Repair Parts Sheet

ZE Series Electric Pumps

Enerpac Level Lift System

Document Document Document Product Date Code

Number Revision Revision Date Beginning With
L4130 A 09/2015 A

NOTICE: Enerpac recommends that all service assembly and kit components
be installed to ensure optimum performance of the repaired product.

Model ZE4420SB-FT-LL
115V • 1Ph • 60 Hz • USA Power Plug

Model ZE4420SE-FT-LL
208-240V • 1Ph • 50 Hz • European Power Plug

Note: Apperance of Level Lift cart

will vary, depending on model.

Table of Contents:
Page Page
Fig. 1A and 1B - Pump, Reservoir and Valve Assy . 2-3 Fig. 9 - Remote Pendant Assembly . . . . . . . . . . . . . . 13
Fig. 2 - Pump Coverplate and Element Assembly. . 4-5 Fig. 10 - Rear E-Box Enclosure Assembly . . . . . . 14-15
Fig. 3 - Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . 6 Fig. 11 - Pressure Transducer Assembly . . . . . . . . . . 16
Fig. 4 - Control Valve Assembly . . . . . . . . . . . . . . . . 7 Fig. 12 - Pump Cable and Cord Ports . . . . . . . . . . . . 16
Fig. 5A and 5B - Control Valve, 4-Way . . . . . . . . . . 8-9 Fig. 13 - Power Board Diagram . . . . . . . . . . . . . . . . . 17
Fig. 6 - Control Valve Manifold Assembly . . . . . . . . . 10 Fig. 14A and 14B - Wiring Diagram . . . . . . . . . . . . 18-19
Fig. 7 - User Adjustable Relief Valve Assembly. . . . . 11 Troubleshooting Procedures . . . . . . . . . . . . . . . . . 20-23
Fig. 8 - Front E-Box Enclosure . . . . . . . . . . . . . . . . . 12

WARNING Before beginning any maintenance or repairs, disconnect pump from AC power supply and be sure that
all pressure gauges indicate zero (0) psi/bar. Appropriate shop and electrical safety procedures are to be followed
during disassembly and reassembly to minimize any possibility of injury.
Note: The quantity of a part included in a kit or repair assembly may be less than the total part quantity shown in the parts list.
 71

65 64
66 63 62
54

149
52

58

72
48

57
55
67
44 2 3

Notes: 42 43
1 Torque to 20-25 ft-lbs [27.1-33.9Nm]

2 Apply Loctite 545 to threads.

3 Torque capscrews in a crossing pattern

to ensure even sealing of gasket.

4 Torque to 120-144 In-lbs [13.6-16.3 Nm].

38
5 Torque to 50-60 In-lbs [5.6-6.8 Nm].
37 40
6 Torque to 35-40 Ft-lbs [47.5-54.2 Nm].
39 4

31

148 35 5

Figure 1A, Pump, Reservoir and Valve Assembly

2
 Repair Parts List for Figures 1A and 1B
Item Part Number Qty. Description Item Part Number Qty. Description
Reservoir, 20 L (includes 57 CBE1025046-1B 4 Motor Mounting Bolt
31 DC9971025SR 1 items 32, 33, 34, 35 and 37 58 DC2669127 3 Wire Nut
32 ★★DC9596026 2 Reservoir Decal 60 DC9741017 2 Cable Tie Mount
33 C187018 1 Magnet, Reservoir 61 DC9876647 2 6" Black Cable Tie
34 DD1425245 1 Flush Plug, 1/2" w/Sealant 62 (See Fig. 11) 1 Rear Enclosure
35 DD1367223SR 1 Sight Glass, 5" 63 DC9936076 1 Seal, Electrical Enclosure
37 ★ DC9551920 1 Reservoir & MPE Gasket 64 (See Fig. 8) 1 Front Enclosure Assembly
38 DC9542920 2 Handle 65 CBE615028-1A 6 SHCS M6X1X10
39 CBE817028-1E 4 BHCS M8 X 16 mm 66 CAE1060108-1A 6 6mm Washer
40 CBE1080120-2A 4 Lock Nut, M8 67 ★★ DC9920026 1 Decal, Read Instruction
42 (See Fig. 2) 1 MPE and Coverplate Assy. 68 ★★ DC9921026 1 Decal, Hot Surface
43 ★ S3037 13 Copper Gasket 69 ★★ DC9953026 1 Decal, ZE Class
44 CBE619028-1A 13 SHCS M6 X 16 mm 71 (See Fig. 3) 1 Oil Filter Assembly
48 DC9538021 2 Lock Nut, 20mm 72 (See Fig. 4) 1 Control Valve Assembly
52 DC9436009 2 Dome Plug 16MM 79 ★★ DC9922026 2 Decal, High Voltage
54 DC9802259 1 Motor 1.5 HP 1PH 115/230V 148 (Not Available) 1 Decal, Product Spec
55 44968E 1 Rubber Ball, 3/8" Diameter 149 ★★ CJ193026 1 Rotation Decal, Clockwise
★★ Items included in and available only as part of Decal Kit ZEDK.
★ Items included in Seal Kit ZE3K.

79
68
69

60
61

34 6
32

33

Figure 1B, Pump, Reservoir and Valve Assembly

3
 29 28

25

1
3
4
6
26
27 3 10 11

2
5
21

24

22

23

12 13
7

8 15
301A
7
19 7
9

301B 302

7
17
Notes:

1 Apply Loctite 545 to threads.

2 Torque to 20 - 22 Ft-lbs [27-30 Nm].

13
3 Increase torque of item 11 if needed
to properly align item 27.

4 Torque hand-tight plus 1-1.5 additional turns.

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

6 Torque to 50-55 Ft-lbs [68-74 Nm].

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

8 Torque to 5-7 In-lbs [0.5-0.8 Nm]. 5 129 20 127

9 Used in place of items 301A and 301B.

(only for shipping purposes)

Figure 2, Pump Coverplate and Element Assembly

4
 Repair Parts List for Figure 2
Item Part Number Qty. Description Item Part Number Qty. Description
10 ♦ DC9704900 1 Pump Element, Main 25 ★ DC9551920 1 Pump Gasket
11 F100094-246 1 Fitting 5-4 FTX-S 26 CBE621028-1A 2 SHCS, M6 X 20
12 F100097-16 1 Fitting, Standard Pump 27 DC9663920 1 Tube, ASM Steel, ZE
13 DC9335646 1 Hose, Bypass, 8" 28 DC9524268 1 Intake Tube, 3" 20L
15 DC9451101 1 Cover Plate, ZE 29 DC9178118 1 Intake Filter
17 B1007006 1 Plug, Socket, SAE #10 127 DC8046646 1 Hose, Oil Filter Pump
19 B1006006 2 Plug, SAE #8 Std. Pump 129 DC8035038 1 Adapter, 5/8 Hose
20 ★ B1908503 1 O-Ring, Oil Filter Pump 301A DC8250006 1 Breather Assembly
21 DC9173690 1 Connector Fitting 301B F100096-38 1 Adapter Fitting
22 ★ BSS0368D 1 Back-up 302 DC9586271 1 Plug, Hex Plastic
(use for shipping only -
23 ★ B1012803 1 O-Ring
replaces items
24 ★ DC9271167 1 Copper Gasket 301A and 301B)
★★ Items included in Seal Kit ZE3K.
★♦ Refer to Enerpac repair parts sheet L2596 for pump element repair parts information.

5
 3 4A

4B
2
3

4C
5

9 8 6 7
Rotate tee fitting back 20 degrees
to clear solenoid and filter.

Figure 3, Oil Filter Assembly

Repair Parts List for Figure 3

Item Part Number Qty. Description Item Part Number Qty. Description
1 DC8120268 1 Steel Tube 5 DC8036038 1 Fitting, 90 1/2 NPT to 5/8"
2 DC8126095 1 Swivel Fitting, 90 Elbow, 1/2" 6 DC8038299 2 Clamp, Hose
3 F100095-26 2 Adapter, 3/8" to 1/2" NPTF 7 DC8273646 1 Hose, 5/8", 14" Long
4A DC3077900 1 Filter Head Assembly 8 DC8184097 1 Fitting 5/8" to 3/8" NPT
4B DC3075223 1 Gauge, Pressure 9 F100095-37 1 Street Tee, .375-18
4C DC3076118 1 Filter Element, PF25
★Note: Item 4A includes items 4B and 4C.

6
 3
1 2 3

6
See Fig. 5A & 5B
4
4

5
1
6

8 2
Notes:

1 Check for O-Rings before assembly.

9 1
2 Press fit into item 9.

5 3 Torque to 22-25 Ft-lbs [29.8-33.8 Nm]

4 Control Valve Model and Serial No.

5 User adjustable relief valve to be

10 3 set at 10,200 psi, + 300 / -100 psi
[703 bar + 20.6 / - 6.8 bar]
7
6 Press fit into item 5.
12
7 Torque to 45-53 Ft-lbs [61.0-71.8 Nm].
11

Figure 4, Control Valve Assembly

Repair Parts List for Figure 4

Item Part Number Qty. Description Item Part Number Qty. Description
1 ❖ B1089028 4 SHCS, .375-16 UNC x 3.50 7 ❖ CBE837028-1A 4 SHCS, M8 x 60
2 ❖ CH272026 1 Decal, Caution 8 ❖ B1051057 1 Spring Pin, .12 x .50
3 ❖ (See Fig. 5A & 5B) 1 Valve, 4W 3P TC 24VDC 9 ❖ (See Fig. 6) 1 Manifold, Sub-Assy.
4 ❖ B1049057 1 Spring PIn, 0.12 x 0.38" 10 ❖ CCA835028-1A 4 SHCS, M8 x 1.25 x 55
5 ❖ DD5775190 1 Adapter, 4-Way, Slider Mt. 11 ❖ DC9356037 1 Gasket, Valve
6 ❖ B1111803 1 O-Ring 12 DC1389900 2 Coupler, Female, CR400
❖ Items included in Replacement Valve Assembly, LLSVA1.

7
 1 14

33

32C

32B
4 32A

(SEE FIGURE 5B FOR ADDITIONAL PARTS)

17

31

Notes:

1 Torque to 50 In-lbs [5.6 Nm].

HYDRAULIC SCHEMATIC
4 Torque to 100 In-lbs [11.2 Nm].

Figure 5A, Control Valve, 4-Way, Three Position Tandem Center, 24VDC

8
 4 1 2

32A 10 2 11 14 15 3 4 32D

26

1 34 13 16 31 8 31 6 7 9 35 9
3 5

Notes:
1 Torque to 50 In-lbs [5.6 Nm]. 3 Torque to 25 In-lbs [2.8 Nm]. 5 Torque to 84-108 In-lbs [9.4-12.2 Nm].

2 Torque to 75 In-lbs [8.4 Nm]. 4 Torque to 100 In-lbs [11.2 Nm].

Figure 5B, Control Valve, 4-Way, Three Position Tandem Center, 24VDC (enlarged view)

Repair Parts List for Figures 5A and 5B

Item Part Number Qty. Description Item Part Number Qty. Description
1 ✦ 68708E 1 Body Assembly, Valve 15 ✦ 46272E 1 Valve Top Plate
2 ✦ 68709E 1 Slider, Tandem Center 16 ✦ B1007016 1 Ball, 1/4" Dia. Ball
3 ✦ B1005016 1 Ball, 3/16" Diameter 17 ✛ ✦ B1003503 1 O-Ring .19 x.31 x .06 BU
4 ✦ 40254E 1 SHCS, 1/4-28 x 1/4 Cup 26 ✛ ✦ B1910503 2 O-Ring
6 ✛ ✦ B1004503 3 O-Ring 27 ✦ 68711E 2 Spring
7 ✛ ✦ 68391E 3 Back-up Washer 31 ✛ ✦ 56020112E 4 O-Ring 5/16 x 7/16 URE
8 ✦ 68383E 3 Seal, Metal 32A ▲ ✦68743A 2 Spool Assembly
9 ✦ 68384E 3 Spring 32B ▲ ✛ ✦ 68743B 2 O-Ring
10 ✛ ✦ B1246503 1 O-Ring 32C ▲ ✦68743C 2 Retainer Cap
11 ✦ 68385E 4 Roller Bearing 32D ▲ ✦68743D 2 Push Rod
12 ✦ 68390E 2 Pin, bearing 33 ▲ ✦46720 2 Coil, 24VDC w/Din Conn.
13 ✦ 94418E 1 Set Screw, 5/16-18 x 1/4" 34 ✱ ✦ 84405 2 SHCS, #6-32 x 1/2 Lg
14 ✦ 68264E 2 SHCS, #10-32 x 1" Lg. 35 ✱ ✦ 68458 1 Plate, Metal Seal
✛ Items included in Slider Valve Seal Kit, LLSVSK. ✦ Items included in Slider Valve Service Assembly, LLSV1.
▲ Items included in 24V Solenoid Assembly DD1666900SR. ✱ Items included only with assemblies DD5662660SR or 68708E.
9
 55 2

53
55 2

55 2 52

1 59 56 53
4 57

54 2
2 3 58
55 2

59

Item 54:
Notes:

1 Torque to 10-12 Ft-lbs [14-16 Nm]

2 Torque to 32-39 Ft-lbs [43-53 Nm]

3 Lubricate all seals and mating surfaces with grease prior to assembly.

4 Coin ball seat at 180-200 psi, using a 10-ton press. Use ball
(Enerpac p/n B1003016) to coin, then discard.

When Oil Filter is Used:

Remove plug from

T port and reinstall it in
drain port on bottom of valve.

Figure 6, Control Valve Manifold Assembly

Repair Parts List for Figure 6

Item Part Number Qty. Description Item Part Number Qty. Description
52 ✲ DC6308038 1 Manifold 56 ✲ P20037 1 Gasket
53 ✲ DC6792245 2 Flush Plug, 1/16" 57 ✲ DC5124290 1 Seat
54 ✲ DC6795245 1 Flush Plug, 3/8" 58 ✲ (See Fig. 7) 1 Relief Valve
55 ✲ DC6794245 4 Flush Plug, 1/4" 59 ✲ R515245-2 2 Plug (for shipping)
✲ Items included in repair kit DC6177950SR. For detailed manifold Note: Remove plugs where hoses and fittings are connected (as re-
repair information, refer to Enerpac repair parts sheet L2600. quired). When oil filter is used, remove item 54 from right side of mani-
fold and reinstall it in drain port on underside of manifold as shown.

10
 Grease before assembly.
3 4 5
9
2 6

7
1
SECTION A-A
Press item 7 into item 6 to 100 psi on a 10-ton press. Insert guide and ball onto
8 the end of Enerpac Special Tool AT-0325C to help hold in place during pressing.

Figure 7, User Adjustable Relief Valve Assembly

Repair Parts List for Figure 7

Item Part Number Qty. Description Item Part Number Qty. Description
1 ✛ DC5138190 1 Body 7 ✛ B1003016 1 1/8 Dia. Ball
2 ✛ BC2512027 1 Set Screw 8 ✛ B1223503 1 O-Ring
3 ✛ B1003503 1 O-Ring ✛ B1001122 1 Lock Nut
4 ✛ DC5127007 1 Plug 9 ✛ DC5124290 1 Seat (not shown)
5 ✛ A8126110 1 Spring ✛ P20037 1 Gasket (not shown)
6 ✛ DC5125013 1 Guide
★✛ Items included in repair kit DC5139900SR. For additional information, refer to Enerpac repair parts sheet L2600.

11
 101A

Figure 8, Front E-Box Enclosure

Repair Parts List for Figure 8

Item Part Number Qty. Description Item Part Number Qty. Description
100 DC9453424 1 Front Enclosure, ZE 105 DC9428008 4 Screw, Hi-Lo #8 x 12
101 ❁ DC8178827 1 PCB, LCD Control Board 107 DC9951404 1 Velcro
101A ❁ DD5316222 1 Firmware, Level Lift (LL) 108 DC9740969 1 Ferrite
103 ★ DC9560026 1 Keypad, LCD, 4 Button 140 ★★ DC9929026 1 Decal, Wire Schematic
104 ★ DC9559026 1 Overlay, LCD, 4 Button
★★ Items included as part of Service Repair Kit DC9686900SR
★★ Items included as part of Decal Kit ZEDK
❁ IMPORTANT: Control board (Item 101) must be factory programmed with Level Lift type LL firmware (item 101A). Mention when ordering.

12
 90 94 96

97

Assembled View
91
(cable shortened for
illustrative purposes)

Note: Enerpac does not provide the pin

connector as a service part.
Use the following AMP parts:
• AMP Housing #770849-4, 1 piece
• AMP Pin #640706-1
For information on AMP connectors, go to:
www.amp.com

Figure 9, Remote Pendant Assembly

Repair Parts List for Figure 9

Item Part Number Qty. Description
90 ★ DC9425424 1 Lower Enclosure
91 ★ DC9508960 1 Cable Assembly
94 ★ DC9357375 1 Keypad Assy, 3 Button
96 ★ DC9428008 4 Screw, Hi-Lo #8 x 1/2
97 ★ B1223503 1 O-Ring
★★ Items included as part of Complete 3- Button Pendant Assembly, ZCP-3

13
Notes:

1 See bottom of figure for wiring harness details.

2 Apply Loctite 243 to threads. 1

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

4
206 210
Torque to 63-69 in-lbs [7.1-7.9 Nm]. 52
5 Disconnect wires from relay and
connect to splitter cables (items 226 and 227). 85
207
6 Red - to RA5 (both relays).
208 228A 5

7 Black - to RA6 (both relays). 209

2 3
230
205

228B 229 227 6

224 226 7
204

201
223

200 215
213
203 216
2
216 216

219

217
4 218 218 4

213 214 2

217A 217B

220

221

RA
8

RA7
231

219
232

Figure 10, Rear E-Box Enclosure Assembly

14
 Repair Parts List for Figure 10
Qty.
Item Part Number Pump Model Pump Model Description
ZE4420SB-FT-LL ZE4420SE-FT-LL
(115V) (208-240V)
46 DA7570217 1 1 Cord Strap (not shown)
52 DC9645268 1 1 Insulation Tube
85 E1001181 3 3 Connector, Push-on, Female (jumper)
200 DC5667101 1 1 Bracket
201 DC9919980 1 1 Relay, Solid State (SSR)
203 CBE419028-1A 2 2 M4X.7X16 SHCS
204 DC9984028 1 1 M6 x 40 Pan Hd. Set Scw
205 DC9452424 1 1 Rear Enclosure ZE
206 ✰ DD2243827SR 1 1 Pwr Board, SSR, LV, 1 PH
207 DC9428008 5 5 Screw Hi-Lo #8X1/2
DC9536380 1 --- Circuit Breaker, 25 Amp
208
DC9534380 --- 1 Circuit Breaker, 12 Amp
DC9592378 1 --- Fuse, Primary 1.25 Amp
209
DC9591378 --- 1 Fuse, Primary, 0.6 Amp
210 DC8156378 1 1 Fuse, Secondary, 2.5A, Slow-Blow
213 CAE1060108-1A 4 4 6MM Flat Washer
214 CBE619028-1A 3 3 M6X1X16 SHCS
215 CCE1060108-6A 2 2 6MM Star Washer
216 CBE1060120-1D 3 3 6MM Nut
217A DC9736960 1 --- Motor Cord ZE 115V (USA Plug)
217B DC9737960 --- 1 Motor Cord ZE 208-230V (European Plug)
218 DC9683021 2 2 Locking Nut, 25mm
219 DC9990960 1 1 Motor Cord Assembly, 1P
220 DC9892960 1 1 Wire Harness PB To SSR
221 DC9893960 1 1 Cable TB600 to SSR
223 DC8119026 1 1 Decal, Ground, ZE
224 DC9538021 2 2 Locking Nut, 20mm
226 DD5669960 1 1 Cable, Relay Power, Black
227 DD5668960 1 1 Cable, Relay Power Red
228A ✰ DD1342980 1 1 Relay, 24VDC Coil, DPDT (A Solenoid)
228B DD1342980 1 1 Relay, 24VDC Coil, DPDT (B Solenoid)
229 C701222 2 2 Washer
230 DD5670028 2 2 BHCS, #6-32 x 0.5" Long
231 ✰ DD1421960 2 2 Cable Assy, Relay Coil
232 ✰ DD5838960 2 2 Solenoid Cable

✰ Item 206 includes items 228A, 231 and 232.

15
 To circuit board pressure transducer
(PRESS TR) terminal. See Fig 13.

1
2
To valve
3 GP port.
1
Notes: 3

1 Apply Loctite #545 to threads on all fittngs.

2 Torque to 44-53 Ft-lbs [43-53 Nm].

3 Torque to 28-34 ft-lbs [38-46 Nm].

Note: Enerpac does not provide the pin connec- Repair Parts List for Figure 11
tor as a service part.
Item Part Number Qty. Description
Use the following AMP parts:
• AMP Housing #770849-2, (1 piece)
1 ★ DC9537021 1 Locking Nut, 16mm
• AMP Pin #640706-1 (2 pieces) 2 ★ DC9525384 1 Pressure Transducer
For information on AMP connectors, go to: www. 3 ★ F100095-7 1 Street Elbow, 0.25"
amp.com
★ Items included as part of Pressure Transducer Service Repair Kit ZPT-U4.
Figure 11, Pressure Transducer Assembly

Proximity Switch
Valve Position

> Level/Temperature Switch

>

>Note: Item not available on Enerpac Level Lift pumps.

Figure 12, Pump Cable and Cord Ports (Viewed From Back of Enclosure)

16
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FILTER
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)ODWULEERQFDEOHWHUPLQDO
1 NC 2

3 4
NO
5 6
COM

(RED)
7 8
COIL
FL3 (BLACK)

FL1 (BLACK)

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&LUFXLW%UHDNHU $6ROHQRLG

❉ $FFHVVRU\QRWDYDLODEOHRQ=(6HULHV/HYHO/LIWSXPSV
Notes:

1 Install insulation tube in this location. 2 Install jumper in this location.

(Fig. 10, Item 52) (Fig. 10, Item 85)

Figure 13, Power Board Components and Connections, Single Phase SSR

Single Phase Transformer Tapping Single Phase Transformer Tapping

100-120 Volts - “B” Voltage 208-240 Volts - “E” Voltage (Europe & Austrailia)
Lead Connect to Terminal Lead Connect to Terminal
FL 1 QC 3 FL 1 QC 1
FL 2 QC 6 FL 2 QC 2
FL 3 QC 7 FL 3 QC 5

17
 WARNING Always disconnect power cord from electrical power supply before
making any repairs, before opening the e-box, before replacing fuses, and before con-
necting or discnnecting any electrical wires, cables or components. Failure to observe
this precation could result in an electric shock. Death or serious injury could occur.

Figure 14A, Wiring Diagram, Level Lift Pump Models ZE4420SB-FT-LL and ZE4420SE-FT-LL

18
Figure 14B, Wiring Diagram, Level Lift Pump Models ZE4420SB-FT-LL and ZE4420SE-FT-LL

19
TROUBLESHOOTING THE PUMP ELECTRICAL AND
ELECTRONIC COMPONENTS WARNING (Continued)
• Use extreme caution when measuring voltag-
Allow only trained and experienced electronic es and performing other diagnostic procedures
technicians to diagnose and service the pump during which power must be connected.
electrical system and micro-controller.
For repair service, contact your local Authorized SUGGESTIONS FOR EFFECTIVE TROUBLESHOOTING:
Enerpac Service Center.
1. Utilize the LCD Screen as much as possible. The LCD
Screen of the Pump is a fault indicator as well as a
WARNING controller. It can indicate most of the possible faults in
Failure to observe and comply with the follow- the system.
ing precautions could result in an electric shock. 2. Ensure the power supply to the pump is of the correct
Death or serious personal injury could result. voltage and capacity. The power cable, plugs and
sockets should be checked for proper condition.
• High voltage is present inside the equipment
3. Suggested sequence for successful troubleshooting of
even when pump motor is off. Before opening or the electrical systems:
removing the cover on any electrical enclosure,
ensure that the equipment is disconnected from a. Identify the symptoms in the pump, use the list
of Symptoms in Column A of the Troubleshooting
the electrical power supply.
Guide.
• Always disconnect power cord from electri-
b. In Column B of the Troubleshooting Guide, the
cal power supply before making any repairs, be- possible causes for the symptoms are listed. The
fore opening the e-box, before replacing fuses, two major categories are 1) Faults External to the
and before connecting or disconnecting any Pump, and 2) Faults Within the Pump System.
electrical wires, cables or components.
Study the possible causes as per the suggestions in
Column B and proceed to Column C. In Column C, various
remedial actions to be taken are listed.
Troubleshooting Guide
Column A Column B Column C

Symptoms Probable Causes Remedial Actions to be Taken

SECTION 1 SECTION 1A, External to the Pump
Pump does 1. Low voltage or no voltage in the external Check the external power supply and correct the fault. Is the voltage
not start power supply correct? Maximum deviation of +/- 10% from the Nominal Voltage
is permissible. Is the power cable too long? Are the power socket
and plug in good working condition? Is the power source or the
generator capable enough to drive the pump at full load?

SECTION 1B, Within the Pump System

1. FAULT Conditions 1. Check for FAULT Conditions:
(See Level Lift instruction sheet for fault (See Level Lift instruction sheet for fault codes)
codes)
a) Check whether any LCD button is stuck. If yes, loosen the LCD
a) Does the LCD display reads "BUTTON board mounting screws and realign the LCD Board. Or, the key
FAULT"? pad is defective, replace the LCD Board. Or, the pendant keypad
was actuated prematurely during power boot-up.

b) Does the Display read "MOTOR b) Check Probable Causes in Column B of Section 1B.
OVERLOAD"?

c) Does the Display read "OIL TEMP"? c) Check electrical push-on connector in the header pins TEMP
inside the E-Box. The push-on connector might have become
loose.

d) Does the Display read "OIL LEVEL"? d) Check the electrical shorting plug in the header pins inside the
E-Box. The push-on connector might have become loose.

Note: The Level Lift pump does not use a TEMP/LEVEL switch.

20
 Troubleshooting Guide (continued)
Column A Column B Column C
Symptoms Probable Causes Remedial Actions to be Taken
SECTION 1B, Within the Pump System (Continued)
Pump does 2. The power cord is damaged: 2. Check the power cord for any loose wires or burnt wire ends. Replace
not start the cable, if found defective. Use the correct size cable, adequate to
the load.

3. Wires in the power incoming terminal block 3. Check that all terminals are tight in the power terminal block, inside
are loose: the E-Box. Disconnect the power supply. Open the E-Box. Check the
terminals for any burnt marks or loose connections.

4. Measure, with a DMM (Digital Multi Meter), 4. If the voltages are not correct, go back to Section 1A, "External to the
the incoming voltage in the power terminal Pump".
block:

SECTION 1C, Additional Troubleshooting Steps for Single-phase Pumps

Pump does 1. Is the LED D602, center right of the power 1. If the LED is lit, the DC voltage is OK, go to Step 6, below. If the LED
not start board, illuminated whenever the Motor is is not lit, continue to Step 2.
turned ON?

2. The circuit breaker, near the power terminal 2. The circuit breaker will automatically reset itself, after an overload
block, is tripped. "MOTOR OVELOAD" will occurrence. If the contact is not made even after cooling down time,
appear on the LCD Screen. unplug the circuit breaker and check the continuity of the Circuit
Breaker terminals. Replace with a correct capacity Circuit Breaker.

3. The circuit breaker might have become loose 3. Insert the circuit breaker firmly into its socket holders.
in its socket holders:

4. The transformer's primary fuse, near the 4. If blown, replace with a correct capacity fuse.
circuit breaker:

5. The transformer primary tappings flying 5. Insert the flying leads of the primary side of the transformer correctly.
leads: Refer to the Transformer Tappings Chart. Contact the Service Partner
or ENERPAC Tech Service.

6. The motor leads on the MOTOR Terminal 6. Check and if loose, tighten the leads.
Block on the PCB:

7. The power leads, L1 & T1, to the SSR: 7. Check and tighten.

8. The firing voltage leads, A1 and A2, to the 8. Check and tighten the firing control terminals. Also check for the
SSR: correct polarity.

9. The SSR firing voltage cable on the PCB 9. Insert the SSR firing cable firmly into the 2 pin PCB socket. If the plug
end: or cable is damaged, replace the cable.

10. If the firing LED of the SSR is illuminated, 10. Replace the SSR.
incoming voltage to the SSR is OK.

11. The wire nuts inside the motor terminal box: 11. Open the motor terminal box and check and tighten all wire nuts.
Check the wiring is as per the wiring decal.

12. If the motor supply voltage is correct: 12. Check and replace the motor.

21
 Troubleshooting Guide (continued)
Column A Column B Column C
Symptoms Probable Causes Remedial Actions to be Taken
SECTION 2 SECTION 2A, External to the Pump
Motor stops Low voltage in the external power supply: Check the external power supply and correct the fault.
under normal Is the voltage correct? Maximum deviation of +/- 10% from the
conditions Nominal Voltage is permissible. Is the power cable too long? Are
the power socket and plug in good working condition? Is the power
source or the generator capable enough to drive the pump at full
load?

SECTION 2B, Within the Pump System:

1. The power cord is damaged: 1. Check the power cord for any loose wires or burnt wire ends.

2. Wires in the power incoming terminal block 2. Check that all terminals are tight in the power terminal block, inside
are loose: the E-Box.

3. Check the incoming voltage in the power 3. If the voltages are not correct, go back to Section 2A, "External to
terminal block: the pump".

4. Has the operator pressed two buttons 4. Operator Error. Two buttons cannot be pressed simultaneously.
simultaneously?

SECTION 2C - Additional Troubleshooting Steps for Single-phase Pumps

a. The power leads to the SSR are loose: a. Check and tighten the power leads, L1 and T1, to the SSR.

b. The motor leads on the MOTOR Terminal b. Tighten the motor leads on the MOTOR Terminal Block on the PCB.
Block on the PCB loose:

c. The wire nuts inside the motor terminal box c. Open the motor terminal box and check and tighten all wire nuts.
are loose:
SECTION 33
Pump and 1. The pendant cable is damaged: 1. Check and replace the pendant cable.
solenoid
valves do not 2. The pendant key pad is damaged: 2. Repair or replace the pendant.
work
3. The system is in LOCAL Mode: 3. Switch the LOCAL Mode to OFF. (See Level Lift instruction sheet)

22
 Troubleshooting Guide (continued)
Column A Column B Column C
Symptoms Probable Causes Remedial Actions to be Taken
SECTION 4
Pump runs 1. The solenoid cable is damaged: 1. Check and replace the solenoid cable.
OK. But
electric 2. The solenoid cables are interchanged: 2. Check whether the correct cable is inserted in the respective
solenoid solenoids. SOL A and B are marked on the rear side of the electrical
valves do not box.
function
3. The solenoid valve plunger is not free: 3. Check the valve manually, if not operational, replace the solenoid.

4. The DC solenoid voltage not correct: 4. Open the E-Box:

• Solenoid A, (Advance ): Does the LED lamp, D513, top left of the
power board, illuminate?
- If the LED is lit, the DC voltage is OK. Check whether the solenoid
cable pins are loose in the header, ADVANCE, top left of the board.
- If the LED is not illuminated, the DC Voltage is not correct: Check
the Secondary AC Fuse F3, top center tiny glass fuse: If blown,
replace the fuse.
- If the AC Fuse F3 is good: the AC Primary Circuit is defective:
Follow the steps above.

• Solenoid B ( Retract ): Does the LED lamp, D523, top center of the
power board, illuminate?
- If the LED is illuminated, the DC voltage is OK. Check whether the
solenoid cable pins are loose in the header, RETRACT, top left of
the board.
- If the LED is not illuminated, the DC Voltage is not correct: Check
the Secondary AC Fuse F3, top center tiny glass fuse: If blown,
replace the fuse.
- If the AC Fuse F3 is OK, the AC Primary Circuit is defective.
Contact the Service Center or the ENERPAC Tech Service

5. The pump configuration is wrong: 5. Check whether the correct pump firmware code is shown on the LCD
Screen.
- The letters "LL" (followed by the firmware version number) should
appear on the LCD screen shortly after power is connected to
the pump. This indicates that the Level LIft firmware has been
programmed into the pump micro-controller.
- Contact the Service Center or ENERPAC Tech Service if questions
regarding pump firmware version.

SECTION 5
Pump AUTO 1. Pump in MANUAL mode: 1. Place the pump in AUTO mode. Refer to the Level Lift instruction
UP or AUTO sheet for a detailed description of pump controls and functions.
DN functions
do not appear 2. Electrical or micro-controller related problem: 2. Take the pump to an Enerpac Authorized Service Center for
on LCD inspection and repair.
screen.

23
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