Enerpac VS-3 Use and care manual

®
Repair Parts Sheet
VS-3 and VSR-3
Directional Control Valves
L729 Rev. C 05/99 For Date Codes Beginning with the Letter "O"
1IC300 1 Remote Pendant
2★CM56167 1 Gasket
3★B1007503 4 O-Ring
4★B1012564 4 Back-up Washer
5DA973950SR 1 Connector Assembly
6 B1351028 6 Socket Head Cap Screw
7F127038 1 Adaptor (VS3)
F130038 1 Adaptor (VSR3)
8B1017028 4 Sckt. Head Cap Screw
9See note below 1 Connector Assy.
10 ★F786167 1 Gasket
Repair Parts List
Item Part Number Qty. Description Item Part Number Qty. Description
★ Items included in and available only as part of Repair Kit VS3-24K.
NOTE: Use the connector that came with the pump or order the connector using the part number form the pump’s repair parts sheet.
Figure 1
TO PROTECT YOUR WARRANTY USE ONLY ENERPAC HYDRAULIC OIL.
NOTE: An electrical schematic of
the pendant assembly
appears on page 4.
6
7
8
10
9
8
6
2
3
1
4
3
4
5
Torque to 11-13 Ft. Lbs.

1M694101 1 Mounting Plate
2DA4726028 3 Cap Screw
3 P181138 2 Screw
4M560345 1 Solenoid Box Top
5M48372 1 Solenoid Valve (N.C)
6A8009372 1 Solenoid Valve (N.O.)
7★B1014503 2 O-Ring
8★M89110 1 Spring
9M559345 1 Solenoid Control Box
10 CL105950SR 1 Valve Block Assy. (See Fig 3)
11 F626900W 1 Receptacle
12 CA292007 1 Strain Relief
13 C690026 1 ID Strip
14 C700270 1 Terminal Strip
15 BL20225 6 Bolt
16 BL20226 6 Nut
17 K533028 6 Machine Screw
18 F594066 4 Washer
19 C703008 3 Wire Lug
20 Y394450 1 Cord (VS-3)
Y393450 1 Cord with Plug (VSR-3)
Repair Parts List for Figure 2
Item Part Number Qty. Description Item Part Number Qty. Description
★ Items included in and available only as part of Repair Kit VS3-24K.
2
NOTE regarding Item 6: To repair only the solenoid's seals
and the plastic insert, you may order a VSR3K. To replace
the entire solenoid, order A8009372.
Figure 2, VS3 Valve Assembly (Electrical)

1CL106950W 2 Piston Assy
2★M31290 2 Seat
3★P182167 2 Gasket
4★B1007016 2 1/4" Ball
5 L843186 2 Spacer
6★L848110 2 Spring
7 AJ100061 1 Plug
8★B159167 1 Gasket
9BL20219 1 Adjusting Screw
10 ★C614177 1 Spring
11 ★B1010016 1 11/32" Ball
12 L342055 2 Nut
13 M22098 1 Plate
14 B1007028 3 Cap screw
15 CH43950W 2 Spacer
16 Y157028 2 Set Screw
17 F378123 2 3/8"-24 UNF Jam Nut
18 ★S3037 2 Gasket
19 B1002028 2 Cap Screw
20 M203028 2 Adjusting Screw (Pilot Relief)
21 ★BL10967 2 Spring
22 ★Y75110 2 Spring
23 ★L429013 2 Ball Guide
24 ★B1003016 2 1/8" Ball
25 M693190SR 1 Valve Body
26 A1006245 2 Plug
Repair Parts List for Figure 3
Item Part Number Qty. Description Item Part Number Qty. Description
★Items included in and available only as part of Repair Kit VS3-24K.
3
26
7
1
12
17
14 16
15
13
21
3
5
4
6
8
9
10
11
Adjust Main Check to
260-280 psi [18-19 bar]
Main Check Seat is a press fit in the
body and is not serviceable.
Torque Item 2 to
25-27 ft-lbs. [34-37 Nm].
Pilot: Adjust to
180-200 psi [12-14 bar].
Prior to installation, new spring
must be compressed to 750 psi
[52 bar] on a 10-ton press.
25
24
23
20
18
19
22
Pilot Relief: Adjust to
475 psi [33 bar]
2
Figure 3, VS3 Valve Block Assembly

4
1IC300 1 Complete Pendant
2 DC2037647 1 Cord
3DA12254270 1 Connector (Straight Pin)
Repair Parts List for Figure 4
Item Part Number Qty. Description
1
2
3
Figure 4, Pendant

5
Figure 5, Wire Connections
Wire Connections
Connect wires from the pendant 5-pin connector to the
terminal block:
Wire "A" -- connect to terminal number 4.
Wire "B" -- connect to terminal number 2.
Wire "C" -- connect to terminal number 5.
Wire "D" -- connect to terminal number 1.
Wire "E" -- connect to terminal number 3.
Connect wires from the power cord to the terminal block:
Green wire -- connect to terminal number 5.
Black wire -- connect to terminal number 4.
White wire -- connect to terminal number 3.
Connect wires from the solenoid coils to the terminal
block as indicated above.
For the best connection to the terminal block, tin the
stripped ends of the wires.
Figure 6, VS3 Wiring Schematic of Terminal Connectors
E
DC
B
A
5-Pin Connector
Power Cord
Connect to Terminal 2
Connect to Terminal 3
Connect to Terminal 3
Connect to Terminal 1
Retract
Solenoid B
Advance
Solenoid A
1
2
3
3
4
5
6
1
2
4
5
6

TROUBLESHOOTING GUIDE
TEST OF VS-3 & VSR-3
1. Inspect valve and push button station. Check for
missing parts, loose electrical connections, and loose
pilot adjustment screw.
2. Make initial test of valve with test pump and single-
acting cylinder with gauge. Observe operation of
valve and determine if valve holds pressure.
3. Place a 1000 psi (70 bar) gauge in the 1/16" pipe plug
ports (figure 3, item 26) on the side of the valve
blocks. Check to make sure the pilot relief and the
pilot are set to the proper settings as shown in figure
3, page 4.
4. Adjust valve, if necessary.
5. If adjustment is not possible, or if valve fails to
function after adjustment, a complete tear-down and
overhaul may be necessary.
OVERHAUL OF VS-3 & VSR-3
1. Completely disassemble the valve and wash
components.
2. Using a small flashlight, check the condition of the
pilot relief seats in the valve block. If these seats are
damaged, they can be repaired. Find the largest drill
bit that fits down the relief bore and grind the bit's tip
to a flat end. (Make the 118°-120° point of the bit's tip
a flat 180°.) Carefully turn the drill bit slowly using a
6
Problem
Valve operates in an
uncontrolled manner.
Valve fails to activate
cylinder or build pressure.
Valve operation is
intermittent or erratic.
Valve continues operation
after control button is
released.
Valve advances the
cylinder to the maximum
pressure of the pump
without pressing the
advance button.
Valve fails to build load.
Valve fails to release
load.
Pilot pressure gradually
increases from its initial
setting.
Pilot pressure decreases
from its initial setting.
The pilot setting is
correct, but the valve still
fails to build load.
Causes
Plunger (in solenoid) may be jammed.
Plunger seals may be extruded.
The plunger in the lower solenoid may be
defective or the spring under the plunger
(M89110-item 8, figure 2) may be too strong.
The spring under the plunger (M89110) may
be too strong.
The pilot pressure on the lower pilot is too
high or the spring under the plunger
(M89110) is too weak.
The spring on the lower solenoid assembly
(M89110) may be resting on top of the
plunger instead of under it.
Upper pilot setting may be too high.
Upper pilot setting may be too low.
Slight leak through or around pilot ball seat.
Bad pilot relief seats.
The lower pilot relief setting may need to be
slightly increased.
Solution
Replace solenoid assemblies (see
page 2)
Replace solenoid assembly (see
page 2). Replace spring (M89110).
Replace spring (M89110).
Replace solenoid assembly (see
page 2). Replace spring (M89110).
Place the spring under the plunger.
Decrease upper pilot setting.
Increase upper pilot setting.
Replace ball seat.
Replace pilot relief seats.
Depress the advance button on the
control, then slowly turn the lower
pilot relief adjusting screw in
(clockwise) one-quarter turn at a time
until the valve begins to builds load.

7
tap wrench. Do not use an electric drill. After flushing
the relief bore, lightly stake the relief ball to the seat.
3. Replace all worn or damaged ball seats and springs.
4. Replace balls, gaskets and seals with new items from
the VS324K kit.
5. Check the condition of solenoid plunger seals.
Replace where extruded or damaged. A slight circular
indentation on the seals will occur as a result of use.
This is not necessarily harmful unless the seal's
surface is cut or torn. Make certain that the seal in the
lower solenoid moves freely against the spring in the
plastic plunger insert.
6. Replace seats and components. Coin all seats by
placing the ball on the seat and pressing to 200 psi (14
bar) on a 10-ton press. Tighten seats to 27 ft-lbs.(37
Nm). Replace main check ball and components.
Replace top plug.
7. Insert coupler into cylinder port. Apply pressure with a
hand pump. Valve should hold pressure. This test will
indicate leakage through top pilot ball seat and main
check ball.
8. If leakage is indicated through main check ball, the
seat may be loose.This seat is not replaceable. The
body will have to be replaced. Order M693190W. Note:
A slightly damaged seat may be repaired at a qualified
Enerpac service center.
ADJUST MAIN CHECK
1. Install valve on remote mounting block. Remove top
plug. Plug outlet (tank) port of adaptor block. Place a
1000 psi (70 bar) gauge in-line from pump. Make sure
the top thread of the adjustment screw (item 9, figure
3) is flush with the top of the valve block, then turn the
adjustment screw in (clockwise) 17 to 18 turns.
Pressurize the inlet port of the remote block to 280 psi
(19 bar).
2. Complete assembly of the valve.
ADJUST PILOT & PILOT RELIEF
1. Place on test pump. Do not connect to cylinder.
Energize valve. Place toggle on Pushbutton Station in
automatic retract position.
2. Turn in the lower pilot adjusting screw (figure 3, item
16) to 10 ft-lbs. (13 Nm). (Note: The spring should
bottom-out.) Back out the upper pilot adjusting screw.
Place a gauge in the lower port. Depress the advance
button. Set the lower pilot relief on the port side to 475
psi (33 bar) full open by using the lower pilot relief
adjusting screw (figure 3, item 20). After setting the
lower pilot relief pressure, set the lower pilot pressure
to 180-200 psi (12-14 bar) using the lower pilot
adjusting screw (figure 3, item 16).
3. Turn in the upper pilot adjusting screw (figure 3, item
16) to 10 ft-lbs. (13 Nm). (Note: The spring should
bottom-out.) Move the gauge to the upper port.
Depress the advance button. Set the upper pilot relief
pressure on the port side to 475 psi (33 bar) full open
by using the upper pilot relief adjusting screw (figure 3,
item 20). After setting the upper pilot relief pressure, set
the upper pilot pressure to 180-200 psi (12-14 bar)
using the upper pilot adjusting screw (figure 3, item 16).
4. If the valve fails to build sufficient load to adjust the
upper pilot, it may be necessary to slightly raise the
lower pilot relief setting. Depress the advance button
and carefully turn in (clockwise) the pilot relief
adjusting screw until the valve begins to build load.
5. After setting pilot pressure, connect to single-acting
cylinder and gauge.
6. Test valve for 25 full cycles, observing operating and
holding. Check with automatic and manual release.
Check holding at several intervals. freely against the
spring in the plastic plunger insert.
7. Replace seats and components. Coin all seats by
placing the ball on the seat and pressing to 200 psi (14
bar) on a 10-ton press. Tighten seats to 27 ft-lbs.(37
Nm). Replace main check ball and components.
Replace top plug.
8. Insert coupler into cylinder port. Apply pressure with a
hand pump. Valve should hold pressure. This test will
indicate leakage through top pilot ball seat and main
check ball.
9. If leakage is indicated through main check ball, the
seat may be loose.This seat is not replaceable. The
body will have to be replaced. Order M693190W. Note:
A slightly damaged seat may be repaired at a qualified
Enerpac service center.

NS-0599C