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Service Instructions Pa-133, 7001 Repair Procedure: L1833 Rev. B 02/06 Refer To Repair Parts Sheet L1252

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Service Instructions

PA-133, 7001 REPAIR PROCEDURE

L1833 Rev. B 02/06 Refer to Repair Parts Sheet L1252


SERVICE INSTRUCTIONS: These Service Instructions are intended to be used by qualified personnel at Authorized Enerpac
Service Centers. Users of Enerpac equipment should see the pump Instruction Sheet (L761) for installation, operation, and
maintenance information.

TOOLS AND EQUIPMENT NEEDED: ■ 10,000 psi 10 ton s/a cylinder


■ PA-133K1R complete repair kit or individual kits for ■ 10,000 psi pressure gauge
each section ■ lightweight grease
■ 100 psi 9 cfm air supply ■ L-1252 repair sheet
■ open or box end wrenches 10,000 psi pressure ■ 10,000 psi hose
gauge o-ring pick ■ o-ring pick
■ screwdriver ■ allen wrenches
■ ENERPAC hydraulic oil ■ torque wrenches

TROUBLESHOOTING AND TESTING: AIR MOTOR TEARDOWN


NOTE: Procedure #1 to be used for pump priming only. Refer to figure 1 on the Repair Parts Sheet.
1. Connect the pump to the air supply and hydraulic hose, 1. Remove the base plate (figure 1, item #27) and screws (item
gauge and cylinder. #28) with the 5/32" allen wrench.
Make sure the reservoir on the air pump is full. 2. Hold the motor down firmly and loosen/remove the v-retainer
2. Activate the pump and build pressure in the hydraulic circuit. (item #14).
If the pump fails to build pressure, try operating the pump in When the clamp is removed, the motor will be pushed
the vertical position with reservoir up and air motor down. away from the pump body with up to 50 lbs. of force
Use as little air pressure as possible so pump cycles only generated by the piston return spring.
once or twice, slowly. This helps purge air from the pumping 3. Remove and inspect the spring (item #16), washer (item
chamber. If the pump still does not prime see step #11of the #15), and plunger (item #18) for excessive or uneven wear.
Air Motor Assembly procedure.
4. Pull air piston out of the open end of the air motor.
Failure to build pressure may also be the result of worn ball
5. Remove and inspect air piston (item 54).
seats or bad seals in the pump body assembly. In this case,
teardown and repair of the pump assembly will be necessary.
AIR MOTOR ASSEMBLY
Do not exceed maximum rated pressure of 10,500 psi.
Refer to figure 1 on the Repair Parts Sheet.
1. Grease the air piston (item #54) and u-cup (item #55) and
If relief pressure exceeds the maximum rating, set the relief gently push into the cylinder bore.
valve, located on the opposite side of the pump from the
2. Position the pump body (figure 1, item #20) so that the
swivel assembly, to 10,200-10,500 psi.
motor assembly can be fastened from the top side and
3. Cycle pump to maximum pressure 5 to 6 times while secure in a vise. Fill pump body with oil (pump will prime
observing air motor performance. The motor should easier).Place the spring (item #16) washer (item #15) and
reciprocate crisply and quickly. plunger (item #18) into position.
If sluggish, the motor may need to be repaired or replaced. 3. Place the motor assembly over the pump body assembly
4. Check load holding capability by building pressure to just and push down firmly to compress the spring while rotating
under the maximum rating. ( 9500-9800 psi ) slightly to allow the plunger to slide into the hydraulic
Also check load at 3000 and 6000 psi. For each pressure, cylinder body. Align the tab on the air motor to fit into the
check to see that there is not significant pressure drop (100- slot on the pump body.
200 psi) in 5 - 10 seconds. 4. Attach the v-retainer (item #14) so that the screw housing
If a pressure loss is detected, check the release valve seat faces the slot opening on the base plate (item #27). Tighten
and seals or discharge seat and seals. to 30-40 in-lbs.
5. Check output flow at 100 psi of input air pressure. The flow rate 5. Assemble the base plate and screws (item #28). Insert
can be measured by timing the advancement of the 10 ton swivel coupler (item #4), o-ring (item #5), and retainer ring
cylinder. The correct rate of advancement is 1 inch every 3 (item #3) into place. Test the pump by cycling to maximum
seconds under no load and 1 inch every 11 seconds under load. pressure several times.
6. Flow can also be measured by pumping into an open
beaker or pan. Correct flow should be 40 cu.in. per minute
at zero psi and 10 cu.in. per minute at 9,500 psi. This value
should be linear from 0-10,000 psi.
HYDRAULIC BODY TEARDOWN
Refer to figures 1 through 5 on Repair Parts Sheet. 10. Line up the vent hole on the reservoir can to the release
body and line up the screw holes in the can with the
1. Remove the fill plug (item #26) and drain the oil from the
threaded holes in the body.
reservoir.
11. Lightly set the reservoir assembly on the body and roll the
2. The air motor assembly (item #21) and base plate must be
bladder lip down past the groove on the body.
removed from the pump at this time. Follow steps 1 and 2 of
the air motor teardown instructions. 12. Slowly pull the reservoir away from the body until the lip
slips into the groove on the body. Feel around the groove to
3. Loosen and remove the relief valve assembly (item #23) and
make sure that the bladder lip is fully settled into the groove
the coupler assembly (item #10). These two steps will allow
and evenly push the can back onto the body while lining up
the treadle (item #1) to be removed from the pump body
the screw holes.
(item #20). Place the loose hardware (items #12 & #13) aside.
13. Install the four screws (item #2) and snug up.
4. Remove the reservoir assembly (item #25) by loosening the
four 1/8" allen head screws (item #2) and pulling the reservoir DO NOT OVER-TIGHTEN.
away from the hydraulic body. Inspect the bladder for tears or 14. Grease the seat (item #24) and place the gasket (item #5) in
holes. If defective, replace the reservoir assembly (item #25). place and position it in the relief valve port.
5. With a 1" wrench remove the release assembly (item #6). 15. Position the treadle (item #1), and with the ball greased in
Also remove the ball (item #7), spring (item #29), ball seat place on the relief valve assembly (item #23), thread the
(item #4), both gaskets (items #5 & #8), and o-ring (item #3). relief valve through the treadle and into the pump body.
6. With a 7/8" wrench remove the hydraulic cylinder assembly Torque to 25 ft-lbs.
(item #17) and ball (item #7). 16. Place the gasket (item #5) with grease on the seat (item #19)
7. Remove the oil filter (item #9). and drop it into the swivel coupler port.
8. This will leave the hydraulic body containing three seats and 17. Place the guide (item #13) into the coupler port. Make sure
gaskets. Remove the seats (items #19 & #24), gaskets (item it lies flat. Drop the ball (item #12) into the guide.
#5),and the spring under the release seat (item #29). 18. Make sure the spring is in the swivel coupler assembly (item
9. Follow figures 2,3,4 & 5 while replacing all the soft seals #10), and then screw the swivel assembly through the
and service items included in the repair kits for each treadle and into the body. Torque to 25 ft-lbs.
individual assembly item. 19. Fill the reservoir with oil and turn in the fill plug (item #26).
Be sure to tighten only finger tight.
HYDRAULIC BODY ASSEMBLY 20. Follow steps 11 through 14 of the air motor assembly for
attachment of the air motor to the pump body and test the
Refer to figures 1 through 6 on the Repair Parts Sheet. pump.
NOTE: Before assembling the seats (figure 1, items #4, #19, &
#24), pre-coin at 200 psi on a 10 ton press. After
replacement of all kit parts on individual items is
complete, begin to re-assemble the pump.
1. Apply grease to the ridged side of the seat (item #19) and
position the gasket (item #5) into place so that the grease
keeps the gasket in place. Drop the seat and gasket into the
port hole for the hydraulic cylinder, gasket first. Drop the ball
in (item #7) and position it on the seat.
2. Thread the rebuilt hydraulic cylinder (item #17) into the hole
and torque to 25 ft-lbs.
3. Place a new spring (item #29) into the release assembly port
on the hydraulic body with the large diameter down. Make
sure the spring is pushed into the housing as far as it can go.
4. Position the gasket (item #5) with grease on the release
assembly (item #6) and insert the seat (item #4). Place the
ball (item #7) onto the seat with grease to hold the ball in
position when inverted.
5. Drop the large gasket (item #8) into the release port and replace
and grease the o-ring (item #3) in the groove in the port.
6. Thread the release assembly (item #6) (with gasket, seat and
ball in place) into the body. Torque to 92-96 ft-lbs.
7. Place a new oil filter (item #9) into the pump body.
8. Hold the reservoir assembly (item #25) and slightly fold the
bladder down inside the can. Apply a light film of grease to
the upper 1" of the inside of the can.
9. Pull the bladder away from the body and roll the bladder lip
down past the groove on the body.

2
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Technical Inquiries:
techservices@enerpac.com 02/13/06

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