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To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch...

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1 2 Notes: Apply Loctite 243 to threads. Torque capscrews in a crossing pattern to ensure even sealing of gaskets. 114 32 44 42 31 Torque 60 - 75 in-lbs. [6.8 - 8.5 Nm] 1 2 43 49 41 35 36 Torque 50 - 60 in-lbs. [5.6 - 6.8 Nm] Torque 11.0 - 13.0 ft-lbs. [14.9 - 17.6 Nm] 1 37 POWERFUL SOLUTIONS. GLOBAL FORCE. L2907 Rev. D 11/13 For Date Codes Beginning with the Letter “B” Repair Parts Sheet Electric Torque Wrench Pump ZU4T Classic Series Figure 1, Reservoir Assembly To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil. Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product. Repair Parts List for Figure 1 Item Part Number Qty. Description Item Part Number Qty. Description 31 DC9379025SR 1 Reservoir, 4L (includes items 32, 35, 36 and 37) 41 SBZ-4 1 Skid Bar w/o Heat Exch. SBZ-4L 1 Skid Bar w/ Heat Exch. DC8136025SR 1 Reservoir, 8L (includes items 32, 35, 36 and 37) 42 (See Figure 3) 1 Assembly, Pump 43 S3037 13 Gasket 32 DC9596026 2 Decal, Enerpac 44 CBE619028-1A 13 Screw, SHCS M6 x 16 35 DC85900SR 1 Sight Glass, 4L and 8L 49 CBE817028-1E 4 BHCS M8 x 12 mm 36 DC8249006 1 Plug, Magnetic, SAE #8 114 DC9920026 1 Decal, Read Instructions 37 DC9551920 1 Gasket, Reservoir Items included in and available only as part of Repair Kit ZU4TK. Skid bar includes screws, item 49.
Transcript
Page 1: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

1

2

Notes:Apply Loctite 243 to threads.

Torque capscrews in a crossing patternto ensure even sealing of gaskets.

114

32

44

42

31

Torque60 - 75 in-lbs.[6.8 - 8.5 Nm]

1 2

43

49

41

35

36

Torque50 - 60 in-lbs.[5.6 - 6.8 Nm]

Torque11.0 - 13.0 ft-lbs.[14.9 - 17.6 Nm]

1

37

POWERFUL SOLUTIONS. GLOBAL FORCE.

L2907 Rev. D 11/13 For Date Codes Beginning with the Letter “B”

Repair Parts Sheet

Electric Torque Wrench PumpZU4T Classic Series

Figure 1, Reservoir Assembly

To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.Enerpac recommends that all kit components be installed to insure optimum performance of the repaired product.

Repair Parts List for Figure 1Item Part Number Qty. Description Item Part Number Qty. Description

31

DC9379025SR 1Reservoir, 4L (includes

items 32, 35, 36 and 37) 41

✦ SBZ-4 1 Skid Bar w/o Heat Exch.

✦ SBZ-4L 1 Skid Bar w/ Heat Exch.

DC8136025SR 1Reservoir, 8L (includes

items 32, 35, 36 and 37)

42 (See Figure 3) 1 Assembly, Pump

43 ★ S3037 13 Gasket

32 ★ DC9596026 2 Decal, Enerpac 44 CBE619028-1A 13 Screw, SHCS M6 x 16

35 DC85900SR 1 Sight Glass, 4L and 8L 49 CBE817028-1E 4 BHCS M8 x 12 mm

36 DC8249006 1 Plug, Magnetic, SAE #8 114 DC9920026 1 Decal, Read Instructions

37 ★ DC9551920 1 Gasket, Reservoir

★ Items included in and available only as part of Repair Kit ZU4TK. ✦ Skid bar includes screws, item 49.

Page 2: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

Figure 2A, Pump Assembly (exploded view)

50

45

65

106109

51

66656

4 7

4

6

6967

62

107

2 7

102

68

66 6564

55

56

57

54

52

Notes:Torque to 16 - 19 ft-lbs. [21.7 - 25.8 Nm]

Torque to 84 - 108 in-lbs. [9.5 - 12.2 Nm]

Torque to 18 - 26 in-lbs. [2.0 - 2.9 Nm]

Apply Loctite 545 to threads.

4

2

6

7

69

Torque84 - 108 in-lbs[9.5 - 12.2 Nm]

105

104

Control Panel Overlay

103

113

2

Page 3: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

Figure 2B, Pump Assembly (side view)

59

108115

47 48 50 61 58 60

65

5

5 8

4 7

Notes:Torque to 84 - 108 in-lbs. [9.5 - 12.2 Nm]Torque to 36 - 40 in-lbs. [4.1 - 4.5 Nm]

Apply Loctite 545 to threads.

Apply Loctite 243 to threads.

4

5

7

8

7071

Repair Parts List for Figures 2A and 2BItem Part Number Qty. Description Item Part Number Qty. Description

★ Items included in and available only as part of Repair Kit ZU4TK.

45 DC9405111 1 Back Bracket

47 B1223503 1 O-Ring

48 DC9538021 1 Lock Nut 20mm

50 CBE615028-1A 2 SHCS M6X10mm

51 DC9435009 2 Dome Plug 1"

52 DC9436009 2 Dome Plug 16mm

54 (See Figure 8)1 Motor, 115V ZU4

1 Motor, 230V ZU4

55 DC9401298 1 Baffl e, Lower ZU4

56 DC9400298 1 Baffl e, Middle ZU4

57 DC9400298 1 Baffl e, Upper ZU4

58 (See Figure 4) 1 Assembly, Middle Bracket

59

DC9444960 1 Power Cord - 115V 15 Amp

DC9445960 1 Power Cord - 230V

w/NEMA 5-15 plug

DC8288960 1 Power Cord - 230V Europe-

an plug, CE RF Compliant.

60 (See Figure 4) 1 Assembly, Front Bracket

61 DC6876647 5 Cable Tie, Black

62 DC9640424 1 Enclosure, Left ZU4

64 DC9641424 1 Enclosure, Right ZU4

65 CBE619028-1A 15 SHCS M6X1X10

66 CAE1060108-1A 9 6mm Washer

67 DC9414424 1 Brush Cap, Left

68 DC9413424 1 Brush Cap, Right

69 ★DC9598026 1 Decal, Brush Cap

70 ★DD1432037 1 Gasket, Valve

71 (See RPS L2908) 1 Valve, Torque Wrench

102 DD1393026 1 Label

103 DC8241037 1 Gasket, Overlay

104 DC8240026 1 Overlay

105 CBE415028-1A 4 SHCS M4

106 DC9740969 1 Ferrite

107 DC9661066 1 Washer, Wavy

108 DC9653028 2 Bolt, #10-32 x 6.5"

109 DC9951405 1 Velcro, 2"

113 CBE1040120-1D 4 Nut, M4

115 B1080066 2 Washer, Lock

148 DC8260026 1 Decal, Spec (not shown)

320 DC7078900 1 Kit, Overlay (not shown)

See Repair Parts Sheet L2752

Heat Exchanger(Optional Accessory)

Control Valve & ManifoldAssemblies (item 71)

See Repair Parts Sheet L2908

3

Page 4: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

This view shows parts for pumps equippedwith a heat exchanger (optional accessory).

Used only on.models withoutheat exchangerassembly.

Torque to30 - 32 in-lbs.[40 - 43 Nm]

Torque to72 - 84 in-lbs.[8.1 - 9.5 Nm]

26 10 11

12A Torque to15 - 18 ft-lbs.[20 - 24 Nm]

13A

27

21

24

2223

15

17

305

25

29 28

19A

Torque to15 - 18 ft-lbs.[20 - 24 Nm]

Torque to15 - 18 ft-lbs.[20 - 24 Nm]

2X Torque to20 - 22 ft-lbs.[27 - 30 Nm]

1Note:Apply Loctite 545 to threads.

1

18

Torque to5 - 7 in-lbs.[.5 - .8 Nm]

1

301

Torque to 15 - 18 ft-lbs.[20 - 24 Nm]

Torque to 45 - 47 ft-lbs.[61 - 64 Nm]

Torque to 45 - 47 ft-lbs.[61 - 64 Nm]

30

126

12B, 19B, 20

13B

126

20

19B

12B

126

Figure 3, Pump Coverplate and Element Assembly

Repair Parts List for Figure 3Item Part Number Qty. Description Item Part Number Qty. Description

10 (See RPS L2596) 1 Pump Element Assy. 22 ★ BSS0368D 1 Back-up

11 F100094-246 1 Fitting 5-4 FTX-S 23 ★ B1012803 1 O-Ring

12A F100097-16 1 Fitting, Standard Pump 24 ★ DC9271167 1 Copper Gasket

12B F100097-16 2 Fitting, Heat Exc. Pump 25 ★ DC9551920 1 Gasket, Universal Pump

13A DC9335646 1 Hose, Bypass 8" 26 CBE621028-1A 2 SHCS, M6 X 20

13B DC9416646 1 Hose, Heat Exc. Pump 23" 27 DC9447920 1 Tube Assy, Steel, ZU

15 DC9407101 1 Cover Plate, Universal 28 DC9600268 1 Intake Tube, 1.6" 4L & 8L

17 B1007006 1 Plug SAE #10 29 DC9178118 1 Intake Filter

18 B1006006 1 Plug, Socket, SAE #8 30 DC9418646 1 Return Hose, Heat Exc.

19A B1006006 2 Plug, SAE #8 Std. Pump 126 DC9639299 2 Clamp, Heat Exc. Pump

19B DC9273097 2 Fitting, Heat Exc. Pump 301 DC8250006 1 Breather Assembly

20 ★ B1908503 2 O-Ring, Heat Exc. Pump 305 F100096-38 1 Adapter Fitting

21 DC9173690 1 Connector Fitting

★ Items included in Seal Kit ZU4TK.

4

Page 5: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

5

Figure 4, Front and Middle Bracket Assemblies

Repair Parts List for Figure 4Item Part Number Qty. Description Item Part Number Qty. Description

48 DC9538021 2 Locking Nut, 20mm 143 CCE1060108-6A 1 Starwasher, 6mm

52 DC9436009 1 Plug, Dome, 16mm 144 DC8307372 1 Switch, Motor

53 DC9437009 1 Plug, Dome, 20mm 145 DC8230108 1 Ring, Locking

80 DC8354111 1 Bracket, Middle, PT/BTW 146 CBE1060120-1D 1 Nut, 6mm

81 DC8193398 1 Contactor 147

DC8309380 1 Circuit Breaker, 12A (230V)

82 CBE415028-1A 6 Screw, SHCS M4 x 10 DC8308380 1 Circuit Breaker, 25A (115V)

83 DC8279480 1 Transformer 148 DC8200380 1 Cap, Circuit Breaker

84 DC8280980 1 Relay 149 DC8292026 1 Decal, On-Off

86 DC9922026 1 Decal, High Voltage 150 DC8237026 1 Decal, CB Reset

87 DD1273960 1 Cable, Solenoid 260 ▲ DC8317960 1 Wire, Contactor to timer

88 DD1275900 1 Pendant Assy (See Fig. 5) 261 ▲ DD1263960 1 Power Cable, Solenoid

89 DA3639028 2 Self Tapping Screw 263 ▲ DC8314960 2 Wire, Transformer Output

140 DC8353111 1 Bracket, Front, PT/BTW 264 ▲ DC8313960 2 Wire, Contactor to Transformer

141 CBE625028-1A 1 Screw, M6 x 1 x 30 Zinc 266 ▲ DD1264960 1 Wire, Contactor to relay and timer

142 DC8281784 1 Timer, 15 Sec. BTW

▲ Items 260 through 266 not shown.

89142

147

140

87

150

148

14552

144

146

82

83

PendantAdvance

Switch

BreakerTransformer Input115V/230V

TransformerOutput 24V

81

8086

82

53

88

141

149

142

143

48

84

2 4

4

5

4

41

42

Notes:Included with switch assembly.

Apply Loctite 243 to threads.

Wires 260 through 266 not shown.

Torque to 14 - 16 in-lbs. [1.6 - 1.8 Nm]

Torque to 5 - 7 in-lbs. [.56 - .79 Nm]

2

1

3

4

5

3

See Figure 10 for electrical diagram.

Page 6: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

6

95

93

99

96

97

91

97

Torque4.0-4.5 in-lbs

[0.45-0.50 Nm]

Torque14-16 in-lbs[1.6-1.8 Nm]

9492

90101

Figure 5, Pendant Assembly

Repair Parts List for Figure 5Item Part Number Qty. Description Item Part Number Qty. Description

90 DC9425424 1 Enclosure, Lower 95 DC8284379 2 Switch Cover

91 DD1276960 1 Pendant Wire, BTW 96 DC9428008 4 Screw, Hi-Low #8 x 1/2

92 DC8282379 1 Pendant Button, NO 97 B1223503 2 O-Ring

93 DC8283379 1 Pendant Button, NC 99 DC8127026 1 Decal, Pendant

94 DC8122424 1 Enclosure, Upper 101 DD1394026 1 Decal, Pressure Relief

Note: Pendant Kit DD1275900SR includes all items shown above.

Page 7: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

7

102 101 175 147 146 11385

Note: Apply Loctite 243

Repair Parts List for Figure 6Item Part Number Qty. Description Item Part Number Qty. Description

85 E1001352 4 Flag Connector, 1/4" 146 DC9583960 1 Ground Earth Wire

101 DC9580380 1 RF In-line fi lter 147 DD1590960 1 RF Filter Cable (brown)

102 DC8290111 1 CE Bracket 148 DD1591960 2 RF Filter Cable (blue)

113 CBE1040120-1D 2 Nut, M4 175 DC9579382 1 Capacitor, 1 Microfarad

Figure 6, Shroud Assembly with R/F Filter (CE Models Only)

Page 8: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

8

124

127

123

Hoses cross before threading through bushings.

Use Loctite #243.Torque to 120-144 in-lbs.[13.6-16.3 Nm]

Note: Refer to Enerpac Repair PartsSheet L2752 for additional heat exchangerparts information.

126

125

Figure 7, Heat Exchanger, 115 and 230 VAC Fan

Repair Parts List for Figure 7Item Part Number Qty. Description 123 ✛ ✾ DC9690808 2 Grommet Rubber .69"-1"

124 ✛ ✾ CBE615028-1A 1 M6X10 SHCS

125 ✛ DC8375900 1 Heat Exch Assy, 115 VAC

✾ DC8376900 1 Heat Exch Assy, 230 VAC

126 ✛ ✾ DC9639299 2 Hose Clamp, 3/8-7/8

127 ✛ ✾ DC9537021 1 Locking Nut, 16 mm

✛ Items included as part of Heat Exchanger Kit ZHE-U115 (115V).

✾ Items included as part of Heat Exchanger Kit ZHE-U230 (230V).

Page 9: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

9

204A 204B 205 206

201

203

200

Figure 8, Motor Assembly

Repair Parts List for Figure 8Item Part Number Qty. Description

85 ▲ ▼ E1001181 2 Terminal, Flag

(not shown)

200 Not available - Housing (order

complete motor)

201 ▲ DC8246736 1 Armature, 115V, ZU4

▼ DC8247736 1 Armature, 230V, ZU4

203 ▲ ▼ DC9661066 1 Spring Washer

204A ▲ ▼ DC9653028 2 Bolt #10-32 x 6.5"

204B ▲ ▼ B1080066 2 Washer, Lock

205 ▲ ▼ DC9656259 2 Brush, ZU4

206 ▲ ▼ DC9655020 2 Brush Cap, ZU4

▲ Items included as part of DC8244259SR Motor Kit (115V).

▼ Items included as part of DC8245259SR Motor Kit (230V).

Repair Parts List for Figure 9Item Part Number Qty. Description241 ✜ ✲ CBE817028-1E 4 BHCS M8 x 12

242A ✜ DC8040920 1 Roll Cage,

4L & 8 L, w/o HX

242B ✲ DC8323920 1 Roll Cage,

4L & 8 L, w/ HX

✜ Items included as part of roll bar kit ZRC-04.

✲ Items included as part of roll bar kit ZRC-04H.

242A242B

241 Torque11.0 - 13.0 ft-lbs.[14.9 - 17.6 Nm]

NOTES:Apply Loctite 2431

1

Figure 9, Roll Bar Assembly

Page 10: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

WARNING: Disconnect power cord from outlet beforeremoving pump shroud or beginning any repairs.

Figure 10, Electrical Diagram, ZU4 Classic Torque Wrench Pump (View 1 of 2)

10

Page 11: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

11

DESCRIPTION a2 b1 b2 RA TR C M1 & M2 S1OFF eleased released OFF OFF OFF STOP OFFON re

released released ON OFF OFF STOP OFF

C, M1 and M2 will be off after the time delay

ON releasedpressed

and released

ON ON ON RUN ON

ON pressed released OFF OFF OFF STOP OFF

Figure 10, Electrical Diagram, ZU4 Classic Torque Wrench Pump (View 2 of 2)

Page 12: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

Tro

uble

sho

otin

g G

uid

e

Sym

pto

ms:

Pro

bab

le C

ause

s:C

heck

and

/or

insp

ect:

Co

rrec

tive

Act

ion:

1. P

ump

doe

s no

t st

art

whe

n O

N/A

DV

b

utto

n is

pre

ssed

.

a.

Po

wer

co

rd u

np

lug

ged

.a.

Is t

he p

ow

er

co

rd p

lug

ged

-in?

a.

No

: P

lug

-in t

he p

ow

er

co

rd.

b. P

um

p o

n/o

ff s

witch in “

OF

F”

po

sitio

n.

b. Is

the s

witch in t

he “

OF

F”

po

sitio

n?

b. Yes: M

ove t

he s

witch t

o t

he “

ON

” p

ositio

n.

c.

No

po

wer

or

line v

oltag

e t

oo

lo

w.

c.

Do

es t

he p

ow

er

outlet

pro

vid

e t

he r

eq

uired

vo

ltag

e

and

curr

ent?

Check d

escrip

tio

n, check lin

e v

oltag

e,

check lin

e f

uses/c

ircuit b

reaker.

c.

No

: R

ep

lace b

low

n f

uses a

nd

/or

chang

e o

ver

to a

n o

utlet

with t

he a

pp

rop

riate

vo

ltag

e a

nd

curr

ent

rating

.

d. P

ow

er

co

rd d

am

ag

ed

.d

. A

re t

here

any v

isib

le d

am

ag

es (kin

ks, lo

ose w

ire,

mis

sin

g insula

tio

n, etc

.) o

n t

he p

ow

er

co

rd?

d. Yes: R

ep

lace t

he p

ow

er

co

rd.

e.

Pend

ant

co

rd d

am

ag

ed

.e.

Are

there

any v

isib

le d

am

ag

es (kin

ks, lo

ose w

ire,

mis

sin

g insula

tio

n, etc

.) o

n t

he p

end

ant

co

rd?

e.

Yes: R

ep

lace t

he p

end

ant

co

rd.

f. P

um

p c

ircuit b

reaker

(A1) tr

ipp

ed

.f.

Is

the p

um

p c

ircuit b

reaker

butt

on e

xte

nd

ed

?f.

Yes: P

ush t

he p

um

p c

ircuit b

reaker

butt

on t

o r

eset.

g. M

oto

r b

rushes n

eed

rep

lacem

ent.

g. A

re t

he b

rushes w

orn

do

wn (.2

5"

or

less), d

am

ag

ed

or

burn

t-o

ut?

g. Yes: R

ep

lace t

he b

rushes.

h.

Tra

nsfo

rmer

(m3) d

efe

ctive. ◆

h.

Is 2

4 V

AC

pre

sent

at

the t

ransfo

rmer

seco

nd

ary

term

inals

?

h.

No

: R

ep

lace t

he t

ransfo

rmer

(m3).

i.

Rela

y (R

A) d

efe

ctive. ◆

i.

Is t

he r

ela

y (R

A) energ

ized

when t

he O

N/A

DV

butt

on

(b2) is

dep

ressed

?

i.

No

: R

ep

lace t

he r

ela

y (R

A).

j.

Tim

er

mo

dule

(T

R) d

efe

ctive. ◆

j.

Do

es t

he t

imer

Mo

dule

“T

R”

co

nta

ct

clo

se w

hen t

he

ON

/AD

V b

utt

on (b

2) is

dep

ressed

?

j.

No

: R

ep

lace t

he t

imer

mo

dule

(T

R).

k.

Co

nta

cto

r (C

) d

efe

ctive. ◆

k.

Do

the c

onta

cto

r “C

” co

nta

cts

clo

se w

hen t

he O

N/

AD

V b

utt

on (b

2) is

dep

ressed

?

k.

No

: R

ep

lace t

he c

onta

cto

r (C

).

l.

Pum

p e

lem

ent

mechanic

ally

blo

cked

. ◆

l.

Do

es t

he m

oto

r (M

1) tr

y t

o s

tart

bu

t n

ot

rota

te w

hen

the m

oto

r is

sw

itched

-on?

l.

Yes: R

em

ove a

nd

insp

ect

the p

um

p e

lem

ent.

Rep

air o

r

rep

lace if

necessary

. R

efe

r to

En

erp

ac R

ep

air P

art

s S

heet

L2596 f

or

ad

ditio

nal in

form

atio

n.

2. P

ump

sto

ps

runn

ing

dur

ing

idle

or

norm

al

oper

atio

n.

a.

Po

wer

co

rd d

am

ag

ed

.a.

Is t

here

any v

isual d

am

ag

e (kin

ks, lo

ose w

ire,

mis

sin

g insula

tio

n, etc

.) o

n t

he p

ow

er

co

rd?

a.

Yes: R

ep

lace t

he p

ow

er

co

rd.

b. Lin

e v

oltag

e t

oo

lo

w.

b. D

oes t

he p

ow

er

outlet

pro

vid

e t

he r

eq

uired

vo

ltag

e

and

curr

ent?

Check d

escrip

tio

n, check lin

e v

oltag

e,

check lin

e f

uses/c

ircuit b

reaker.

b. N

o: R

ep

lace b

low

n f

uses a

nd

/or

chang

e o

ver

to a

n o

utlet

with t

he a

pp

rop

riate

vo

ltag

e a

nd

curr

ent

rating

.

c.

Pum

p c

ircuit b

reaker

(A1) tr

ipp

ed

.c.

Is t

he p

um

p c

ircuit b

reaker

butt

on e

xte

nd

ed

?c.

Yes: P

ush t

he p

um

p c

ircuit b

reaker

butt

on t

o r

eset.

d. A

uto

matic s

hut-

off

has o

ccurr

ed

.d

. D

oes t

he p

um

p m

oto

r shut

off

ap

pro

xim

ate

ly 1

5-2

0

seco

nd

s a

fter

the O

N/A

DV

butt

on is r

ele

ased

?

d. Yes: N

orm

al o

pera

tio

n. T

imer

mo

dule

(T

1) auto

matically

shuts

-off

pum

p if

the O

N/A

DV

butt

on is n

ot

dep

ressed

ag

ain

within

ap

pro

xim

ate

ly 1

5-2

0 s

eco

nd

s.

◆ I

t is

reco

mm

end

ed

that

these t

roub

lesho

oting

ste

ps b

e p

erf

orm

ed

by a

n E

nerp

ac A

uth

orize

d S

erv

ice C

ente

r.

To

fi n

d y

our

neare

st

Enerp

ac A

uth

orize

d S

erv

ice C

ente

r,

ple

ase v

isit u

s a

t w

ww

.ene

rpac

.co

m.

C

onta

ct

info

rmatio

n f

or

Enerp

ac w

orld

wid

e lo

catio

ns c

an b

e f

ound

on t

he b

ack p

ag

e o

f th

is d

ocum

ent.

Im

po

rtan

t: a

ll re

pair p

roced

ure

s s

ho

uld

be p

erf

orm

ed

on

ly b

y a

tra

ined

and

qualifi

ed

rep

air t

echnic

ian.

W

AR

NIN

G: D

isco

nnect

po

wer

co

rd f

rom

outlet

befo

re

rem

ovin

g p

um

p s

hro

ud

or

beg

innin

g a

ny r

ep

airs.

12

Page 13: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

13

Tro

uble

sho

otin

g G

uid

e (C

ont

inue

d)

Sym

pto

ms:

Pro

bab

le C

ause

s:C

heck

and

/or

insp

ect:

Co

rrec

tive

Act

ion:

3. W

renc

h d

oes

not

adva

nce

whe

n O

N/A

DV

but

ton

is

dep

ress

ed a

nd h

eld

d

own.

a.

User

ad

justa

ble

relie

f valv

e s

et

too

lo

w.

a.

Is p

ressure

set

hig

h e

no

ug

h f

or

the b

oltin

g

ap

plic

atio

n?

a.

No

: R

ais

e r

elie

f valv

e p

ressure

. R

efe

r to

Enerp

ac

Instr

uctio

n S

heet

L2906 f

or

ad

justm

ent

pro

ced

ure

.

b.

To

rque g

reate

r th

an w

rench c

ap

acity a

t fu

ll

pre

ssure

.

b.

Is t

orq

ue w

rench s

ized

to

o s

mall?

b.

Yes: U

se t

orq

ue w

rench w

ith larg

er

cap

acity.

c.

Ad

vance fl o

w lin

e r

estr

icte

d o

r b

locked

.c. Is

a r

estr

ictio

n in fl o

w s

usp

ecte

d?

c. Y

es: C

heck c

oup

lers

fo

r fu

ll eng

ag

em

ent.

d.

Ad

vance s

ole

no

id c

oil

(S1) d

efe

ctive. ◆

d.

Is lin

e v

oltag

e p

resent

at

term

inals

of

ad

vance

so

leno

id c

oil

(S1)?

d.

Yes: R

ep

lace a

dvance s

ole

no

id c

oil

(S1).

e.

Rela

y (R

A) d

efe

ctive. ◆

e.

Do

es t

he r

ela

y (R

A) clo

se w

hen t

he O

N/A

DV

butt

on

(b2) is

dep

ressed

?

e.

No

: R

ep

lace t

he r

ela

y (R

A).

f.

Co

ntr

ol valv

e o

ut

of

ad

justm

en

t o

r d

am

ag

ed

. ◆

f.

Is t

he c

ontr

ol valv

e o

pera

ting

pro

perly?

f.

No

: R

ep

air o

r re

pla

ce c

ontr

ol valv

e. R

efe

r to

Enerp

ac

Rep

air P

art

s S

heet

L2

90

8 f

or

ad

ditio

nal in

form

atio

n.

g.

Pum

p e

lem

ent

wo

rn o

r d

am

ag

ed

. ◆

g.

Do

es t

he p

um

p a

pp

ear

to b

e o

pera

ting

pro

perly?

g.

No

: R

em

ove a

nd

insp

ect

the p

um

p e

lem

ent.

Rep

air o

r

rep

lace if

necessary

. R

efe

r to

En

erp

ac R

ep

air P

art

s S

heet

L2596 f

or

ad

ditio

nal in

form

atio

n.

4. W

renc

h w

ill n

ot

retr

act

whe

n O

N/

AD

V b

utto

n is

re

leas

ed.

a.

Retu

rn fl o

w lin

e r

estr

icte

d o

r b

locked

.a. Is

a r

estr

ictio

n in fl o

w s

usp

ecte

d?

a. Y

es: C

heck c

oup

lers

fo

r fu

ll eng

ag

em

ent.

b.

Co

ntr

ol valv

e o

ut

of

ad

justm

en

t o

r d

am

ag

ed

. ◆

b.

Is t

he c

ontr

ol valv

e o

pera

ting

pro

perly?

b.

No

: R

ep

air o

r re

pla

ce c

ontr

ol valv

e. R

efe

r to

Enerp

ac

Rep

air P

art

s S

heet

L2

90

8 f

or

ad

ditio

nal in

form

atio

n.

c.

Pum

p e

lem

ent

wo

rn o

r d

am

ag

ed

. ◆

c.

Do

es t

he p

um

p a

pp

ear

to b

e o

pera

ting

pro

perly?

c.

No

: R

em

ove a

nd

insp

ect

the p

um

p e

lem

ent.

Rep

air o

r

rep

lace if

necessary

. R

efe

r to

En

erp

ac R

ep

air P

art

s S

heet

L2596 f

or

ad

ditio

nal in

form

atio

n.

5. P

ump

doe

s no

t au

tom

atic

ally

shu

t-off

aft

er O

N/A

DV

b

utto

n is

rel

ease

d.

a.

Tim

er

mo

dule

(T

R) d

efe

ctive.

a.

Do

es t

he p

um

p c

ontinue r

unnin

g f

or

mo

re t

han 2

0

seco

nd

s a

fter

the O

N/A

DV

butt

on is r

ele

ased

?

a.

Yes: R

ep

lace T

imer

Mo

dule

(T

R).

◆ I

t is

reco

mm

end

ed

that

these t

roub

lesho

oting

ste

ps b

e p

erf

orm

ed

by a

n E

nerp

ac A

uth

orize

d S

erv

ice C

ente

r.

To

fi n

d y

our

neare

st

Enerp

ac A

uth

orize

d S

erv

ice C

ente

r, p

lease v

isit u

s a

t w

ww

.ene

rpac

.co

m.

C

onta

ct

info

rmatio

n f

or

Enerp

ac w

orld

wid

e lo

catio

ns c

an b

e f

ound

on t

he b

ack p

ag

e o

f th

is d

ocum

ent.

Im

po

rtan

t: a

ll re

pair p

roced

ure

s s

ho

uld

be p

erf

orm

ed

on

ly b

y a

tra

ined

and

qualifi

ed

rep

air t

echnic

ian.

Co

ntinued

on n

ext

pag

e

W

AR

NIN

G: D

isco

nnect

po

wer

co

rd f

rom

outlet

befo

re

rem

ovin

g p

um

p s

hro

ud

or

beg

innin

g a

ny r

ep

airs.

Page 14: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

14

Tro

uble

sho

otin

g G

uid

e (C

ont

inue

d)

Sym

pto

ms:

Pro

bab

le C

ause

s:C

heck

and

/or

insp

ect:

Co

rrec

tive

Act

ion:

6. P

ump

fails

to

bui

ld p

ress

ure

or

bui

lds

less

tha

n fu

ll p

ress

ure.

a.

Lo

w o

il le

vel.

a.

Check o

il le

vel in

sig

ht

gla

ss. Is

oil

level lo

w?

a.

Yes: A

dd

oil

as r

eq

uired

. R

efe

r to

Enerp

ac Instr

uctio

n

Sheet

L2906 f

or

instr

uctio

ns.

b.

Relie

f valv

e s

et

too

lo

w. ◆

b.

Is t

he r

elie

f valv

e s

et

too

lo

w f

or

the a

pp

licatio

n?

b.

Yes: R

ais

e t

he r

elie

f valv

e s

ett

ing

. R

efe

r to

Enerp

ac

Instr

uctio

n S

heet

L2906 f

or

ad

justm

ent

pro

ced

ure

.

c.

Exte

rnal syste

m leak.

c.

Is a

n e

xte

rnal le

ak v

isib

le?

c.

Yes: R

ep

air leak(s

) as r

eq

uired

.

d.

To

rque w

rench m

alfunctio

nin

g.

d.

Do

es t

he t

orq

ue w

rench a

pp

ear

to b

e o

pera

ting

pro

perly?

d.

No

: R

ep

air t

orq

ue w

rench in a

cco

rdance w

ith

manufa

ctu

rer'

s instr

uctio

ns.

e.

Co

ntr

ol valv

e o

ut

of

ad

justm

en

t o

r d

am

ag

ed

. ◆

e.

Is t

he c

ontr

ol valv

e o

pera

ting

pro

perly?

e. N

o: R

ep

air o

r re

pla

ce c

ontr

ol valv

e. R

efe

r to

Enerp

ac

Rep

air P

art

s S

heet

L2

90

8.

f.

Pum

p e

lem

ent

wo

rn o

r d

am

ag

ed

. ◆

f. D

oes t

he p

um

p a

pp

ear

to b

e o

pera

ting

pro

perly?

f. N

o: R

em

ove a

nd

insp

ect

the p

um

p e

lem

ent.

Rep

air o

r

rep

lace if

necessary

. R

efe

r to

En

erp

ac R

ep

air P

art

s S

heet

L2596 f

or

ad

ditio

nal in

form

atio

n.

7. P

ump

run

s ho

t.a.

Ad

vance o

r re

tract

fl o

w r

estr

icte

d.

a. Is

a r

estr

ictio

n in fl o

w s

usp

ecte

d?

a. Y

es: C

heck c

oup

lers

fo

r fu

ll eng

ag

em

ent.

b.

Hig

h a

mb

ient

tem

pera

ture

.b

. Is

the p

um

p r

unnin

g h

ot?

b.

Yes: In

sta

ll a h

eat

exchang

er.

c.

Heat

exch

an

ger

airfl o

w r

estr

icte

d (m

od

els

eq

uip

ped

with h

eat

exchang

er

only

).

c.

Is h

eat

exch

an

ger

airfl o

w o

bstr

ucte

d?

c.

Yes:

Rem

ove a

ny d

irt

fro

m h

eat

exch

an

ger

ven

ts.

Be s

ure

that

airfl o

w is n

ot

ob

str

ucte

d b

y o

bje

cts

or

walls

.

d.

Heat

exchang

er

fan n

ot

op

era

tio

nal

(mo

dels

eq

uip

ped

with h

eat

exchang

er

only

).

d.

Do

es t

he f

an t

urn

-on w

hen t

he p

um

p m

oto

r is

on?

d.

No

: C

heck h

eat

exchang

er

fan m

oto

r and

wirin

g. R

ep

air o

r

rep

lace c

om

po

nents

as r

eq

uired

.

◆ I

t is

reco

mm

end

ed

that

these t

roub

lesho

oting

ste

ps b

e p

erf

orm

ed

by a

n E

nerp

ac A

uth

orize

d S

erv

ice C

ente

r.

To

fi n

d y

our

neare

st

Enerp

ac A

uth

orize

d S

erv

ice C

ente

r, p

lease v

isit u

s a

t w

ww

.ene

rpac

.co

m.

C

onta

ct

info

rmatio

n f

or

Enerp

ac w

orld

wid

e lo

catio

ns c

an b

e f

ound

on t

he b

ack p

ag

e o

f th

is d

ocum

ent.

Im

po

rtan

t: a

ll re

pair p

roced

ure

s s

ho

uld

be p

erf

orm

ed

on

ly b

y a

tra

ined

and

qualifi

ed

rep

air t

echnic

ian.

W

AR

NIN

G: D

isco

nnect

po

wer

co

rd f

rom

outlet

befo

re

rem

ovin

g p

um

p s

hro

ud

or

beg

innin

g a

ny r

ep

airs.

Page 15: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

15

NOTES:

Page 16: To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.4 1 4 2 4 Notes: Included with switch assembly. Apply Loctite 243 to threads. Wires 260 through 266 not shown. Torque to 14

Australia and New ZealandActuant Australia Ltd.

Block V Unit 3

Regents Park Estate

391 Park Road

Regents Park NSW 2143

(P.O. Box 261) Australia

T +61 (0)2 9743 8988

F +61 (0)2 9743 8648

[email protected]

Brazil Power Packer do Brasil Ltda.

Rua Luiz Lawrie Reid, 548

09930-760 - Diadema (SP) - Brazil

T +55 11 5525 2311

Toll Free: 0800 891 5770

[email protected]

CanadaActuant Canada Corporation

6615 Ordan Drive, Unit 14-15

Mississauga, Ontario L5T 1X2

T +1 905 564 5749

F +1 905 564 0305

Toll Free:

T +1 800 268 4987

F +1 800 461 2456

[email protected]

ChinaActuant (China) Industries Co. Ltd.

No. 6 Nanjing East Road,

Taicang Economic Dep Zone

Jiangsu, China

T +86 0512 5328 7500

F +86 0512 5335 9690

Toll Free: +86 400 885 0369

[email protected]

France, Switzerland, North Africa and French speaking African countriesENERPAC

Une division d’ACTUANT France S.A.

ZA de Courtaboeuf

32, avenue de la Baltique

91140 VILLEBON /YVETTE

France

T +33 1 60 13 68 68

F +33 1 69 20 37 50

[email protected]

Germany and AustriaENERPAC GmbH

P.O. Box 300113

D-40401 Düsseldorf

Willstätterstrasse 13

D-40549 Düsseldorf, Germany

T +49 211 471 490

F +49 211 471 49 28

[email protected]

IndiaENERPAC Hydraulics Pvt. Ltd.

No. 1A, Peenya Industrial Area

IInd Phase, Bangalore, 560 058, India

T +91 80 40 792 777

F +91 80 40 792 792

[email protected]

ItalyENERPAC S.p.A.

Via Canova 4

20094 Corsico (Milano)

T +39 02 4861 111

F +39 02 4860 1288

[email protected]

JapanApplied Power Japan LTD KK

Besshocho 85-7

Kita-ku, Saitama-shi 331-0821, Japan

T +81 48 662 4911

F +81 48 662 4955

[email protected]

Middle East, Egypt and LibyaENERPAC Middle East FZE

Office 423, LOB 15

P.O. Box 18004, Jebel Ali, Dubai

United Arab Emirates

T +971 (0)4 8872686

F +971 (0)4 8872687

[email protected]

RussiaRep. office Enerpac

Russian Federation

Admirala Makarova Street 8

125212 Moscow, Russia

T +7 495 98090 91

F +7 495 98090 92

[email protected]

Southeast Asia, Hong Kongand TaiwanActuant Asia Pte Ltd.

83 Joo Koon Circle

Singapore 629109

T +65 68 63 0611

F +65 64 84 5669

Toll Free: +1800 363 7722

[email protected]

South KoreaActuant Korea Ltd.

3Ba 717, Shihwa Industrial Complex

Jungwang-Dong, Shihung-Shi,

Kyunggi-Do

Republic of Korea 429-450

T +82 31 434 4506

F +82 31 434 4507

[email protected]

Spain and PortugalENERPAC SPAIN, S.L.

Avda. Los Frailes, 40 – Nave C & D

Pol. Ind. Los Frailes

28814 Daganzo de Arriba

(Madrid) Spain

T +34 91 884 86 06

F +34 91 884 86 11

[email protected]

Sweden, Denmark, Norway, Finland and IcelandEnerpac Scandinavia AB

Fabriksgatan 7

412 50 Gothenburg

Sweden

T +46 (0) 31 799 0281

F +46 (0) 31 799 0010

[email protected]

The Netherlands, Belgium, Luxembourg,Central and Eastern Europe, Baltic States, Greece, Turkey and CIS countriesENERPAC B.V.

Galvanistraat 115

6716 AE Ede

P.O. Box 8097

6710 AB Ede

The Netherlands

T +31 318 535 911

F +31 318 535 848

[email protected]

Enerpac Integrated Solutions B.V.Opaalstraat 44

7554 TS Hengelo

P.O. Box 421

7550 AK Hengelo

The Netherlands

T +31 74 242 20 45

F +31 74 243 03 38

[email protected]

South Africa and other English speaking African countriesEnerpac Africa Pty Ltd.

No. 5 Bauhinia Avenue

Cambridge Office Park

Block E

Highveld Techno Park

Centurion 0157

South Africa

T: +27 12 940 0656

United Kingdom and IrelandENERPAC Ltd.,

Bentley Road South

Darlaston, West Midlands

WS10 8LQ

England

T +44 (0)121 50 50 787

F +44 (0)121 50 50 799

[email protected]

USA, Latin America and CaribbeanENERPAC

P.O. Box 3241

Milwaukee WI 53201 USA

T +1 262 293 1600

F +1 262 293 7036

User inquiries:

T +1 800 433 2766

Distributor inquiries/orders:

T +1 800 558 0530

F +1 800 628 0490

Technical inquiries:

[email protected]

[email protected]

Enerpac Worldwide Locations e-mail: [email protected] internet: www.enerpac.com

All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.

For the location of your nearest authorized Enerpac Service Center, visit us atwww.enerpac.com

092713


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