To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil.

Transcription

1 Repair Parts Sheet 3, 4, and 5 Series Global Electric Pumps L46 Rev. E 11/07 For Date Codes Beginning with the Letter "A". To Protect Your Warranty, Use Only ENERPAC Hydraulic Oil. Enerpac recommends that all kit components be installed to insure optimum performance of the repaired pump. CONTENTS Pump Section Figure 1 Pump and Reservoir Assembly Figure & 3 Basic Pump Assembly Figure 4 By-Pass Valve Assembly Figure 5 Relief Valve Assembly Electrical Section Figure Electrical Enclosure Figure 18- Pump Wiring Diagrams Options Section Figure 6 Pressure Switch Assembly Figure 7 Heat Exchanger Assembly Figure 8 Level Switch Assembly Figure 9 Foot Switch Assembly Figure 10 Wiring Diagram, Foot Switch Figure 11 & 1 Pendant Assembly

2 Notes: 1) Keep filter oriented within the perimeter of the geroter. ) Torque to 4 46 in. lbs [4,7 5, Nm]. 3) Apply Loctite 545 when Vibra seal is not applied. 4) Torque to 4 47 in. lbs [4,7 5,3 Nm]. 35 See Note 3 See Note VALVE See Note See Note 4 SCALE 1:8 DETAIL FOR WORKHOLDING VERSION See Note VALVE 41, Torque to Ft.lbs [-6 Nm] 40 See Note 4 17, See Note See Note Torque to in.lbs [4,5 5,6 Nm] See Note See Note 3 60 Figure 1, Pump and Reservoir Assembly

3 1 PA60105SR 1 Reservoir,.5 Gal. (10 L) PA605SR 1 Reservoir, 5 Gal. ( L) DC71105SR 1 Reservoir, 10 Gal. (40 L) DC63SR 1 Sight Glass,.5 Gal. Pumps (10 L) DC63SR 1 Sight Glass, 5 Gal. Pumps ( L) DC7963SR 1 Sight Glass, 10 Gal. Pumps (40 L) 3 DC Return Pipe.5 Gal. Pump (10 L) DC Return Pipe 5 Gal. Pump ( L) DC Return Pipe 10 Gal. Pump (40 L) 4 G4606 Decal 5 A Plug 6 C Magnet 7 CV838950SR 1 Filter Assembly 8 DA Pipe.5 Gal. Pumps (10 L) CA Pipe 5 Gal. Pumps ( L) DA Pipe 10 Gal. Pumps (40 L) 9 A Plug 10 1 Gasket 11 Pump, Basic 1 See Pump Section 1 10 Gasket 13 DC BHSCS M6X16 Zinc 14 DC Knob 16 DC Lock Nut 17 PA Shipping Plug (.75 NPT) 18 CU Breather Tag 19 PA Coupling A Plug DA Hole Plug - Global CBE B 4 Motor Screw, M10X30 3 CH76 1 Caution Decal 4 CJ Decal, Rotation,.6" x 3." 6 DC Spider 7 DC Coupler 8 DC Key 9 DC 79959SR 1 Motor 110/ V, 1.5 hpm 50 Hz. DC5659SR 1 Motor 11 HP, 115/30V, 1 Ph., 60 Hz. DC3459SR 1 Motor 0V, 1.5 HP DC559SR 1 Motor 1 1 HP, 30/380/460V, 3 Ph, 60 Hz./50Hz. 1.0 HP motors Repair Parts List for Figure 1 9 DC559SR 1 Motor 440V,.5 HP, 50 Hz. DC34359SR 1 Motor 0V, 3 HP DC59859SR 1 Motor 3 HP, 30/380V, 3 Ph, 60Hz./50Hz. DC59959SR 1 Motor 3 HP, 575V, 3 Ph, 60Hz./50Hz. DC79859SR 1 Motor, 575V, 1.5 HP 30 1 Motor Gasket 33 CBE10801-A 4 M8 Loc Nut 34 CBE B 4 Screw, M8 X DC Nameplate - Hushh DC6101 Adapter Plate 5 & 10 Gal. (, 40 L) 37 PA Cover Plate,.5 Gal. Pump (10 L) DC Cover Plate, 5 & 10 Gal. Pumps (, 40 L) 38 DC6191 Rollbar 39 DC Screw, Flat Head Socket Cap 40 DC M6x10 mm BHCS 5 & 10 Gal. (, 40 L) 41 B SHCS X 1.5 Lg. 4 C Copper Gasket 43 1 Gasket 44 DA Connector - Global 45 Directional Valve 1 See Valve Parts Sheet 45 WMK01 1 WMK0 1 WMK1 1 Manifold Kit WMK 1 (5,000 psi, 350 bar) WMK 1 WMK41 1 WMK Electrical Enclosure 1 See Electrical Section 47 CAE A 4 Washer 49 DC Pipe 51 O-ring 5 Back-up Ring 53 B X.5 SHCS 55 DC Filler Screen 56 DC WH Cover Plate.5 gal. (10 L) DC WH Cover Plate 5, 10 gal. (, 40 L) 57 S Spring 58 B " Ball 60 DC Washer Indicates Items Included in and Available Only as Part of Pump Repair Kit GPE304050K Indicates Items Included in and Available Only as Part of Pump Repair Kit (Viton) GPE304050KV Indicates Items Included in and Available Only as Part of Pump Repair Kit (EPR). GPE304050KE Used only on 40 liter reservoir 3

4 Notes: 1. To be installed using Koeing plug setting tool such that ball is [0,-0,6] below sleeve.. Apply Loctite #71 to threads. 3. Use Loctite Sealant #545 for pipe fittings. 4. Point item #36 tube at item #34 upper roller bearing. 5. Grease all needle bearings with Lithium grease. 6. Apply grease to screen to hold in place during assembly Torque to ft.lbs [ 3 Nm] 17 15, 9 Torque to ft.lbs [9 10 Nm] 14 8 Torque to in.lbs [7,8 8,7 Nm] Places See note Torque to -5 ft.lbs [88 33 Nm] See note See Note 5. See Note Torque to 14 ft.lbs [18 30 Nm] , 4 Detail C 34 7 See Note 5 Torque to 14 ft.lbs [18 30 Nm] ( Places) Locations Torque to 4-45 In. Lbs. [4,7-5, Nm] See Detail C See Note 4. Torque to -5 Ft. Lbs. [8-33 Nm] Torque to Ft. Lbs. [-3 Nm], 46 SECTION B-B See Note 3. Orientation as shown REF4710F3 Figure, Two-stage Basic Pump Assembly 4

5 1 CCA A 1 Retaining Ring BSS475D Thrust Washer 3 BSS4599D 1 Needle Bearing 4 DA SR 1 Hex Cam & Bearing Assy. 5 DC Eccentric 6 CW51107 Needle Bearing 7 DC SR 1 Upper Plate with Bearing 8 DA Retaining Ring 9 BSS5484D 1 Middle Plate 10 3/16" Diameter Ball 11 BSS5117DSR 1 Gerotor Set 1 BSS5371DSR 1 Bottom Plate 13 CAA B Dowel Pin 14 CBA A 6 Screw 15 BSS5974D 10 Screw 16 DC616900SR 1 By-Pass Valve Assy. (Urethane) DC730900SR 1 By-Pass Valve Assy. (EPR) DC731900SR 1 By-Pass Valve Assy. (Viton) 17 DA SR 3 Piston Block, 3 Series, (Urethane) DA SR 3 Piston Block, 3 Series, (Viton DA SR 3 Piston Block, 3 Series, (EPR) DA SR 3 Piston Block, 4, 5, Series (Urethane) DA498900SR 3 Piston Block, 4, 5, Series (Viton) DA SR 3 Piston Block, 4, 5, Series (EPR) 18 9 O-Ring 19 DC Connector Block (Global) BSS5898D 1 Support Plate DC Tube Assembly Repair Parts List for Figure B UNC Schs x 1.5 Lg 3 DC645900SR 1 User Adjustable Relief Valve (Nitrile) DC79900SR 1 User Adjustable Relief Valve (Viton) DC78900SR 1 User Adjustable Relief Valve (EPR) 4 DC Tube Assemble, Relief 5 DC Key 6 DA High Pressure Plate 7 DC Top Plate 8 CBA A Socket Head Capscrew 9 CAE Washer (Packaging) 30 A Pipe Plug 31 BSS5409D 5 Plug 3 B /4" Ball 33 DA Jam Nut (Genesis) 34 DA Bearing - Global Pump 35 CA Male Elbow 36 F Male Connector 37 F /8 Tube x 1/8 NPT Male Pre 38 DC Nylon 11 Tubing 3/8 x 11" 39 DC Male Connector (Prestolok) 40 PA9097 Beaded Hose Barb Elbow 41 DC Hose Hydraulic 4 PA5599 Nylon Hose Clamp (Heyco) 43 1 O-Ring 44 DC Coupler 45 CCA8908-1D M8 x 40 HSHC 46 B108 4 SAE F/W 5 /16 PLN. 47 DC Oriface for Relief Valve Indicates Items Included in and Available Only as Part of Pump Repair Kit GPE304050K Indicates Items Included in and Available Only as Part of Pump Repair Kit (Viton) GPE304050KV Indicates Items Included in and Available Only as Part of Pump Repair Kit (EPR). GPE304050KE 5

6 8 14 B Torque to ft lbs (-3Nm) see note 1 Torque to 14- ft lbs (18-30 Nm) ( places) 6, See note 4 torque to -5 ft lbs [8-33 Nm] Torque to 14- ft lbs (18-30 Nm) ( places) 16 Torque to 14- ft lbs (18-30 Nm) ( places) 34 9 places B Torque to ft lbs (- Nm) See note & 4 orient as shown see note 3 7 Torque to 4-46 in lbs [4,7-5, Nm] see View A 3 17 Torque to ft lbs (9-10 Nm) 31 9 View A Section B-B D4889 Notes: 1.) To be installed using Koeing plug setting tool such that ball is [0, - 0,60] below sleeve..) Use Loctite sealant #545 for pipe fittings. 3.) Grease all needle bearings prior to assembly. 4.) Point tube item # towards upper bearing item #7. Figure 3, Single Stage Basic Pump Assembly 6

7 Repair Parts List for Figure 3 1 CCA A 1 Retaining Ring-Controlled E BSS475D Ring 3 BSS4599D 1 Needle Bearing 4 DA SR 1 Hex Cam and Bearing Assembly 5 DC Eccentric 6 CW Needle Bearing 7 DA Bearing - Global Pump 8 BSS5409D 5 Plug 9 A /16 Flush Plug with Sealant 10 DC510101SR 1 Bottom Plate with Bearing 11 DC61SR 1 High Press Plate with Bearing 1 DC Top Plate 13 CCA837081A 6 SOC. HD. Capscrew (Atlas) 14 DA SR 3 Piston Block Assy., 3 Series DA SR 3 Piston Block Assy., 4, 5 Series 15 DC Connector Block (Global) 16 BSS5898D 1 Support Plate 17 B UNC SHCS x 1.5 LG 18 DC /4" Tube x 3/8" NPT Straight 19 1 O-Ring Global CA Male Elbow DC Tube Assembly DC85155 Bearing Washer 3 DC Thrust Bearing 4 DC Key 5 B108 4 SAE F/W 5/16 PLN 6 CAE A 8 Washer 7 CCA A SHC Screw CCA8908-1D M8 x 40 HSHC 8 CBA A Socket Head Capscrew 9 1 O-Ring 30 DC Coupler 31 DA Jam Nut (Genesis) 3 DC645900SR 1 User Adj. Relief Valve 10, DC Tube Assy., Relief 34 F Male Connector 35 F Male Elbow 36 DC Single Stage Relief Valve T 37 DC Hose Hydraulic 38 PA5599 Nylon Hose Clamp (Heyco) 39 PA9097 Beaded Hose Barb Elbow Indicates Items Included in and Available Only as Part of Pump Repair Kit GPE304050K Indicates Items Included in and Available Only as Part of Pump Repair Kit (Viton) GPE304050KV Indicates Items Included in and Available Only as Part of Pump Repair Kit (EPR). GPE304050KE 7

8 REF4676F DC End Plug, By-pass DC616900SR 1 By-pass Valve Assembly 3 O-ring, Global 4 1 Back-up Ring Figure 4, Bypass Valve Assembly Repair Parts List for Figure 4 Indicates Items Included in and available only as Part of Repair Kit DC616900K. Indicates Items Included in and available only as Part of Viton Repair Kit DC616900KV. Indicates Items Included in and available only as Part of EPR Repair Kit DC616900KE. NOTE: Starred items are also included in the Pump Repair Kit. 5 1 O-ring 6 BSS5409D 1 Plug 7 DC Piston, New Bypass 8 DC Spring 9 DC Orifice Torque to 15-5 ft. lbs. [,3-33,9 Nm] Apply Loctite 4. 1 DC Seat 1 O-ring 3 DC645900SR 1 Relief Valve Assembly 4 DC Piston Guide 5 Spacer 6 Back-up Ring 7 1 O-ring Figure 5, Relief Valve Assembly Repair Parts List for Figure 5 Indicates Items Included in and available only as Part of Repair Kit DC645900K. Indicates Items Included in and available only as Part of Viton Repair Kit DC645900KV. Indicates Items Included in and available only as Part of EPR Repair Kit DC645900KE. NOTE: Starred items are also included in the Pump Repair Kit. 8 8 DC75013 Spring Guide 9 CS Spring 10 DC Plunger 11 CCA A 1 M3 X 4MM Set screw 1 DC Threaded Body 13 DC Piston

9 Mounting for VM Pin # Wire # Common Wire #3 Closed Wire #4 Normally Open 10 Wire 4 9 Wire Wire 3 Ground 8 7 Green/Yellow 6 11 Mounting for VM3/VM NOTE: Apply Loctite pipe sealant on all threads. D4867F11 Figure 6, Pressure Switch Block Repair Parts List for Figure 6, IC CJ Male Elbow 90 7 DA Liquid Tight Connector CJ Pipe Tee 8 DC86900SR 1 Cord Assembly 3 CJ Reducer Bushing 9 E Connector, Global 4 CN Pipe Nipple 10 G536L 1 1 " Gauge 0-15,000 psi 5 DA Pressure Switch 11 Y Street Tee 6 DA Fitting 9

10 .38 I.D. X.63 O.D. X LG. Hydraulic Hose Air Flow 1 ø.506 [1,85] Slots Places 46F1 Figure 7, Heat Exchanger Repair Parts List for Figure 7 Item Part Number Qty. Description HE1 (4 VDC) HE (115 VAC) 1 DC83470SR DC833470SR 1 Fan PA34471SR PA34471SR 1 Heat Exchanger Core 1 PA615F14 Figure 8, Level / Temperature Switch Repair Parts List for Figure 8 Item Part Number Qty. Description 1 LS1 1 Level Switch 10

11 1 5 Common Black Jumper Wire 16 8 Green Red Black Wire NC Bottom Terminal White Wire NC (Top Terminal) No (Bottom Terminal) Wire Connections Red from cord to switch "A" terminal "COM." Black from cord to switch "B" terminal "COM." White from cord to switch "B" terminal "NORMALLY CLOSED" Green from cord to ground screw. Black jumper wire from switch "A" terminal "NORMALLY CLOSED" to switch "B" terminal "NORMALLY OPEN." 10, 11, 1 13 Terminal designation are for wiring only, not true function of switch. 9 Figure 9, Foot Switch Assembly Repair Parts List for Figure 9 1 DC Cord Assy. 1 B Lock Washer 5 CH Foot Switch 13 F Loop Clamp 8 CA683900SR 1 Guard Assy. 14 G4406 Decal 9 M98 Cap Screw 15 DA Blank Decal - Service 10 B Button Head Screw #10x CH76 1 Caution Decal 11 B Hex Nut Note: Terminal designations are for wiring only and do not reflect the true functions of the switch. Red Black Green Figure 10, Wiring Diagram, Foot Switch 11

12 1 C P R C Metal jumper installed by square D during manufacturing DETAIL B Rear view of contacts Red Tighten terminal screws to 5 6 in. lbs. Pin (4) & (5) with no wire connected Black White Pendant Schematic Black Red Red VIEW "C-C" Green (not used) White White Black Figure 11, Two-button Pendant (IC43) Repair Parts List for Figure 11 Item Part Number Qty. Description 1 DC SR 1 Cord Assembly 1 C C Detail B Rear view of contacts PENDANT SCHEMATICS VIEW "C-C" Red Black Black Red Pin (4) & (5) with no wire connected Black White Green (not used) White Red White REF4715CF16 Tighten Terminal Screws to 5-6 in. lbs. Figure 1, Single Button Pendant (IC3) Repair Parts List for Figure 1 Item Part Number Qty. Description 1 DC SR 1 Cord Assembly 1

13 NOTES: 1. Crimping of AMP PIDG terminals shall be done with a double crimp, ratchet type crimping tool for insulated terminals.. All wires, except ground wires, must have wire labels (Item 16) on both ends of wire. Wire numbers shall be per schematic. strip strip To transformer 18 secondary strip strip 18 To Rectfier strip 1 To Starter ReF4719CF5 Figure 13, Electrical Enclosure Complete Electrical Enclosure Assemblies Part Number Description Part Number Description DC767900SR Enclosure 115V DC895900SR Enclosure 30V, 3 PH DC870900SR Enclosure 115V, 1PH, Amp Plug DC354900SR Enclosure 30 V, 3 PH Dump DC389900SR Enclosure 115V Jog/Hold DC770900SR Enclosure 380/400/440V DC35900SR Enclosure 115V Dump DC355900SR Enclosure 380/400/440 V Dump DC357900SR Enclosure 115V Canada Dump DC77900SR Enclosure 460V, 3 PH DC SR Enclosure 0V Japan VSP DC356900SR Enclosure 460V Dump DC375900SR Enclosure 0V Japan Dump DC773900SR Enclosure 575V, 3 PH DC768900SR Enclosure 30V, 1PH DC357900SR Enclosure 575V Dump DC353900SR Enclosure 30 V, 1 PH Dump Repair Parts List for Figure 13 Item Part No. Qty. Description Item Part No. Qty. Description 1 6 Female Insert, 7-Positions, Female Stamped Contact, Angle Panel Base Mount, Coding Pins, Protective Cover, Panel Base, DC Selector Switch, -position 8 1 Mounting Collar (included in DC9537) 14 DA Cord Grip 18 Std. Hardware Wire 18 Awg. Strand Copper, Red Std. Hardware Wire 18 Awg. Strand Copper, Blue Std. Hardware Wire 18 Awg. Strand Copper -, Gr/Yel Std. Hardware Wire 16 Awg. Strand Copper O, Yel 7 Std. Hardware AMP34541 PIDG Spade Tongue Terminal Nylon #-16 #6 Screw 0.50" W 35 PA Enclosure Box 9 1 Legend Plate (included in DC9537) 36 Std. Hardware 1 #4-40 x 3/8" Self Tapping Machine Screw Indicates parts in Electrical enclosure repair kit EBRK-1. Kit contains (3) 90 housings, (1) straight housing, () female contacts, (4) coding pins, (4) female inserts, () protective covers, (4) hoods, (4) male inserts, (4) male contacts, (1) spiral spintop and (1) de-insertion tool. Item Part No. Qty. Description DC Connector Crimp Tool Amp Pro-Crimper II, #

14 To heat exchanger To pendant To heat exchanger 30 To solenoid "A" To solenoid "A" To pendant strip ground block To ground screw To pendant To heat exchanger To rectifier To transformer secondary To rectifier A1 L1 L A 18 4 To level switch 19 4 To transformer 17 5 To fuse secondary 19 4 To rectifier Notes: 1. Use heat shrink tubing to cover metal portion of faston.. Crimping of Amp PIDG crimp terminals shall be done with a double crimp, ratchet-type crimping tool for insulated terminals. To transformer primary To starter To starter strip ground 7 strip. See 6 38 Note To selector switch strip To starter X X SECONDARY PRIMARY H1 H3 H H To fuses REF47F6 Figure 14, 115 & 30 Volt Back Panel Repair Parts List for Figure DC D-line IEC Starter, 18 Amp 4 VAC 50/60 Hz. coil 1 N.O. Aux. 6 Std. Hardware 4 AMP PIDG Faston Recept. Nylon #-18 #6 Screw 0.50" W 11 DC VA Transformer 115/30 PIRI. 7 Sec. 7 Std. Hardware 5 AMP PIDG Spade Tongue Terminal #-16 #6 Screw 0.50" W 13 DA Rectifier 10 Amp 30 Std. Hardware 6 AMP PIDG Ring Tongue Terminal 15 DC Terminal Strip Nylon #-16 #10 Screw 0.31" W 17 Std. Hardware * Wire #18 AWG Strand Copper, Black 3 DC Fuse 115 V, FNQ-R Std. Hardware * Wire #18 AWG Strand Copper, Red DC Fuse 30 V, FNQ-R Std. Hardware * Wire #18 AWG Strand Copper, White 33 DC Fuse Holder 600 V Std. Hardware * Wire #18 AWG Strand Copper, Blue 34 DC Fuse Cover 600 V for fuse size Std. Hardware * Wire #18 AWG Strand Copper, Gr/Yel 13/3" x 15" 4 Std. Hardware 3 AMP36861 PIDG Spade Tongue 36 Std. Hardware #4/40x3/8" Self-tapping Screw Terminal #-16 #6 Screw 0.97" W 37 Std. Hardware 8 #8/3x3/8" Self-tapping Screw 5 Std. Hardware 6 AMP 353 IDG Spade Tongue Terminal 38 Std. Hardware 4 3/8" Diameter Heat Shrink Tubing #-16 #8 Screw 0.375" W 40 DC Finger-safe covers for Transformer 41 Std. Hardware 3 #8 x 3 x 1/" Self-tapping Screw 14

15 Notes: 1. Use heat shrink tubing to cover metal portion of faston.. Crimping of AMP PIDG crimp terminals shall be done with a double crimp, ratchettype crimping tool for insulated terminals. 3. Wire #4 is to be ran to the transformer but not terminated. Wire to be long enough to reach either H1, H, H3, H4, dr H5. 30 To heat exchanger To pendant To heat exchanger To solenoid "A" To solenoid "E" To pendant strip ground block To ground screw To rectifier To tranformer primary To heat exchanger 17 5 To pendant To transformer secondary To rectifier To level switch To fuses 19 4 To transformer secondary 19 4 To rectifier To starter To starter 19 7 strip ground switch strip To selector switch To starter 18 7 To selector switch REF473CF To fuses Figure 15, 380, 400, 440, 460, 575 Volt Back Panel Repair Parts List for Figure DC D-line IEC Starter 18 Amp Nylon #-18 #6 Screw 0.50" W 4 VAC 50/60 Hz. Coil 7 Std.Hardware 5 AMP PIDG Spade Tongue 1 DC VA Transformer 400, Terminal #-16 #6 Screw 0.50" W 440, 460, 575 Volt PRI, 7 Sec. 30 Std.Hardware 6 AMP PIDG Ring Tongue Terminal 13 DA Rectifier Nylon #-16 #10 Screw 0.31" W 15 DC Terminal Strip 3 DC Fuse 380 V & 400 V, FNQ-R-0.5 DC Fuse 440 V, FNQ-R Std.Hardware * Wire #18 AWG Strand Copper, Black DC Fuse 460 V, FNQ-R Std.Hardware * Wire #18 AWG Strand Copper, Red DC Fuse 575 V, FNQ-R Std.Hardware * Wire #18 AWG Strand Copper, White 33 DC Fuse Holder Std.Hardware * Wire #18 AWG Strand Copper, Blue 34 DC Fuse Cover Std.Hardware * Wire #18 AWG Strand Copper, Gr/Yel 36 Std.Hardware #4/40 x 3/8" Self-Tapping Screw 4 Std.Hardware 3 AMP36861 PIDG Spade Tongue 37 Std.Hardware 8 #8/3 x 3/8" Self-tapping Screw Terminal #-16 #6 Screw 0.97" W 5 Std.Hardware 6 AMP353 PIDG Spade Tongue Terminal 38 Std.Hardware 4 3/8" Diameter Tubing #-16 #8 Screw 0.375" W 40 DC Transformer Covers 6 Std.Hardware 4 AMP PIDG Faston Recept. 41 Std.Hardware 3 #8/3 x 1/" Self-Tapping Screw 15

16 30 strip ground block To heat exchanger To ground screw To pendant To transformer secondary 18 4 To rectifier To level switch 17 5 To fuses 19 4 To transformer secondary To pendant To heat exchanger Notes: 1. Use heat shrink tubing to cover metal portion of faston. Crimping of Amp PIDG crimp termnals shall be done with a double crimp, ratchettype crimping tool for insulated terminals. 3. All wires, except ground wires, must have Labels shall be lovated a max. of 1/"from terminating device.wire numbers shall be per schematic. 4. AC & DC wire shall be routed seperate whenever possible blue wires are DC. To solenoid "A" To solenoid "B" strip ground strip To heat exchanger To rectifier To transformer primary To starter To fuses To selector switch strip To starter 18 7 To selector switch 39 Label to be placed on enclosure floor, tight to front edge Figure 16, Japan VSP Sub-panel Assembly Repair Parts List for Figure DC D-Line IEC starter 11 DC Transformer, Hushh 00 low 13 DA Rectifier-global pump 15 DC Terminal strip 16 Std.Hardware Wire Markers 17 Std.Hardware * Wire #18 AWG Strand Copper, Black 18 Std.Hardware * Wire #18 AWG Strand Copper, Red 19 Std.Hardware * Wire #18 AWG Strand Copper, White Std.Hardware * Wire #18 AWG Strand Copper, Blue Std.Hardware * Wire #18 AWG Strand Copper, Gr/Yel 4 Std.Hardware 3 AMP36861 PIDG Spade Tongue Terminal #-16 #6 Screw 0.97" W 5 Std.Hardware 6 AMP353 PIDG Spade Tongue Terminal #-16 #8 Screw 0.375" W 6 Std.Hardware 4 AMP PIDG Faston Recept. Nylon #-18 #6 Screw 0.50" W 7 Std.Hardware 5 AMP PIDG Spade Tongue Terminal #-16 #6 Screw 0.50" W 30 Std.Hardware 1 AMP PIDG Ring Tongue Terminal Nylon #-16 #10 Screw 0.31" W 33 DC Fuse holder 600v 34 DC Fuse cover 600v 35 PA Electrical enclosure 36 Std.Hardware #4/40 x 3/8" Self-Tapping Screw 37 Std.Hardware 8 #8/3 x 3/8" Self-tapping Screw 38 Std.Hardware 4 3/8" Diameter Tubing 39 DC Industrial label 40 DC Finger-safe covers for trans 41 Std.Hardware 3 #8/3 x 1/" Self-Tapping Screw 4 DC Ground label 43 DC Sub-panel 16

17 strip ground block 30 To ground screw 4 To pendant (x) To transformer secondary To rectifier To solenoid B 18 4 To level switch To heat exchanger To fuses To starter To heat exchanger To solenoid 'A' To solenoid 'B' To heat exchanger To selector switch 18 To pendant 18 To rectifier To transformer primary 5 17 To transformer 19 4 secondary 19 4 To recitifier 7 strip (x) To solenoid "A" (x) (x) 17 5 To starter To starter 7 19 strip ground 7 strip 38 6 (4x) To fuses strip strip 38 6 REF4854C 35 To starter Label to be placed on enclosure floor, tight to 7 18 To selector switch front edge. Notes: 1. Use heat shrink tubing to cover metal portion of Faston.. Crimping of Amp PIDG crimp terminals shall be done with a double crimp, ratchet-type crimping tool for insulated terminals. 3. All wires, except ground wires, must have wire labels (Item #16) on both ends of the wire. Labels shall be located a maximum of 1/" from terminating device. Wire numbers shall be per schematic. 4. AC & DC wire shall be routed seperate whenever possible, blue wires are DC. Figure 17, Dump Japan Sub-panel Assembly Repair Parts List for Figure DC D-Line IEC starter 11 DC Transformer, Hushh 00 low 13 DA Rectifier-global pump 15 DC Terminal strip 16 Std.Hardware Wire Markers 17 Std.Hardware * Wire #18 AWG Strand Copper, Black 18 Std.Hardware * Wire #18 AWG Strand Copper, Red 19 Std.Hardware * Wire #18 AWG Strand Copper, White Std.Hardware * Wire #18 AWG Strand Copper, Blue Std.Hardware * Wire #18 AWG Strand Copper, Gr/Yel 4 Std.Hardware 3 AMP36861 PIDG Spade Tongue Terminal #-16 #6 Screw 0.97" W 5 Std.Hardware 6 AMP353 PIDG Spade Tongue Terminal #-16 #8 Screw 0.375" W 6 Std.Hardware 4 AMP PIDG Faston Recept. Nylon #-18 #6 Screw 0.50" W 7 Std.Hardware 7 AMP PIDG Spade Tongue Terminal #-16 #6 Screw 0.50" W 30 Std.Hardware 1 AMP PIDG Ring Tongue Terminal Nylon #-16 #10 Screw 0.31" W 33 DC Fuse holder 600v 34 DC Fuse cover 600v 35 PA Electrical enclosure 36 Std.Hardware #4/40 x 3/8" Self-Tapping Screw 37 Std.Hardware 8 #8/3 x 3/8" Self-tapping Screw 38 Std.Hardware 4 3/8" Diameter Tubing 39 DC Industrial label 40 DC Finger-safe covers for trans 41 Std.Hardware 3 #8/3 x 1/" Self-Tapping Screw 4 DC Ground label 43 DC Sub-panel 17

18 NOTES: 1. Two jumpers connect to transformer. Initially terminate for 115 Volt.. Transformer primary jumpers to be connected and fuses to be installed during pump assembly based on voltage. 115 volt Jumper H1 & H3 Jumper H & H4 *Fuse FNQ-R volt Jumper H & H3 *Fuse FNQ-R Ground wiring to be #18 green with yellow stripe. 4. 4VAC Control wiring to be #18 red. 5. 4VAC Neutral wiring to be #18 white. 6. All 4DC wiring to be #18 blue. 7. Wire numbers 1-9 high AC voltage Wire numbers VAC Wire numbers VDC 8. LC - Level switch PSC - Pressure switch HEC - Heat exchanger PC - Pendant AC - Solenoid A BC - Solenoid B 9. NCP - Non-connected pin position for coding in male plug on cord. CD - Coding pin position in female on enclosure. REF4681CF9 Figure 18, Electrical Diagram 110/30 Volt 1-phase 18

19 NOTES: 1. Do not connect wire #4 to transformer during initial panel build.. Transformer primary wire #4 to be connected and fuses to be installed during pump assembly based on voltage. 380V and 400V connect wire #4 to H, fuses BBS-05* 440V connect wire #4 to H3, fuses FNQ-R-.0.5* 460V connect wire #4 to H4, fuses FNQ-R-0.4* 575V connect wire #4 to H5, fuses FNQ-R-0.5* 3. Ground wiring to be #18 green with yellow stripe. 4. 4VAC control wiring to be #18 red 5. 4VAC neutral wiring to be #18 white 6. All 4VDC wiring to be #18 blue 7. Wire numbers 1-9 high AC voltage Wire numbers VAC Wire numbers VDC 8. LC - Level switch PSC - Pressure switch HEC - Heat exchanger PC - Pendant AC - Solenoid A BC - Solenoid B 9. NCP - Non-connected pin position for coding in male plug on cord CD - Coding pin position in female on enclosure D4864F10 Figure 19, Electrical Diagram 380/440/460/575 Volt 3-Phase 19

20 Motor Wiring Short dash lines represent exchange wiring for pumps with no electric enclosures. Motor terminal box wiring for electric valve version 190, 39 V / 3-phase. Ground L3 L L1 Motor terminal box wiring for manual valve version 110 V / 1-phase. Terminal box cover shown with back side of switch. Motor terminal box wiring for electric valve version 110 V / 1-phase. Ground L1 L T4 T5 T6 T3 T9 T1 T8 T7 T4 T8 T T1 T3 T5 Motor terminal box wiring for electric valve version 380, 400, 415, 640, 480, 575 V / 3-phase. (Terminal box cover shown with back side of switch.) Motor terminal box wiring for manual valve version V / 1-phase. Motor terminal box wiring for electric valve version V / 1-phase. Ground Ground L L1 Ground L1 L T4 T7 T5 T8 T6 T9 T3 T1 T T5 T3 T T8 T4 T1 T4 T8 T T1 T3 T5 Figure Enerpac Worldwide Locations info@enerpac.com internet: Africa China Germany, Austria Middle East, Turkey and Spain and Portugal ENERPAC Middle East FZE Actuant China Ltd. and Switzerland Caspian Sea ENERPAC Office 43, JAFZA 15 1F, 69 Fute N. Road ENERPAC GmbH ENERPAC Middle East FZE C/San José Artesano 8 P.O. Box Waigaoqiao Free Trade Zone P.O. Box Office 43, JAFZA 15 Pol. Ind. Jebel Ali, Dubai Pudong New District D Düsseldorf P.O. Box Alcobendas United Arab Emirates Shanghai, China Willstätterstrasse13 Jebel Ali, Dubai (Madrid) Spain Tel: +971 (0) Tel: D Düsseldorf United Arab Emirates Tel: Fax: +971 (0) Fax: Germany Tel: +971 (0) Fax: Tel: Fax: +971 (0) Fax: Australia, New Zealand Actuant Australia Ltd. Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 43 (P.O. Box 61) Australia Tel: Fax: Brazil Power Packer do Brasil Ltda. Rua dos Inocentes, Sao Paulo (SP) Tel: Fax: Toll Free in Brazil: Tel: vendasbrasil@enerpac.com Canada Actuant Canada Corporation 6615 Ordan Drive, Unit Mississauga, Ontario L5T 1X Tel: Fax: Toll Free: Tel: Fax: Technical Inquiries: techservices@enerpac.com Actuant China Ltd. (Beijing) 709B Diyang Building Xin No. Dong San Huan North Rd. Beijing City China Tel: Fax: Central and Eastern Europe, Greece ENERPAC GmbH P.O. Box D Düsseldorf Willstätterstrasse13 D Düsseldorf Germany Tel: Fax: France, Switzerland francophone ENERPAC, Une division de ACTUANT France S.A. ZA de Courtaboeuf 3, avenue de la Baltique VILLEBON /YVETTE France Tel: Fax: India ENERPAC Hydraulics (India) Pvt. Ltd. Office No. 9,10 & 11, Plot No. 56, Monarch Plaza, Sector 11, C.B.D. Belapur Navi Mumbai , India Tel: Tel: Fax: Italy ENERPAC S.p.A. Via Canova Corsico (Milano) Tel: Fax: Japan Applied Power Japan Ltd. Besshochou 85-7 Saitama-shi, Kita-ku, Saitama Japan Tel: Fax: 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 Russia and CIS (excl. Caspian Sea Countries) Actuant LLC Admiral Makarov Street 8 15 Moscow, Russia Tel: Fax: Singapore Actuant Asia Pte. Ltd. 37C, Benoi Road Pioneer Lot, Singapore Tel: Fax: Toll Free: Technical Inquiries: techsupport@enerpac.com.sg South Korea Actuant Korea Ltd. 3Ba 717, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea Tel: Fax: The Netherlands, Belgium, Luxembourg, Sweden, Denmark, Norway, Finland and Baltic States ENERPAC B.V. Galvanistraat 115, 6716 AE Ede P.O. Box 8097, 6710 AB Ede The Netherlands Tel: Fax: Technical Inquiries Europe: techsupport.europe@enerpac.com United Kingdom, Ireland Enerpac Ltd Bentley Road South Darlaston, West Midlands WS10 8LQ, United Kingdom Tel: +44 (0) Fax: +44 (0) USA, Latin America and Caribbean ENERPAC P.O. Box N. Baker Road Milwaukee, WI 539 USA Tel: Fax: User inquiries: Inquiries/orders: Technical Inquiries: techservices@enerpac.com 11/7/07