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]
Torque60-75 in-lbs[6.8-8.5 Nm]
Torque10L, 20L132-148 in-lbs[14.9-16.7 Nm]
Torque40L Only 35-45 in-lbs[4.0-5.1 Nm]
Torque50-60 in-lbs[5.6-6.8 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 to50 - 55 ft-lbs.[68 - 74 Nm]
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]
Torque to15 - 18 ft-lbs.[20 - 24 Nm]
Torque to45 - 47 ft-lbs.[61 - 64 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:
• 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.
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:
• 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)
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
Torque14-18 in-lbs[1.6-2.0 Nm]
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
Torque14-18 in-lbs[1.6-2.0 Nm]
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.
Repair Parts List for Figure 7 Item Part Number Qty. Description
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.
Repair Parts List for Figure 8 Item Part Number Qty. Description
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.
Repair Parts List for Figure 9 Item Part Number Qty. Description
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