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

Cordless hydraulic pumps - dump & hold
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Operation and Maintenance Manual
XC2 Series Cordless Hydraulic Pumps - Dump & Hold
Models XC2302S and XC2304S
Document Number: L4588
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 - Dump & Hold Models XC2302S and XC2304S Document Number: L4588 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 ............................. 13 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 Always use a saddle to protect the plunger. repaired before being used. • 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 XC2302S and XC2304S 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 Electric Solenoid XC2302S Operated, 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 XC2304S 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 XC2302S & XC2304S 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 XC2302S and XC2304S...

  • 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 Be sure that any residual hydraulic pressure inside 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 various hydraulic components and devices typically recommended for Key: use with a single-acting cylinder or tool. However, actual items required 4. Coupler (male) 7.
  • Page 12 To ensure compatibility and proper operation, use NOTICE Run time between battery charges is mostly only the specified Enerpac 54V Lithium-Ion battery with dependent on the pressure required for the application. the pump. Refer to Section 3.5 for battery specifications The higher the required pressure setting, the shorter the and model number.

  • Page 13: Operation

    7.0 OPERATION Connect the remote pendant to the connector on the front of the pump housing. Refer to instructions in Section 5.3. 7.1 Power Switch If ordered with the pump: Attach the shoulder strap (optional accessory) to the ring at each end of the The pump is equipped with a two-position rocker style pump carrying handle.
  • Page 14 NOTICE If the motor still fails to start, take the pump to • Hydraulic flow is blocked when the solenoid valve is an Enerpac authorized service center for inspection and de-energized. However, the pump is not designed to diagnosis. hydraulically hold or support the load while persons are working in the area.

  • Page 15: Maintenance

    If the pump will not operate electrically via the pendant controls when the battery is Refer to procedure in Section 7.9. fully charged, take the pump to an Enerpac authorized If a pressure gauge has been installed, verify that service center for diagnosis and repair.
  • Page 16 Check oil for contamination by comparing the color of the With the power switch in the ON (      ❙       ) position, press oil in the reservoir fill tube to new unused Enerpac HF oil. and hold the DUMP button to relieve any Unused Enerpac HF oil is a crisp blue color.
  • Page 17 Remove the oil fill plug and fill the reservoir with Press and hold the JOG button to start the new Enerpac oil. Refer to Section 8.2 for hydraulic motor. While the motor is running, check the gauge oil requirements and Section 8.3 for detailed oil fill reading to verify the relief valve pressure setting.
  • Page 18 5/16 inch 7/32 inch Figure 15: Relief Valve Pressure Adjustment g. After adjusting the pressure setting, release the NOTICE Maximum system pressure limited JOG button to stop the motor. Then, press and approximately 10,400-10,800 psi [717 - 744 bar] by an hold the DUMP button to relieve hydraulic internal safety relief valve.

  • Page 19: Cleaning

    WARNING To avoid a shock hazard, do not insert any objects inside the vents. Do not spray water or cleaners The Enerpac Connect App is available for download on inside the vents. the Apple App Store and on Google Play.
  • Page 20 If pump starts and operates normally, repair or replace the pendant. 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 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 Troubleshooting Guide (continued) Problem Possible Cause Action 4. Cylinder advances and d. Pump element internal Contact Enerpac authorized service center. retracts erratically leakage, wear and/or damage. (continued) 5. Pump slows down Battery discharged. Charge battery. Replace battery if it is damaged and stops.

  • Page 23: Repair Parts Section

    14.0 REPAIR PARTS SECTION CONTENTS PAGE FIGURE 16: MAIN ASSEMBLY ......................... 24 FIGURE 17: SHROUD HALVES & PENDANT ....................26 FIGURE 18: RIGHT-HAND SHROUD COMPONENTS ..................28 FIGURE 19: PUMP BASE ASSEMBLY ......................30 FIGURE 20: POWER UNIT & RESERVOIR ASSEMBLY .................. 32 FIGURE 21: CONTROL VALVE ASSEMBLY, 3-WAY, 2-POSITION, SOLENOID-OPERATED ......
  • Page 24 Figure 16: Main Assembly 25A, 25C, 25D XC2302S 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. Torque to 8-24 oz-in [0.06 - 0.17 Nm]. Torque to 120-144 in-lbs [13.6 - 16.3 Nm].
  • Page 25 Parts List for Figure 16 Part Number Item Description Model XC2302S Model XC2304S Screw, SHCS Hex, M5 CBZ517028-1A CBZ517028-1A  Pin, 6 mm x 45 mm Lg DD3417059 DD3417059  Cable Tie, Screw Mount DD7326217 DD7326217  Cable Assembly, 3/2 Sol Valve DD7336960SR DD7336960SR Grommet...
  • Page 26 Figure 17: Shroud Halves & Pendant 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]. Item 15 is supplied with all XC2300 Series pumps as standard equipment. L4588_e...
  • Page 27 Parts List for Figure 17 Part Number Item Description Model XC2302S Model XC2304S 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 18: Right-Hand Shroud Components Circuit App Board Connections Pendant 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 18 Item Description Part Number Screw, M4 x 10 Thrd FRM DD3883028  Shroud, Right-Hand DD7921424  Retainer, XC2 Oil Fill DD7926160 ✫ Circuit App Board DD7929827  Tube, Oil Vent DD7962268  Threaded Insert, Oil Fill DD7966225 ✫...
  • Page 30 Figure 19: 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. L4588_e...
  • Page 31 Parts List for Figure 19 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 20: 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]. Torque to 90-95 ft-lbs [122.0 - 128.8 Nm]. Secure with Loctite 2760 thread locking compound. Refer to manufacturer’s technical data sheet for application instructions. Install on eccentric housing (item 23).
  • Page 33 Parts List for Figure 20 Part Number Item Description Model XC2302S Model XC2304S Ball Cap A8038570 A8038570  Spring, Compression A8126110 A8126110  Ball, 0.125, Stl B1003016 B1003016  Ball, 0.156, Stl B1004016 B1004016  O-Ring, Round, 0.219, 0.344, 0.063 B1004503 B1004503 ★ ...
  • Page 34 Press fit, 125-175 psi [8.6 - 12.0 bar] on a 10 ton press. Torque to 10-12 ft-lbs [13.6 - 16.2 Nm]. Coin 125-175 psi [8.6 - 12.0 bar] on a 10 ton press with 1/4" ball (Enerpac part no. B1007016). Coin 50-75 [3.4 - 5.2 bar] psi on a 10 ton press.
  • Page 35 Parts List for Figure 21 Item Description Part Number Ball, 0.063, Steel B1001016 ✪ O-Ring, Round, 0.625, 0.813, 0.094 B1012503   ✪ O-Ring, Round, 0.875, 1.125, 0.125 B1017503   ✪ Spring Pin, 0.094, 0.250, Stl, Plain B1032057 ✪ Retaining Ring, SAP DC7754359 ✪...
  • Page 36 Figure 22: 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. L4588_e...
  • Page 37 Parts List for Figure 22 Item Description Part Number Ring Gear DC7089228  Bearing DC7096155  Assembly, Eccentric Shaft (See Figure 23)  Key, Ring Gear DC7452251    Bushing DC7464108  Eccentric Housing DD8425001  Items included in Eccentric Housing Service Kit, XC2ECK. ...
  • Page 38 Figure 23: Eccentric Shaft Assembly Sectional View Note: Position grey coated side of thrust washer (item 4) toward eccentric (item 3). Figure 24: Pump Element L4588_e...
  • Page 39 Parts List for Figure 23 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 40 Figure 25: 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 41 Parts List for Figure 25 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 42 • 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 43 ECC541N Power Cord, United Kingdom - 240V ECC542U Parts List for Figure 27 Item Description Part Number Shoulder Strap, XC2 Series Pumps SSTRP55 Corded Remote Pendant, 20 ft [6 m] CC132 Pendant Extension Cord, 10 ft [3 m] CC010 L4588_e...
  • Page 44 Figure 28: Hydraulic Schematic PUMP OUTLET PORT 24VDC 2 POSITION, 3 WAY DIRECTIONAL CONTROL VALVE CHECK (ELECTRIC SOLENOID OPERATED) VALVE USER-ADJUSTABLE RELIEF VALVE ELECTRIC MOTOR PUMP Note: Pump internal safety relief valve set at 10,400- OIL INTAKE FILTER 10,800 psi [717 - 744 bar]. HYDRAULIC RESERVOIR L4588_e...
  • Page 45 Figure 29: Electrical Schematic L4588_e...
  • Page 46 NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ L4588_d...
  • Page 47 NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ L4588_d...
  • 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...

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