.
Note: The pump is not designed for use in the
inverted (upside-down) position.
OK
5.2 Two Stage Flow
Models P-77, P-80, P-801 and P-84
Two-speed pumps provide two stage flow. Under
no-load, the pump operates in the high flow first
stage for rapid advance. When the load is contacted,
the pump automatically shifts to the second stage
for building pressure. After the pump shifts, pumping
takes less effort.
Note: For best performance, operate pump handle
at moderate speed during the high flow first stage.
Rapid handle speed in the first stage will prevent the
pump from delivering full volume of oil.

5.3 Pump Operation

OK

Models P-18, P-39, P-77, P-80 and P-801

All pump models except the P-84 are designed for
use with single-acting cylinders and are equipped
with an integral release valve.
1. Close the release valve by turning knob clockwise
Figure 7, Pump Orientation until it stops. See Figure 8.
CAUTION: Close release valve finger tight
5.0 OPERATION ONLY. Using tools on release valve can
damage it and cause the pump to
5.1 Before Using the Pump malfunction.
1. Check all system fittings and connections to be
2. Operate pump handle to deliver hydraulic power
sure they are tight and leak free.
to system. Pressure will be maintained until
2. Check oil level in reservoir and add oil if required. release valve is opened.
Refer to instructions in Section 9.1.
3. Open the release valve by turning knob counter-
3. Read and understand the following precautions clockwise. Pressure will be released, allowing oil
before operating pump: to flow back to the reservoir.
WARNING: In certain situations the pump
handle can “kick back”. Always keep your
body to the side of the pump, away from
the line of force of the handle.
WARNING: When operating the pump
handle, keep hands and fingers away from
pinch point area between pump handle OPEN CLOSE
and lifting/transport handle.
CAUTION: Always remove shipping
plug(s) from pump outlet port(s) and
replace with proper hydraulic fitting(s)
before operating pump handle. If pump handle is
operated with shipping plug(s) installed, plug(s) could
eject from port(s) with great force, resulting in Figure 8, Release Valve (all except P-84)
possible personal injury.
CAUTION: Never add extensions to pump CAUTION: If release valve knob is difficult
handle. Extensions cause unstable pump to turn or becomes stuck, immediately
operation. discontinue using pump. Have pump
inspected and repaired by an Enerpac Authorized
CAUTION: To prevent mechanical Service Center.
damage, do not pull on pump handle after
it has reached the end of its travel. Do not
apply side force to pump handle.
IMPORTANT: To reduce handle effort at high
pressure, take short strokes. Maximum leverage is
obtained in the last 5 degrees of stroke.

5
5.4 Pump Operation - Model P-84
The model P-84 is equipped with a 4-way, 3-position
control valve. It is designed for use with double-
acting cylinders. See figures 9 and 10.
1. Position lever on 4-way valve to select function as
follows:
(A) Flow directed to port “A”; port “B” returns flow
to the reservoir.
(N) Neutral - ports “A” and “B” open to the reservoir.
(B) Flow directed to port “B”; port “A” returns flow
to the reservoir.
WARNING: Valve contains no load holding
device. Be sure load is supported by
blocking, mechanical stands or other
appropriate supports before moving valve lever to the
neutral (N) position.
A B A B A B
(A) (N)
Figure 9, 4-Way Valve Diagram (P-84)
2. Operate pump to perform work.
3. Change valve positions as needed.
WARNING: Operate double-acting
cylinder only when both hoses are
connected to the pump. If one coupler is
left unconnected, high pressure will build behind the
coupler which could cause personal injury and/or
equipment damage.
6.0 AIR REMOVAL
Removing air from the hydraulic system will help the
cylinder to advance and retract smoothly.
6.1 Pump With Single-Acting Cylinder
1. Loosen and remove oil fill plug to provide reservoir
venting during the following steps.
2. Fully close release valve.
3. Position pump in the horizontal position at higher
elevation than cylinder. See Figure 11.
4. Position cylinder with the plunger end down (up if
using pull cylinder).
5. Operate pump to fully extend the cylinder (retract
if using pull cylinder).
(B) 6. Open release valve to retract cylinder (extend if
using pull cylinder). This will force the trapped air
to move up to the pump reservoir.
7. Repeat steps 2 through 6 as needed, until cylinder
operation is smooth.
8. Add oil if necessary. See Section 9.1.
9. Reinstall oil fill plug.

6.2 Pump With Double-Acting Cylinder

1. Loosen oil fill plug several turns to allow reservoir
(B) (A) venting during the following steps.
2. Position pump in the horizontal position at higher
(N) elevation than cylinder. See Figure 11.
3. Put cylinder in horizontal position with ports up.
4. Fully advance and retract the cylinder 2 to 3 times.
5. Repeat steps 2 through 4 as needed, until cylinder
operation is smooth.
6. Add oil if necessary. See Section 9.1.
7. Reinstall oil fill plug.

7.0 RELIEF VALVE ADJUSTMENT

Port Port 1. All models except P-84: Install a 0-15,000 psi
“B” “A” [0-1000 bar] pressure gauge in the pump oil
outlet port. Close the release valve (turn knob fully
Figure 10, Control Valve Lever Positions clockwise until it stops).
and Hose Connections (P-84)

air

air Double-acting
Cylinder
Single-acting
Cylinder

Figure 11, Air Removal

6
2. Model P-84 only: install a 0-15,000 psi [0-1000
bar] pressure gauge in the pump “A” port. Install
a pipe plug in the pump “B” port. Move the control
valve lever to the (A) position.
3. Using a 1/4" Allen wrench, remove the dust plug Dust
over the relief valve adjustment screw. Plug
• On models P-18 and P-39, the relief valve is
located on the top surface of the pump head. See
Figure 12.
• On models, P-77, P-80, P-801 and P-84, the
relief valve is located on the side of the pump
head. See Figure 13.
Figure 13, Relief Valve (P-77, P-80, P-801 and P-84)
Note: To obtain an accurate setting during the
following steps, always decrease the pressure to a
point below the desired final setting and then slowly
increase the pressure until the final setting is reached.
4. Using a 7/32" Allen wrench, loosen the relief valve
adjustment screw about 2 turns. See Figure 14.
5. While operating the pump handle, slowly turn
the relief valve adjustment screw clockwise until
pressure increases to the desired setting. The
pressure setting is indicated when additional Decrease Increase
pumping does not result in a higher pressure
reading on the gauge.
Figure 14, Relief Valve Adjustment Screw
WARNING: Never set the relief valve
pressure above 10,500 psi [725 bar].
8.0 BYPASS VALVE ADJUSTMENT
Serious personal injury could result if this
maximum limit is exceeded. Damage to pump and
MODELS P-77, P-80, P-801 and P-84
components may also occur. The bypass valve controls the pressure at which a
6. All models except P-84: After the desired two-speed pump shifts from the first to the second
setting is obtained, turn the release valve counter stage. See Figure 15.
clockwise to relieve system pressure. Check that The bypass valve is factory set and should not
pressure gauge indicates zero (0) psi/bar. require readjustment unless the pump is overhauled
7. Model P-84 only: After the desired setting is or repaired. If needed, readjustment should be
obtained, move the valve handle to the (N) neutral performed only by an Enerpac Authorized Service
position to relieve system pressure. Check that Center.
pressure gauge indicates zero (0) psi/bar.
8. All models except P-84: Remove pressure gauge
from pump oil outlet port. Reinstall dust plug over Bypass
Valve
relief valve adjustment screw.
9. Model P-84 only: Remove pressure gauge from
pump “A” port. Remove pipe plug from pump
“B” port. Reinstall dust plug over relief valve
adjustment screw.

Dust
Plug

Figure 15, Bypass Valve

(P-77, P-80, P-801 and P-84)

Figure 12, Relief Valve (P-18 and P-39)

7
9.0 MAINTENANCE
Use only Enerpac hydraulic oil with the pump to
promote long pump life and to protect your warranty.
Viton and EPR seal kits are available for some hand
pump models. Contact your Enerpac representative
for more information on these products and their
applications.
9.1 Adding Oil to the Pump
WARNING: Always add oil with cylinders
fully retracted (extended if pull cylinders)
or the system will contain more oil than the
reservoir can hold.
Check oil level regularly and add oil if needed. Refer
to the following steps:
1. Place pump in the horizontal position on a level
surface.
2. Remove oil fill plug from reservoir.
3. Check oil level. See Figure 16. If oil level is low,
add additional oil until oil level is up to the bottom
thread of the oil fill plug opening.
IMPORTANT: Do not overfill! Some air space must
be present in reservoir to allow proper operation. If
the reservoir contains too much oil, a vacuum will
form, preventing oil flow when pump is operated.
4. Reinstall oil fill plug after adding oil. Be sure that
plug is fully installed (not loose).
5. Remove air from system if necessary. See Section
6.0. Recheck oil level after removing air.
Oil Fill Plug
Fill Line
FILL TO
BOTTOM
OF THREADS
Figure 16, Reservoir Oil Level
WARNING: The oil fill plug contains an
integral pressure relief passage, a safety
feature that prevents over-pressurization
of the reservoir. Use only the oil fill plug supplied with
the pump or a genuine Enerpac replacement plug of
identical specifications.
CAUTION:. Never attempt to return more
oil to the reservoir than it is capable of
holding.
8
9.2 Changing the Oil
Drain all oil from reservoir and refill with clean
Enerpac oil every 12 months. If pump is used in dirty
environments, change the oil more frequently.
1. Remove oil fill plug from reservoir.
2. Tilt pump to drain out old oil.
IMPORTANT: Dispose of used oil in accordance with
all applicable laws and regulations.
3. Fill reservoir with new Enerpac oil. Refer to
Section 9.1 for additional information.
4. Reinstall oil fill plug.
9.3 Lubrication
To extend pump life and improve performance,
lubricate the three pump handle pins regularly, using
roller bearing grease. See Figure 17.
Pin 2 Pin 3
Pin 1
Figure 17, Lubrication Points
9.4 Keeping Oil Lines Clean
Always install dust caps when coupler halves are
disconnected. To help prevent failure of pump and
other components, use every precaution to guard
the system against entrance of dirt and other foreign
matter.
10.0 TROUBLESHOOTING GUIDE
The information in the troubleshooting guide (see
Table 3) is intended only as an aid to help diagnose
and correct selected problems that may occur.
A system failure may or may not be the result of a
pump malfunction. To determine the cause of the
problem, the complete system must be included in
any diagnostic procedure.
For repair service, contact your local Enerpac
Authorized Service Center. Only an Enerpac
Authorized Service Center should service the pump
or system components.
 Table 3, Troubleshooting Guide - ULTIMA Series Hand Pumps
Problem Possible Cause Solution

Cylinder does 1. Low oil level in pump reservoir.
not advance, 2. Release valve open or not fully
advances slowly, closed.
or advances
3. Relief valve setting too low.
erratically.
4. Hydraulic coupler not properly
connected.
5. Load is too heavy.
6. Air trapped in system.
7. Reservoir overfilled.
8. Cylinder plunger binding.
1. Add oil according to the instructions in Section 9.1.
2. Close the release valve.
3. Set the relief valve pressure according to
instructions in Section 7.0.
4. Check that all couplers are fully tightened.
5. Do not attempt to lift more than rated tonnage.
6. Remove air according to the instructions in
Section 6.0.
7. Remove excess oil from reservoir.
Note: If cylinder operates normally when pump oil fill
plug is loosened, reservoir may be overfilled with oil.
8. Check for damage to cylinder. Have cylinder
serviced by an Enerpac Authorized Service Center.

Cylinder 1. Leaking connection. 1. Check that all connections are tight and leak free.
advances, but 2. Leaking seals. 2. Locate leak(s) and have equipment serviced by an
does not hold Enerpac Authorized Service Center.
3. Internal leakage in pump.
pressure.
4. Bypass valve setting too low. 3. Have pump serviced by an Enerpac Authorized
(Models P-77, P-80, P-801 and Service Center.
P-84) 4. Have an Enerpac Authorized Service Center adjust
the bypass valve setting.

Cylinder does 1. Release valve closed. 1. Open the release valve.

not retract, 2. Reservoir overfilled. 2. Remove excess oil from reservoir.
retracts part
3. Hydraulic coupler not properly Note: If cylinder operates normally when pump oil fill
way, or retracts
connected. plug is loosened, reservoir may be overfilled with oil.
more slowly than
normal. 4. Air trapped in system. 3. Check that all couplers are fully tightened.
5. Hose inside diameter too 4. Remove air according to the instructions in
narrow. Section 6.0.
6. Cylinder retraction spring 5. Use larger diameter hydraulic hose.
broken or other cylinder 6. Have cylinder serviced by an Enerpac Authorized
damage. Service Center.
7. In-line valve closed. 7. Ensure that in-line valves (if used) are correctly
set.

Note: For the location of your nearest Enerpac Authorized Service Center go to www.enerpac.com

9
 Instruction Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE.
Hydraulic Hose / Fittings
L2255 Rev. B 11/11
Index:
English:........................................................................... 1-4 Español: ..................................................................... 13-16
Deutsch: ..........................................................................5-8 Italiano:........................................................................17-20
Français:........................................................................9-12 Nederlands: .................................................................21-24

IMPORTANT RECEIVING INSTRUCTIONS

Visually inspect all components for shipping damage. If any shipping
damage is found, notify carrier at once. Shipping damage is NOT
covered by warranty. The carrier is responsible for all repair or
replacement cost resulting from damage in shipment.

DESCRIPTION
Enerpac supplies two different types of hydraulic hoses: thermoplastic
and heavy duty rubber. The thermoplastic hose has four layers, including
two high strength steel wire braids. The rubber hose is reinforced with
two layers of braided steel webbing.

WARNING
Do not use Enerpac hoses in systems exceeding 10,000 psi [700 bar].

HOSE COMPARISON
Hose 700 Series Thermoplastic 900 Series Rubber

Design Factor 4 to 1 2 to 1

Expansion Low May expand under pressure

Less flexible Most flexible at low temperatures, but

Flexibility
tight bends can lead to damage

Less tolerant to different types

Tolerance to Fluids Inert to most fluids
of fluid

Tolerance to Heat Sensitive to heat More tolerant to heat

Durability of Outer
Abrasion-resistant Easily abused
Covering

Tolerance to High
Very tolerant Less tolerant
Pressure Cycling

(1)
SAFETY INFORMATION

To avoid personal injury during system operation, read and follow all
CAUTIONS, WARNINGS, and INSTRUCTIONS included with or attached
to each product. ENERPAC CANNOT BE RESPONSIBLE FOR DAMAGE
RESULTING FROM UNSAFE USE OF PRODUCT, LACK OF
MAINTENANCE, OR INCORRECT PRODUCT OR SYSTEM
APPLICATION. Contact Enerpac when in doubt about applications and
safety precautions.

WARNING
Be certain that ALL system components, including couplers, fittings, pipes,
and tubing, are rated for the maximum operating pressure of the system. The
system operating pressure must not exceed the pressure rating of the lowest
rated component in the system or system failure may occur, resulting in serious
personal injury or equipment damage.

WARNING
Always wear proper personal protective gear, when operating hydraulic
equipment.

WARNING
Make sure that all system components are protected from
external sources of damage, such as excessive heat, flame, weld
spatter, moving machine parts, sharp edges, and corrosive
chemicals. Do not expose hoses to temperatures of 150°F [65°C]
or higher.

WARNING
NEVER make or break hydraulic connections while the
system is under pressure.

WARNING
Wear proper personal protective gear when operating
hydraulic equipment.

WARNING
Do not handle hoses under pressure. Replace damaged
hoses immediately. Hydraulic fluid escaping through a small
hole can penetrate the skin, causing serious injury. If oil is
injected under the skin, see a doctor immediately.

CAUTION
Do not use hydraulic hose to carry hydraulic components
such as pumps or cylinders.

CAUTION
Use only the manufacturer's recommended fluid. Do not mix fluids in a
system. Use only fluids that are compatible with system components, or seals and
hoses will be damaged. Synthetic and fireproof fluids require special seals and
hoses. Contact the nearest authorized service center or the manufacturer for
recommendation.

(2)
INSTALLATION
Hydraulic Hoses
1. Before operating, visually inspect the system.
2. Check to be sure there are no cracks, kinks, cuts, or other damage
which might cause the hose to leak. Rubber guards protect crimped
areas at each end of the hose.
3. Make sure all hose ends, couplers, or union ends are R=4Ω in.
clean and threads are in good condition. R=11,4 cm
4. Hose should not be twisted or bent too sharply. The
bend radius should always be at least 4.5 inches
(11,4 cm). Always use as few bends as possible.
5. 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.
6. Make sure all hose connections between pump and
cylinder are tight and leak free. Do not over-tighten connections or
use tools to tighten connections. Excessive torque may cause
premature thread failure and may cause high pressure fittings to split
at pressure lower than rated capacity. When using quick disconnect
fittings, make sure the fittings are correctly and completely fastened
together.

Fittings and Tubing

The following guidelines should be used whenever fittings are used in
hydraulic systems.
1. Care must be taken that threaded fittings are not cross-threaded.
2. Be sure connections are sealed using high grade pipe thread sealer.
3. Tape or sealing compound should be confined to threaded areas only.
Keep first thread free of tape to avoid pieces of tape getting into the
system.

CAUTION
Use care to ensure that pieces of tape do not enter the hydraulic system.
Pieces of tape in the fluid impairs fluid flow, causing system malfunctions.

4. Vibration and system shock-loads are the primary cause of

fitting/tubing leaks. Use commercially available tube supports to
extend the life of your system. The most critical area to use a tube
support is 4-7 inches behind a fitting.
5. Tubing is not rigid. Long runs must be supported. Unsupported
sections can lead to premature fitting failure. Always hard mount
valves and gauges. Never allow tubing to be their sole support!

(3)
MAINTENANCE
This section refers to components commonly found in a hydraulic system.

General
1. Keep the components clean at all times. Many hydraulic service
problems are caused by dirt and/or metallic particles in the hydraulic
system. To avoid these problems, the use of proper maintenance
including rust prevention and cleanliness will help extend the life of
your hydraulic system.
2. Use only an approved clean hydraulic fluid and change fluid as
recommended by the manufacturer. Change fluids more often if unit is
used under extreme conditions.
3. Change or clean the filter in the system periodically if one is used.

Hydraulic Hoses
1. Hydraulic hoses should be left in carton until needed.
2. Store hoses at a temperature between 50º to 75ºF [10º to 24ºC ] and
at a humidity between 20 and 70 percent.
3. Never store hoses in a hot, damp room, in direct sunlight or near heat
sources.
4. Do not stack hoses. The weight of the pile will tend to flatten the hose
on the bottom. Hanging in a rack is preferred.
5. Do not carry or drag hydraulic assemblies by pulling or pushing on
couplings or hoses.

Fittings and Couplers

1. All coupler threads, either male or female, must be kept clean and
lubricated regularly. Cover couplers with dust caps when not
connected to system. Do not remove covers or plugs until component
is ready to be used.
2. Keep dust caps on couplers when not in use. Make certain that all
unused couplers are sealed with dust caps/thread protectors.
3. Be sure all hose connections are free of grit and grime.

(4)
 STEEL CYLINDERS
RCD Series - Double Acting Center Hole

Capacity Range ................................................... 30 - 500 tons

Stroke Range ....................................................... 3 - 10.13 in.
Maximum Pressure ............................................. 10,000 psi

 Induction hardened piston rod for added strength

eliminating the need for a loadcap.
 Performance Nitride/QPQ corrosion resistant technology
on the piston rod and retaining nut for extended cylinder life.
 Large center hole for greater flexibility.

RCD307A Shown

Base Mounting Hole Dimensions

RELIEF VALVE
Relief valve prevents damage in case of over Model Bolt Circle Thread Thread Depth
pressurization. (in) (in) (in)
30 Ton 3.63 3/8 - 16 UNC .62

Cylinders
60 Ton 5.12 1/2 - 13 UNC .55
100 Ton 7.00 5/8 - 11 UNC .75

HOSES - pages 78 - 79
Heavy duty and thermo plastic hydraulic
• Refer to Base Mounting D
hoses to meet your requirements and safety
Table
factor. F

&

C
E
C

Model Push Stroke Oil Push Pres. A B C D E F Wgt.

Capacity (in) Capacity Effect @ Minimum Extended Body Piston Center Collar Collar (lbs)
(tons) Required Area Cap. Height Height O.D. O.D. Hole Threads Threads
(cu.in.) (sq.in.) (psi) (in) (in) (in) (in) Dia. (in) Length
(in) (in)
RCD307A 36 7 50.55 7.22 8,310 13 20 4.5 2.5 1.31 4 1/2-12 1.66 48
RCD6010A 64 10.12 128.94 12.73 9,426 17.25 27.37 6.26 3.62 2.13 6 1/4-12 1.91 101
RCD1003A 103 3 61.88 20.63 9,694 10 13 8.38 5.0 3.13 8 3/8-12 2.38 135
RCD1006A 103 6 123.76 20.63 9,694 13.50 19.50 8.38 5.0 3.13 8 3/8-12 2.38 175
RCD10010A 103 10.13 208.84 20.63 9,694 18.12 28.25 8.38 5.0 3.13 8 3/8-12 2.38 235
RCD1505 150 5 78 31.6 9,491 13.13 18.13 10 6 3.13 --- --- 240
RCD2006C 246 6 172 49.3 10,000 16.25 22.25 12 8 4.13 --- --- 385
RCD3006C 434 6 296 91.5 10,000 18.75 24.75 15 9.5 4.25 --- --- 720
RCD5006C 646 6 463 129.3 10,000 21.5 27.5 17.75 12 5.25 --- --- 1230

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