Enerpac ZU4 Series Handbuch

Service Information Sheet

POWERFUL SOLUTIONS. GLOBAL FORCE.

ZU4 Classic Bolting Pump

Single-Solenoid Control Valve Upgrade

INTRODUCTION

This document applies to all Enerpac ZU4 Classic Bolting Pumps

equipped with dual-solenoid valves. It includes instructions for

performing the following product upgrade procedures:

• Replacement of the existing VE Series dual-solenoid control

valve with the new single-solenoid VE Series control valve.

• Replacement of the existing front and middle brackets with

new brackets that are electrically compatible with the single-

solenoid control valve.

ELECTRICAL SERVICE KITS AND VALVES

To upgrade an existing pump to use the new single-solenoid

control valve, a new electrical service kit must rst be installed.

Refer to Table 1 for service kit model numbers and descriptions.

TABLE 1 - ELECTRICAL SERVICE KITS

Pump Voltage Service Kit

Model Number

Description

115V ZTERK-115 ZTW 115V Electrical

Service Kit

230V

NORTH AMERICA

ZTERK-230 ZTW 230V Electrical

Service Kit

230V CE

EUROPE AND ASIA (Contact Enerpac)

Each electrical service kit includes a new front electrical bracket,

middle electrical bracket and pendant. The pump's existing rear

electrical bracket is reused.

New single-solenoid control valves are available in various

voltages and congurations as described in Table 2.

TABLE 2 - CONTROL VALVE MODELS, SINGLE-SOLENOID

Pump

Voltage

Valve Model Description

115V VE42Q-115 115V 10,000 PSI [700 bar]

VE42QM-115 115V 10,000 PSI [700 bar]

- Multiport

VE42E-115 115V 11,600 PSI [800 bar]

VE42EM-115 115V 11,600 PSI [800 bar]

- Multiport

230V VE42Q-230 230V 10,000 PSI [700 bar]

VE42QM-230 230V 10,000 PSI [700 bar]

- Multiport

VE42E-230 230V 11,600 PSI [800 bar]

VE42EM-230 230V 11,600 PSI [800 bar]

- Multiport

Note: Control valves and electrical service kits must be ordered

separately.

230 VOLT CE MODELS  IMPORTANT NOTE

Consult your local Authorized Enerpac Service Center before

beginning electrical upgrade procedures on 230V pumps with

CE style electrical components. Power cord wire colors and

various other wiring details are dierent for 230V CE models.

A complete wiring diagram covering all pump wiring

congurations and voltages - including 230V CE models - is

shown in Figure 14 of this document.

BEFORE YOU BEGIN

WARNING:

Disconnect power from pump before

beginning the following procedure. Be sure hydraulic

pressure is zero (0) psi/bar.

CAUTION:

Standard safety procedures are to be

followed during disassembly and reassembly to

minimize any possibility of injury.

CAUTION:

Allow only trained and qualied personnel

to perform the electrical wiring procedures described in

this document.

IMPORTANT: Some components on the new front and middle

brackets are pre-wired at the factory, prior to shipment Be

careful not to disturb wiring when unpacking the shipment or

during installation procedures.

Note: The graphics contained in this document are provided for

reference and instructional purposes only. Various pump features

and/or congurations may be dierent than shown for your pump.

Optional features may be shown that are not present on your pump.

Figure 1, New Components (typical)

L2915 Rev. B 08/22

Middle Bracket*

VE Series Control

Valve Assembly

(single-solenoid)

Included with

Electrical

Service Kit

Front Bracket

and Pendant

(not shown)

Notes:

• Save the old bracket capscrews for later use. They will be used

to re-secure the new front and middle brackets.

• a new pendant is supplied with the new front bracket. The old

pendant can be discarded.

• Discard the old valve gasket and capscrews. A new gasket and

capscrews are included with the new valve.

INSTALLATION AND WIRING OF NEW FRONT AND

MIDDLE BRACKET ASSEMBLIES

1. Secure the new front and middle brackets to the pump cover

plate, using the capscrews from the old brackets. Apply

Loctite 545 sealant to capscrew threads before installation.

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

WARNING:

Be certain that power cord is disconnected

before making electrical connections in the following

steps.

IMPORTANT: Wire colors and other wiring details are dierent for

230V models sold in the European Union, parts of Asia and various

other regions outside of North America. Refer to the wiring diagram

in Figure 14 of this document for CE style wiring details. Consult your

local Authorized Enerpac Service Center if assistance is required.

2. Connect green (ground) wire from power cord and the green

and yellow striped (solenoid ground) wire to the motor

ground screw. Tighten screw to secure wires. See Figure 6.

3. Insert white (neutral) wire from power cord into L5 terminal of

contactor. Tighten screw on the contactor to secure the wire.

See Figure 7.

4. Connect black (hot) wire of power cord to top pin (pin 1) of

circuit breaker. See Figure 8.

5. Using a wire tie, secure the power cord wires to the top of

the middle bracket. See Figure 9.

REMOVAL OF OLD COMPONENTS

1. Disconnect pump power cord from electrical outlet. Be sure

pressure gauge indicates zero (0) psi/bar.

2. Loosen solenoid plug retaining screws. Unplug solenoid

plugs from old control valve.

3. Remove capscrews and old control valve. Remove and

discard old valve gasket. See Figure 3.

4. Loosen capscrews and remove pump shroud halves. See

Figure 2. Save capscrews for use during reinstallation.

5. Loosen screw at contactor terminal L5. Disconnect white

(neutral) power cord wire from contactor.

6. Disconnect black (hot) power cord wire from top pin (pin 1)

of circuit breaker.

7. Disconnect two black motor wires from terminals T2 and T4

of contactor.

8. At top of motor, disconnect green (ground) power cord wire.

Also disconnect two yellow and green striped solenoid

ground wires.

9. Loosen capscrews and remove the existing front and middle

brackets from the pump cover plate.

Figure 2, Removing the Shroud Halves

Figure 3, Removing Old Valve

Figure 4, Removing Old Front and Middle Brackets

Figure 7, Middle Bracket Contactor Connections

Figure 5, Installing new Front and Middle Brackets

Figure 6, Ground Wire Connection to Pump Motor

MOTOR

GROUND

SCREW

WHITE WIRE

(from power cord)

Terminal L5

of Contactor

C3 C4

TERMINAL L5TERMINALS T2 AND T4

PIN 1 OF

CIRCUIT BREAKER

BLACK WIRES

(from motor)

Terminals T2 and T4

of Contactor

Green Wire

(from power cord)

Green and Yellow

Striped Wire

(from solenoid plug)

Figure 9, Wire Tie Installation (Middle Bracket)

Figure 11, Solenoid Plug

Wire Tie at

Middle Bracket WARNING:

Disconnect power

before making electrical

connections.

WARNING:

Allow only trained

and qualied personnel to

perform the electrical upgrades

described in this document.

IMPORTANT:

230 volt CE models:

Some electrical wire colors will be

dierent. Refer to wiring diagram in

Figure 14 for additional 230V CE wiring

information.

Figure 10, Mounting Screw Securing Gauge Bracket

Figure 8, Front Bracket Connections

BLACK WIRE

(from power cable)

Pin 1 (top pin)

of Circuit Breaker

C3 C4

TERMINAL L5TERMINALS T2 AND T4

PIN 1 OF

CIRCUIT BREAKER

Figure 12, Valve Installation Details

Figure 13, Shroud Reinstallation

INSTALLATION OF NEW VALVE ASSEMBLY

Refer to exploded view in Figure 12 during the following steps.

Refer to other gures as indicated.

1. Install oil return tube into port on bottom of valve manifold.

2. Be sure valve mounting surface on pump coverplate is

clean. Remove any dirt or dust from this area.

3. Install new backup ring and new O-Ring on pump oil supply

tube.

4. Mount the new valve assembly and gasket to the pump

cover plate using the four socket head capscrews provided

with the valve. Apply Loctite 545 sealant to threads of

capscrews as installed. Torque to 16-19 ft-lbs [22-25 Nm].

Note: The front two capscrews are also used to help secure the

gauge bracket. See Figure 10.

5. Plug the solenoid cord into the solenoid to the valve and

hand tighten the plug retaining screw. See Figure 11.

FINAL ASSEMBLY AND TESTING

Install the shroud halves. Torque the shroud mounting screws to

18-20 in-lbs [2,0- 2,9 Nm]. See Figure 13

Check pump for proper operation. Refer to operating instructions

in Enerpac instruction sheet L2906.

Standard Valves

E and Q Series Models

Valves with Multi-Port Manifold

EM and QM Series Models

Key:

1. Capscrews

2. Valve Assembly

3. Gasket

4. Oil Return Tube

5. Multi-Port Manifold

6. O-Ring

7. Back-up Ring

8. Oil Inlet Connection

(on pump)

Line Volt age In

A 1

M 1

115 Vo lts or 230 Volts 60 or 50 Hz., AC

Blac k, 12

Whit e, 12 AW G

Circuit Br eaker

Pump

Motor

Po wer Co rd

DC 8286.96 0 fo r 115V, DC8287960 for 230V

DC8288960 for CE 230V

m 3

Dual Pr imary

Transforme r

25 VA . Cl ass 2

DC 827 9480SR

m 3

LINE EM I In-Line

Filter

F 1

Green, 12

M 2

Heat Exch. Fa n

DC 8276 470 :115V

DC 8277 470 :230V

S 1

Advanc e

Solenoi d

R A

Ri ght

Se condary

24 VA C

Lef t

Pr imary

230 VA C

Ri ght

Se condary

24 VA C

Lef t

Pr imary

115 VA C

Transformer Input Cord

DC 8313960

DC 8312.96 0

for 115 V and 230 V

US A & Cana da

LO AD DC 9580380

CE 230 V

(D C9 583 960

for CE 230 V)

HE Fan Co rd

DC 8346960

HE Fan Co rd

DC 834 6960

DD12 63960

C. L3

RA 6

Sol. Ca ble,

non-rectied, DIN

DD1273 .9 60

Transformer Input Cord

DC8313960

Brown, CE

Blue, CE

Green/Yellow, CE

RA 4

831 5960

K 1

EMI In-Line Capacitor

DC 9579382 for CE 230V.

1 microFarad, 275 Volts

Sol. Cable, non- rectied, DIN. DD1273.960

230 V Models Only

Contacto r

DC 8193398

24 VAC

(from terminals

6 and 10 of transformer

See view 1 of 2)

R A

b 2

MOTO R ON &

CYL. ADVA NC E

b 1

MOTOR OF F/

CYL. RETRAC T

a 2

Co ntrol

ON /OFF Switch

DC 8307372

PE ND AN T

Advance Solenoi d

Re lay

Timer Module

DC 8281784

Pendant Co rd.

DD1276 960

Ca ble, Tran sformer Output

DC 831 4960

Pendan t Co rd

DC 8285 960

Pend ant Co rd

DD 1276960

CO M

ADV

OF F

RA 8

TR 2

TR 6

Ca ble, Time r

to Co ntactor

DC 831 7960

CTR 1

C/SW

Ca ble, Co ntac tor to Relays and Timer Module

DD 1264960

TR 3

Cabl e, Tr ansformer Output

DC 8314960

C/SW

Pendan t Co rd.

DD1276 .9 60

FUNCTIONAL CHART:

DESCRIPTION a2 RA TRTR Cb1 b2 M1 & M2 S1

OF Freleas ed re le ased OF FOFF OF FSTO POFF

ON re leas ed re le ased ON OF FOFF ST OP OF F

C, M1 and M2

will be o 

afte r th e ti me

de la y

ON re leas ed

pres se d

and

re le ased

ON ON ON RUN ON

ON pr e sse drelea se dOFF OF FOFF ST OP OF F

Figure 14, Electrical Diagram, ZU4 Classic Bolting Pump (View 1 of 2)

Line Voltage In

A 1

M 1

115 Vo lts or 230 Volts 60 or 50 Hz., AC

Blac k, 12

Whit e, 12 AW G

Circuit Br eaker

Pump

Motor

Po wer Co rd

DC 8286.96 0 fo r 115V, DC8287960 for 230V

DC8288960 for CE 230V

m 3

Dual Pr imary

Transforme r

25 VA . Cl ass 2

DC 827 9480SR 1

m 3

LINE EM I In-Line

Filter

F 1

Green, 12

M 2

Heat Exch. Fa n

DC 8276 470 :115V

DC 8277 470 :230V

S 1

Advanc e

Solenoi d

R A

Ri ght

Se condary

24 VA C

Lef t

Pr imary

230 VA C

Ri ght

Se condary

24 VA C

Lef t

Pr imary

115 VA C

Transformer Input Cord

DC 8313960

DC 8312.96 0

for 115 V and 230 V

US A & Cana da

LO AD DC 9580380

CE 230 V

(D C9 583 960

for CE 230 V)

HE Fan Co rd

DC 8346960

HE Fan Co rd

DC 834 6960

DD12 63960

C. L3

RA 6

Sol. Ca ble,

non-rectied, DIN

DD1273 .9 60

Transformer Input Cord

DC8313960

Brown, CE

Blue, CE

Green/Yellow, CE

RA 4

831 5960

K 1

EMI In-Line Capacitor

DC 9579382 for CE 230V.

1 microFarad, 275 Volts

Sol. Cable, non- rectied, DIN. DD1273.960

230 V Models Only

Contacto r

DC 8193398

24 VAC

(from terminals

6 and 10 of transformer

See view 1 of 2)

R A

b 2

MOTO R ON &

CYL. ADVA NC E

b 1

MOTOR OF F/

CYL. RETRAC T

a 2

Co ntrol

ON /OFF Switch

DC 8307372

PE ND AN T

Advance Solenoi d

Re lay

Timer Module

DC 8281784

Pendant Co rd.

DD1276 960

Ca ble, Tran sf ormer Output

DC 831 4960

Pendan t Co rd

DC 8285 960

Pend ant Co rd

DD 1276960

CO M

ADV

OF F

RA 8

TR 2

TR 6

Ca ble, Time r

to Co ntactor

DC 831 7960

CTR 1

C/SW

Ca ble, Co ntac tor to Relays and Timer Module

DD 1264960

TR 3

Cabl e, Tr ansformer Output

DC 8314960

C/SW

Pendan t Co rd.

DD1276 .9 60

FUNCTIONAL CHART:

DESCRIPTION a2 RA TRTR Cb1 b2 M1 & M2 S1

OF Freleas ed re le ased OF FOFF OF FSTO POFF

ON re leas ed re le ased ON OF FOFF ST OP OF F

C, M1 and M2

will be o 

afte r th e ti me

de la y

ON re leas ed

pres se d

and

re le ased

ON ON ON RUN ON

ON pr e sse drelea se dOFF OF FOFF ST OP OF F

Figure 14, Electrical Diagram, ZU4 Classic Bolting Pump (View 2 of 2)

Enerpac Worldwide Locations ✦

e-mail:i[email protected]

✦

internet: www.enerpac.com

Africa

ENERPAC Middle East FZE

Office 423, JAFZA 15

P. O. Box 18004

Jebel Ali, Dubai

United Arab Emirates

Tel: +971 (0)4 8872686

Fax: +971 (0)4 8872687

Australia, New Zealand

Actuant Australia Ltd.

Block V Unit 3

Regents Park Estate

391 Park Road

Regents Park NSW 2143

(P.O. Box 261) Australia

Tel: +61 297 438 988

Fax: +61 297 438 648

Brazil

Power Packer do Brasil Ltda.

Rua dos Inocentes, 587

04764-050 - Sao Paulo (SP)

Tel: +55 11 5687 2211

Fax: +55 11 5686 5583

Toll Free in Brazil:

Tel: 0800 891 5770

[email protected]

Canada

Actuant Canada Corporation

6615 Ordan Drive, Unit 14-15

Mississauga, Ontario L5T 1X2

Tel: +1 905 564 5749

Fax: +1 905 564 0305

Toll Free:

Tel: +1 800 268 4987

Fax: +1 800 461 2456

Technical Inquiries:

[email protected]

China

Actuant Industries Co. Ltd.

No. 6 Nanjing Road

Taicang Economic Dep Zone

Jiangsu, China

Tel: +86 0512 5328 7529

+86 0512 5328 7500 7529

Fax: +86 0512 5335 9690

Actuant China Ltd. (Beijing)

709B Diyang Building

Xin No. 2

Dong San Huan North Rd.

Beijing City

100028 China

Tel: +86 10 845 36166

Fax: +86 10 845 36220

Central and Eastern Europe, Greece

ENERPAC GmbH

P. O. Box 300113

D-40401 Düsseldorf

Willstätterstrasse13

D-40549 Düsseldorf

Germany

Tel: +49 211 471 490

Fax: +49 211 471 49 28

France, Switzerland francophone

ACTUANT - ENERPAC

France S.A., ZA de Courtaboeuf

32, avenue de la Baltique

91140 Villebon / Yvettte

France

Tel: +33 1 60 13 68 68

Fax: +33 1 69 20 37 50

Germany, Austria

and Switzerland

ENERPAC GmbH

P. O. Box 300113

D-40401 Düsseldorf

Willstätterstrasse13

D-40549 Düsseldorf

Germany

Tel: +49 211 471 490

Fax: +49 211 471 49 28

India

ENERPAC Hydraulics

(India) Pvt. Ltd.

No. 1A,

Peenya Industrial Area,

llnd Phase

Bangalore, 560 058 India

Tel: +91 80 40 792 777

Fax: +91 80 40 792 792

Italy

ENERPAC S.p.A.

Via Canova 4

20094 Corsico (Milano)

Tel: +39 02 4861 111

Fax: +39 02 4860 1288

Japan

Applied Power Japan LTD KK

Besshochou 85-7

Kita-ku,

Saitama-shi 331-0821

Japan

Tel: +81 48 662 4911

Fax: +81 48 662 4955

Middle East, Turkey and

Caspian Sea

ENERPAC Middle East FZE

Office 423, JAFZA 15

P. O. Box 18004

Jebel Ali, Dubai

United Arab Emirates

Tel: +971 (0)4 8872686

Fax: +971 (0)4 8872687

Russia and CIS

(excl. Caspian Sea Countries)

Actuant LLC

Admiral Makarov Street 8

125212 Moscow, Russia

Tel: +7-495-9809091

Fax: +7-495-9809092

Scandinavia

ENERPAC Scandinavia AB

Fabriksgatan 7

41250 Gothenburg

Sweden

Tel: +46 31 7990281

Fax: +46 31 7990010

Singapore

Actuant Asia Pte. Ltd.

37C, Benoi Road Pioneer Lot,

Singapore 627796

Tel: +65 68 63 0611

Fax: +65 64 84 5669

Toll Free: +1800 363 7722

Technical Inquiries:

[email protected]

South Korea

Actuant Korea Ltd.

3Ba 717,

Shihwa Industrial Complex

Jungwang-Dong, Shihung-Shi, Kyunggi-Do

Republic of Korea 429-450

Tel: +82 31 434 4506

Fax: +82 31 434 4507

Spain and Portugal

ENERPAC SPAIN, S.L.

Avda. Los Frailes, 40 – Nave C & D

Pol. Ind. Los Frailes

28814 DAGANZO DE ARRIBA (Madrid)

Spain

Tel: +34 91 661 11 25

Fax: +34 91 661 47 89

The Netherlands, Belgium,

Luxembourg, Denmark, Norway, Finland

and Baltic States

ENERPAC B.V.

Galvanistraat 115, 6716 AE Ede

P. O. Box 8097, 6710 AB Ede

The Netherlands

Tel: +31 318 535 911

Fax: +31 318 525 613

+31 318 535 848

Technical Inquiries Europe:

[email protected]

United Kingdom, Ireland

Enerpac Ltd

Bentley Road South

Darlaston, West Midlands

WS10 8LQ, United Kingdom

Tel: +44 (0)121 50 50 787

Fax: +44 (0)121 50 50 799

USA, Latin America

and Caribbean

ENERPAC

P. O. Box 3241

6100 N. Baker Road

Milwaukee, WI 53209 USA

Tel: +1 262 781 6600

Fax: +1 262 783 9562

User inquiries:

+1 800 433 2766

Inquiries/orders:

+1 800 558 0530

Technical Inquiries:

[email protected]

ENERPAC

704 W. Simonds

Dallas, TX 75159 USA

Tel: +1 972 287 2390

Fax: +1 972 287 4469

102808

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

For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com

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