Enerpac XC2 Series Operation And Maintenance Manual
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Enerpac XC2 Series Operation And Maintenance Manual

Cordless hydraulic pumps
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Operation and Maintenance Manual
XC2 Series Cordless Hydraulic Pumps
Models XC2202M and XC2204M
Document Number: L4586
Document Revision: E
Issue Date: January 2024
Language: English
EN
To reduce the risk of injury, user must read and understand this document before use.

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  • Page 1 Operation and Maintenance Manual XC2 Series Cordless Hydraulic Pumps Models XC2202M and XC2204M Document Number: L4586 Document Revision: E Issue Date: January 2024 Language: English To reduce the risk of injury, user must read and understand this document before use.
  • Page 2 XXX kg | XXX lbs AAXXXXXXXXXX Assembled in the USA Note: A typical XC2 Series nameplate is shown above. Nameplate data will vary depending on pump model and configuration. AVAILABLE LANGUAGES An electronic copy of this document is available online in multiple languages: •...

  • Page 3: Table Of Contents

    CONTENTS PAGE SAFETY ..............................4 COMPLIANCE ............................6 PRODUCT DATA ............................7 FEATURES AND COMPONENTS ......................9 DESCRIPTION ............................10 BATTERY ..............................11 OPERATION ............................. 12 MAINTENANCE ............................15 CLEANING ............................... 19 10.0 STORAGE ..............................19 11.0 SAFE DISPOSAL PROCEDURE ......................19 12.0 FIRMWARE UPDATES ..........................

  • Page 4: Safety

    All hoses, fittings and couplers used force hydraulic tools is required prior to the operation of with the pump must be rated at 10,150 psi [700 bar] the pump. If training is needed, contact your local Enerpac minimum. distributor or authorized service center for information •...
  • Page 5 • Avoid situations where loads are not directly centered • Use the Enerpac XC2 Series pump only with the on the cylinder plunger. Off-center loads produce specified Enerpac 54 volt Li-Ion battery. Use of any considerable strain on cylinders and plungers.

  • Page 6: Compliance

    Understand the meaning of each symbol before using the pump. Selected symbols are shown in the following chart: Enerpac declares that the model XC2202M and XC2204M cordless hydraulic pumps have been tested and conform to applicable standards and are approved to carry the CE,...

  • Page 7: Product Data

    3.0 PRODUCT DATA 3.1 Specifications Sound For Use With Operating Temp Range* Motor Rating Motor Speed Pump Hydraulic Pressure** Control Valve Cylinder or Models Connection Tool Type: ˚ F ˚ C Lever Operated, XC2202M Manual 3-way, Single-acting 3/8" NPTF +14 to +122 -10 to +50 0.94 0.70...
  • Page 8 Pendant Extension Cord, 10 ft [3 m] CC010 XC2204M Shoulder Strap, XC2 Series Pumps SSTRP55 Note: Refer to Enerpac website or catalog for a complete description of available pump accessories. 3.7 External Dimensions Dimension Models XC2202M & XC2204M Item inch 11.7...

  • Page 9: Features And Components

    16. Battery Charger 17. Remote Pendant Item may be included with pump or may need to be purchased sepa- rately. Refer to Enerpac website or catalog for ordering information. Optional Accessory Figure 1: Features & Components, Models XC2202M and XC2204M...

  • Page 10: Description

    Refer to Figure 4 for an example of a typical single- acting system setup. The Enerpac XC2 Series cordless pumps combine the performance of a powered pump with the portability of a To prevent the pump from starting while hydraulic hand operated pump.

  • Page 11: Battery

    Note: Hydraulic components are sold separately and are not included with the pump. Note: Shown in this graphic are Key: various hydraulic components and 1. Swivel Connector 4. Coupler (male) 7. Safety Holding Valve devices typically recommended for 2. Pressure Gauge 5.

  • Page 12: Operation

    To ensure compatibility and proper operation, use by the pump’s built-in trigger or the optional remote only the specified Enerpac 54V Lithium-Ion battery with pendant. The trigger switch and pendant buttons are the pump. Refer to Section 3.5 for battery specifications non-functional when the power switch is in the OFF ( O ) and model number.
  • Page 13 Pump relief valve is factory set to approximately 10,150 psi [700 bar]. If a lower setting is desired, readjust the relief valve pressure as described in Section 8.5. 7.3 Operating Precautions WARNING Never allow any personnel to be under an object that is being supported only by the pump hydraulics.
  • Page 14 7.6 Remote Pendant Operation To stop the pump motor at any time, fully release the trigger switch. A corded remote pendant is available as an optional accessory. 7.5 Control Valve Operation The pendant cable connection is located on the front of The pump’s manual control valve is operated by a rotary the pump, beside hydraulic port “A”.

  • Page 15: Maintenance

    Be sure the pump is on a level surface. NOTICE If motor still fails to start, take pump to an Enerpac Remove the oil fill plug from the fill opening. Use a authorized service center for inspection and diagnosis.
  • Page 16 Check oil for contamination by comparing the color of the pump power switch is in the OFF (      O       ) position. oil in the reservoir fill tube to new unused Enerpac HF oil. Remove the oil fill plug from the fill opening. Use a Unused Enerpac HF oil is a crisp blue color.
  • Page 17 Turn off the pump power switch ( O ). 10. Remove the oil fill plug and fill the reservoir with new Enerpac oil. Refer to Section 8.2 for hydraulic Relieve any residual hydraulic pressure and oil requirements and Section 8.3 for detailed oil fill disconnect the hydraulic hose from the pump “A”...
  • Page 18 5/16 inch 7/32 inch Figure 16: Relief Valve Pressure Adjustment g. After adjusting the pressure setting, release the NOTICE Maximum system pressure limited trigger switch to stop the motor. approximately 10,400-10,800 psi [717 - 744 bar] by an internal safety relief valve. h.

  • Page 19: Cleaning

    Do not spray water or cleaners inside the vents. The Enerpac Connect App is available for download on the Apple App Store and on Google Play. • Wipe the pump exterior with a dry, soft cloth. Avoid using strong detergents or cleaners.
  • Page 20 (pumps equipped with the pendant. optional remote pendant only) h. Motor and/or electronic Contact Enerpac authorized service center. control board damaged. i. Pump jammed due to Contact Enerpac authorized service center. obstruction. Possible internal damage to pump.
  • Page 21 “R” position while gently rocking the pump from side-to-side. b. Bypass valve malfunction. Contact Enerpac authorized service center. c. Oil intake screen clogged Contact Enerpac authorized service center. with debris. d. Control valve internal Contact Enerpac authorized service center.
  • Page 22 Refer to procedure in Section 7.9. b. External hydraulic leak. Tighten connections. Replace damaged components. c. Control valve internal Contact Enerpac authorized service center. leakage, wear and/or damage. d. Pump element internal Contact Enerpac authorized service center. leakage, wear and/or damage.

  • Page 23: Repair Parts Section

    14.0 REPAIR PARTS SECTION CONTENTS PAGE FIGURE 17: MAIN ASSEMBLY ......................... 24 FIGURE 18: SHROUD HALVES ........................26 FIGURE 19: RIGHT-HAND SHROUD COMPONENTS ..................28 FIGURE 20: PUMP BASE ASSEMBLY ......................30 FIGURE 21: POWER UNIT & RESERVOIR ASSEMBLY .................. 32 FIGURE 22: RELEASE VALVE &...
  • Page 24 Figure 17: Main Assembly 25A, 25C, 25D XC2202M Only Notes: Torque to 18-26 in-lbs [2-3 Nm]. Secure with Loctite 243 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions. Before installing handle, rotate valve shaft counter-clockwise until it stops. Torque to 120-144 in-lbs [13.6-16.3 Nm].
  • Page 25 Parts List for Figure 17 Part Number Item Description Model XC2202M Model XC2204M Washer, Lock #10 B1086066 B1086066  Screw, SHCS Hex, M5 CBZ517028-1A CBZ517028-1A    Handle, Valve Lever DD3398070 DD3398070  Pin, 6 mm x 45 mm Lg DD3417059 DD3417059 ...
  • Page 26 Figure 18: Shroud Halves Notes: Torque to 18-26 in-lbs [2-3 Nm]. Secure with Loctite 243 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions. Torque to 25-30 in-lbs [2.8-3.4 Nm]. L4586_e...
  • Page 27 Parts List for Figure 18 Part Number Item Description Model XC2202M Model XC2204M Plug, Soc Hd St Thread 0.750-16 B1006006 B1006006  Washer, Flat CAE1050108-1A CAE1050108-1A  Screw, SHCS Hex, M5 CBZ517028-1A CBZ517028-1A  Plug, Dome, 28 mm DD4112009 DD4112009 ...
  • Page 28 Figure 19: Right-Hand Shroud Components Circuit App Board Connections Pendant Trigger Connector Cable Notes: Torque to 120-144 in-lb [13.6 - 16.3 Nm]. Torque to 60-80 in-lb [6.8 - 9.0 Nm]. Torque to 8-10 in-lb [0.9 - 1.1 Nm]. Secure with Loctite 271 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions.
  • Page 29 Parts List for Figure 19 Item Description Part Number Screw, M4 x 10 Thrd FRM DD3883028  Trigger, Variable Speed DD7874372 ✬ Shroud, Right-Hand DD7921424  Retainer, XC2 Oil Fill DD7926160 ✫ Circuit App Board DD7929827  Tube, Oil Vent DD7962268 ...
  • Page 30 Figure 20: Pump Base Assembly Notes: Torque to 18-26 in-lb [2.0 - 3.0 Nm]. Torque to 10-12 in-lb [1.13 - 1.36 Nm]. Pull wires for switch through hole in housing. Pull wires through hole in housing. L4586_e...
  • Page 31 Parts List for Figure 20 Item Description Part Number Screw, Flat Hd M5 CBA517028-1B  Plate, Battery Interface w/Cable DD7953101  Bracket, Motor, XC2 DD8251111 Screw, M5 x 10, Thread Forming,Torx DD8781028   Base, XC2 Pump DD8836005  Switch, Rocker DPST 30 VDC 10A DD8866372SR Items included in 54V Battery Guide Kit, XC2BGK.
  • Page 32 Figure 21: Power Unit & Reservoir Assembly Notes: Torque to 45-60 in-lbs [5.1 - 6.8 Nm]. Torque to 12-15 ft-lbs [16.3 - 20.3 Nm]. Secure with Loctite 2760 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions. Install on eccentric housing (item 16).
  • Page 33 Parts List for Figure 21 Part Number Item Description Model XC2202M Model XC2204M Ball Cap A8038570 A8038570  Spring, Compression A8126110 A8126110  Ball, 0.125, Stl B1003016 B1003016  O-Ring, Round, 0.219, 0.344, 0.063 B1004503 B1004503 ★   ★       O-Ring, Round, 0.313, 0.438, 0.063 B1011803 B1011803...
  • Page 34 Figure 22: Release Valve & Eccentric Housing Assembly 12 10 Notes: Torque valve body to 90-95 ft-lbs [122.0 -128.8 Nm]. Secure with Loctite 243 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions. Lubricate seals before assembly. Apply PTFE tape.
  • Page 35 Parts List for Figure 22 Item Description Part Number Ball, 0.156, Steel B1004016  Ball, 0.250, Steel B1007016 ✾ ★ O-Ring, Round, 0.875, 1.063, 0.094 B1118903 ✾ ★ Set Screw, Flat, HS, M5 CCA513028-5A  Adapter CF927038 Gasket CL344167 ✾ ★ Compression Spring DC10140110 ✾...
  • Page 36 Figure 23: Release Valve Subassembly Sectional View (enlarged) Notes: Apply grease to O-ring and back-up ring after assembly to spindle, before assembly to body. Turn CCW to assemble. Turn in until groove is seen in body through hole. Apply Loctite #243 to threads. Refer to manufacturer’s technical data sheet for application instructions.
  • Page 37 Parts List for Figure 23 Item Description Part Number O-Ring, Viton B1110203 ★ ✾ Back-Up Ring, Split B1110564 ★ ✾ Body, Release Valve DD2988013 ✾ Spindle, Release Valve DD2992010 ✾ Set Screw DD3400027 ✾ Items included in Release Valve Service Kit, XC1MVSK. ✾...
  • Page 38 Figure 24: Eccentric Shaft & Housing Subassembly Notes: Position grey coated side of bushing (item 5) toward eccentric (item 3). Spin test after assembly (1 full eccentric rotation). Use a pick to align the gears with the ring gear. L4586_e...
  • Page 39 Parts List for Figure 24 Item Description Part Number Ring Gear DC7089228  Bearing DC7096155  Assembly, Eccentric Shaft (See Figure 25)  Key, Ring Gear DC7452251    Bushing DC7464108  Eccentric Housing DD8425001  Items included in Eccentric Housing Service Kit, XC2ECK. ...
  • Page 40 Figure 25: Eccentric Shaft Assembly Sectional View Notes: Position grey coated side of thrust washer (item 4) toward lip seal (item 1). Figure 26: Pump Element L4586_e...
  • Page 41 Parts List for Figure 25 Item Description Part Number Lip Seal DC7090476  Eccentric, 4mm DC7117537  Subassembly, Eccentric Shaft DC7870950   Washer, Thrust DC7186108 DC7191251  Spring, Wave DC7750410  Subassembly, Cam DC7755950  Items included in Eccentric Housing Service Kit, XC2ECK. ...
  • Page 42 Figure 27: Pump Element Components 0.59 - 0.63 inch [15.0 - 15.9 mm] Notes: Torque to 9.6-11.8 ft-lb [13 - 16 Nm]. Torque to 44.3-52.3 ft-lb [60 - 71 Nm]. Torque to 18.5-22.1 ft-lb [25 - 30 Nm]. Adjust length of bypass end cap (item 18) to between 0.59-0.63 inch [15.0 - 15.9 mm] from spot face.
  • Page 43 Parts List for Figure 27 Item Description Part Number Plug, Flush, Hex 27.0 Stl Teflon A1006245 ✦ Ball Cap A8038570 ✦ Spring, Compression A8126110 ✦ Ball, 0.125 Stl B1003016 ✦ Ball 0.188 Stl B1005016 ✦ Back Up Ring, Split B1006564 ★ ✦...
  • Page 44 • Charger must be purchased separately if not included in the shipment with the battery or tool. Unit is auto-voltage sensing, 100-240 VAC, 50/60 Hz. • North America, Europe and Australia: Charger and power cord includes one Enerpac EC1F54 battery charger and the AC power cord for use in the selected region. Charger not sold without power cord.
  • Page 45 Power Cord, United Kingdom - 240V ECC542U Parts List for Figure 29 Item Description Part Number Shoulder Strap, XC2 Series Pumps SSTRP55 Corded Remote Pendant, 10 ft [3 m] CC131 Corded Remote Pendant, 20 ft [6 m] CC132 Pendant Extension Cord, 10 ft [3 m]...
  • Page 46 Figure 30: Hydraulic Schematic PUMP OUTLET PORT 3-WAY, 2-POSITION, DIRECTIONAL CONTROL VALVE CHECK VALVE USER-ADJUSTABLE RELIEF VALVE ELECTRIC MOTOR Note: Pump internal safety PUMP relief valve set at 10,400 - 10,800 psi [717 - 744 bar]. OIL INTAKE FILTER HYDRAULIC RESERVOIR L4586_e...
  • Page 47 Figure 31: Electrical Schematic L4586_e...
  • Page 48 ENERPAC TOOL GROUP CORP N86 W12500 Westbrook Crossing Menomonee Falls, WI 53051, USA © 2023 Enerpac Tool Group, All Rights Reserved. www.enerpac.com...

This manual is also suitable for:

Xc2202mXc2204m

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