Enerpac ZU4 Series Manual

Service Information Sheet
POWERFUL SOLUTIONS. GLOBAL FORCE.
ZU4 Classic Bolting Pump
Single-Solenoid Control Valve Upgrade
INTRODUCTION
This document applies to all Enerpac ZU4 Classic Bolting Pumps
equipped with dual-solenoid valves. It includes instructions for
performing the following product upgrade procedures:
• Replacement of the existing VE Series dual-solenoid control
valve with the new single-solenoid VE Series control valve.
• Replacement of the existing front and middle brackets with
new brackets that are electrically compatible with the single-
solenoid control valve.
ELECTRICAL SERVICE KITS AND VALVES
To upgrade an existing pump to use the new single-solenoid
control valve, a new electrical service kit must rst be installed.
Refer to Table 1 for service kit model numbers and descriptions.
TABLE 1 - ELECTRICAL SERVICE KITS
Pump Voltage Service Kit
Model Number
Description
115V ZTERK-115 ZTW 115V Electrical
Service Kit
230V
NORTH AMERICA
ZTERK-230 ZTW 230V Electrical
Service Kit
230V CE
EUROPE AND ASIA (Contact Enerpac)
Each electrical service kit includes a new front electrical bracket,
middle electrical bracket and pendant. The pump's existing rear
electrical bracket is reused.
New single-solenoid control valves are available in various
voltages and congurations as described in Table 2.
TABLE 2 - CONTROL VALVE MODELS, SINGLE-SOLENOID
Pump
Voltage
Valve Model Description
115V VE42Q-115 115V 10,000 PSI [700 bar]
VE42QM-115 115V 10,000 PSI [700 bar]
- Multiport
VE42E-115 115V 11,600 PSI [800 bar]
VE42EM-115 115V 11,600 PSI [800 bar]
- Multiport
230V VE42Q-230 230V 10,000 PSI [700 bar]
VE42QM-230 230V 10,000 PSI [700 bar]
- Multiport
VE42E-230 230V 11,600 PSI [800 bar]
VE42EM-230 230V 11,600 PSI [800 bar]
- Multiport
Note: Control valves and electrical service kits must be ordered
separately.
230 VOLT CE MODELS  IMPORTANT NOTE
Consult your local Authorized Enerpac Service Center before
beginning electrical upgrade procedures on 230V pumps with
CE style electrical components. Power cord wire colors and
various other wiring details are dierent for 230V CE models.
A complete wiring diagram covering all pump wiring
congurations and voltages - including 230V CE models - is
shown in Figure 14 of this document.
BEFORE YOU BEGIN
WARNING: Disconnect power from pump before
beginning the following procedure. Be sure hydraulic
pressure is zero (0) psi/bar.
CAUTION: Standard safety procedures are to be
followed during disassembly and reassembly to
minimize any possibility of injury.
CAUTION: Allow only trained and qualied personnel
to perform the electrical wiring procedures described in
this document.
IMPORTANT: Some components on the new front and middle
brackets are pre-wired at the factory, prior to shipment Be
careful not to disturb wiring when unpacking the shipment or
during installation procedures.
Note: The graphics contained in this document are provided for
reference and instructional purposes only. Various pump features
and/or congurations may be dierent than shown for your pump.
Optional features may be shown that are not present on your pump.
Figure 1, New Components (typical)
L2915 Rev. B 08/22
*
Middle Bracket*
VE Series Control
Valve Assembly
(single-solenoid)
Included with
Electrical
Service Kit
*
Front Bracket
and Pendant
(not shown)

2
Notes:
• Save the old bracket capscrews for later use. They will be used
to re-secure the new front and middle brackets.
• a new pendant is supplied with the new front bracket. The old
pendant can be discarded.
• Discard the old valve gasket and capscrews. A new gasket and
capscrews are included with the new valve.
INSTALLATION AND WIRING OF NEW FRONT AND
MIDDLE BRACKET ASSEMBLIES
1. Secure the new front and middle brackets to the pump cover
plate, using the capscrews from the old brackets. Apply
Loctite 545 sealant to capscrew threads before installation.
Torque capscrews to 84-108 in-lbs [9.5-12.2 Nm]. See Figure
5.
WARNING: Be certain that power cord is disconnected
before making electrical connections in the following
steps.
IMPORTANT: Wire colors and other wiring details are dierent for
230V models sold in the European Union, parts of Asia and various
other regions outside of North America. Refer to the wiring diagram
in Figure 14 of this document for CE style wiring details. Consult your
local Authorized Enerpac Service Center if assistance is required.
2. Connect green (ground) wire from power cord and the green
and yellow striped (solenoid ground) wire to the motor
ground screw. Tighten screw to secure wires. See Figure 6.
3. Insert white (neutral) wire from power cord into L5 terminal of
contactor. Tighten screw on the contactor to secure the wire.
See Figure 7.
4. Connect black (hot) wire of power cord to top pin (pin 1) of
circuit breaker. See Figure 8.
5. Using a wire tie, secure the power cord wires to the top of
the middle bracket. See Figure 9.
REMOVAL OF OLD COMPONENTS
1. Disconnect pump power cord from electrical outlet. Be sure
pressure gauge indicates zero (0) psi/bar.
2. Loosen solenoid plug retaining screws. Unplug solenoid
plugs from old control valve.
3. Remove capscrews and old control valve. Remove and
discard old valve gasket. See Figure 3.
4. Loosen capscrews and remove pump shroud halves. See
Figure 2. Save capscrews for use during reinstallation.
5. Loosen screw at contactor terminal L5. Disconnect white
(neutral) power cord wire from contactor.
6. Disconnect black (hot) power cord wire from top pin (pin 1)
of circuit breaker.
7. Disconnect two black motor wires from terminals T2 and T4
of contactor.
8. At top of motor, disconnect green (ground) power cord wire.
Also disconnect two yellow and green striped solenoid
ground wires.
9. Loosen capscrews and remove the existing front and middle
brackets from the pump cover plate.
Figure 2, Removing the Shroud Halves
Figure 3, Removing Old Valve
Figure 4, Removing Old Front and Middle Brackets

3
Figure 7, Middle Bracket Contactor Connections
Figure 5, Installing new Front and Middle Brackets
Figure 6, Ground Wire Connection to Pump Motor
MOTOR
GROUND
SCREW
WHITE WIRE
(from power cord)
Terminal L5
of Contactor
T5
T1
L5
L1
T6
T4
T3
T2
L6
L4
L3
L2
C3 C4
TERMINAL L5TERMINALS T2 AND T4
PIN 1 OF
CIRCUIT BREAKER
BLACK WIRES
(from motor)
Terminals T2 and T4
of Contactor
Green Wire
(from power cord)
Green and Yellow
Striped Wire
(from solenoid plug)

4
Figure 9, Wire Tie Installation (Middle Bracket)
Figure 11, Solenoid Plug
Wire Tie at
Middle Bracket WARNING:
Disconnect power
before making electrical
connections.
WARNING: Allow only trained
and qualied personnel to
perform the electrical upgrades
described in this document.
IMPORTANT: 230 volt CE models:
Some electrical wire colors will be
dierent. Refer to wiring diagram in
Figure 14 for additional 230V CE wiring
information.
Figure 10, Mounting Screw Securing Gauge Bracket
Figure 8, Front Bracket Connections
BLACK WIRE
(from power cable)
Pin 1 (top pin)
of Circuit Breaker
T5
T1
L5
L1
T6
T4
T3
T2
L6
L4
L3
L2
C3 C4
TERMINAL L5TERMINALS T2 AND T4
PIN 1 OF
CIRCUIT BREAKER

5
Figure 12, Valve Installation Details
5
Figure 13, Shroud Reinstallation
INSTALLATION OF NEW VALVE ASSEMBLY
Refer to exploded view in Figure 12 during the following steps.
Refer to other gures as indicated.
1. Install oil return tube into port on bottom of valve manifold.
2. Be sure valve mounting surface on pump coverplate is
clean. Remove any dirt or dust from this area.
3. Install new backup ring and new O-Ring on pump oil supply
tube.
4. Mount the new valve assembly and gasket to the pump
cover plate using the four socket head capscrews provided
with the valve. Apply Loctite 545 sealant to threads of
capscrews as installed. Torque to 16-19 ft-lbs [22-25 Nm].
Note: The front two capscrews are also used to help secure the
gauge bracket. See Figure 10.
5. Plug the solenoid cord into the solenoid to the valve and
hand tighten the plug retaining screw. See Figure 11.
FINAL ASSEMBLY AND TESTING
Install the shroud halves. Torque the shroud mounting screws to
18-20 in-lbs [2,0- 2,9 Nm]. See Figure 13
Check pump for proper operation. Refer to operating instructions
in Enerpac instruction sheet L2906.
Standard Valves
E and Q Series Models
Valves with Multi-Port Manifold
EM and QM Series Models
Key:
1. Capscrews
2. Valve Assembly
3. Gasket
4. Oil Return Tube
5. Multi-Port Manifold
6. O-Ring
7. Back-up Ring
8. Oil Inlet Connection
(on pump)
1
2
3
4
3
4
2
1
6
7
6
7
88

6
Line Volt age In
A 1
M 1
115 Vo lts or 230 Volts 60 or 50 Hz., AC
Blac k, 12
Whit e, 12 AW G
Circuit Br eaker
T5
Pump
Motor
Po wer Co rd
DC 8286.96 0 fo r 115V, DC8287960 for 230V
DC8288960 for CE 230V
m 3
Dual Pr imary
Transforme r
25 VA . Cl ass 2
DC 827 9480SR
1
2
5
4
10
8
7
6
m 3
1
2
5
4
10
8
6
LINE EM I In-Line
Filter
F 1
Green, 12
C
C
M 2
Heat Exch. Fa n
DC 8276 470 :115V
DC 8277 470 :230V
S 1
Advanc e
Solenoi d
6
4
R A
7
Ri ght
Se condary
24 VA C
Lef t
Pr imary
230 VA C
Ri ght
Se condary
24 VA C
Lef t
Pr imary
115 VA C
Transformer Input Cord
.
DC 8313960
T
C
DC 8312.96 0
for 115 V and 230 V
US A & Cana da
LO AD DC 9580380
CE 230 V
(D C9 583 960
for CE 230 V)
T
HE Fan Co rd
DC 8346960
HE Fan Co rd
DC 834 6960
DD12 63960
C. L3
RA 6
T
Sol. Ca ble,
non-rectied, DIN
DD1273 .9 60
C
Transformer Input Cord
DC8313960
C
T
1
2
L2
L1
T3
T2
L4
T6
L6
T4
L5
Brown, CE
Blue, CE
Green/Yellow, CE
RA 4
DC
831 5960
K 1
EMI In-Line Capacitor
DC 9579382 for CE 230V.
1 microFarad, 275 Volts
Sol. Cable, non- rectied, DIN. DD1273.960
230 V Models Only
C
Contacto r
DC 8193398
C1
24 VAC
(from terminals
6 and 10 of transformer
See view 1 of 2)
7
8
3
2
R A
TR
b 2
MOTO R ON &
CYL. ADVA NC E
b 1
MOTOR OF F/
CYL. RETRAC T
1
TR
a 2
Co ntrol
ON /OFF Switch
DC 8307372
PE ND AN T
Advance Solenoi d
Re lay
Timer Module
DC 8281784
Pendant Co rd.
DD1276 960
Ca ble, Tran sformer Output
DC 831 4960
Pendan t Co rd
DC 8285 960
Pend ant Co rd
DD 1276960
6
CO M
ADV
OF F
SW
RA 8
TR 2
TR 6
Ca ble, Time r
to Co ntactor
DC 831 7960
CTR 1
C/SW
Ca ble, Co ntac tor to Relays and Timer Module
DD 1264960
C
RA
TR 3
Cabl e, Tr ansformer Output
DC 8314960
C/SW
Pendan t Co rd.
DD1276 .9 60
FUNCTIONAL CHART:
2
3
C2
C3
DESCRIPTION a2 RA TRTR Cb1 b2 M1 & M2 S1
OF Freleas ed re le ased OF FOFF OF FSTO POFF
ON re leas ed re le ased ON OF FOFF ST OP OF F
C, M1 and M2
will be o 
afte r th e ti me
de la y
ON re leas ed
pres se d
and
re le ased
ON ON ON RUN ON
ON pr e sse drelea se dOFF OF FOFF ST OP OF F
Figure 14, Electrical Diagram, ZU4 Classic Bolting Pump (View 1 of 2)

7
Line Voltage In
A 1
M 1
115 Vo lts or 230 Volts 60 or 50 Hz., AC
Blac k, 12
Whit e, 12 AW G
Circuit Br eaker
T5
Pump
Motor
Po wer Co rd
DC 8286.96 0 fo r 115V, DC8287960 for 230V
DC8288960 for CE 230V
m 3
Dual Pr imary
Transforme r
25 VA . Cl ass 2
DC 827 9480SR 1
2
5
4
10
8
7
6
m 3
1
2
5
4
10
8
6
LINE EM I In-Line
Filter
F 1
Green, 12
C
C
M 2
Heat Exch. Fa n
DC 8276 470 :115V
DC 8277 470 :230V
S 1
Advanc e
Solenoi d
6
4
R A
7
Ri ght
Se condary
24 VA C
Lef t
Pr imary
230 VA C
Ri ght
Se condary
24 VA C
Lef t
Pr imary
115 VA C
Transformer Input Cord
.
DC 8313960
T
C
DC 8312.96 0
for 115 V and 230 V
US A & Cana da
LO AD DC 9580380
CE 230 V
(D C9 583 960
for CE 230 V)
T
HE Fan Co rd
DC 8346960
HE Fan Co rd
DC 834 6960
DD12 63960
C. L3
RA 6
T
Sol. Ca ble,
non-rectied, DIN
DD1273 .9 60
C
Transformer Input Cord
DC8313960
C
T
1
2
L2
L1
T3
T2
L4
T6
L6
T4
L5
Brown, CE
Blue, CE
Green/Yellow, CE
RA 4
DC
831 5960
K 1
EMI In-Line Capacitor
DC 9579382 for CE 230V.
1 microFarad, 275 Volts
Sol. Cable, non- rectied, DIN. DD1273.960
230 V Models Only
C
Contacto r
DC 8193398
C1
24 VAC
(from terminals
6 and 10 of transformer
See view 1 of 2)
7
8
3
2
R A
TR
b 2
MOTO R ON &
CYL. ADVA NC E
b 1
MOTOR OF F/
CYL. RETRAC T
1
TR
a 2
Co ntrol
ON /OFF Switch
DC 8307372
PE ND AN T
Advance Solenoi d
Re lay
Timer Module
DC 8281784
Pendant Co rd.
DD1276 960
Ca ble, Tran sf ormer Output
DC 831 4960
Pendan t Co rd
DC 8285 960
Pend ant Co rd
DD 1276960
6
CO M
ADV
OF F
SW
RA 8
TR 2
TR 6
Ca ble, Time r
to Co ntactor
DC 831 7960
CTR 1
C/SW
Ca ble, Co ntac tor to Relays and Timer Module
DD 1264960
C
RA
TR 3
Cabl e, Tr ansformer Output
DC 8314960
C/SW
Pendan t Co rd.
DD1276 .9 60
FUNCTIONAL CHART:
2
3
C2
C3
DESCRIPTION a2 RA TRTR Cb1 b2 M1 & M2 S1
OF Freleas ed re le ased OF FOFF OF FSTO POFF
ON re leas ed re le ased ON OF FOFF ST OP OF F
C, M1 and M2
will be o 
afte r th e ti me
de la y
ON re leas ed
pres se d
and
re le ased
ON ON ON RUN ON
ON pr e sse drelea se dOFF OF FOFF ST OP OF F
Figure 14, Electrical Diagram, ZU4 Classic Bolting Pump (View 2 of 2)

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For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com