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 DC9379025SR 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 S3037 3 Gasket 32 H DC9596026 2 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 DC8249006 Plug, Magnetic, SAE #8 4 DC9920026 Decal, Read Instructions 37 H DC955920 Gasket, Reservoir H Items included in and available only as part of Repair Kit ZU4TK. Skid bar includes screws, item 49.
57 56 55 64 66 65 6 54 52 5 68 62 07 69 67 50 4 45 7 4 7 65 Note: See Repair Parts PartsSheet Sheet L2908 for valve components. L2908_avdel for valve components. 65 6 66 98 70 4 6 7 Notes: Torque to 84-08 in-lbs. [9.5-2.2 Nm] Torque to 8-26 in-lbs. [2.0-2.9 Nm] Apply Loctite 545 to threads. 06 09 Figure 2A, Pump Assembly (exploded view) 2
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 B223503 O-Ring 6 DC6876647 5 Cable Tie, Black 48 DC953802 Lock Nut 20 mm 62 (See Figure 7) Enclosure, Left ZU4 50 CBE65028-A SHCS M6 x 0mm 64 DC964424 Enclosure, Right ZU4 5 DC9435009 2 Dome Plug " 65 CBE69028-A 6 SHCS M6 x x 0 52 DC9436009 3 Dome Plug 6mm 66 CAE06008-A 6 6MM Washer 54 (See Figure 0) Motor, 5V ZU4 67 DC944424 Brush Cap, Left Motor, 230V ZU4 68 DC943424 Brush Cap, Right 55 DC940298 Baffle, Lower ZU4 69 DC9598026 Decal, Brush Cap 56 DC9400298 Baffle, Middle ZU4 70 DD432037 Gasket, Valve 57 DC9400298 Baffle, Upper ZU4 7 (see RPS L2908_avdel) Valve 58 (See Figure 4) Assembly, Middle Bracket 98 DD474 Guard, Transducer DC9444960 Power Cord - 5V 5 Amp 06 DC9740969 Ferrite DC9445960 Power Cord - 230V 07 DC966066 Washer, Wavy 59 w/nema 5-5 plug 08 DC9653028 Bolt, #0-32 x 6.5" DC8288960 Power Cord - 230V European 09 DC995405 Velcro, 2" plug, CE RF Compliant. 5 B080066 2 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. 59 5 47 48 50 58 6 60 5 8 08 5 4 5 7 8 Notes: Torque to 84-08 in-lbs. [9.5-2.2 Nm] Torque to 36-40 in-lbs. [4.-4.5 Nm] Apply Loctite 545 to threads. Apply Loctite 243 to threads. 65 4 7 Figure 2B, Pump Assembly (side view) 3
Torque to 72-84 in-lbs. [8. - 9.5 Nm] 26 0 Torque to 30-32 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, 20 29 28 2A Torque to 5-8 ft-lbs. [20-24 Nm] 27 2X Torque to 20-22 ft-lbs. [27-30 Nm] 3 26 25 Torque to 5-8 ft-lbs. [20-24 Nm] 9A Torque to 8 5-8 ft-lbs. [20-24 Nm] 30 305 2 24 22 23 Torque to 5-7 in-lbs. [.5 -.8 Nm] Torque to 45-47 ft-lbs. [6-64 Nm] 5 20 Torque to 45-47 ft-lbs. 9 [6-64 Nm] 2 Torque to 5-8 ft-lbs. [20-24 Nm] Note: Apply Loctite 545 to threads. 26 7 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 F00094-246 Fitting 5-4 FTX-S 23 H B02803 O-Ring 2A F00097-6 Fitting, Standard Pump 24 H DC92767 Copper Gasket 2B F00097-6 2 Fitting, Heat Exc. Pump 25 H DC955920 Gasket, Universal Pump 3A DC9335646 Hose, Bypass 8" 26 CBE62028-A 2 SHCS, M6 x 20 3B DC946646 Hose, Heat Exc. Pump 23" 27 DC9447920 Tube Assy, Steel, ZU4 5 DC94070 Cover Plate, Universal 28 DC9600268 Intake Tube,.6" (4 litres) 7 B007006 Plug SAE #0 29 DC9788 Intake Filter 8 B006006 Plug, Socket, SAE #8 30 DC948646 Return Hose, Heat Exc. 9A B006006 2 Plug, SAE #8 Std. Pump 26 DC9639299 2 Clamp, Heat Exc. Pump 9B DC9273097 2 Fitting, Heat Exc. Pump 30 DC8250006 Breather Assembly 20 H B908503 2 O-Ring, Heat Exc. Pump 305 F00096-38 Adapter Fitting 2 DC973690 Connector Fitting H Items included in Seal Kit ZU4TK. 4
8 80 82 86 83 84 85 4 87 2 20 Torque to 9 in lbs [.0.2 Nm] 43 42 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 DC9645268 A/R Insulation Tube 8 DC9429054 6 Standoff 4 DC996 Bracket RF Filter 230V Eur CE 82 DC88827 Power Board 42 DC9580380 RF Filter 230V Eur CE 83 DC9428008 6 Screw Hi-Lo #8x/2 43 DC8006008 Lock Nut # 6-32 230V Eur CE 84 DC9536380 Circuit Breaker 25 Amp (5V) 46 DC9583960 2 Gnd. Wire 230V Eur CE (not shown) DC9534380 Circuit Breaker 2 Amp (230V) 47 DC9893960 Cable, TB600 to SSR (not shown) 85 E008 A/R Jumper Connector 74 E003528 /4 Flag Connector (not shown) 86 DC9592378 Fuse.25A (5V) 75 DC9579382 Capacitor, µf x 2 (not shown) DC959378 Fuse 0.75A (230V) 20 DC856378 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 DC9993930SR. Complete middle bracket assembly for 230V models (except CE): Order part number DC9994930SR. Complete middle bracket assembly for 230V European CE models: Order part number DC9995930SR. 5
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
89 84 88 48 200 203 2 20 2 Notes: Apply Loctite 243 to threads. Torque to 4-8 in-lbs. [.6-2.0 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 DC953802 Nut, Locking, 20 mm 84 DD342980 Relay, LY3F 24VDC Coil, 4 Amps DPDT 88 DD420960 Cable Assembly, Solenoid Valve 89 DA3639028 Screw, Self Tapping 200 DD47 Bracket, Front Electrical 20 DC999980 Relay, Solid State 203 CBE49028-A 2 Screw, Socket Hd. Cap, M4 x 6 Zinc Plated 22 DC9893960 Cable, Terminal Block to Solid State Relay 222 DD42960 Cable Assembly, Relay Coil 223 DD344960 Cable Assembly, Terminal Block to Relay Not Shown. 7
00 03 0 Back View Front View 04 05 Torque to 5.0-5.5 in-lbs. [.57-.62 Nm] Figure 7, Enclosure Assembly (left side) Repair Parts List for Figure 7 Item Part Number Qty. Description 00 DC942424 Enclosure, Left, ZU4 0* DC878827 PCB LCD Control Board 03 DC9560026 Keypad Shroud, LCD 4 Button 04 DC9559026 Overlay Shroud, LCD 4 Button 05 DA9428008 Screw, Hi-Lo #8 x /2 Items included as part of Repair Kit DC9560900SR, Keypad Assembly (4 button). * NOTE: If LCD board is replaced the AVDEL Firmware must be uploaded. For further information contact AVDEL UK. 8
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 B223503 O-ring 2 DC953802 Locking Nut 20 mm 9
25 Hoses cross before threading through bushings. Use Loctite #243. Torque to 20-44 in-lbs. [3.6-6.3 Nm] 26 24 27 23 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 DC9690808 2 Grommet Rubber.69"-" 24 CBE65028-A M6 x 0 SHCS 25 DC8375900 Heat Exch Assy, 5 VAC DC8376900 Heat Exch Assy, 230 VAC 26 DC9639299 2 Hose Clamp, 3/8-7/8 27 DC953702 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
204A 204B 205 206 200 20 203 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 DC8246736 Armature, 5V, ZU4 DC8247736 Armature, 230V, ZU4 203 DC966066 Spring Washer 204A DC9653028 2 Bolt #0-32 x 6.5" 204B B080066 2 Washer, Lock 205 DC96562598 2 Brush, ZU4 206 DC9655020 2 Brush Cap, ZU4 Items included as part of DC8244259SR Electric Motor Kit (5V). Items included as part of DC8245259SR Electric Motor Kit (230V).
5 Volts or 230 Volts 60 or 50 Hz., AC Line Voltage In Power Cord DC9444960 for 5V, DC9445960 for 230V DC8288960 for CE 230V POWER BOARD White, 2 AWG Blue CE TB LINE 2 Green, 2 Green/Yellow, CE (DC9583960 for CE 230 V LINE LOAD F EMI In-Line Filter DC9580380 CE 230V Black, 2 2 TB LINE Brown, CE A Circuit Breaker DC9536380 (25A, 5 V) DC9534380 (2A, 230 V) TB MOTOR L SSR DC999980 Brown Cable - TB to Relay DD344960 F Fuse DC9592378 (.25A, 5 V) DC959378 (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 DC9579382 for CE 230 V microfarad, 275 Volts A A2 5 R A TB LINE 2 Pump Motor M Heat Exch. Fan DC8276470 (5 V) DC8277470 (230 V) TB MOTOR 2 HE Fan Cord DC8346960 M 2 HE Fan Cord DC8346960 Cable - TB to Relay DD344960 3 Sol. Cable DD420960 Blue Blue 4 6 RA 3 Brown S Advance Solenoid DD246660 (5 V) DD247660 (230 V) R A POWER BOARD Figure, Electrical Diagram, ZU4 Pump (View of 2) 2
Relay Coil Cable DD42960 LCD CONTROL BOARD MICROCONTROLLER CIRCUITS POWER BOARD F 3 Fuse DC856378 (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 DD342980 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
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