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Enerpac E Series Repair Parts Sheet
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Enerpac E Series Repair Parts Sheet

Electric manual valve pump
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Document
Number
L4348
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.
Fully relieve hydraulic pressure, disconnect hydraulic hoses and unplug AC power cord from electrical
WARNING
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.
Document
Revision
A
Repair Parts Sheet
E-Series
Electric Manual Valve Pump
Document
Revision Date
04/2019
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)
Product Date Code
Beginning With
A

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Summary of Contents for Enerpac E Series

  • Page 1 L4348 04/2019 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. Models: • EP3204JB (110-120 VAC - NEMA 5-15 plug) • EP3204JI (200-250 VAC - NEMA 6-15 plug) •...
  • Page 2 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 Figure 1 - Pump Exterior See Figure 1A 14 5 11 2 Notes: Torque to 13-16 ft-lbs [18-22 Nm]. Torque to 10-12 ft-lbs [14-16 Nm]. Repair Parts List for Figure 1 Item Part Number Qty. Description k DC7887026 CE Safety Label Read Instructions DD6799026 Decal, Product Specification DD7216026...

  • Page 4: Wiring Diagram

    Figure 1A - Speed Control Potentiometer and Cable Kit: DD7060960K Orientation Holes Orientation tab See Figure 13 for main electrical wiring diagram. Notes: Remove nut. Insert potentiometer through endcap, aligning orientation tab. Reinstall nut and torque to 8-10 in-lbs [0.9-1.1 Nm]. Apply decal, turn potentiometer shaft fully clockwise.
  • Page 5 Figure 2 - Miscellaneous Assemblies See Figure 2E See Figure 2D See Figure 3 See Figure 4 Refer to Figures 2A through 2C for electrical cable assemblies.
  • Page 6 Figure 2A - DC Power Cable Assembly: DD7061960 Black Section A-A J2 Connector Black Figure 2C - Serial Communications Cable Assembly: DD7064960 Black 1 Black 3 Red 2 Red 2 Serial Communication Port White 3 White 1 1 2 3 Section B-B Section A-A Figure 2C - Jumper Connection: DD7125960...
  • Page 7 Figure 2D - Pump Handle Kit: DD5789800SR Note: Torque to 42-47 in-lbs [4.7-5.3 Nm]. Repair Parts List for Figure 2D Item Part Number Qty. Description CAE1050108-1A Flat Washer DIN125A M5 CCE523028-1A Screw-SHCS, Hex, M5 x 0.8 x 25, 12.9, Zinc DD6789800 Casting Handle Pump DD7167026...
  • Page 8 Figure 2E - 2 Button, Pendant Assembly: DD5278900SR1 See Figure 13 for main electrical wiring diagram. DD7349026 (order decal separately - not included in kit) Note: Torque to finger tight plus an additional 1/4 turn. Repair Parts List for Figure 2E Item Part Number Qty.
  • Page 9 Figure 3 - Motor Controller Cover Assembly 11 2 11 2 Notes: Install ground cable with ring terminal between star washers. Torque to 8-10 in-lbs [0.9-1.1 Nm]. • Attach all wires including ground wire! • Remove lip seal from old cover and attach to new Remove adhesive backing before installation.
  • Page 10 Figure 4 - Power/App Assembly 11 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]. Repair Parts List for Figure 4 Item Part Number Qty.
  • Page 11 Figure 5 - Motor Stator Assembly SEE DETAIL ‘A’ See Figure 5B See Figure 5A SEE CROSS SECTION ‘A’ DETAIL ‘A’ - COUNTERWEIGHT ORIENTATION 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.
  • Page 12 CROSS SECTION ‘A’ (Figure 5) See Figure 5D ORIENT FERRULE FOR COMPRESSION FITTING WITH SMALL OD TOWARD TUBE END Repair Parts List for Figure 5 Item Part Number Qty. Description B1086066 Lockwasher CAE1060108-1A Washer-Flat, M6, 6.4 ID x 12 OD x 1.6, Din 125A, Zinc CBE519028-1A Screw-SHCS, Hex, M5 x 0.8 x 16, 8.8, Zinc CBE619028-1A...
  • Page 13 Figure 5A - Flareless Tube Kit - A Port: DD7038268SR Item pre-assembled prior to shipment. (Assembled View) Note: Torque to 150-160 in-lbs [203-217 Nm]. Repair Parts List for Figure 5A Item Part Number Qty. Description CU421096 Ferrule, Ferulok, 0.25 Tube DD7038268 Tube, Flareless, A Port F100093-21...
  • Page 14 Figure 5C - Bulkhead Fitting Kit: DD7105093K Note: Torque to 150-160 in-lbs [203-217 Nm]. Repair Parts List for Figure 5C Item Part Number Qty. Description DD7105093 Bulkhead Fitting, 3/8" NPT x 0.25 Flareless DD7106044 Retaining Ring, External, 13/16" Shaft DD7447037 Gasket, Bulkead, E-Pulse Note: Bulkhead Fitting Kit DD7105093K includes all items listed in the table above.
  • Page 15 Figure 6 - Reservoir and End Cap Assembly Notes: Torque to 60-70 in-lbs [6.8-7.9 Nm]. Torque to 106-133 in-lbs [12-15 Nm].
  • Page 16 Screw-SHCS, Hex, M8 x 1.25 x 20, 8.8, Zinc DD6788025-P03 Reservoir, Machined, 1 Gal, Yellow DD6795870 Foot, Rubber DD7164108 Washer, Rubber Sealing, M6 See Figure 8 Endcap Assembly, Front See Figure 7 Endcap Assembly, Rear DD7290026 Decal, Enerpac Logo, Die-cut S3037 Gasket (See Figure 5, item 19)
  • Page 17 Figure 7 - Rear End Cap Assembly 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]. See Figure 7A...
  • Page 18 Repair Parts List for Figure 7 Item Part Number Qty. Description CCE1040108-7A Lock Washer, External Tooth For M4 DD6786020 End Cap, Rear, Machined, Black DD7017037 Gasket, Endcap DD7030037 Gasket Tape, 3/16" THK x 1/4" W x 12.25" L DD7060960 Cable Assembly, Potentiometer DD7328001 Screw, Thread Forming, M4 x 12 Long DD7331217...
  • Page 19 Figure 8 - Front End Cap Assembly 10 1 Notes: Apply Loctite 2760. See Figure 8A Torque to 8-10 in-lbs [0.9-1.1 Nm]. Install to full depth. Torque to 25-30 in-lbs [2.8-3.4 Nm].
  • Page 20 Repair Parts List for Figure 8 Item Part Number Qty. Description B1240503 O-Ring, 2-1/8 ID, 0.070 W DC8228009 Dome Plug 1/2" DD3883028 Screw M4 x 10 Thread FRM, TRX DD6784020 End Cap, Front, Machined, Black DD6990808 Grommet, Valve, Rubber, 4/3m DD6997020 Cap, Gauge DD7002646...
  • Page 21 Figure 9 - Housing Assembly Notes: 15 5 Apply grease to aid assembly of housing to manifold. Torque to 7-9 ft-lbs [9.4-12.2 Nm]. Apply Loctite 2760, and torque to 55-65 in-lbs [6.2-7.3 Nm]. Install flush with top surface, after adding oil. Orient as shown.
  • Page 22 Repair Parts List for Figure 9 Item Part Number Qty. Description CAE1060055-1A Acorn Nut M6 CCA1042044-1C Wiper Ring CCA627028-5A Screw-Set, Flat, HS, M6 x 1 x 35, 45H, Plain DD7004900 Shaft, Sub Assembly DD7008476 Seal, Rotary 17 x 42 x 7 Figure 9A - Eccentric Kit: DD72575375SR Eccentric is shipped pre-assembled.
  • Page 23 Figure 9B - Pump Housing Kit: DD7005900SR Assemble into center hole of pattern. Flush Notes: Press item 1 and 2 togather flush as shown. 400 psi using 10 ton press. Press using finger. Repair Parts List for Figure 9B Item Part Number Qty.
  • Page 24 Figure 9C - Piston Block Assembly Kits: DD7230900SR & DD7231900SR Manifold Piston Block O-Ring (Fig. 9D, Item 3) Piston (Ø 9mm or Ø 6mm) (Pump manifold viewed from below) Ø 9mm Ø 6mm Ø 6mm Ø 9mm Ø 9mm Ø 6mm Housing IMPORTANT: Side with oil port must face toward manifold.
  • Page 25 Figure 9D - Piston Block Seal Kit: EPPBSK See Figure 5 (item 20) for locations. This kit does not contain manifold gasket DD7319037. Order separately if needed. See Figure 5, item 15. See Figure 9 for location See Figure 9C for locations See Figure 9E for location...
  • Page 26 Figure 10 - Direct Drive Pump Assembly 13 9 See Figure 10A Notes: Torque to 13-16 ft-lbs [18-22 Nm]. Torque to 6-8 ft-lbs [8-11 Nm]. Coin at 300 psi on 10 ton press after assembly, Torque to orientation, 28 ft-lbs [40 Nm] min. Press into manifold 500 psi on 10 ton press.
  • Page 27 Figure 10A - Rebuild Kit, User-Adjustable Relief Valve: DD7234290K These parts not included in kit. Refer to Figure 10. Notes: Torque to 84-108 in-lbs [9.5-12.2 Nm]. Press fit 150-200 psi on 10 ton press, Item 1 onto item 5. Torque to 13-16 ft-lbs [18-22 Nm]. Coin 150 psi on 10 ton press.
  • Page 28 Figure 11 - 3/2 Manual Valve Assembly 3/2 Manual Valve (See Figure 11A) Notes: Apply Loctite 243. Torque to 36-48 in-lbs [4.1-5.4 Nm]. Repair Parts List for Figure 11 Item Part Number Qty. Description B1004016 Ball, 5/32 Dia. CCA513028-5A Screw-Set, Flat, HS, M5 x 0.8 x 8, 45H, Plain...
  • Page 29 Figure 11A - 3/2 Manual Valve Kits: EP2MVSK and XC1MVSK EP2MVSK XC1MVSK Notes: • Valve replacement kit XC1MVSK includes all items shown (1 through 11). Apply Loctite 243. • Valve rebuild seal kit EP2MVSK includes Torque to 21-26 in-lbs [2.4-3.0 Nm]. all items EXCEPT item 10.
  • Page 30 Figure 12 - Hydraulic Schematic Diagram Valve Assembly Pump Assembly User Adj. RV Optional (0-10,500 PSI) Removable Gauge Bypass Pressure (3000 PSI)
  • Page 31 Figure 13 - Electrical Wiring Diagram...
  • Page 32 Figure 14 - Pump Cover Removal/Installation Instructions Rotate Approx. 30˚ Cover Pull Out Reservoir End Cap Hook Reservoir Removal/installation instructions: 1. Remove 2 pump handle screws and washers. 2. Remove pump handle. 3. Open cover and remove wire connections. 4. Rotate cover approximately 30˚ from closed position. 5.
  • Page 33 NOTES:...
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  • Page 36 www.enerpac.com...

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Ep3204jbEp3204jiEp3204je