To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.

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1 Repair Parts Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. AVDEL Pump Unit Model ZU4 RPS627-04/202 For Date Codes Beginning with the Letter E 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. Figure, Reservoir Assembly Repair Parts List for Figure Item Part Number Qty. Description Item Part Number Qty. Description 3 DC SR Reservoir, 4L (includes 32, SBZ-4 Skid Bar w/o Heat Exch. 4 35, 36 and 37) SBZ-4L Skid Bar w/ Heat Exch. DC997025SR Reservoir, 20L (includes 42 (See Figure 3) Assembly, Pump items 32, 35, 36 and 37) 43 H S Gasket 32 H DC Decal, Enerpac 44 CBE69028-A 3 Screw, SHCS M6 x 6 35 DC85900SR Sight Glass, (4 litres) 49 CBE87028-E 4 Screw, BHCS M8 x 2 35 DD367223SR 5 Sight Glass, (20 litres) 36 DC Plug, Magnetic, SAE #8 4 DC Decal, Read Instructions 37 H DC Gasket, Reservoir H Items included in and available only as part of Repair Kit ZU4TK. Skid bar includes screws, item 49.

2 Note: See Repair Parts PartsSheet Sheet L2908 for valve components. L2908_avdel for valve components Notes: Torque to in-lbs. [ Nm] Torque to 8-26 in-lbs. [ Nm] Apply Loctite 545 to threads Figure 2A, Pump Assembly (exploded view) 2

3 Repair Parts List for Figures 2A and 2B Item Part Number Qty. Description Item Part Number Qty. Description 45 DC9405 Back Bracket 60 (See Figure 6) Assembly, Front Bracket 47 B O-Ring 6 DC Cable Tie, Black 48 DC Lock Nut 20 mm 62 (See Figure 7) Enclosure, Left ZU4 50 CBE65028-A SHCS M6 x 0mm 64 DC Enclosure, Right ZU4 5 DC Dome Plug " 65 CBE69028-A 6 SHCS M6 x x 0 52 DC Dome Plug 6mm 66 CAE06008-A 6 6MM Washer 54 (See Figure 0) Motor, 5V ZU4 67 DC Brush Cap, Left Motor, 230V ZU4 68 DC Brush Cap, Right 55 DC Baffle, Lower ZU4 69 DC Decal, Brush Cap 56 DC Baffle, Middle ZU4 70 DD Gasket, Valve 57 DC Baffle, Upper ZU4 7 (see RPS L2908_avdel) Valve 58 (See Figure 4) Assembly, Middle Bracket 98 DD474 Guard, Transducer DC Power Cord - 5V 5 Amp 06 DC Ferrite DC Power Cord - 230V 07 DC Washer, Wavy 59 w/nema 5-5 plug 08 DC Bolt, #0-32 x 6.5" DC Power Cord - 230V European 09 DC Velcro, 2" plug, CE RF Compliant. 5 B Washer, Lock Items included in and available only as part of Repair Kit ZU4TK. Note: Refer to Repair Parts Sheet L2908_avdel for valve (item 7) replacement parts Notes: Torque to in-lbs. [ Nm] Torque to in-lbs. [ Nm] Apply Loctite 545 to threads. Apply Loctite 243 to threads Figure 2B, Pump Assembly (side view) 3

4 Torque to in-lbs. [ Nm] 26 0 Torque to in-lbs. [40-43 Nm] Used only on. models without heat exchanger assembly. 26 This view shows parts for pumps equipped with a heat exchanger (optional accessory). 30 3A 2B, 9B, A Torque to 5-8 ft-lbs. [20-24 Nm] 27 2X Torque to ft-lbs. [27-30 Nm] Torque to 5-8 ft-lbs. [20-24 Nm] 9A Torque to ft-lbs. [20-24 Nm] Torque to 5-7 in-lbs. [ Nm] Torque to ft-lbs. [6-64 Nm] 5 20 Torque to ft-lbs. 9 [6-64 Nm] 2 Torque to 5-8 ft-lbs. [20-24 Nm] Note: Apply Loctite 545 to threads Figure 3, Pump Coverplate and Element Assembly Repair Parts List for Figure 3 Item Part Number Qty. Description Item Part Number Qty. Description 0 (See RPS L2596) Pump Element Assy. 22 H BSS0368D Back-up F Fitting 5-4 FTX-S 23 H B02803 O-Ring 2A F Fitting, Standard Pump 24 H DC92767 Copper Gasket 2B F Fitting, Heat Exc. Pump 25 H DC Gasket, Universal Pump 3A DC Hose, Bypass 8" 26 CBE62028-A 2 SHCS, M6 x 20 3B DC Hose, Heat Exc. Pump 23" 27 DC Tube Assy, Steel, ZU4 5 DC94070 Cover Plate, Universal 28 DC Intake Tube,.6" (4 litres) 7 B Plug SAE #0 29 DC9788 Intake Filter 8 B Plug, Socket, SAE #8 30 DC Return Hose, Heat Exc. 9A B Plug, SAE #8 Std. Pump 26 DC Clamp, Heat Exc. Pump 9B DC Fitting, Heat Exc. Pump 30 DC Breather Assembly 20 H B O-Ring, Heat Exc. Pump 305 F Adapter Fitting 2 DC Connector Fitting H Items included in Seal Kit ZU4TK. 4

5 Torque to 9 in lbs [.0.2 Nm] Note: Remove these two nuts and assemble Item 4 before assembing Item 82 to Item 80. Torque nuts to 9 in-lbs. [.0.2 Nm] 2 Notes: RF Filter (item 42) is used only on the CE pump version. Wires (items 46) cable (item 47) and capacitor (item 75) are not shown. These items are used only on the CE pump version. Capacitor (item 75) is spliced to RF filter LOAD wire connections. Figure 4, Middle Bracket Assembly, LCD Electric Repair Parts List for Figure 4 Item Part Number Qty. Description Item Part Number Qty. Description 80 DC9404 Middle Bracket 87 DC A/R Insulation Tube 8 DC Standoff 4 DC996 Bracket RF Filter 230V Eur CE 82 DC88827 Power Board 42 DC RF Filter 230V Eur CE 83 DC Screw Hi-Lo #8x/2 43 DC Lock Nut # V Eur CE 84 DC Circuit Breaker 25 Amp (5V) 46 DC Gnd. Wire 230V Eur CE (not shown) DC Circuit Breaker 2 Amp (230V) 47 DC Cable, TB600 to SSR (not shown) 85 E008 A/R Jumper Connector 74 E /4 Flag Connector (not shown) 86 DC Fuse.25A (5V) 75 DC Capacitor, µf x 2 (not shown) DC Fuse 0.75A (230V) 20 DC Fuse, Secondary, F3, 3.5A, Slow B Used only on CE version. A/R = As Required. Complete middle bracket assembly for 5V models: Order part number DC SR. Complete middle bracket assembly for 230V models (except CE): Order part number DC SR. Complete middle bracket assembly for 230V European CE models: Order part number DC SR. 5

6 Primary fuse (item 86) Secondary fuse (item 20) Terminal not used on ZU4 AVDEL Pro Series pumps. torque wrench pumps. Terminal used only if if optional level/temperature switch is is installed. NOTE: Note: switch Switch not available on pumps equipped with 4 or liters 2 gallon reservoirs. [4 or 8 liter] reservoirs. Figure 5, Power Board, Single Phase SSR Single Phase Transformer Tapping 00 to 20 Volts Lead Connect to Terminal FL QC 3 FL 2 QC 6 FL 3 QC 7 Single Phase Transformer Tapping 200 to 240 Volts Lead Connect to Terminal FL QC FL 2 QC 3 FL 3 QC 6 6

7 Notes: Apply Loctite 243 to threads. Torque to 4-8 in-lbs. [ Nm] Wire assembly items 22, 222 and 223 are not shown. 20 Figure 6, Front Bracket Assembly Repair Parts List for Figure 6 Item Part Number Qty. Description 20 CBE04020-D 2 Nut, 4 mm 48 DC Nut, Locking, 20 mm 84 DD Relay, LY3F 24VDC Coil, 4 Amps DPDT 88 DD Cable Assembly, Solenoid Valve 89 DA Screw, Self Tapping 200 DD47 Bracket, Front Electrical 20 DC Relay, Solid State 203 CBE49028-A 2 Screw, Socket Hd. Cap, M4 x 6 Zinc Plated 22 DC Cable, Terminal Block to Solid State Relay 222 DD42960 Cable Assembly, Relay Coil 223 DD Cable Assembly, Terminal Block to Relay Not Shown. 7

8 Back View Front View Torque to in-lbs. [ Nm] Figure 7, Enclosure Assembly (left side) Repair Parts List for Figure 7 Item Part Number Qty. Description 00 DC Enclosure, Left, ZU4 0* DC PCB LCD Control Board 03 DC Keypad Shroud, LCD 4 Button 04 DC Overlay Shroud, LCD 4 Button 05 DA Screw, Hi-Lo #8 x /2 Items included as part of Repair Kit DC SR, Keypad Assembly (4 button). * NOTE: If LCD board is replaced the AVDEL Firmware must be uploaded. For further information contact AVDEL UK. 8

9 For cable details contact AVDEL 2 Solenoid Cable (See Figure 6) Figure 8, Cable Assembly Repair Parts List for Figure 8 Item Part Number Qty. Description B O-ring 2 DC Locking Nut 20 mm 9

10 25 Hoses cross before threading through bushings. Use Loctite #243. Torque to in-lbs. [ Nm] Note: Refer to Enerpac Repair Parts Sheet L2752 for additional heat exchanger parts information. Figure 9, Heat Exchanger, 5 and 230 VAC Fan Repair Parts List for Figure 9 Item Part Number Qty. Description 23 DC Grommet Rubber.69"-" 24 CBE65028-A M6 x 0 SHCS 25 DC Heat Exch Assy, 5 VAC DC Heat Exch Assy, 230 VAC 26 DC Hose Clamp, 3/8-7/8 27 DC Locking Nut, 6 mm Items included as part of Heat Exchanger Kit ZHE-U5 (5V). Items included as part of Heat Exchanger Kit ZHE-U230 (230V). 0

11 204A 204B Figure 0, Motor Assembly Repair Parts List for Figure 0 Item Part Number Qty. Description 85 E008 2 Terminal, Flag (not shown) 200 Not available - Housing (order complete motor) 20 DC Armature, 5V, ZU4 DC Armature, 230V, ZU4 203 DC Spring Washer 204A DC Bolt #0-32 x 6.5" 204B B Washer, Lock 205 DC Brush, ZU4 206 DC Brush Cap, ZU4 Items included as part of DC SR Electric Motor Kit (5V). Items included as part of DC SR Electric Motor Kit (230V).

12 5 Volts or 230 Volts 60 or 50 Hz., AC Line Voltage In Power Cord DC for 5V, DC for 230V DC for CE 230V POWER BOARD White, 2 AWG Blue CE TB LINE 2 Green, 2 Green/Yellow, CE (DC for CE 230 V LINE LOAD F EMI In-Line Filter DC CE 230V Black, 2 2 TB LINE Brown, CE A Circuit Breaker DC (25A, 5 V) DC (2A, 230 V) TB MOTOR L SSR DC Brown Cable - TB to Relay DD F Fuse DC (.25A, 5 V) DC (0.75A, 230 V) TRANSFORMER TAPPINGS VARY DEPENDING ON INCOMING VOLTAGE QC FL not connected FL FL2 FL3 QC4 QC2 QC3 QC5 QC6 QC7 SSR FIRING OUTPUT K T EMI In-Line Capacitor DC for CE 230 V microfarad, 275 Volts A A2 5 R A TB LINE 2 Pump Motor M Heat Exch. Fan DC (5 V) DC (230 V) TB MOTOR 2 HE Fan Cord DC M 2 HE Fan Cord DC Cable - TB to Relay DD Sol. Cable DD Blue Blue 4 6 RA 3 Brown S Advance Solenoid DD (5 V) DD (230 V) R A POWER BOARD Figure, Electrical Diagram, ZU4 Pump (View of 2) 2

13 Relay Coil Cable DD42960 LCD CONTROL BOARD MICROCONTROLLER CIRCUITS POWER BOARD F 3 Fuse DC (3.5A - Slow Blow) DC POWER SUPPLIES POWER TRANSISTOR CIRCUITS Pendant RA7 PENDANT R A 7 8 Solenoid Switching Relay 4 Amps DPDT, 24 VDC Coil DD RA8 4 3 PRESSURE TRANSDUCER CIRCUITS RETRACT NOT USED ADVANCE + Red POWER BOARD Black Relay Coil Cable DD42960 Figure, Electrical Diagram, ZU4 Pump (View 2 of 2) 3

14 Enerpac Worldwide Locations Australia and New Zealand Actuant Australia Ltd. Block V Unit 3, Regents Park Estate 39 Park Road, Regents Park NSW 243 (P.O. Box 26) Australia T F sales-au@enerpac.com Brazil Power Packer do Brasil Ltda. Rua dos Inocentes, Sao Paulo (SP) T F Toll Free: vendasbrasil@enerpac.com Canada Actuant Canada Corporation 665 Ordan Drive, Unit 4-5 Mississauga, Ontario L5T X2 T F Toll Free: T F customer.service@actuant.com China (Taicang) Actuant (China) Industries Co.Ltd. No. 6 Nanjing East Road, Taicang Economic Dep Zone Jiangsu, China T F Toll Free: T sales-cn@enerpac.com France, Switzerland, North Africa and French speaking African countries ENERPAC Une division d ACTUANT France S.A.S. ZA de Courtaboeuf 32, avenue de la Baltique 940 VILLEBON /YVETTE France T F sales-fr@enerpac.com Germany and Austria ENERPAC GmbH P.O. Box 3003 D-4040 Düsseldorf Willstätterstrasse 3 D Düsseldorf, Germany T F sales-de@enerpac.com India ENERPAC Hydraulics Pvt. Ltd. No. A, Peenya Industrial Area IInd Phase, Bangalore, , India T F sales-in@enerpac.com Italy ENERPAC S.p.A. Via Canova Corsico (Milano) T F sales-it@enerpac.com Japan Applied Power Japan LTD KK Besshocho 85-7 Kita-ku, Saitama-shi , Japan T F sales-jp@enerpac.com Middle East, Egypt and Libya ENERPAC Middle East FZE Office 423, LOB 5 P.O. Box 8004, Jebel Ali, Dubai United Arab Emirates T +97 (0) F +97 (0) sales-ua@enerpac.com Russia Rep. office Enerpac Russian Federation Admirala Makarova Street Moscow, Russia T F sales-ru@enerpac.com Singapore Actuant Asia Pte Ltd. 83 Joo Koon Circle, Singapore T F Toll Free: T sales-sg@enerpac.com South Korea Actuant Korea Ltd. 3Ba 77, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea T F sales-kr@enerpac.com Spain and Portugal ENERPAC SPAIN, S.L. Avda. Los Frailes, 40 Nave C & D Pol. Ind. Los Frailes 2884 Daganzo de Arriba (Madrid) Spain T F sales-es@enerpac.com Sweden, Denmark, Norway, Finland and Iceland Enerpac Scandinavia AB Fabriksgatan Gothenburg, Sweden T +46 (0) F +46 (0) scandinavianinquiries@enerpac.com The Netherlands, Belgium, Luxembourg, Central and Eastern Europe, Baltic States, Greece, Turkey and CIS countries ENERPAC B.V. Galvanistraat AE Ede P.O. Box AB Ede The Netherlands T F sales-nl@enerpac.com Enerpac Integrated Solutions B.V. Opaalstraat TS Hengelo P.O. Box AK Hengelo The Netherlands T F integratedsolutions@enerpac.com South Africa and other English speaking African countries ENERPAC AFRICA ( PTY ) Ltd. Cambridge Office Park, Block E 5 Bauhinia Avenue Highveld Techno Park, Centurion Republic of South-Africa T 0027 (0) sales-za@enerpac.com United Kingdom and Ireland ENERPAC Ltd., Bentley Road South Darlaston, West Midlands WS0 8LQ England T +44 (0) F +44 (0) sales-uk@enerpac.com USA, Latin America and Caribbean ENERPAC World Headquarters P.O. Box 324 Milwaukee, WI USA N86 W2500 Westbrook Crossing Menomonee Falls, Wisconsin 5305 T F User inquiries: Distributor inquiries/orders: Technical inquiries: techservices@enerpac.com sales-us@enerpac.com 4

To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.

Repair Parts Sheet POWERFUL SOLUTIONS. GLOBAL FORCE. Hydra-Lift Models IPL-100 and IPL-101 L4066 Rev. A 03/13 For Date Codes Beginning with the Letter C To Protect Your Warranty, Use Only ENERPAC Hydraulic