Enerpac E Series Use and care manual

E-Series
Electric Manual Valve Pump
Document
Number
Document
Revision
Document
Revision Date
Product Date Code
Beginning With
L4348 A 04/2019 A
Repair Parts Sheet
WARNING
Fully relieve hydraulic pressure, disconnect hydraulic hoses and unplug AC power cord from electrical
outlet before beginning any inspection, maintenance or repair procedures. Failure to observe these precautions
could result in death or serious personal injury. Appropriate shop safety procedures are to be followed during
disassembly and reassembly to minimize any possibility of injury.
Models:
• EP3204JB (110-120 VAC - NEMA 5-15 plug)
• EP3204JI (200-250 VAC - NEMA 6-15 plug)
• EP3204JE (200-250 VAC - Schuko CEE 7/7 plug)
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.

2
Table of Contents:
Figure 1 - Pump Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1A - Speed Control Potentiometer and Cable Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2 - Miscellaneous Assemblies .............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2A - DC Power Cable Assembly.............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2B - Serial Communication Cable Assembly .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2C - Jumper Connection ................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2D - Pump Handle Kit ..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2E - 2 Button, Pendant Assembly ............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3 - Motor Controller Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4 - Power/App Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 5 - Motor Stator and Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5A - Flareless Tube Kit - A Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 5B - Motor Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 5C - Bulkhead Fitting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 6 - Reservoir and End Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 7 - Rear End Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 7A - Power Cord Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 8 - Front End Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 8A - Water Ingress Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 9 - Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 9A - Eccentric Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 9B - Pump Housing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 9C - Piston Block Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 9D - Piston Block Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 9E - Intake Suction Filter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 10 - Direct Drive Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 10A - Rebuild Kit, User-Adjustable Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 11 - 3/2 Manual Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 11A - 3/2 Manual Valve Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 12 - Hydraulic Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 13 - Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 14 - Pump Cover Removal/Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Notes:
• Parts lists indicate the total quantity of each part used in a figure.
• The quantity of a part supplied in a repair kit or service assembly may be less than the total quantity shown in the
parts list.
• Information contained in this document is subject to change without notice due to design variables, product
improvements and other factors. Copyright © 2019 Enerpac. All rights reserved.
Page

3
Notes:
Torque to 13-16 ft-lbs [18-22 Nm].
2
Torque to 10-12 ft-lbs [14-16 Nm].
5
8
7
1
6
9
5
3
10
11 2
14 5
See Figure 1A
Figure 1 - Pump Exterior
Repair Parts List for Figure 1
Item Part Number Qty. Description
1kDC7887026 1 CE Safety Label Read Instructions
3DD6799026 1 Decal, Product Specification
5DD7216026 1 Decal, Manual Valve Operation
6DD7248009 1 Plug, Dome, 7.5 Dia
7DD7349026 1 Decal, Pendant, Momentary/Continuous
8DD7355026 1 Decal, Gauge Cap
9DD7417026 1 Decal, Unplug Cord
10 DD7441026 1 Decal, Valve Schematic, 3/2M
11 DD7557006 1 Plug, SAE #8, Zero-Leak
14 R515245-2 1 Plug
k- Included in Pump Cover Kit DD6792098SR.

4
Notes:
Remove nut. Insert potentiometer through endcap, aligning
orientation tab. Reinstall nut and
torque to 8-10 in-lbs [0.9-1.1 Nm].
1
Apply decal, turn potentiometer shaft fully clockwise.
Align knob with max line and push on to install.
2
Wiring Diagram
J3 CONNECTOR POTENTIOMETER
END
END
CONTROLLER
APPLICATION
BLACK
WHITE
RED
1
2
3
SPEED
BLACK
WHITE
RED
POT 1 POT 1
1
2
3
See Figure 13 for main electrical wiring diagram. Orientation tab
Orientation Holes
31
2
1
2
Figure 1A - Speed Control Potentiometer and Cable Kit: DD7060960K
Repair Parts List for Figure 1A
Item Part Number Qty. Description
1DD6798026 1 Decal, Potentiometer, Speed Control
2DD7029020 1 Knob Potentiometer
3DD7060960 1 Cable Assembly
Note: Speed Control Potentiometer and Cable Kit DD7060960K includes all items listed in the table above.

5
See Figure 3
See Figure 4
See Figure 2D
See Figure 2E
Refer to Figures 2A through 2C
for electrical cable assemblies.
Figure 2 - Miscellaneous Assemblies

6
Repair Parts List for Figure 2A, 2B and 2C
Item Part Number Qty. Description
--- See Figure 2A 1 Cable Assembly, DC Power Supply
--- See Figure 2B 1 Cable Assembly, Serial Communications
--- See Figure 2C 1 Cable, Jumper, J8 and J9 Connection
--- DC9876647 3 Black Cable Tie 6" (not shown)
V+
V-
Red
Black
Red
Black
J2 Connector
2
J2
A
ASection A-A
1
1
2
Figure 2A - DC Power Cable Assembly: DD7061960
Serial Communication Port
Black 1
Red 2
White 3 J6
Black 3
Red 2
White 1
A
A
Section A-A
B
BSection B-B
1
2
3123
Figure 2C - Serial Communications Cable Assembly: DD7064960
Figure 2C - Jumper Connection: DD7125960

7
4
1
2
3
1
Note:
Torque to 42-47 in-lbs [4.7-5.3 Nm].
1
Figure 2D - Pump Handle Kit: DD5789800SR
Repair Parts List for Figure 2D
Item Part Number Qty. Description
1CAE1050108-1A 2 Flat Washer DIN125A M5
2CCE523028-1A 2 Screw-SHCS, Hex, M5 x 0.8 x 25, 12.9, Zinc
3DD6789800 1 Casting Handle Pump
4DD7167026 1 Decal, Troubleshoot
Note: Pump Handle Kit DD5789800SR includes all items listed in the table above.

8
1a
1b
2
1c
1d
1
3
4
See Figure 13 for main electrical wiring diagram.
Note:
Torque to finger tight plus an additional 1/4 turn.
1
DD7349026
(order decal separately - not included in kit)
Figure 2E - 2 Button, Pendant Assembly: DD5278900SR1
Repair Parts List for Figure 2E
Item Part Number Qty. Description
1a
DD7094380 1
Light Pipe
1b Seal
1c Washer
1d Nut
2DD7280424 1 Cover
3DD7294960 1 Bottom
4DC9538021 1 Locking Nut 20mm
Note: 2 Button, Pendant Assembly DD5278900SR1 includes all items listed in the table above.

9
1214 13 10 1
5
1
3
11 2
1
11 23 4
6A
6B
8
7
5
5
Notes:
Install ground cable with ring terminal between star washers.
Torque to 8-10 in-lbs [0.9-1.1 Nm].
1
2
Remove adhesive backing before installation.
3
Torque to 6-7 in-lbs [0.7-0.8 Nm].
4
See parts list (items 6A & 6B)
for voltage options.
5
• Attach all wires including ground wire!
• Remove lip seal from old cover and attach to new
cover if applicable (only one side has a lip seal).
• See wiring diagram Figure 13 for wire connections.
• See pump cover removal/installation instructions
Figure 14.
Figure 3 - Motor Controller Cover Assembly
Repair Parts List for Figure 3
Item Part Number Qty. Description
1 BF1607027AX 2 Set Screw, #8-36 x 0.438, Cup Point, Zinc
3 CCE1040108-7A 2 Lock Washer, External Tooth For M4
5 kDD6792098-P03 1 Pump Cover
6A DD6987827K 1 Motor Controller Kit, 120V (Model EP3204JB)
6B DD7318827K 1 Motor Controller Kit, 230V, 240V (Models EB3204JI and EP3204JE)
7 sDD7513001 2 Screw, Thread Forming, M4.55 x 10 Long
8 kDD7462037 2 Gasket, 4.0mm Dia x 5.50mm L Cord Stock
--- kSee Figure 1 1 CE Safety Label Read Instructions
10 kCBE411028-1A 3 Screw-SHCS, Hex, M4 x 0.7 x 6, 8.8, Zinc
11 DD7516122 2 Nut-Hex Full, #8-36, GRD 2, Zinc
12 DD7609111 1 Bracket, Motor Controller Restraint
13 kDD7326217 3 Cable Tie, Screw Mount
14 kDC9922026 1 Decal High Voltage
s- Each motor controller kit (items 6A and 6B) includes two thread forming screws (item 7).
k - Included in Pump Cover Kit DD6792098SR.

10
4
5
9
13
8
6
73 4 12 12 1 11 3111 2 2
Notes:
Install ground cable with ring terminal between star washers.
Torque to 8-10 in-lbs [0.9-1.1 Nm].
Remove adhesive backing before installation.
Torque to 6-7 in-lbs [0.7-0.8 Nm].
1
2
3
4
Figure 4 - Power/App Assembly
Repair Parts List for Figure 4
Item Part Number Qty. Description
1BF1607027AX 1 Set Screw, #8-36 x 0.438, Cup Point, Zinc
2kCBE411028-1A 3 Screw-SHCS, Hex, M4 x 0.7 x 6, 8.8, Zinc
3CCE1040108-7A 2 Lock Washer, External Tooth For M4
4DC9876647 3 Black Cable Tie 6"
5kDD6792098-P03 1 Cover, Machined, 1 Gal, Yellow
6DD7298900 1 Power App Board Assembly
7kDD7326217 3 Cable Tie, Screw Mount
8DD7448037 1 Lip Seal, E-Pulse
9kDD7462037 2 Gasket, 4.0mm Dia x 5.50mm L Cord Stock
11 DD7516122 1 Nut-Hex Full, #8-36, GRD 2, Zinc
12 DD7609111 1 Bracket, Motor Controller Restraint
13 DD7513001 2 Screw, Thread Forming, M4.55 x 10 Long
--- kSee Figure 1 1 Decal, Unplug Cord (not shown)
k- Included in Pump Cover Kit DD6792098SR.

11
2
4
6
19
SEE CROSS
SECTION ‘A’
14
4
1
3 10
2
5
3
3
1
4
3
See Figure 5B
See Figure 5A
Notes:
Insert tubes and torque to 150-160 in-lbs [203-217 Nm].
(At manifold end prior to installing pump into reservoir)
Apply Loctite 243.
Torque to 42-47 in-lbs [4.7-5.3 Nm].
Bend tube vertical while installing pump into reservoir.
1
2
3
4
Align mark on counterweight with mark on shaft. (See detail A)
5
SEE DETAIL ‘A’
DETAIL ‘A’ - COUNTERWEIGHT ORIENTATION
Figure 5 - Motor Stator Assembly

12
CROSS SECTION ‘A’ (Figure 5)
Repair Parts List for Figure 5
Item Part Number Qty. Description
1B1086066 1 Lockwasher
2CAE1060108-1A 6 Washer-Flat, M6, 6.4 ID x 12 OD x 1.6, Din 125A, Zinc
3CBE519028-1A 1 Screw-SHCS, Hex, M5 x 0.8 x 16, 8.8, Zinc
4CBE619028-1A 9 Screw-SHCS, Hex, M6 x 1 x 16, 8.8, Zinc
6DD6763101 1 Plate, Counterweight
10 DD7027070 1 Handle, Valve
14 DD7319037 1 Gasket, Manifold
19 S3037 3 Gasket
ORIENT FERRULE FOR COMPRESSION
FITTING WITH SMALL OD TOWARD
TUBE END
See Figure 5D

13
Repair Parts List for Figure 5A
Item Part Number Qty. Description
1CU421096 1 Ferrule, Ferulok, 0.25 Tube
2DD7038268 1 Tube, Flareless, A Port
3F100093-21 1 Nut, Ferulok, 7/16-20 THD, 0.25
Note: Flareless Tube Kit - A Port DD7038268SR includes all items listed in the table above.
1
1
Item pre-assembled
prior to shipment.
(Assembled View)
{
32
1
Note:
Torque to 150-160 in-lbs [203-217 Nm].
1
Figure 5A - Flareless Tube Kit - A Port: DD7038268SR
Repair Parts List for Figure 5B
Item Part Number Qty. Description
1DD6770259 1 Motor Stator Assembly
2DD6771257 1 Motor Rotor
3DD7003021 1 Nut, Flange M10 x 1.25, With Counterbore
Note: Motor Replacement Kit DD6770259K includes all items listed in the table above.
1
2
3
2
6
3
Notes:
Apply Loctite 243.
Torque to 42-47 in-lbs [56.9-63.7 Nm].
Torque to 100-120 in-lbs [11-14 Nm].
2
3
6See Figure 13 for electrical wire connections.
Figure 5B - Motor Replacement Kit: DD6770259K

14
Repair Parts List for Figure 5C
Item Part Number Qty. Description
1DD7105093 1 Bulkhead Fitting, 3/8" NPT x 0.25 Flareless
2DD7106044 1 Retaining Ring, External, 13/16" Shaft
3DD7447037 1 Gasket, Bulkead, E-Pulse
Note: Bulkhead Fitting Kit DD7105093K includes all items listed in the table above.
1
3 21 2
3
Note:
Torque to 150-160 in-lbs [203-217 Nm].
7
7
Figure 5C - Bulkhead Fitting Kit: DD7105093K

15
1
1
2
5
2
2
10
4
3
9B
9A
2
Notes:
Torque to 60-70 in-lbs [6.8-7.9 Nm].
Torque to 106-133 in-lbs [12-15 Nm].
1
2
Figure 6 - Reservoir and End Cap Assembly

16
Repair Parts List for Figure 6
Item Part Number Qty. Description
1CAE1060055-1A 2 Acorn Nut M6
2CBE821028-1A 8 Screw-SHCS, Hex, M8 x 1.25 x 20, 8.8, Zinc
3DD6788025-P03 1 Reservoir, Machined, 1 Gal, Yellow
4DD6795870 2 Foot, Rubber
5DD7164108 2 Washer, Rubber Sealing, M6
9A See Figure 8 1 Endcap Assembly, Front
9B See Figure 7 1 Endcap Assembly, Rear
10 DD7290026 2 Decal, Enerpac Logo, Die-cut
--- S3037 3 Gasket (See Figure 5, item 19)

17
4
10
11
1
3
5
See Figure 7A
9
5
1
4
Notes:
Torque to 25-30 in-lbs [2.8-3.4 Nm].
Remove adhesive backing before installation.
Remove nut. Insert potentiometer through endcap and reinstall nut.
Torque to 8-10 in-lb [0.9-1.1 Nm].
1
4
5
Figure 7 - Rear End Cap Assembly

18
1
4
3
230V 240V
115V
Notes:
2
Torque to finger tight plus an additional 1/4 turn.
2
Power cord varies depending on voltage and region.
See parts list for details.
3
2
3
3
3
See Figure 13 for electrical wiring connections.
Figure 7A - Power Cord Replacement Kit
Repair Parts List for Figure 7
Item Part Number Qty. Description
1CCE1040108-7A 2 Lock Washer, External Tooth For M4
3DD6786020 1 End Cap, Rear, Machined, Black
4DD7017037 1 Gasket, Endcap
5DD7030037 1 Gasket Tape, 3/16" THK x 1/4" W x 12.25" L
9DD7060960 1 Cable Assembly, Potentiometer
10 DD7328001 5 Screw, Thread Forming, M4 x 12 Long
11 DD7331217 3 Cable Tie, Screw Mount
12 DD7439960 1 Cable Assembly, Power, Motor Controller
13 DD7463118 2 Filter, 20 x 10 x 100
Repair Parts List for Figure 7A
Item Part Number Qty. Description
1DC9538021 1 Locking Nut 20mm
2DD7044960SR 1 Power Cord, 115 VAC, 50/60 Hz, NEMA 5-15 (Model EP3204JB)
3DD7045960SR 1 Power Cord, 208/230 VAC, 50/60 Hz, NEMA 6-15 (Model EP3204JI)
4DD7046960SR 1 Power Cord, 208/240 VAC, 50/60 Hz, CEE 7/7 EHUK (Model EP3204JE)
Note: Item 1 NOT included in power cord kits. Order separately.

19
2
4
6
9 5
8
7
12
13
14
See Figure 8A
10 1
3
5
1 4
2
Notes:
Apply Loctite 2760.
Install to full depth.
Torque to 25-30 in-lbs [2.8-3.4 Nm].
1
4
5
Torque to 8-10 in-lbs [0.9-1.1 Nm].2
Figure 8 - Front End Cap Assembly

20
2
3
3
Note:
Remove adhesive backing before installation.
Press item 2 into
ends of covers
4
4
Figure 8A - Water Ingress Seal Kit: EPWISK1
Repair Parts List for Figure 8
Item Part Number Qty. Description
1B1240503 1 O-Ring, 2-1/8 ID, 0.070 W
2DC8228009 1 Dome Plug 1/2"
3DD3883028 2 Screw M4 x 10 Thread FRM, TRX
4DD6784020 1 End Cap, Front, Machined, Black
5DD6990808 1 Grommet, Valve, Rubber, 4/3m
6DD6997020 1 Cap, Gauge
7DD7002646 2 Hose, Rubber, 9.52 x 15.88 x 50L
8DD7017037 1 Gasket, Endcap
9DD7021223 1 Sight Gage
10 DD7022225 1 Insert, Sight Gage
12 DD7107305 2 Threaded Rod, M6 x 1.0 x 300 Long
13 DD7328001 1 Screw, Thread Forming, M4 x 12 Long
14 DD7331217 1 Cable Tie, Screw Mount
Repair Parts List for Figure 8A
Item Part Number Qty. Description
1DD7448037 1 Lip Seal, E-Pulse
2DD7462037 4 Gasket, 4.0mm Dia x 5.50mm L Cord Stock
3DD7030037 1 Gasket Tape, 3/16" THK x 1/4" W x 12.25" L
Note: Water Ingress Seal Kit EPWISK1 includes all items listed in the table above.