Repair Parts Sheet

POWERFUL SOLUTIONS. GLOBAL FORCE. ZA4 PUMP

L2672 Rev. J 05/2018 For Date Codes Beginning with the Letter “B”
45
1 5 62
63

4 57

69 NOTES:

1 Loctite 243
2 Loctite 545
3 28 – 32 ft lbs [38 – 43 Nm]
4 20 – 25 ft lbs [27 – 34 Nm]
5 60 – 72 in lbs [6.8 – 8.1 Nm]

REMOVE
149

54

58 2

59
53

55

79

65 2 3

Figure 1, Air Motor Assembly

Repair Parts List for Figure 1, ZA4 Pump

Item Part Number Qty. Description Item Part Number Qty. Description
45 DC8056070 1 Handle ZA4 62 ❖ B1461046X 2 0.25-28X1.25 Hex Head Screw
53 DD4308251 1 Hardened Motor Key ❖ CBE625046-1A 2 M6 x 30mm Hex Head Screw
54 DC8030900SR 1 Air Motor Kit 63 CAE1060108-1A 2 6MM Washer
(includes 53, 55 & 57) 65 DC8103662 1 Air Valve
55 44968 1 Rubber Ball 3/8" 70 Duro. 69 DC8099026 1 Decal ZA Class
57 CBE1027028-1A 4 M10X35 SHCS 79 B1053271 1 1/2 NPT Shipping Plug
58 DC8097095 1 1/2 NPT Short Pipe 149 CJ193026 1 Rotation Decal
59 DC8032116 1 Air Muffler
❖ Item 62: Screw holes on pump housing may be either imperial or metric thread. Use the correct screw for your pump.

1
 TORQUE
TORQUE 35–40 ft–lbs
132–148 in–lbs [47.5–54.2 Nm]
[14.9–16.7 Nm] 35 34

TORQUE
50–60 in–lbs
33 67 [5.6–6.8 Nm]

NOTES:
44 TORQUE
1 Loctite 243
50–60 in–lbs
43 [5.6–6.8 Nm]
TORQUE
8.0–10.0 ft–lbs 35
[8.8–11.0 Nm] 42
38
37 41
39

36

TORQUE
50–60 in–lbs 49 1
[5.6–6.8 Nm]
40 31 TORQUE
11.0–13.0 ft–lbs
[14.9–17.6 Nm]
32 148

Figure 2, Reservoir Assembly

Repair Parts List for Figure 2

Item Part Number Qty. Description Item Part Number Qty. Description
31 DC9379025SR 1 Reservoir 4L 38 DC9542920 2 Handle,10L,20L,40L
(Includes 32,33,34,35 & 37)
38A DC9895101 4 Lift Plate 10L,20L,40L
31 DC9589025SR 1 Reservoir 8L
(Includes 32,33,34,35 & 37) 39 CBA819028-1E 8 BHCS M8X16 mm

31 DC9970025SR 1 Reservoir 10L 40 CBE1080120-2A 8 Lock Nut M8

(Includes 32,33,34,35 & 37) 41 DC9590920 1 Skid Bar 4L & 8L
31 DC9971025SR 1 Reservoir 20L 42 See Fig. 3 Basic Assembly
(Includes 32,33,34,35 & 37)
43 HS3037 13 Copper Gasket
31 DC9972025SR 1 Reservoir 40L
(Includes 32,33,34,35 & 37) 44 CBE619028-1A 13 SHCS M6-1X16
32 DC9596026 2 Reservoir Decal 49 CBE817028-1E 4 BHCS M8X12
33 C187018 1 Magnet 67 DC9920026 1 Decal, Read Instruction
34 DD1425245 1 1/2” Flush Plug w/Sealant 70 HDC9356037 1 Valve Gasket (Not shown)
35 DC85900SR 1 Sight Glass 4L & 8L 70 HF786167 1 Valve Gasket VM32 (not shown)
35 DC2621223 1 3” Sight Glass 10L --- DC6665098 1 Plate For No Valve (not shown)
35 DC2622223 1 5” Sight Glass 20L --- VALVE See Valve Chart
35 DC9969223 1 7” Sight Glass 40L 148 Not Available 1 Decal, Product Spec
(DC6661026)
36 B1006006 1 Plug SAE#8 (4L & 8L)
37 H DC9551920 1 Reservoir & MPE Gasket
H Items included in Seal Kit ZE3K.

Model Repair Part Sheet Number

VALVE CHART

VM22 L2649
VM32 L2612
3-T-P-B-I (VM33) L2613
3-T-P-B-X (VM33L) L2613
4-T-P-B-I (VM43) L2613
4-T-P-B-X (VM43L) L2613

2
 29 27
28
Torque to 72-84 in-lbs.
2X Torque to [8,1-9,5 Nm] Torque
20-22 ft-lbs 50-55 ft-lbs
[27-30 Nm]
1 26 10 11 [68-74 Nm]
25 Torque
21 45-47 ft-lbs
24 [61-64 Nm]

23 22

Torque
2
5 - 7 in-lbs
[0,5 - 0,8 Nm] 301A
15
2
Torque 19 301B Torque
15-18 ft-lbs 12 15-18 ft-lbs 13
[20-24 Nm]
[20-24 Nm]
Torque
18 15-18 ft-lbs
[20-24 Nm]
Notes:

17 1 Apply Loctite 545 to threads before installation.

2 Location of breather assembly (item 301A) and

adapter (item 301B) on pump coverplate
(item 15) will vary, depending on pump date of
manufacture.

Figure 3, Basic Assembly

Repair Parts List for Figure 3

Item Part Number Qty. Description Item Part Number Qty. Description
10 Pump Element 1 see RPS L2596 for MPE 24 H DC9271167 1 Copper Gasket
11 F100094-246 1 Fitting 5-4 FTX-S 25 DC9551920 1 Reservoir & MPE Gasket
12 F100097-16 1 Fitting, Standard Pump 26 CBE621028-1A 2 SHCS M6X20
13 DC9335646 1 Hose, Bypass 8” 27 DC9663920 1 Tube ASM Steel ZE Pump
15 DC9451101 1 Cover Plate ZE DC9524268 1 Intake Tube 3” 20L
17 B1007006 1 Plug SAE #10 28 DC9602268 1 Intake Tube 4” 8L
18 A1009245 1 3/8 Flush Plug DC9601268 1 Intake Tube 2” 10L
19 B1006006 2 Plug SAE #8 Standard Pump DC9603268 1 Intake Tube 6.5” 40L
21 DC9173690 1 Connector Fitting 29 DC9178118 1 Intake Filter
22 H B1012564 1 Back-up 301A DC8250006 1 Breather Assembly
23 H B1012203 1 O-Ring 301B F100096-38 1 Adapter Fitting
H Items included in Seal Kit ZE3K.

3
 45o 2
3 150 162 3 58

2 153 1
152 151 3 154

3
Torque
15-32 FT-LBS
[20.3-48.4 Nm]

1
3 150
19
Torque
TOP VIEW 45-47 FT-LBS
STANDARD MUFFLER [61-64 Nm]
20

156

158 157
Torque
40-45 IN-LBS
[4.5-5.1 Nm]

155
BOTTOM VIEW

NOTES:
1 Torque 28-32 FT-LBS [38-43 Nm]
2 Torque 15 FT-LBS [20 Nm] Minimum
3 Loctite 545

Figure 4, Heat Exchanger

Repair Parts List for Figure 4

Item Part Number Qty. Description Item Part Number Qty. Description
19 DC8035038 2 Adapter 154 DC8032116 1 Muffler, Parker
20 B1908503 2 O-Ring BUNA-N 155 DC8039471 1 Heat Exchanger Coil
58 DC8097095 1 1/2 NPT Short Pipe 156 DC8043646 2 Hose 5/8 ID
150 DC8036038 2 Elbow 5/8 Barbed to 1/2 NPT 157 DC9989647 1 Cable Tie 12.5”
151 DC8046646 1 Hose 5/8 ID 4.9” 158 CB40299 4 Hose Clamp
152 DC8038299 2 Hose Clamp 5/8” 162 DA1235095 1 Fitting 1/2 NPT
153 DC8126095 1 Elbow 1/2 NPT

4
 4L and 8L Reservoirs 10L, 20L and 40L Reservoirs

Torque 256
8.0-10.0 Ft-Lbs
[8,8-11,0 Nm]

257
255

253
254

Torque
8.1-10.0 Ft-Lbs
[18,8-11,0 Nm]

242

1 241 Torque
NOTES: 11.0-13.0 FT-LBS
1
Loctite 243 [14.9-17.6 Nm]

Figure 5, Roll Bar Assembly

Repair Parts List for Figure 5

Item Part Number Qty. Description Item Part Number Qty. Description
241 CBE817028-1E 4 BHCS M8x12 256 DC9460268 2 Roll Bar Spacer 10L
242 DC8040920 1 Roll Cage, 4L & 8L DC9461268 2 Roll Bar Spacer 20L
253 CBE819028-1E 8 M8 X16 BHCS DC9462268 2 Roll Bar Spacer 40L
254 CBE1080120-2A 8 M8 Lock Nut 257 DC9988028 4 M8 X 50 FHCS
255 DC9618920 2 Roll Bar Side 10, 20 and 40L

ROLL BAR KITS

Part Number Fits Reservoir Size:
ZRC-04 4L and 8L
ZRB-10 10L
ZRB-20 20L
ZRB-40 40L

5
TROUBLESHOOTING:
Only qualified hydraulic technicians should service the pump or system components. A system failure may or may not
be the result of a pump malfunction. To determine the cause of the problem, the complete system must be included
in any diagnostic procedure.

TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE REPAIR ACTION

Pump will not No air to pump Make sure air is not shut off to pump
start Check air line for blockage

Low air pressure Check air pressure setting at air pressure regulator

Low air SCFM Make sure air compressor has enough SCFM to operate pump

Air valve not working Replace air valve

Air motor not working Replace air motor

Pump fails to External leak in system Repair any external components that are leaking
build pressure

Internal leak in pump See RPS L2596 for basic pump assembly

Internal leak in valve See RPS for specific control valve as listed on valve chart

Internal leak in system component Repair system component

Pump builds less Relief valve set too low Adjust relief valve
than full pressure

External leak in system Repair leak

Internal leak in pump Back pressure test, locate and repair leak (See RPS L2596)

Internal leak in valve See RPS for specific control valve as listed on valve chart

Internal leak in system component Repair system component

Pump builds full Load greater than cylinder Higher capacity cylinder is needed to lift load
pressure, but load capacity at full pressure
does not move
Flow to cylinder blocked Check system components

6
NOTES:

7
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