Repair Parts Sheet ZU4 Electric PumpDD1366223SR 1 3" Sight Glass 10 L DD1367223SR 1 5" Sight Glass...

1

2

Notes:Apply Loctite 243 to threads.

Torque capscrews in a crossing patternto ensure even sealing of gaskets.

114

44

43

42

37

31

32

40

39

38

34 33 35148 49 41 31 32 36

38A

35

10, 20 and 40 Liter

4 and 8 Liter10, 20 and 40 Liter

Torque8-10 ft-lbs[8.8-11.0 Nm]

Torque11.0-13.0 ft-lbs[14.9-17.6 Nm]

Torque35-40 ft-lbs[47.5-54.2 Nm]

Torque50-60 in-lbs[5.6-6.8 Nm]


Torque10L, 20L132-148 in-lbs[14.9-16.7 Nm]

Torque40L Only 35-45 in-lbs[4.0-5.1 Nm]


1

1

All Models

148

2

Repair Parts Sheet

ZU4 Electric Pump

L2610 Rev. Q 07/19 For Date Codes Beginning with the Letter “A”, “B”, “C” or “D” IMPORTANT:• For ZU4 torque wrench pumps with Date Code “E” or later, use repair parts sheet L2974.• For ZU4 foundation repair and post tensioning pumps, use repair parts sheet L2703.• For ZU4 classic bolting pumps, use repair parts sheet L2727 or L2907.

Figure 1, Reservoir Assembly

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.

Index:English .................................................................1-24Français .............................................................25-32Deutsch .............................................................33-40Italiano ...............................................................41-48Español ..............................................................49-56Nederlands ........................................................57-64Portuguese ........................................................65-72Suomalainen ......................................................73-80Norsk .................................................................81-88Svensk ...............................................................89-96

..........................................................97-104

2

Figure 2, Pump Assembly

1

2

2

1

1

HItems included in and available only as part of Repair Kit ZU4K.

Repair Parts List for Figures 1 and 2

Item Part Number Qty. Description Item Part Number Qty. Description

3

DC9379025SR 1 Reservoir 4L (Includes 32, 35, 36 and 37) DC8136025SR 1 Reservoir 8L (Includes 32, 35, 36 and 37)

31 DC9970025SR 1 Reservoir 10L

(Includes 32, 33, 34, 35 and 37) DC9971025SR 1 Reservoir 20L (Includes 32, 33, 34, 35 and 37) DC9972025SR 1 Reservoir 40L (Includes 32, 33, 34, 35 and 37)

32 H DC9596026 2 Decal, Enerpac Reservoir

33 C187018 1 Magnet

34 DD1425245 1 1/2" Flush Plug w/Sealant

35

DC85900SR 1 Sight Glass 4 L and 8 L

DD1366223SR 1 3" Sight Glass 10 L DD1367223SR 1 5" Sight Glass 20 L

DD1368223SR 1 7" Sight Glass 40 L

36 DC8249006 1 Plug, Magnetic SAE #8

37 H DC9551920 1 Reservoir Gasket Z

38 DC9542920 2 Reservoir Handle Z

38A DC9895101 4 Lift Plate (10, 20 and 40L)

39 CBE819028-1E 8 BHCS M8X16mm

40 CBE1080120-2A 8 Lock Nut M8

41 DC9590920 1 Skid Plate

42 (See Figure 3) Basic Assembly

43 H S3037 13 Gasket

44 CBE619028-1A 13 SHCS M6X16 mm

45 DC9405111 1 Back Bracket ZU4

47 B1223503 1 O-ring

48 DC9538021 1 Locking Nut 20 mm

49 CBE817028-1E 4 BHCS M8X12 mm

50 CBE615028-1A 1 SHCS M6X10 mm

51 DC9435009 2 Dome Plug 1"

52 DC9436009 1 Dome Plug 16 mm

53 DC9437009 1 Dome Plug 20 mm

54 (see Figure 9)

1 Motor 115V ZU4

1 Motor 230V ZU4

55 DC9401298 1 Baffle Lower ZU4

56 DC9400298 1 Baffle Middle ZU4 57 DC9402298 1 Baffle Upper ZU4

58 (see figures 4A, 1 Middle Bracket Assembly

through 4D)

59

DC9444960 1 Power Cord-115V 15 Amp

DC9445960 1 Power Cord-230V w/NEMA 5-15 plug DC8288960 1 Power Cord-230V, European

plug,CE RF compliant

60

(see figures 5A, 1 Front Bracket Assembly 5B and 5C)

61 DC9876647 1 Cable Tie, Black

62 (see Figure 6) 1 Enclosure, Left ZU4

63 DC9410111 1 Plate Close Out ZU4

64

DC9641424 1 Enclosure Right ZU4, Black

DC9411424 1 Enclosure Right ZU4, Yellow

65 CBE619028-1A 15 M6X16 SHCS

66 CAE1060108-1A 9 Flat Washer M6

67 DC9414424 1 Brush Cap Left ZU4

68 DC9413424 1 Brush Cap Right ZU4

69 H DC9598026 2 Decal Brush Cap ZU4

70

H DC9356037 1 Valve Gasket

H F786167 1 Valve Gasket (VM22 and VM32 only)

71 (see valve chart) 1 Control Valve Assy.

75 DC2749768 1 Return Tube

CBE843028-1A 6 SHCS M8X80 (VM22 only)

76 CBE825028-1A 6 SHCS M8X30 (VM32 only)

CBE837028-1A 4 SHCS M8X60 (all other models)

78

DC9512960 1 Cable Assy. Solenoid Valve 3-way

DC9512960 2 Cable Assy. Solenoid Valve 4-way

106 DC9740969 1 Ferrite

109 DC9951405 1 Velcro, 2 inch

107 DC9661066 1 Wavy Washer

108 DC9653028 2 Bolt #10-32x6.5"

114 DC9920026 1 Decal, Read Instructions

115 B1080066 2 Star Washer

148 (not available) 1 Decal, Prod. Spec.

Valve and Manifold Chart

Model Repair Part Sheet No. ModelRepair Part Sheet No.

VE32, VE32D L2612 VM32 L2614VE33 L2600 3-T-P-B-I (VM33) L2613VE42A (DC7023950) L2617 3-T-P-B-X (VM33L) L2613VE42AM (DC7024950) L2617 4-T-P-B-I (VM43) L2613VE42E (DC6167950) L2617 4-T-P-B-X (VM43L) L2613VE42EM (DC6402950) L2617 VM43LPS (Date Code “A”) L2633VE42Q (DC6443950) L2617 VM43LPS (Date Code “B”) L2699VE42QM (DC6403950) L2617 VM43LPS (Date Code “C”) L2956VE43 L2600 VM43LPSV L2699VM22 L2649

HItems included in and available only as part of Repair Kit ZU4K.

4

13B

30

126

20B

19B

12B

12B, 19B, 20B

Torque to45 - 47 ft-lbs.[61 - 64 Nm]

This view shows parts for oil filterand heat exchanger assemblies(optional accessories)

Used only onmodels withoutheat exchangerassembly


Torque to72 - 84 in-lbs.[8,1 - 9,5 Nm] 26 10 11

12A Torque to15 - 18 ft-lbs.[20 - 24 Nm]

13A

27

21

24

2223

15305

17

18

25

29 28

126 129 12720A

19ATorque to15 - 18 ft-lbs.[20 - 24 Nm]




Torque to15 -18 ft-lbs.[20 - 24 Nm]

2X Torque to20 - 22 ft-lbs.[27 - 30 Nm]

301

1

1

2

2

2

1

Torque to 5 - 7 in-lbs

[0,5 - 0,8 Nm]

Notes:

Apply Loctite 545 to threads before installation.

Location of breather assembly (item 301) and adapter (item 305) on pump coverplate (item 15) will vary, depending on pump date of manufacture.

10 Pump Element 1 See RPS L2596 for MPE

11 F100094-246 1 Fitting 5-4 FTX-S

12A F100097-16 1 Fitting, Standard Pump

12B F100097-16 2 Fitting, Heat Exc. Pump

13A DC9335646 1 Hose Bypass 8"

13B DC9416646 1 Hose, Heat Exc. Pump 23"

15 DC9407101 1 Coverplate, Universal

17 B1007006 1 Plug Socket SAE #10

18 B1006006 1 Plug, Socket

19A B1006006 2 Plug, SAE #8 Std. Pump

19B DC9273097 2 Fitting, Heat Exc. Pump

20A H B1908503 1 O-ring, Oil Filter Pump

20B H B1908503 2 O-ring, Heat Exc. Pump

21 DC9173690 1 Connector Fitting

22 H BSS0368D 1 Back-Up

23 H B1012803 1 O-ring

24 H DC9271167 1 Copper Gasket

25 H DC9551920 1 Gasket Universal Pump

26 CBE621028-1A 4 SHCS M6X20

27 DC9447920 1 Tube Assy. Steel Z Pump

DC9600268 1 Intake Tube 1.6" (4L and 8L)

28 DC9601268 1 Intake Tube 2" (10L)

DC9524268 1 Intake Tube 3" (20L)

DC9603268 1 Intake Tube 6.5" (40L)

29 DC9178118 1 Intake Filter

30 DC9418646 1 Hose HX Return 5"

126 DC9418646 1 Clamp, Heat Exc. Pump

127 DC9639299 1 Hose, Oil Filter Pump

129 DC8035038 1 Adapter, 5/8 Hose

301 DC8250006 1 Breather Assy

305 F100096-38 1 Adapter

Repair Parts List for Figure 3 Item Part Number Qty. Description Item Part Number Qty. Description

Figure 3, Basic Assembly

5

81 80 8286

83

84

Pendant

RetractAdvance

86

210

Figure 4A, Middle Bracket Assembly, LCD Electric (Date Code “A”)

80 DC9404111 1 Middle Bracket ZU4

81 DC9429054 6 Circuit Board Standoff .515

82 H (see below) 1 PCB Power Board (not sold separately)

83 DC9428008 6 Screw Hi-Lo #8X1/2

84 DC9536380 1 Circuit Breaker 25 Amp (115 V only)

DC9534380 1 Circuit Breaker 12 Amp (230 V only)

86 DC9592378 1 Fuse 1.25A (115 V only)

DC9591378 1 Fuse 0.75A (230 V only)

210 DC8156378 1 Fuse, Secondary F3, 3.5 A, Slow-Blow

H See instructions under parts list for additional information.

Note: Pumps with Date Code “A” may have been updated with Date Code “B” or “C” parts. (see figures 4B and 4C)

Date code “A” pumps: If the middle bracket assembly requires replacement, both the middle and front bracket assemblies must be replaced. Order the correct repair kit for your pump:

• Repair Kit DC9993930SR - Replacement Middle and Front Bracket Assemblies (115V)• Repair Kit DC9994930SR - Replacement Middle and Front Bracket Assemblies (230V)• Repair Kit DC9995930SR - Replacement Middle and Front Bracket Assemblies (230V, CE Compliant)

Important: Both new bracket assemblies must be installed together as a set. The new style middle bracket assembly is not electrically compatible with the old style front bracket assembly.

Repair Parts List for Figure 4A Item Part Number Qty. Description

6

Figure 4B, Middle Bracket Assembly, LCD Electric (Date Code “B”)

HSee instructions under parts list for additional information.

Note: Pumps with Date Code “B” may have been updated with Date Code “C” parts. (see Figure 4C)

80 DC9404111 1 Middle Bracket

81 DC9429054 6 Standoff

82 H (see below) 1 Pwr. Board (not sold separately)

83 DC9428008 6 Screw Hi-Lo #8x1/2

84 DC9536380 1 Circuit Breaker 25 Amp (115V)

DC9534380 1 Circuit Breaker 12 Amp (230V)

85 E1001181 Jumper Connector

86 DC9592378 1 Fuse 1.25A (115V)

DC9591378 1 Fuse 0.75A (230V)

87 DC9645268 Insulation Tube

88 DC9919980 1 SSR

89 CCA521028-1A 2 SHCS, M5 x 20

146 DC9898960 1 W Harness, PB to SSR (not shown)

147 DC9893960 1 Wire L1 to PB (not shown)

210 DC8156378 1 Fuse, Secondary, F3, 3.5A, Slow B

Repair Parts List for Figure 4B Item Part Number Qty. Description Item Part Number Qty. Description

as needed

as needed

Date code “B” pumps: If the middle bracket assembly requires replacement, both the middle and front bracket assemblies must be replaced. Order the correct repair kit for your pump:


Important: Both new bracket assemblies must be installed together as a set. The new style middle bracket assembly is not electrically compatible with the old style front bracket assembly.

7

Torque to 9 – 11 in lbs[1.0 – 1.2 Nm]

Notes:Remove these 2 nuts and assembleItem 141 before assembing Item 82 to Item 80. Torque nuts to 9 – 11 in lbs[1.0 – 1.2 Nm].

81 80 82 86 83 84

141

1

142

143

1

85

87

210

Notes:Wires (items 146, 147) and capacitor (item 175) not shown (CE version only).

• Date Code “C” – Capacitor spliced to RF filter LINE wire connections.

• Date Code “D”– Capacitor spliced to RF filter LOAD wire connections.

2

2

Figure 4C, Middle Bracket Assembly, LCD Electric (Date Codes “C” and “D”)

=Used only on CE version. HItem not shown.

80 DC9404111 1 Middle Bracket

81 DC9429054 6 Standoff

82 DC8181827 1 Power Board

83 DC9428008 6 Screw Hi-Lo #8x1/2

84 DC9536380 1 Circuit Breaker 25 Amp (115V)

DC9534380 1 Circuit Breaker 12 Amp (230V)

85 E1001181 Jumper Connector

86 DC9592378 1 Fuse 1.25A (115V)

DC9591378 1 Fuse 0.75A (230V)

87 DC9645268 Insulation Tube

141 DC9916111 1 Bracket RF Filter 230V Eur CE

142 = DC9580380 1 RF Filter 230V Eur CE

143 = DC8006008 4 Lock Nut # 6-32 230V Eur CE

146 = DC9583960 1 Gnd. Wire 230V Eur CE (not shown)

147 = DC9893960 2 Cable, TB600 to SSR (not shown)

174 = E1001352 2 1/4 Flag Connector (not shown)

175 = DC9579382 1 Capacitor, 1 µf x 2 (not shown)

210 DC8156378 1 Fuse, Secondary, F3, 3.5A, Slow B

220 H DC9892960 1 Wire Harness, PB to SSR

Repair Parts List for Figure 4C Item Part Number Qty. Description Item Part Number Qty. Description

as needed

as needed

Date Code “C” and “D” pumps: Replacement middle and front bracket assemblies may be ordered as a set:


8

Secondaryfuse (item 210)

Primary fuse(item 86)

Figure 4D, Power Board, Single Phase SSR

Single Phase Transformer Tapping 100 to 120 Volts

Lead Connect to Terminal

FL 1 QC 3

FL 2 QC 6

FL 3 QC 7

Single Phase Transformer Tapping 200 to 240 Volts

Lead Connect to Terminal

FL 1 QC 1

FL 2 QC 2

FL 3 QC 5

Note: Fan terminal not used on pumps with date code “D” and later.

9

80 DC8150111 1 Middle Bracket, CE

141 CBE419028-1A 2 SHCS, M4 x 16mm Zinc

142 DC9580380 1 RF Filter 230V Eur CE

143 CBE1040120-1D 2 Nut, M4 Zinc

146 DC9583960 1 Ground Wire 230V Eur CE (not shown)

147 DC9893960 2 Cable, TB600 to SSR (not shown)

174 E1001352 2 1/4 Flag Connector (not shown)

175 DC9579382 1 Capacitor, 1 µf x 2 (not shown)

Apply Loctite 243Torque to 9 – 11 in lbs[1.0 – 1.2 Nm]

80

141143

142

Notes:Wires (items 146, 147) and capacitor (item 175) not shown.

• Date Code “C” – Capacitor spliced to RF filter LINE wire connections.

• Date Code “D”– Capacitor spliced to RF filter LOAD wire connections.

1

1

Figure 4E, Middle Bracket Assembly, Standard Electric Pumps - No LCD (Date Codes “C” and “D”, CE version only)

Repair Parts List for Figure 4D Item Part Number Qty. Description

Note: Middle bracket assembly shown above is used only on standard electric CE version models. Standard electric models that are not CE version do not use a middle bracket.

10

MODEL NO. SERIAL NO. MAX PRES PSI BAR

SUPPLY VOLTAGE115 SINGLE PHASE, 50 OR 60 Hz, 1.125 HP

208-230V, SINGLE PHASE, 50 CR 60 Hz, 1125 HP

RESERVOIR CAPACITYGALLON / [LITER]

PUMP PERFORMANCE

10 [4]20 [8]25 [10]50 [20]10.0 [40]

PSI [BAR]100 [6.9]

10000 [700]700 [11.5]

80 [1.0]

CU.IN/MIN L/MIN

SPECIFICATIONS

PATENT PENDINGCSA CE

DC9595.026

147174 145 144 142 146 140 148 141 143

Figure 5A, Front Bracket Assembly (all electric pumps with Date Code “A” and LCD electric pumps with Date Code “B”)

140 DC9403111 1 Front Bracket ZU4

141 =CAE1040108-1A 2 Washer

142 =DC9580380 1 RF In-Line Filter, CE

143 = CAE407028-3A 2 Screw M4 Pan Head

144 = B1080066 2 Lockwasher #10

145 = CBE1040120-1D 2 Nut M4

146 = DC9583960 1 Ground Earth Wire 230V Eur, CE

147 = DC9893960 2 Cable, TB600 to SSR

148 H (not available) 1 Specification Decal ZU4

H = (not available) 1 Specification Decal ZU4, CE

174 E1001352 2 1/4 Flag Connector

= Used only on CE version.

H Not available as a service part.

Repair Parts List for Figure 5A Item Part Number Qty. Description

11

Apply Loctite 243to threads


142

145

141

140

143

144

Apply ThermalCompound

Figure 5B, Front Bracket Assembly (standard electric pumps with Date Code “B” - No LCD)

140 DC9403111 1 Front Bracket, ZU4 (steel)

141 =CAE1040108-1A 2 Washer

142 =CBE421028-1A 2 SHCS M4 x 20 Zinc

143 =DC9889111 1 Heat Sink, SSR (not available)

144 =DC9919980 1 Relay, Solid State

145 =CCA521028-1A 2 SHC Screw

146 H= DC9898960 1 Wire Harness, PB to SSR

147 H= DC9893960 1 Cable, TB600 to SSR.

HItems not shown.

=Used only on pumps without LCD.

Note: All items listed above are included in Repair Kit DC9891827SR

Repair Parts List for Figure 5B Item Part Number Qty. Description

IMPORTANT: Heat sink (item 143) is no longer available as a replacement part. If heat sink is damaged, order new aluminum front bracket (Figure 5C, item 200), capscrews (Figure 5C, item 203) and hex nuts (Figure 5C, item 202). Heat sink is not needed with aluminum front bracket.

12

Apply Loctite 243 to threads.

203


200

201202

1

Figure 5C, Front Bracket Assembly (all electric pumps with Date Codes “C” and “D”)

200 ✷ DC9957111 1 Front Bracket, ZU4 (aluminum)

201 ✷ DC9919980 1 SSR

202 ✷ CBE1040120-1D 2 Nut, Zinc M4

203 ✷ CBE419028-1A 2 SHCS M4 x 16mm Zinc

221 ✷ H DC9893960 1 Cable, TB600 to SSR

HItems not shown.

✷Included in Repair Kit DC9992930SR.

Repair Parts List for Figure 5C Item Part Number Qty. Description

13

101

102

Back View

Front View

100

104105

103

Figure 6, Enclosure Assembly (left side)

100

DC9412424 1 Enclosure Left ZU4, Yellow

DC9640424 1 Enclosure Left ZU4, Black

DC8178827 1 PCB LCD Control Board

101 DC8180827 1 PCB STD Board 115V

DC8179827 1 PCB STD Board 230V

102

DC9536380 1 Circuit Breaker 25 Amp (standard board 115 V only)

DC9534380 1 Circuit Breaker 12 Amp (standard board 230 V only)

103

H DC9560026 1 Keypad Shroud LCD-4 Button

= DC9562026 1 Keypad Shroud STD-1 Button

104

H DC9559026 1 Overlay Shroud LCD-4 Button

= DC9563026 1 Overlay Shroud STD-1 Button

105 H= DC9428008 4 Screw Hi-Lo #8X1/2

HItems included as part of Repair Kit DC9560900SR, Keypad Assy. (4-button).

=Items included as part of Repair Kit DC9562900SR, Keypad Assy. (1-button).

Repair Parts List for Figure 6 Item Part Number Qty. Description

Torque to 5.0-5.5 in-lbs.[.57-.62 Nm]

14

110

112

111

Figure 7, Pendant Assembled to Pump

ZCP-3 1 Pendant Assy. 3 Button

110 ZCP-2 1 Pendant Assy. 2 Button

ZCP-1 1 Pendant Assy. 1 Button

ZCP-220 1 Pendant Assy. 2 Button 20 Ft Wire

111 H B1223503 1 O-ring

112 H DC9538021 1 Locking Nut 20 mm

HItems included in Pendant Assembly.

See Repair Parts Sheet L2625 for Pendant Parts.


15

124

127

123

Hoses cross before threading through bushings.

Use Loctite #243.Torque to 120-144 in-lbs.[13.6-16.3 Nm].

126

125

123 H DC9690808 2 Grommet Rubber .69"-1"

124 H CBE615028-1A 1 M6X10 SHCS

125 H DC8375900 1 Heat Exch Assy, 115V Non PT/BTW

125 H DC8376900 1 Heat Exch Assy, 230V Non PT/BTW

126 H DC9639299 2 Hose Clamp 3/8-7/8

127 H DC9537021 1 Locking Nut 16 mm

HItems included as part of Kit ZHE-U115 and ZHE-U230.

See Repair Parts Sheet L2752 (pumps with 115 or 230 VAC fan) or L2656 (older pumps with 24 VDC fan) for additional heat exchanger parts information.


Figure 8, Heat Exchanger

Optional Accessories Option See Repair Code Accessory & Instruction Sheet:

F ZPF Filter Kit L2628

H

ZHE – E4 & ZHE – E10

Heat Exchanger 24 VDC L2656

H

ZHE – E4 & ZHE – E10

Heat Exchanger 115/230 VAC L2752

L ZLS – U4 Level/Temp Switch L2630

P ZPS – U4 Pressure Switch L2631

T ZPT – U4 Pressure Transducer L2627

U ZCF – 2 Foot Switch L2629

16

204A 204B 205 206

201

203

200

85 E1001181 2 Terminal, Flag (not shown)

200 Not available - Housing (order complete motor)

201

✲ DC8246736 1 Armature, 115V, ZU4

✜ DC8247736 1 Armature, 230V, ZU4

203 ✲ ✜ DC9661066 1 Spring Washer

204A ✲ ✜ DC9653028 2 Bolt #10-32 x 6.5"

204B ✲ ✜ B1080066 2 Star Washer

205 ✲ ✜ DC9656259 2 Brush, ZU4

206 ✲ ✜ DC9655020 2 Brush Cap, ZU4

✲ DC8244259SR Complete 115 V motor - includes above parts.

✜ DC8245259SR Complete 230 V motor - includes above parts.


Figure 9, Motor Assembly

17

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nP

ump

mot

or d

oes

not

star

t w

hen

a m

otor

bu

tton

is p

ushe

d

Pum

p st

ops

runn

ing

durin

g id

le o

r no

rmal

op

erat

ion

a) N

o po

wer

sup

ply

b) N

o po

wer

sup

ply

c) P

ower

cor

d da

mag

ed

d) P

enda

nt d

efec

tive

e) B

rush

es o

n th

e m

otor

are

wor

n ou

t

f) N

o po

wer

to

the

pow

er b

oard

g) N

o po

wer

to

the

pow

er b

oard

h) C

ircui

t br

eake

r is

ope

n

i) Th

e tr

ansf

orm

er o

n th

e po

wer

boa

rd

is d

efec

tive

j) Th

e m

otor

is d

efec

tive

k) T

he p

ump

unit

is m

echa

nica

lly

bloc

ked

a) P

ower

cor

d da

mag

ed

b) L

ow v

olta

ge o

n po

wer

sup

ply

c) C

ircui

t br

eake

r tr

ips

d) B

ypas

s va

lve

mal

func

tion

e) D

amag

ed o

r w

orn

gear

pum

p

a)

Is th

e po

wer

cor

d pl

ugge

d in

?

b) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.c)

A

re th

ere

any

visi

ble

dam

ages

(kin

k, lo

ose

wire

, mis

sing

in

sula

tion,

etc

.) on

the

pow

er c

ord?

d) D

oes

the

shro

ud-m

otor

-but

ton

star

t the

mot

or?

C

heck

the

cont

inui

ty a

cros

s th

e ke

ypad

but

tons

C

heck

the

cont

inui

ty th

roug

h th

e ca

ble

asse

mbl

y e)

A

re th

e br

ushe

s ru

n do

wn

(.25”

or

less

, dam

aged

or

burn

t ou

t?f)

Is th

e po

wer

cor

d co

rrec

tly h

ardw

ired

to th

e po

wer

boa

rd?

g) Is

line

vol

tage

pre

sent

at t

erm

inal

TB

1 on

the

pow

er b

oard

?h)

Let

the

Circ

uit b

reak

er c

ool d

own

for

at le

ast a

min

ute.

D

oes

the

pum

p m

otor

sta

rt a

fter

that

tim

e?

i) Is

the

20 V

AC

sec

onda

ry v

olta

ge p

rese

nt b

etw

een

pin

#5

and

pin

#8 o

n th

e tr

ansf

orm

er?

j) D

oes

the

mot

or r

un o

r at

leas

t kic

k on

whe

n di

rect

ly

hard

wire

d to

line

vol

tage

?k)

Doe

s th

e m

otor

kic

k on

but

not

rot

ate

whe

n a

mot

or b

utto

n is

pus

hed?

a)

Are

ther

e an

y vi

sibl

e da

mag

es (k

ink,

loos

e w

ire, m

issi

ng

insu

latio

n, e

tc.)

on th

e po

wer

cor

d?b)

Doe

s th

e po

wer

out

let p

rovi

de th

e re

ques

ted

volta

ge a

nd

curr

ent?

Che

ck d

escr

iptio

n, c

heck

vol

tage

, che

ck fu

ses.

c)

Let t

he C

ircui

t bre

aker

coo

l dow

n fo

r at

leas

t a m

inut

e.

Doe

s th

e pu

mp

mot

or s

tart

afte

r th

at ti

me?

d) I

s th

e by

pass

set

ting

out o

f ran

ge?

Is th

e by

pass

val

ve

inop

?e)

D

oes

the

gear

pum

p ro

tate

eas

ily a

nd p

rodu

ce fl

ow?

a) N

o: p

lug

in t

he p

ower

cor

d

b) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

c) Y

es: r

epla

ce t

he p

ower

cor

d

d) Y

es: c

heck

the

pen

dant

N

o: R

epla

ce k

eypa

d as

sem

bly

N

o: R

epla

ce c

able

ass

embl

ye)

Yes

: rep

lace

the

bru

shes

f) N

o: c

onne

ct t

he p

ower

cor

d to

ter

min

al T

B1

on t

he

elec

tric

-boa

rdg)

No:

cha

nge

the

pow

er c

ord

h) Y

es: t

est t

he p

ump

unde

r w

orki

ng c

ondi

tions

for

at le

ast

30 m

inut

es, (

a) c

hang

e th

e C

ircui

t bre

aker

if it

trip

s ag

ain

durin

g th

is te

st, (

b) r

epea

t the

test

and

cha

nge

the

mot

or if

th

e C

ircui

t bre

aker

trip

s ag

ain

durin

g th

is s

econ

d te

st, (

c)

repe

at th

e te

st a

nd s

ee “

Byp

ass

valv

e m

alfu

nctio

n” a

nd

“Dam

aged

or

wor

n ge

ar p

ump”

for

poss

ible

cau

se if

the

Ciru

it br

eake

r tr

ips

agai

ni)

No:

cha

nge

the

pow

er b

oard

j) N

o: c

hang

e th

e m

otor

k) Y

es: c

heck

the

pum

p un

it

a) Y

es: r

epla

ce t

he p

ower

cor

d

b) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

c) Y

es: t

est t

he p

ump

unde

r wor

king

con

ditio

ns fo

r at l

east

30

min

utes

, (a)

cha

nge

the

Circ

uit b

reak

er if

it tr

ips

agai

n du

ring

this

test

, (b)

repe

at th

e te

st a

nd c

hang

e th

e m

otor

if

the

Circ

uit b

reak

er tr

ips

agai

n du

ring

this

sec

ond

test

, (c)

re

peat

the

test

and

see

“B

ypas

s va

lve

mal

func

tion”

and

“D

amag

ed o

r wor

n ge

ar p

ump”

for p

ossi

ble

caus

e if

the

Ciru

it br

eake

r trip

s ag

ain

d) I

nspe

ct, t

est

and

adju

st t

he b

ypas

s va

lve.

Rep

lace

or

rebu

ild if

nec

essa

rye)

Rem

ove

and

insp

ect

the

gear

pum

p. R

epla

ce

if ne

cess

ary

Sta

ndar

d E

lect

ric

Tro

uble

-Sho

oti

ng G

uid

e

18

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nLC

D s

cree

n do

es n

ot

show

“FI

RM

WA

RE

” an

d re

visi

on n

umbe

r du

ring

the

boot

seq

uenc

e

LCD

scr

een

show

s “P

OW

ER

OFF

” af

ter

conn

ectin

g th

e pu

mp

to

the

pow

er s

uppl

y

LCD

scr

een

does

not

sh

ow “

OK

” af

ter

the

boot

seq

uenc

e

a) N

o po

wer

sup

ply

b) N

o po

wer

sup

ply

c) P

ower

cor

d da

mag

ed

d) P

rimar

y or

sec

onda

ry f

use

blow

n on

th

e P

ower

-boa

rde)

No

pow

er t

o th

e P

ower

-boa

rdf)

No

pow

er t

o th

e P

ower

-boa

rd

g) T

he D

C p

ower

sup

ply

on t

he P

ower

-bo

ard

is d

efec

tive

h) T

he f

lat

ribbo

n ca

ble

betw

een

Pow

er-

boar

d an

d C

ontr

ol-b

oard

is d

efec

tive

or d

isco

nnec

ted

i) C

ontr

ol-b

oard

dam

aged

a) A

fter

dis

conn

ectin

g th

e pu

mp

from

th

e po

wer

sup

ply

it w

as r

econ

nect

ed

to p

ower

sup

ply

befo

re b

oot-

dow

n se

quen

ce w

as f

inis

hed

b) L

ow p

ower

sup

ply

a) A

ny o

f th

e be

low

men

tione

d fa

ult

cond

ition

sb)

Con

trol

-boa

rd d

amag

ed

a) Is

the

pow

er c

ord

plug

ged

in?

b) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.c)

Are

ther

e an

y vi

sibl

e da

mag

es (k

ink,

loos

e w

ire, m

issi

ng

insu

latio

n, e

tc.)

on th

e po

wer

cor

d?d)

Is a

ny o

f the

two

fuse

s on

the

Pow

er-b

oard

bur

nt-t

hrou

gh

(insp

ect v

isua

lly o

r m

easu

re r

esis

tanc

e)?

e) Is

the

pow

er c

ord

corr

ectly

har

dwire

d to

the

Pow

er-b

oard

?

f) Is

line

vol

tage

pre

sent

at t

erm

inal

TB

1 (“

LIN

E”) o

n th

e P

ower

-boa

rd?

g) Is

the

35 V

DC

vol

tage

pre

sent

bet

wee

n pi

n #1

of th

e fa

n-te

rmin

al a

nd p

in #

2 of

the

filte

r-te

rmin

al?

h) Is

the

flat r

ibbo

n ca

ble

disc

onne

cted

or

dam

aged

(che

ck

visu

ally

bot

h en

ds fo

r co

nnec

tion

and

entir

e ca

ble

for

dam

ages

[kin

ks, b

roke

n w

ire, m

issi

ng in

sula

tion,

etc

.])i)

Is th

e vo

ltage

acr

oss

C8

betw

een

3.2

and

3.4

VDC

?

a) N

/A

b) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.

a) D

oes

the

scre

en s

how

any

of t

he b

elow

men

tione

d fa

ult

mes

sage

s?b)

The

mes

sage

“FI

RM

WA

RE”

and

rev

isio

n nu

mbe

r di

d sh

ow

up b

ut n

o “O

K”?

a) N

o: p

lug

in t

he p

ower

cor

db)

No:

rep

lace

blo

wn

fuse

s an

d/or

cha

nge

over

to

an o

utle

t w

ith t

he a

ppro

pria

te v

olta

ge a

nd c

urre

nt r

atin

gc)

Yes

: rep

lace

the

pow

er c

ord

d) Y

es: r

epla

ce t

he r

efer

ring

fuse

e) N

o: c

onne

ct t

he p

ower

cor

d to

ter

min

al T

B1

(“LI

NE

”) o

n th

e P

ower

-boa

rdf)

No:

cha

nge

the

pow

er c

ord

g) N

o: c

hang

e th

e P

ower

-boa

rd

h) Y

es: C

onne

ct r

esp.

rep

lace

the

fla

t rib

bon

cabl

e

i) Y

es: d

isco

nnec

t pu

mp

from

pow

er s

uppl

y, w

ait

until

“P

OW

ER

OFF

” di

sapp

ears

fro

m s

cree

n or

in c

ase

ther

e is

no

mes

sage

wai

t at

leas

t 20

sec

onds

whi

le s

cree

n is

co

mpl

etel

y bl

ank

than

rec

onne

ct. I

f th

e sa

me

faul

t oc

curs

ag

ain:

cha

nge

the

Con

trol

-boa

rd

a) D

isco

nnec

t pu

mp

from

pow

er s

uppl

y ag

ain,

wai

t un

til

“PO

WE

R O

FF”

disa

ppea

rs f

rom

scr

een

and

scre

en is

co

mpl

etel

y bl

ank

than

rec

onne

ct

b) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

a) Y

es: s

ee r

efer

ring

faul

t co

nditi

on

b) Y

es: d

isco

nnec

t pu

mp

from

pow

er s

uppl

y, w

ait

until

“P

OW

ER

OFF

” di

sapp

ears

fro

m s

cree

n or

in c

ase

ther

e is

no

mes

sage

wai

t at

leas

t 20

sec

onds

whi

le s

cree

n is

co

mpl

etel

y bl

ank

than

rec

onne

ct. I

f th

e sa

me

faul

t oc

curs

ag

ain:

cha

nge

the

Con

trol

-boa

rd

LCD

Ele

ctri

c T

roub

le-S

hoo

ting

Gui

de

19

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nin

cas

e a

pres

sure

tr

ansd

ucer

is m

ount

ed

to t

he p

ump

: LC

D

scre

en d

oes

not

show

0

psi o

r an

app

ropr

iate

pr

essu

re r

eadi

ng a

fter

th

e bo

ot s

eque

nce

LCD

scr

een

show

s “B

UTT

ON

FA

ULT

” af

ter

the

boot

seq

uenc

e

LCD

scr

een

show

s “C

HA

NG

E F

ILTR

” af

ter

the

boot

seq

uenc

e

LCD

scr

een

show

s “S

ET

PR

ES

” af

ter

the

boot

seq

uenc

e

LCD

scr

een

show

s “O

IL

TEM

P F

AU

LT”

afte

r th

e bo

ot s

eque

nce

a) T

he p

ower

sup

ply

to t

he p

ress

ure

tran

sduc

er is

mis

sing

b) P

ress

ure

tran

sduc

er is

not

cor

rect

ly

conn

ecte

d

c) P

ress

ure

tran

sduc

er is

dam

aged

a) A

but

ton

has

been

pus

hed

durin

g th

e bo

ot s

eque

nce

b) A

but

ton

is s

tuck

in t

he p

ushe

d-po

sitio

n

a) F

ilter

is c

logg

ed (o

nly

in c

ase

filte

r is

bu

ilt in

)b)

Jum

per

on t

he f

ilter

ter

min

al is

loos

e or

off

a) P

ress

ure

switc

h is

dis

conn

ecte

d (o

nly

in c

ase

a pr

essu

re s

witc

h is

bui

lt in

)b)

Pre

ssur

e sw

itch

is d

amag

ed (o

nly

in

case

a p

ress

ure

switc

h is

bui

lt in

)c)

Jum

per

on t

he p

ress

ure

switc

h te

rmin

al is

loos

e or

off

a) O

il-Te

mp

switc

h is

dis

conn

ecte

d (o

nly

in c

ase

a O

il-Te

mp

switc

h is

bui

lt in

)b)

Oil-

Tem

p sw

itch

is d

amag

ed (o

nly

in

case

a O

il-Te

mp

switc

h is

bui

lt in

)c)

Jum

per

on t

he O

il-Te

mp

switc

h te

rmin

al is

loos

e or

off

a) Is

the

volta

ge a

cros

s th

e pr

essu

re tr

ansd

ucer

term

inal

15.

0 -

15.5

VD

C?

b) Is

the

pres

sure

tran

sduc

er te

rmin

al d

isco

nnec

ted

or h

as a

w

ire c

ome

loos

e fro

m th

e pr

essu

re tr

ansd

ucer

term

inal

?c)

Is th

ere

an A

mp

sign

al in

the

pres

sure

tran

sduc

er c

ircui

t tha

t is

in p

ropo

rtio

n w

ith th

e ex

pect

ed p

ress

ure

read

ing?

(4 -

20

mA

equ

als

0 -

15,0

00 p

si)

a) N

/A

b) Is

any

of t

he p

enda

nt o

r sh

roud

but

tons

tang

ible

stu

ck in

th

e pu

shed

-pos

ition

?

a) D

oes

the

filte

r st

atus

-indi

cato

r sh

ow “

full”

?

b) Is

the

filte

r ju

mpe

r (b

lue,

fully

insu

late

d, fe

mal

e di

scon

nect

) co

mpl

etel

y im

pose

d on

the

filte

r te

rmin

al?

a) Is

the

pres

sure

sw

itch

term

inal

loos

e or

is a

wire

loos

e?

b) Is

the

resi

stan

ce o

f the

pre

ssur

e sw

itch

uneq

ual 0

Ohm

?

c) Is

the

pres

sure

sw

itch

jum

per

(blu

e, fu

lly in

sula

ted,

fem

ale

disc

onne

ct) c

ompl

etel

y im

pose

d on

the

pres

sure

sw

itch

term

inal

?

a) Is

the

Oil-

Tem

p sw

itch

term

inal

loos

e or

is a

wire

loos

e?

b) Is

the

resi

stan

ce o

f the

Oil-

Tem

p sw

itch

uneq

ual 0

Ohm

?

c) Is

the

Oil-

Tem

p sw

itch

jum

per

(blu

e, fu

lly in

sula

ted,

fem

ale

disc

onne

ct) c

ompl

etel

y im

pose

d on

the

Oil-

Tem

p sw

itch

term

inal

?

a) N

o: c

hang

e th

e P

ower

-boa

rd

b) Y

es: r

econ

nect

res

p. r

epai

r th

e pr

essu

re t

rans

duce

r te

rmin

al

c) N

o: c

hang

e th

e pr

essu

re t

rans

duce

r

a) D

isco

nnec

t pu

mp

from

pow

er s

uppl

y, w

ait

until

“P

OW

ER

O

FF”

disa

ppea

rs f

rom

scr

een

and

scre

en is

com

plet

ely

blan

k th

an r

econ

nect

and

mak

e su

re n

o bu

tton

is p

ushe

d du

ring

the

boot

seq

uenc

e.b)

Yes

: in

case

of

a pe

ndan

t bu

tton

: cha

nge

the

pend

ant,

in

case

of

a sh

roud

but

ton:

cha

nge

the

Con

trol

-boa

rd

a) Y

es: c

hang

e fil

ter

b) N

o: r

epla

ce t

he f

ilter

jum

per

with

a n

ew b

lue,

ful

ly

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

-#:

10-1

53F)

and

pus

h do

wn

firm

ly t

o co

mpl

etel

y im

pose

on

the

filte

r te

rmin

al

a) Y

es: r

econ

nect

or

repa

ir th

e pr

essu

re s

witc

h te

rmin

al

b) Y

es: r

epla

ce t

he p

ress

ure

switc

h

c) N

o: r

epla

ce t

he p

ress

ure

switc

h ju

mpe

r w

ith a

new

blu

e,

fully

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

#:

10-

153F

) and

pus

h do

wn

firm

ly t

o co

mpl

etel

y im

pose

on

the

pre

ssur

e sw

itch

term

inal

a) Y

es: r

econ

nect

or

repa

ir th

e O

il-Te

mp

switc

h te

rmin

al

b) Y

es: r

epla

ce t

he O

il-Te

mp

switc

h

c) N

o: r

epla

ce t

he O

il-Te

mp

switc

h ju

mpe

r w

ith a

new

blu

e,

fully

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

#:

10-

153F

) and

pus

h do

wn

firm

ly t

o co

mpl

etel

y im

pose

on

the

Oil-

Tem

p sw

itch

term

inal

20

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nLC

D s

cree

n sh

ows

“OIL

LEV

EL

FAU

LT”

afte

r th

e bo

ot s

eque

nce

LCD

scr

een

on,

back

light

off

or b

ackl

ight

sh

ows

dark

are

as

Men

u on

the

LC

D

scre

en is

not

acc

essi

ble

Pum

p m

otor

doe

s no

t st

art

whe

n pe

ndan

t on

-off

butt

on is

pus

hed

a)O

il le

vel i

s lo

wb)

Oil-

Leve

l sw

itch

is d

isco

nnec

ted

(onl

y in

cas

e a

Oil-

Leve

l sw

itch

is b

uilt

in)

c) O

il-Le

vel s

witc

h is

dam

aged

(onl

y in

ca

se a

Oil-

Leve

l sw

itch

is b

uilt

in)

d) J

umpe

r on

the

Oil-

Leve

l sw

itch

term

inal

is lo

ose

or o

ff

a) B

ackl

ight

s da

mag

ed

a) C

ontr

ol-b

oard

mou

ntin

g sc

rew

s ar

e lo

ose

b) C

ontr

ol-b

oard

dam

aged

a) P

enda

nt c

onne

ctio

n lo

ose

or

pend

ant

dam

aged

b) B

ad o

r lo

ose

wire

ter

min

atio

n

c) C

ircui

t br

eake

r is

ope

n

d) B

rush

es o

n th

e m

otor

are

wor

n ou

t

e) T

rans

isto

r Q

600

is d

amag

ed

f) Th

e m

otor

is d

efec

tive

g) T

he p

ump

unit

is m

echa

nica

lly

bloc

ked

a) C

heck

oil

leve

lb)

Is th

e O

il-Le

vel s

witc

h te

rmin

al lo

ose

or is

a w

ire lo

ose?

c) Is

the

resi

stan

ce o

f the

Oil-

Leve

l sw

itch

uneq

ual 0

Ohm

?

d) Is

the

Oil-

Leve

l sw

itch

jum

per

(blu

e, fu

lly in

sula

ted,

fem

ale

disc

onne

ct) c

ompl

etel

y im

pose

d on

the

Oil-

Leve

l sw

itch

term

inal

?

a) N

/A

a) I

s on

e or

mor

e of

the

Con

trol

-boa

rd m

ount

ing

scre

ws

lo

ose

or m

issi

ng?

b) N

/A

a) W

ith th

e LC

D s

cree

n sh

owin

g “O

K”

push

the

shro

ud M

enu

butto

n 9

times

to g

et to

the

DIA

GN

OS

E sc

reen

. Do

the

pend

ant b

utto

ns p

ushe

d cr

eate

a “

1” r

eadi

ng in

the

corr

ect

posi

tion

on th

e LC

D s

cree

n?b)

Is

a m

otor

wire

loos

e or

bro

ken

or a

re th

e sc

rew

s on

the

mot

or te

rmin

al T

B60

0 (“

MO

TOR

”) s

lack

y?c)

Let

the

Circ

uit b

reak

er c

ool d

own

for

at le

ast a

min

ute.

D

oes

the

pum

p m

otor

sta

rt a

fter

that

tim

e?

d) A

re th

e br

ushe

s ru

n do

wn,

dam

aged

or

burn

t out

?

e) D

oes

the

mot

or L

ED li

ght u

p w

hen

a m

otor

but

ton

is

push

ed?

f) D

oes

the

mot

or r

un o

r at

leas

t kic

k on

whe

n di

rect

ly

hard

wire

d to

line

vol

tage

?g)

Doe

s th

e m

otor

kic

k on

but

not

rot

ate

whe

n a

mot

or b

utto

n is

pus

hed?

a) A

dd o

ilb)

Yes

: rec

onne

ct o

r re

pair

the

Oil-

Leve

l sw

itch

term

inal

c) Y

es: r

epla

ce t

he O

il-Le

vel s

witc

h

d) N

o: r

epla

ce t

he O

il-Le

vel s

witc

h ju

mpe

r w

ith a

new

bl

ue, f

ully

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

-#: 1

0-15

3F) a

nd p

ush

dow

n fir

mly

to

com

plet

ely

impo

se o

n th

e O

il-Le

vel s

witc

h te

rmin

al

a) C

hang

e th

e C

ontr

ol-b

oard

a) Y

es: r

epla

ce a

nd/o

r re

-tig

hten

the

mis

sing

/loos

e sc

rew

s

b) C

hang

e th

e C

ontr

ol-b

oard

a) N

o: r

econ

nect

the

pen

dant

to

the

pend

ant

term

inal

on

the

Pow

er-b

oard

and

che

ck a

gain

. In

case

the

re is

stil

l no

sig

nal:

chan

ge t

he p

enda

nt

b) Y

es: r

econ

nect

res

p. r

epai

r th

e m

otor

wire

c) Y

es: t

est

the

pum

p un

der

wor

king

con

ditio

ns f

or a

t le

ast

30 m

inut

es, (

a) c

hang

e th

e C

ircui

t br

eake

r if

it tr

ips

agai

n du

ring

this

tes

t, (b

) rep

eat

the

test

and

cha

nge

the

mot

or

if th

e C

ircui

t br

eake

r tr

ips

agai

n du

ring

this

sec

ond

test

, (c

) rep

eat

the

test

and

see

“B

ypas

s va

lve

mal

func

tion”

an

d “D

amag

ed o

r w

orn

gear

pum

p” f

or p

ossi

ble

caus

e if

the

Circ

uit

brea

ker

trip

s ag

ain

d) Y

es: r

epla

ce t

he b

rush

es

e) N

o: c

hang

e th

e P

ower

-boa

rd

f) N

o: c

hang

e th

e m

otor

g) Y

es: c

heck

the

pum

p un

it

21

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nP

ump

mot

or d

oes

not

run

mom

enta

rily

whe

n pe

ndan

t up

arr

ow b

utto

n is

pus

hed

(Jog

fun

ctio

n)

Pum

p m

otor

doe

s no

t st

art

whe

n sh

roud

on-

off

butt

on is

pus

hed

(whe

re

appl

icab

le a

ccor

ding

to

pum

p ty

pe)

Hea

t ex

chan

ger-

Fan

does

not

run

with

mot

or

runn

ing

(Att

entio

n:

ther

e is

1 s

econ

d de

lay

betw

een

mot

or a

nd

fan

star

ting

to r

un !)

(o

nly

appl

icab

le if

hea

t ex

chan

ger

is

built

in)

a) P

enda

nt c

onne

ctio

n lo

ose

or p

enda

nt

dam

aged

b) B

ad o

r lo

ose

wire

ter

min

atio

n

c) C

ircui

t br

eake

r is

ope

n

d) B

rush

es o

n th

e m

otor

are

wor

n ou

t

e) T

rans

isto

r Q

600

is d

amag

edf)

The

mot

or is

def

ectiv

e

g) T

he p

ump

unit

is m

echa

nica

lly

bloc

ked

a) T

he m

otor

is d

efec

tive

b) T

he p

ump

unit

is m

echa

nica

lly

bloc

ked

a) H

eate

xcha

nger

-Fan

is d

isco

nnec

ted

b) H

eate

xcha

nger

-Fan

is d

amag

edc)

The

fan

driv

er o

n th

e P

ower

-boa

rd is

da

mag

ed

a) W

ith th

e LC

D s

cree

n sh

owin

g “O

K”

push

the

shro

ud M

enu

butto

n 9

times

to g

et to

the

DIA

GN

OS

E sc

reen

. Do

the

pend

ant b

utto

ns p

ushe

d cr

eate

a “

1” r

eadi

ng in

the

corr

ect

posi

tion

on th

e LC

D s

cree

n?b)

Is a

mot

or w

ire lo

ose

or b

roke

n or

are

the

scre

ws

on th

e m

otor

term

inal

TB

600

(“M

OTO

R”)

sla

cky?

c) L

et th

e C

ircui

t bre

aker

coo

l dow

n fo

r at

leas

t a m

inut

e. D

oes

the

pum

p m

otor

sta

rt a

fter

that

tim

e?

d) A

re th

e br

ushe

s ru

n do

wn,

dam

aged

or

burn

t out

?

e) D

oes

the

mot

or L

ED li

ght u

p w

hen

a m

otor

but

ton

is p

ushe

d?f)

Doe

s th

e m

otor

run

or

at le

ast k

ick

on w

hen

dire

ctly

har

dwire

d to

line

vol

tage

?g)

Doe

s th

e m

otor

kic

k on

but

not

rot

ate

whe

n a

mot

or b

utto

n

is p

ushe

d?

a) D

oes

the

mot

or r

un o

r at

leas

t kic

k on

whe

n di

rect

ly h

ardw

ired

to li

ne v

olta

ge?

b) D

oes

the

mot

or k

ick

on b

ut n

ot r

otat

e w

hen

a m

otor

but

ton

is

pus

hed?

a) Is

the

Hea

texc

hang

er-F

an te

rmin

al lo

ose

or is

a w

ire lo

ose?

b) Is

the

resi

stan

ce o

f the

Hea

texc

hang

er-F

an b

elow

300

kO

hm?

c) D

oes

the

fan

LED

D53

3 lig

ht u

p to

geth

er w

ith th

e m

otor

LED

D

602?

a) N

o: r

econ

nect

the

pen

dant

to

the

pend

ant

term

inal

on

the

Pow

er-b

oard

and

che

ck a

gain

. In

case

the

re is

stil

l no

sign

al: c

hang

e th

e pe

ndan

tb)

Yes

: rec

onne

ct r

esp.

rep

air

the

mot

or w

irec)

Yes

: tes

t th

e pu

mp

unde

r w

orki

ng c

ondi

tions

for

at

leas

t 30

min

utes

, (a)

cha

nge

the

Circ

uit

brea

ker

if it

trip

s ag

ain

durin

g th

is t

est,

(b) r

epea

t th

e te

st a

nd c

hang

e th

e m

otor

if

the

Circ

uit

brea

ker

trip

s ag

ain

durin

g th

is s

econ

d te

st,

(c) r

epea

t th

e te

st a

nd s

ee “

Byp

ass

valv

e m

alfu

nctio

n”

and

“Dam

aged

or

wor

n ge

ar p

ump”

for

pos

sibl

e ca

use

if th

e C

ircui

t br

eake

r tr

ips

agai

nd)

Yes

: rep

lace

the

bru

shes

e)

No:

cha

nge

the

Pow

er-b

oard

f) N

o: c

hang

e th

e m

otor

g) Y

es: c

heck

the

pum

p un

it

a) N

o: c

hang

e th

e m

otor

b) Y

es: c

heck

the

pum

p un

it

a) Y

es: r

econ

nect

or

repa

ir th

e H

eate

xcha

nger

-Fan

ter

min

alb)

Yes

: rep

lace

the

Hea

texc

hang

er-F

anc)

N

o: c

hang

e th

e P

ower

-boa

rd

22

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nP

ump

does

not

pro

vide

hy

drau

lic -

flow

and

-p

ress

ure

whe

n ei

ther

th

e A

dvan

ce-

or t

he

Ret

ract

-but

ton

is

push

ed

Pum

p sh

uts

off

at a

pr

essu

re s

igni

fican

tly

high

er o

r lo

wer

tha

n th

e pr

e-se

t pr

essu

re (m

enu-

item

SE

TPR

ES

, onl

y ap

plic

able

if p

ress

ure

tran

sduc

er is

bui

lt in

)

Pum

p sh

uts

off

at a

pr

essu

re s

igni

fican

tly

high

er o

r lo

wer

tha

n th

e pr

e-se

t pr

essu

re (o

nly

appl

icab

le if

pre

ssur

e sw

itch

is b

uilt

in)

a) P

enda

nt c

onne

ctio

n lo

ose

or p

enda

nt

dam

aged

b) C

ontr

ol-b

oard

mou

ntin

g sc

rew

s ar

e lo

ose

(if r

unni

ng in

the

loca

l mod

e)c)

The

driv

er f

or s

olen

oid

A (B

) on

the

Pow

er-b

oard

is d

amag

ed

d) T

he d

river

for

sol

enoi

d A

(B) o

n th

e P

ower

-boa

rd is

dam

aged

e) S

olen

oid

A (B

) is

dam

aged

f) Th

e va

lve

is d

amag

ed

g) T

he p

ump

is d

amag

ed

a) W

rong

pre

ssur

e se

ttin

g

b) T

he p

ower

sup

ply

to t

he p

ress

ure

tran

sduc

er is

mis

sing

c) P

ress

ure

tran

sduc

er is

not

cor

rect

ly

conn

ecte

dd)

Pre

ssur

e tr

ansd

ucer

is d

amag

ed

a) W

rong

pre

ssur

e se

ttin

g

b) T

he p

ress

ure

switc

h is

not

cor

rect

ly

conn

ecte

dc)

The

pre

ssur

e sw

itch

is d

amag

ed

a) W

ith th

e LC

D s

cree

n sh

owin

g “O

K”

push

the

shro

ud M

enu

butto

n 9

times

to g

et to

the

DIA

GN

OS

E sc

reen

. Do

the

pend

ant b

utto

ns p

ushe

d cr

eate

a “

1” r

eadi

ng in

the

corr

ect

posi

tion

on th

e LC

D s

cree

n?b)

Is o

ne o

r m

ore

of th

e C

ontr

ol-b

oard

mou

ntin

g sc

rew

s lo

ose

or m

issi

ng?

c) D

oes

the

Adv

ance

(Ret

ract

) LED

D51

3 (D

523)

on

the

Pow

er-

boar

d lig

ht u

p w

hen

the

Adv

ance

= A

rrow

-up

(Ret

ract

=

Arr

ow-d

own)

but

ton

is p

ushe

d?d)

Doe

s th

e co

il vo

ltage

to s

olen

oid

A (B

) rea

d be

twee

n 18

and

19

VD

C w

hen

the

Adv

ance

= A

rrow

-up

(Ret

ract

= A

rrow

-do

wn)

but

ton

is p

ushe

d?e)

Doe

s th

e co

il vo

ltage

to s

olen

oid

A (B

) rea

d be

twee

n 18

and

19

VD

C w

hen

the

Adv

ance

= A

rrow

-up

(Ret

ract

= A

rrow

-do

wn)

but

ton

is p

ushe

d?f)

Doe

s th

e co

il vo

ltage

to s

olen

oid

A (B

) rea

d be

twee

n 18

and

19

VD

C w

hen

the

Adv

ance

= A

rrow

-up

(Ret

ract

= A

rrow

-do

wn)

but

ton

is p

ushe

d an

d do

es th

e re

ferr

ing

sole

noid

bu

ild u

p th

e m

agne

tic fi

eld

(che

ck w

ith s

crew

driv

er)?

g) s

ee th

e re

ferr

ing

hydr

aulic

trou

ble-

shoo

ting

guid

e

a) S

tep

into

the

SET

PR

ES m

ode

by \

push

ing

the

Men

u bu

tton

once

. Doe

s th

e S

ETP

RES

scr

een

show

the

corr

ect v

alue

?b)

Is th

e vo

ltage

acr

oss

the

pres

sure

tran

sduc

er te

rmin

al 1

5.0

- 15

.5 V

DC

?c)

Is th

e pr

essu

re tr

ansd

ucer

term

inal

dis

conn

ecte

d or

has

a

wire

com

e lo

ose

from

the

pres

sure

tran

sduc

er te

rmin

al?

d) Is

ther

e an

Am

p si

gnal

in th

e pr

essu

re tr

ansd

ucer

circ

uit t

hat

is in

pro

port

ion

with

the

expe

cted

pre

ssur

e re

adin

g? (4

- 2

0 m

A e

qual

s 0

- 15

,000

psi

)

a) Is

the

pres

sure

set

ting

on th

e pr

essu

re s

witc

h co

rrec

t?

(Che

ck th

e pr

essu

re u

sing

a r

efer

ence

gau

ge in

the

hydr

aulic

circ

uit)

b) Is

the

pres

sure

sw

itch

term

inal

dis

conn

ecte

d or

has

a w

ire

com

e lo

ose

from

the

pres

sure

tran

sduc

er te

rmin

al?

c) D

oes

the

pres

sure

sw

itch

open

(clo

se) a

t the

app

ropr

iate

pr

essu

re?

(Che

ck th

e pr

essu

re u

sing

a r

efer

ence

gau

ge in

th

e hy

drau

lic c

ircui

t)

a) N

o: r

econ

nect

the

pen

dant

to

the

pend

ant

term

inal

on

the

Pow

er-b

oard

and

che

ck a

gain

. In

case

the

re is

stil

l no

sign

al: c

hang

e th

e pe

ndan

t

b) Y

es: r

epla

ce a

nd/o

r re

-tig

hten

the

mis

sing

/loos

e sc

rew

s

c) N

o: c

hang

e th

e P

ower

-boa

rd

d) N

o: c

hang

e th

e P

ower

-boa

rd

e) Y

es: r

epla

ce t

he r

efer

ring

sole

noid

f) Y

es: r

epla

ce t

he v

alve

a) N

o: c

orre

ct t

he p

ress

ure

sett

ing

usin

g th

e A

rrow

-up

and

Arr

ow-d

own

butt

on a

nd t

he M

enu

butt

on t

o sa

ve t

he n

ew

sett

ing

b) N

o: c

hang

e th

e P

ower

-boa

rd

c) Y

es: r

econ

nect

res

p. r

epai

r th

e pr

essu

re t

rans

duce

r te

rmin

ald)

No:

cha

nge

the

pres

sure

tra

nsdu

cer

a) N

o: a

djus

t th

e pr

essu

re s

witc

h to

the

app

ropr

iate

pr

essu

re

b) Y

es: r

econ

nect

res

p. r

epai

r th

e pr

essu

re t

rans

duce

r sw

itch

c) N

o: r

epla

ce t

he p

ress

ure

switc

h

23

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nP

ump

shut

s of

f in

dica

ting

“CH

AN

GE

FI

LTR

” on

the

LC

D

scre

en

Pum

p sh

uts

off

indi

catin

g “O

IL T

EM

P

FAU

LT”

on t

he L

CD

sc

reen

Pum

p sh

uts

off

indi

catin

g “O

ILLE

VE

L FA

ULT

” on

the

LC

D

scre

en w

ith n

o O

il-Le

vel

switc

h bu

ilt in

or

with

en

ough

Oil

left

in t

he

rese

rvoi

r

Pum

p sh

uts

off

with

no

faul

t in

dica

tion

a) F

ilter

is c

logg

ed (o

nly

in c

ase

filte

r is

bu

ilt in

)b)

Jum

per

on t

he f

ilter

ter

min

al is

loos

e or

off

a) O

il te

mpe

ratu

re is

abo

ve 1

75 +

/- 1

0 ºF

(onl

y in

cas

e a

Oil-

Tem

p sw

itch

is

built

in)

b) O

il-Te

mp

switc

h is

dis

conn

ecte

d (o

nly

in c

ase

a O

il-Te

mp

switc

h is

bu

ilt in

)c)

Jum

per

on t

he O

il-Te

mp

switc

h te

rmin

al is

loos

e or

off

d) O

il-Te

mp

switc

h is

dam

aged

(onl

y in

ca

se a

Oil-

Tem

p sw

itch

is b

uilt

in)

a) O

il le

vel i

s be

low

the

min

imum

b) O

il-Le

vel s

witc

h is

dis

conn

ecte

d (o

nly

in c

ase

a O

il-Le

vel s

witc

h is

bui

lt in

)c)

Jum

per

on t

he O

il-Le

vel s

witc

h te

rmin

al is

loos

e or

off

d) O

il-Le

vel s

witc

h is

dam

aged

(onl

y in

ca

se a

Oil-

Leve

l sw

itch

is b

uilt

in)

a) M

ore

than

one

but

ton

push

ed a

t a

time

a) D

oes

the

filte

r st

atus

-indi

cato

r sh

ow “

full”

?

b) Is

the

filte

r ju

mpe

r (b

lue,

fully

insu

late

d, fe

mal

e di

scon

nect

) co

mpl

etel

y im

pose

d on

the

filte

r te

rmin

al?

a) Is

the

Oil

tem

pera

ture

abo

ve 1

75 +

/- 1

0 ºF

?

b) Is

the

Oil-

Tem

p sw

itch

term

inal

loos

e or

is a

wire

loos

e?

c) Is

the

Oil-

Tem

p sw

itch

jum

per

(blu

e, fu

lly in

sula

ted,

fem

ale

disc

onne

ct) c

ompl

etel

y im

pose

d on

the

Oil-

Tem

p sw

itch

term

inal

?

d) Is

the

resi

stan

ce o

f the

Oil-

Tem

p sw

itch

uneq

ual 0

Ohm

w

hile

the

Oil

tem

pera

ture

is s

igni

fican

tly b

elow

17

5 +/

- 10

ºF?

a) N

/A

b) Is

the

Oil-

Leve

l sw

itch

term

inal

loos

e or

is a

wire

loos

e?

c) Is

the

Oil-

Leve

l sw

itch

jum

per

(blu

e, fu

lly in

sula

ted,

fem

ale

disc

onne

ct) c

ompl

etel

y im

pose

d on

the

Oil-

Leve

l sw

itch

term

inal

?

d) Is

the

resi

stan

ce o

f the

Oil-

Leve

l sw

itch

uneq

ual 0

Ohm

? a)

N/A

a) Y

es: c

hang

e fil

ter

b) N

o: r

epla

ce t

he f

ilter

jum

per

with

a n

ew b

lue,

ful

ly

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

-#:

10-1

53F)

and

pus

h do

wn

firm

ly t

o co

mpl

etel

y im

pose

on

the

filte

r te

rmin

al

a) S

top

oper

atin

g th

e pu

mp,

let

the

oil c

ool d

own,

che

ck

the

appl

icat

ion

and

the

hydr

aulic

set

up w

heth

er a

he

atex

chan

ger

or a

big

ger

oil v

olum

e is

nec

essa

ryb)

Yes

: rec

onne

ct o

r re

pair

the

Oil-

Tem

p sw

itch

term

inal

c) N

o: r

epla

ce t

he O

il-Te

mp

switc

h ju

mpe

r w

ith a

new

bl

ue, f

ully

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

-#: 1

0-15

3F) a

nd p

ush

dow

n fir

mly

to

com

plet

ely

impo

se o

n th

e O

il-Te

mp

switc

h te

rmin

ald)

Yes

: rep

lace

the

Oil-

Tem

p sw

itch

a) F

ill a

dditi

onal

oil

into

the

res

ervo

ir, f

ollo

w r

efer

ring

inst

ruct

ions

in t

he In

stru

ctio

n S

heet

, che

ck t

he a

pplic

atio

n w

heth

er a

big

ger

oil v

olum

e is

nec

essa

ryb)

Yes

: rec

onne

ct o

r re

pair

the

Oil-

Leve

l sw

itch

term

inal

c) N

o: r

epla

ce t

he O

il-Le

vel s

witc

h ju

mpe

r w

ith a

new

bl

ue, f

ully

insu

late

d, f

emal

e di

scon

nect

(Gar

dner

-Ben

der

item

-#: 1

0-15

3F) a

nd p

ush

dow

n fir

mly

to

com

plet

ely

impo

se o

n th

e O

il-Le

vel s

witc

h te

rmin

ald)

Yes

: rep

lace

the

Oil-

Leve

l sw

itch

a) R

e-st

art

the

pum

p an

d op

erat

e un

der

norm

al w

orki

ng

cond

ition

s, p

ay a

tten

tion

not

to p

ush

two

or m

ore

butt

ons

at a

tim

e

24

P

rob

lem

P

oss

ible

Cau

se

Che

ck A

ctio

n R

epai

r A

ctio

nP

ump

shut

s of

f in

dica

ting

“MTR

O

VE

RLO

AD

” on

the

LC

D

scre

en

Pum

p sh

ows

“LO

W

VO

LT”

on t

he L

CD

sc

reen

Pum

p sh

uts

off

indi

catin

g “P

OW

ER

O

FF”

on t

he L

CD

scr

een

a) L

ow p

ower

sup

ply

b) C

ircui

t br

eake

r is

ope

n

c) T

he p

ump

unit

is m

echa

nica

lly

bloc

ked

a) L

ow p

ower

sup

ply

a) V

ery

low

pow

er s

uppl

y

a) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.b)

Let

the

Circ

uit b

reak

er c

ool d

own

for

at le

ast a

min

ute.

Doe

s th

e pu

mp

mot

or s

tart

afte

r th

at ti

me?

c) D

oes

the

mot

or k

ick

on b

ut n

ot r

otat

e w

hen

a m

otor

but

ton

is

push

ed?

a) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.

a) D

oes

the

pow

er o

utle

t pro

vide

the

requ

este

d vo

ltage

and

cu

rren

t? C

heck

des

crip

tion,

che

ck v

olta

ge, c

heck

fuse

s.

a) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

b) Y

es: t

est

the

pum

p un

der

wor

king

con

ditio

ns f

or a

t le

ast

30 m

inut

es, (

a) c

hang

e th

e C

ircui

t br

eake

r if

it tr

ips

agai

n du

ring

this

tes

t, (b

) rep

eat

the

test

and

cha

nge

the

mot

or

if th

e C

ircui

t br

eake

r tr

ips

agai

n du

ring

this

sec

ond

test

, (c

) rep

eat

the

test

and

see

“Th

e pu

mp

unit

is m

echa

nica

lly

bloc

ked”

for

pos

sibl

e ca

use

if th

e C

ircui

t br

eake

r tr

ips

agai

nc)

Yes

: che

ck t

he p

ump

unit

a) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

a) N

o: r

epla

ce b

low

n fu

ses

and/

or c

hang

e ov

er t

o an

out

let

with

the

app

ropr

iate

vol

tage

and

cur

rent

rat

ing

25

P

rob

lèm

e

Cau

se p

oss

ible

V

érifi

cati

on-

So

luti

on

Act

ion

Le m

oteu

r de

la p

ompe

ne

dém

arre

pa

s lo

rsqu

e le

bou

ton

du

mot

eur

est

enfo

ncé

La p

ompe

s’

arrê

te e

n m

ode

rale

nti o

u no

rmal

a) A

ucun

e al

imen

tatio

n

b) A

ucun

e al

imen

tatio

n

c) C

ordo

n d’

alim

enta

tion

endo

mm

agé

d) T

irant

déf

ectu

eux

e) L

es b

ross

es d

u m

oteu

r so

nt

usée

s

f) P

anne

au d

e pu

issa

nce

sans

al

imen

tatio

n

g) P

anne

au d

e pu

issa

nce

sans

al

imen

tatio

nh)

Le

disj

onct

eur

est

ouve

rt

i) Le

tra

nsfo

rmat

eur

Repair Parts Sheet ZU4 Electric PumpDD1366223SR 1 3" Sight Glass 10 L DD1367223SR 1 5" Sight Glass...

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Transcript of Repair Parts Sheet ZU4 Electric PumpDD1366223SR 1 3" Sight Glass 10 L DD1367223SR 1 5" Sight Glass...