Enerpac DC8143900 Gebrauchs- und Pflegehandbuch

Torque 120-144 in-lbs

[13,5-16 Nm]

Torque 120-144 in-lbs

[13,5-16 Nm]

Pump Element Date Code

(begins with “A”, “B”, “C” or “D”)

Repair Parts Sheet/Service Instruction Sheet

Z-CLASS Pump Element 3-6

L2596 Rev. G 10/13 For Date Codes Beginning with the Letter “A”, “B”, “C” and “D”

To Protect Your

Warranty, Use Only

ENERPAC Hydraulic

Oil.

Enerpac recommends

that all kit components

be installed to assure

optimum performance of

the repaired product.

Figure 1, Pump Element Assembly (typical)

High-pressure port

By-pass port

Safety relief valve

By-pass valve

Intake

Service Instructions....................... English ................ 10-15

Entretien ........................................ Français .............. 16-24

Serviceanleitung ............................ Deutsch............... 25-33

Istruzioni Di Servizio ...................... Italiano ................ 34-42

Instrucciones De Mantenimiento... Español ............... 43-51

Onderhoudsinstructies .................. Hollands.............. 52-59

Instruções de serviço .................... Português ........... 60-68

Huolto-ohjeet................................. Suomalainen ....... 69-76

Serviceinstrukser ........................... Norsk .................. 77-84

Serviceinstruktioner....................... Svensk ................ 85-92

Service I......................................... Japanese .......... 93-100

ce I................................................. Chinese........... 101-107

Item Figure Description

1 2A, 2B Top Plate Assembly

2 3A, 3B Eccentric Assembly

3 4 Piston Ring Assembly

4 5 Gear Pump Assembly

Torque 144-168 in.-lbs

[16-19 Nm]

Torque 17-19 Ft.-lbs

[23-26 Nm]

Note: Plug installed

in smaller port.

Section A-A

1 ★DC8107101 1

Top Plate 3 Piston (new style)

2 ★DC9240155 1 Bearing, Needle 25x32x16CL

3 ★DC9041776 1 Lip Seal 17x25x4SC

4 ★A1006245 4 1/16 Flush Plug

5 DA5999900SR 1 1/8 NPT Relief Valve

Repair Parts List for Figure 2A

Item Part Number Qty. Description

★ Items included in Repair Kit DC9280900SR

Figure 2A, Top Plate Assembly for Gear Reduction Motor

(ZU Series - All Date Codes)

Item 1 Notes:

•Old style 3 piston top plate DC9223101 used on ZU Series pumps made before 05/2006 is no longer available.

•New style 3 piston top plate DC8107101 can be used as a replacement part for all ZU Series pumps.

1 ⑥DC8350101 1

Top Plate 6 Piston (steel)

②③ DC8351101 1

Top Plate 2 and 3 Piston (steel)

2 ②③⑥ DC9026155 1 Bearing, Needle 40x47x12

3 ②③⑥ DC9027776 1 Oil Lip Seal 40x52x5

4 ③A1006245 2 1/16 Flush Plug (for 3 piston)

②⑥ A1006245 3 1/16 Flush Plug (for 2 & 6 piston)

5 ②③⑥ DA5999900SR 1 1/8 NPT Relief Valve

6 ⑥CCA625028-1A 6 SHCS M6x1.0x30

Repair Parts List for Figure 2B (see graphic above)

Item Part Number Qty. Description

Torque 144-168 in.-lbs

[16-19 Nm]

Torque 17-19 Ft.-lbs

[23-26 Nm]

(2 piston

only)

Section A-A

(6 piston only)

1 ✜DC8105101 1

Top Plate 2 and 3 Piston

2 ✜ DC9026155 1 Bearing, Needle 40x47x12

3 ✜DC9027776 1 Oil Lip Seal 40x52x5

4 ✜A1006245 2 1/16 Flush Plug (for 3 piston)

✜A1006245 3 1/16 Flush Plug (for 2 & 6 piston)

5 ✜DA5999900SR 1 1/8 NPT Relief Valve

6 ✜CCA625028-1A 6 SHCS M6x1.0x30

Repair Parts List for Figure 2B (see graphic above)

Item Part Number Qty. Description

✜ Items included in Repair Kit DC9279900SR (use for 2, 3 or 6 piston)

② Items included in Repair Kit DC9281900SR (2 piston)

③ Items included in Repair Kit DD1121900SR (3 piston)

⑥ Items included in Repair Kit DC9278900SR (6 piston)

Figure 2B, Top Plate Assembly for Direct Drive Motor

(ZE, ZG and ZW Series - Steel Top Plate -

Date Code D only)

Note: For ZE, ZG

and ZW Series

pumps with pump

element date codes

A, B or C, see next

page.

(ZA Series - Aluminum Top Plate -

Date Codes A, B, C and D)

Note: On ZE, ZG and ZW Series pump elements with date code A, B or C, the old aluminum top plate must be replaced with a new steel top

plate, part number DC8350101 (6 piston) or DC8351101 (2 & 3 piston). The eccentric assembly must also be replaced when the top plate is

replaced (old style eccentric assembly is not compatible with new top plate design). Repair kit required will vary, depending on pump model:

❷ Indicates items included in Repair Kit DD1319900SR – Use for 2 piston pump element, date codes A, B or C.

❸Indicates Items included in Repair Kit DD1320900SR – Use for 3 piston pump element, date codes A, B or C.

➏ Indicates Items included in Repair Kit DD1321900SR – Use for 6 piston pump element, date codes A, B or C.

Discard all old top plate parts (items 1-6 of fig. 2B) and all old eccentric parts (items 1, 4, 5 and 6 of fig. 3B). Replace with new kit parts.

IMPORTANT: Failure to install all kit parts will result in permanent damage to pump. Such damage is not covered under warranty.

Torque 144-168 in.-lbs

[16-19 Nm]

Torque 17-19 Ft.-lbs

[23-26 Nm]

(2 piston

only)

Section A-A

(6 piston only)

Figure 2B, Steel Top Plate Assembly for Direct Drive

Motor (Replaces original aluminum top plate assembly -

ZE, ZG and ZW Series - Date Codes A, B and C)

1 ❻DC8350101 1

Top Plate 6 Piston (steel)

❷❸ DC8351101 1

Top Plate 2 and 3 Piston (steel)

2 ❷❸❻ DC9026155 1 Bearing, Needle 40x47x12

3 ❷❸❻ DC9027776 1 Oil Lip Seal 40x52x5

4 ❸A1006245 2 1/16 Flush Plug (for 3 piston)

❷❻ A1006245 3 1/16 Flush Plug (for 2 & 6 piston)

5 ❷❸❻ DA5999900SR 1 1/8 NPT Relief Valve

6 ❻CCA625028-1A 6 SHCS M6x1.0x30

Repair Parts List for Figure 2B (see graphic above)

Item Part Number Qty. Description

IMPORTANT: ZE, ZG and ZW Series pumps with pump element date code A, B or C:

New top plate and eccentric must be replaced as a set. Be sure to install ALL kit parts (see bottom of page).

Figure 3B, Eccentric Assembly for Direct Drive Motor

(Replaces original eccentric assembly - ZE, ZG and ZW

Series - Date Codes A, B and C)

1 ❷❸❻ DC9214537 1 Eccentric, Induction

4 ❷❸❻ BSS4725D 2 Ring

5 ❷❸❻ DC4107155 1 Bearing, Needle 35x42x20

6 ❷❸❻ DC4328350 1 Hex Cam

7 ❷❸❻ DD1277108 1 Locating Washer

Repair Parts List for Figure 3B (see graphic above)

Item Part Number Qty. Description

IMPORTANT: Locating washer (item 7) must be installed on all ZE, ZG

and ZW Series pump elements that are being updated from aluminum

to steel top plate assemblies. Note: Locating washer (item 7) is larger in

diameter than rings (item 4). Be sure to install parts in correct locations.

Figure 3A, Eccentric Assembly for Gear Reduction Motor

(ZU Series - All Date Codes)

1 ★ DC9214537 1 Eccentric, Induction

4 ★BSS4725D 2 Ring

5 ★DC4107155 1 Bearing, Needle 35x42x20

6 ★DC4328350 1 Hex Cam

7 ★DD1277108 1 Locating Washer (used on

ZE, ZG and ZW only)

Repair Parts List for Figure 3B (see graphic above)

Item Part Number Qty. Description

1 ★(not sold 1 Eccentric, Universal

separately)

4 ★BSS4725D 2 Ring

5 ★DC4107155 1 Bearing, Needle 35x42x20

6 ★DC4328350 1 Hex Cam

Repair Parts List for Figure 3A (see graphic above)

Item Part Number Qty. Description

Figure 3B, Eccentric Assembly for Direct Drive

(ZE, ZG and ZW Series - Date Code D Only)

(ZA Series - All Date Codes)

★ Items available as part of Eccentric Assembly kit

DC9238900SR. ★ Items available as part of Eccentric Assembly kit

DC9215900SR.

Note: Locating washer (item 7) is used on all ZE, ZG and ZW pumps

with date code D. Locating washer (item 7) is NOT USED on ZA Series

pump elements.

Note: Locating washer (item 7) is larger in diameter than rings (item 4).

Be sure to install parts in proper locations.

Note: Item 7

not used on

ZA Series

Detail A

See

Detail A

SECTION A-A

SECTION C-C

8910 13 14

Torque to 144-168 in.-lbs

[16,3-19 Nm]

ZRKS

By-pass

cap height

See

Fig. 5A

Figure 4, Piston Ring Assembly (6 Piston Shown)

1 DC9294101 1 Piston Ring 2 Piston

DC9221101 1 Piston Ring 3 Piston

DC9216101 1 Piston Ring 6 Piston

2 A1006245 6 1/16 Flush Plug

3 ✝BSS5358D 6 Seat, Piston Inlet

4 ✝B1005016 12 3/16" Diameter Ball

5 ✝BSS5809D 12 Spring

6 ✝BSS5357D 6 Seat, Piston Outlet

7 ✝BSS5356D 6 Retaining Ring

8 DC9292051 1 Piston Bypass

9 ★B1006564 1 B/U Washer

10 ★B1006803 1 O-ring, 0.25" O.D.

11 ❉DC394110 1 Spring

12 ❉(See Figure 5A) 1 Bypass End Cap

13 ★B1013203 7 O-ring, Viton, 0.56" O.D.

14 ★B1005203 1 O-ring, Viton

15 DC9244920 6 Piston Assembly

16 BSS5509D 6 Spring

17 ★DC9293016 2 Ball Nylon 3/16"

Repair Parts List for Figure 4 (Note: part quantities will vary - quantities for 6 piston shown)

Item Part Number Qty. Description Item Part Number Qty. Description

✝Items included in and available only as a part of Piston Check Kit ZRKS. Each kit includes three sets of components.

Order two kits for six piston pumps.

★Items included in and available only as a part of Seal Kit ZRK.

❉ Models built before October 2008: order a new bypass end cap when replacing spring. See Figure 5A for part numbers.

Notes: See Figure 4A for seat tool drawing. See Figure 5A for bypass cap height and piston ring assembly part number.

Corner must

be Sharp

or Undercut

See

Detail A

.153 .002

.215 .002

.315

Detail A

(scale 4:1)

.166

.030

.188

SECTION A-A

3.930

.379

.395

R.150

.620

1.100

Figure 4A

Figure 5A Specifications, Settings and Repair Kits

Pump Model Pump Element

Replacement Kit

Gear Pump

Replacement Kit

Piston Ring

Replacement Kit

By-Pass

Setting (PSI)

By-Pass End

Cap Height

Relief Valve

Setting (PSI)

ZA4xxxxx DC9705900SR 10KPSI DC9298920SR DC9222900SR 1425 - 1475 0.94" (23.9 mm) ◆10300 - 10800

ZA4xxxTx-E DC9706900SR 11.6KPSI DC9298920SR DC9222900SR 1425 - 1475 0.94" (23.9 mm) ◆11700 - 12000

ZA4xxxTx-Q DC9705900SR 10KPSI DC9298920SR DC9222900SR 1425 - 1475 0.94" (23.9 mm) ◆10300 - 10800

ZE3xxxxx DC9700900SR 10KPSI DC9299920SR DD1106900SR 825 - 875 0.99" (25.1 mm) ▲10300 - 10800

ZE3xxxxx Single

Stage DC9703900SR 10KPSI DC9296920SR DC9282900SR Not

Applicable 0.99" (25.1 mm) ◆10300 - 10800

ZE3xxxx-E DD1505900SR 11.6KPSI DC9299920SR DD1106900SR 825-875 0.99" (25.1 mm) ◆11700 - 12000

ZE4xxxxx DC9704900SR 10KPSI DC9300920SR DD1103900SR 1225 - 1275 0.95" (24.1 mm) ✱10300 - 10800

ZE4xxxxx Single

Stage DC9709900SR 10KPSI DC9296920SR DC9222900SR Not

Applicable 0.99" (25.1 mm) ◆10300 - 10800

ZE4xxxx-E DD1506900SR 11.6KPSI DC9300920SR DD1103900SR 1225 - 1275 0.95" (24.1 mm) ✱11700 - 12000

ZE5xxxxx DC9710900SR 10KPSI DC9301920SR DD1101900SR 1100 - 1150 0.96" (24.4 mm) ✱10300 - 10800

ZE5xxxx-E DD1507900SR 11.6KPSI DC9301920SR DD1101900SR 1100 - 1150 0.96" (24.4 mm) ✱11700 - 12000

ZE5xxxxx Single

Stage DC9713900SR 10KPSI DC9296920SR DC9217900SR Not

Applicable 0.99" (25.1 mm) ✱10300 - 10800

ZE6xxxxx DC9715900SR 10KPSI DC9299920SR DC9217900SR 2400 - 2450 0.85" (21.6 mm) ◆10300 - 10800

ZE6xxxxx Single

Stage DC9713900SR 10KPSI DC9296920SR DC9217900SR Not

Applicable 0.99" (25.1 mm) ✱10300 - 10800

ZG5xxxxx DD1123900SR 10KPSI DC9298920SR DC9222900SR 1600-1650 0.92" (23.4 mm) ◆10300 - 10800

ZG5xxxxx-B DC8143900SR 10KPSI DC9296920SR DC9222900SR 1600-1650 0.92" (23.4 mm) ◆10300 - 10800

ZG6xxxxx DC9715900SR 10KPSI DC9299920SR DC9217900SR 2400 - 2450 0.85" (21.6 mm) ◆10300 - 10800

ZU4xxxxx DC9707900SR 10KPSI DC9299920SR DD1103900SR 1050 - 1100 0.96" (24.4 mm) ✱10300 - 10800

ZU4xxxTx-E DC9708900SR 11.6KPSI DC9299920SR DD1103900SR 1050 - 1100 0.96" (24.4 mm) ✱11700 - 12000

ZU4xxxTx-Q DC9707900SR 10KPSI DC9299920SR DD1103900SR 1050 - 1100 0.96" (24.4 mm) ✱10300 - 10800

ZW3xxxxx DD1491900SR 5KPSI DC9296920SR DD1492900SR 1400 - 1450 0.93" (23.6 mm) ▲5300 - 5600

ZW4xxxxx DC9717900SR 5KPSI DC9298920SR DD1103900SR 1100 - 1150 0.96" (24.4 mm) ✱5300 - 5600

ZW4xxxxx Single

Stage DC9718900SR 5KPSI DC9296920SR DC9222900SR Not

Applicable 0.99" (25.1 mm) ◆5300 - 5600

ZW5xxxxx DC9714900SR 5KPSI DC9300920SR DD1101900SR 1025 - 1075 0.99" (25.1 mm) ✱5300 - 5600

ZW5xxxxx Single

Stage DC9719900SR 5KPSI DC9296920SR DC9217900SR Not

Applicable 0.99" (25.1 mm) ◆5300 - 5600

6, 7

Figure 5, Gear Pump Assembly

Key to Figure 5A - By-Pass End Cap Height:

◆Use bypass end cap DC9208020 (Figure 4, Item 12).

✱Use bypass end cap DC8373020 (Figure 4, Item 12).

▲Use bypass end cap DC8374020 (Figure 4, Item 12).

1 1 Gear Pump

2 ✝DC9219155 1 Bearing Ball 20x52 x15

3 ★✝ B1400503 1 O-ring

4 ★✝ B1402503 1 O-ring

5 CCA633028-1A 12 SHCS M6x1.0 x50

(6 piston only)

6 ✜DC9638101 1 Intake Spacer

7 DC9642097 1 Intake Elbow

Repair Parts List for Figure 5

Item Part Number Qty. Description

★ Items included in and available only as a part of Seal Kit ZRK.

✝ Items included in complete gear pump replacement kit.

See chart in Figure 5A.

✜Intake spacer used only on pump elements with date codes

“A” and “B”.

Figure 6

Pressure port

Safety relief valve

Low pressure

by-pass valve

(closed)

Circular groove in

gear pump feeds all

piston inlet checks

(up to 6 sets)

Gear pump

Intake

Inlet check

Outlet check

1.0 FIRST STAGE, LOW PRESSURE - HIGH FLOW

1st stage = low pressure – high flow

• By-pass valve is closed.

• All low-pressure gear pump flow is routed through the high-pressure pistons inlet and outlet checks, (up to six sets) and then

out the pressure port.

Low Pressure, High Flow

Intake Oil

Figure 7

2.0 SECOND STAGE, HIGH PRESSURE - LOW FLOW

2nd stage = high pressure – low flow

• By-pass opens at pre-set pressure.

• Low pressure, gear pump flow, supercharges high pressure pistons. Remaining gear pump oil returns to tank via the by-pass

valve.

• Eccentric driven piston reciprocates to build high pressure.

Pressure port

Safety relief valve

Return to tank

to oil cooler

Low pressure

by-pass valve

(open) Circular groove in

gear pump feeds all

piston inlet checks

(up to 6 sets)

Gear pump

Intake

Inlet check

Outlet check

High Pressure, Low Flow

Low Pressure, High Flow

Intake Oil

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 for installation, operation, and maintenance

information.

■REQUIRED TOOLS AND TEST EQUIPMENT:

✓Hydraulic hand pump capable of 10,000 psi

✓Test bench with sump, ammeter, V152 valve,

flow meter, and test cylinder

✓High pressure gauge (0-15,000 psi)

✓High pressure hose (10,000 psi working pressure rating)

✓Torque wrench (torque rating)

✓Magnet to remove check balls

✓O-ring pick

✓Flat bottom punch 5/32"

✓Flat bottom punch 11/64"

✓White Assembly grease

✓Allen wrench 5 mm

✓Enerpac Hydraulic Oil

✓VM2, 3 way, 2 position, directional control valve

✓Hydraulic press

✓Seat assembly tool #DC9505816 (drawing available

from Enerpac)

✓Retaining Ring Tool #AT0229 (drawing available from

Enerpac)

1.0 TROUBLESHOOTING

Problem Possible Cause Action

Motor current draw is

excessive or trips

circuit breaker.

Pump runs and delivers

flow, but will not build

pressure.

Low or no flow at

0 psi.

Pump fails to maintain

pressure.

a) Low voltage at pump.

b) Defective motor.

c) Bypass valve malfunction.

d) Damaged or worn gear pump.

e) Power cord damaged or wiring incorrect.

a) Defective or misadjusted external

relief valve.

b) Oil leaks from one or more

components within the reservoir.

c) Valve malfunction or improper

adjustment.

d) Bypass valve worn.

a) Motor rotation reversed (3-phase only).

b) Bypass valve is malfunctioning.

c) Pump component parts are leaking.

d) Oil intake screen is clogged with debris.

e) Gear pump malfunction.

f) Direction valve malfunction or improper

adjustment.

a) Defective directional valve.

b) Defective final outlet check.

c) Oil leaks from one or more

components within the pump

assembly or valve assembly.

a) Check voltage at pump while pump is at operating

pressure. If below 90% of rated line voltage replace

extension cord with heavier gauge and/or move to

another electric circuit.

b) Remove the motor. Test and replace if necessary.

c) Inspect, test, and adjust the bypass valve. Replace or

rebuild if required.

d) Remove and inspect the gear pump.

Replace if necessary.

e) Replace or repair as necessary.

a) Inspect the relief valve. Reset or replace if required.

b) Perform the back-pressure test.

c) Adjust or repair.

d) Remove and inspect the bypass valve. Rebuild or

replace if necessary.

a) Reverse 2 of 3 motor wire connections.

b) Remove and inspect the bypass valve. Rebuild or

replace if necessary.

c) Perform the backpressure test to isolate leaks.

d) Remove the pump from the reservoir and inspect the

intake screen. Flush components of contamination.

Replace damaged components and hydraulic oil.

e) Disassemble the pump and inspect the gear pump.

Replace if necessary.

f) Adjust or repair.

a) Repair or replace.

b) Repair or replace.

c) Remove the pump from the reservoir and perform the

back-pressure test outlined in test procedure.

Service Instructions

Z-Class Pump 3-6

L2596 Rev. G 10/13

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