Graco 313998J - HFR, Repair - Parts Owner's Manual

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Graco 313998J - HFR, Repair - Parts Owner's Manual | Manualzz

Repair - Parts

HFR

Hydraulic, Plural-Component, Fixed-Ratio Proportioner.

For pouring and dispensing sealants and adhesives and polyurethane foam.

For professional use only. Not for use in explosive atmospheres.

313998J

EN

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information and maximum

working pressure.

Patent Pending

24C352_313998_7

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Product Configurator . . . . . . . . . . . . . . . . . . . . . . . 5

Whip Hose Bundles . . . . . . . . . . . . . . . . . . . . . . 7

Individual B (Blue) Heated Whip Hose . . . . . . . . 7

Individual A (Red) Heated Whip Hose . . . . . . . . 7

B (Blue) Individual . . . . . . . . . . . . . . . . . . . . . . . . 8

A (Red) Individual . . . . . . . . . . . . . . . . . . . . . . . . 9

Hose Bundling Accessories . . . . . . . . . . . . . . . 10

Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B (Blue) Applicator Orifice . . . . . . . . . . . . . . . . . 11

Iso A (Red) Applicator Orifice . . . . . . . . . . . . . . 12

AC Power Pack with S-Head/L-Head Hoses,

Optional Boom . . . . . . . . . . . . . . . . . . . . . . 13

Dispense Valve Interface Kit . . . . . . . . . . . . . . 13

Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump Feed Kits . . . . . . . . . . . . . . . . . . . . . . . . . 14

B (Blue) and A (Red) Feed Tanks . . . . . . . . . . 15

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Important Two-Component Material Information 19

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 19

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 19

Keep Components A (Red) and B (Blue) Separate

19

Moisture Sensitivity of Isocyanates . . . . . . . . . . 20

Foam Resins with 245 fa Blowing Agents . . . . . 20

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 20

A (Red) and B (Blue) Components . . . . . . . . . . . . 20

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 22

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pumpline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Hydraulic Power Pack Repair . . . . . . . . . . . . . . 32

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Base Machine Sub-Assemblies . . . . . . . . . . . . 47

Power Pack Module Sub-Assemblies . . . . . . . . 54

Heater Options . . . . . . . . . . . . . . . . . . . . . . . . . 57

Heater Sub-Assemblies . . . . . . . . . . . . . . . . . . 65

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

DC Power Pack Pressure Adjustment Kit, 24C067

72

DC Power Pack Hydraulic Pressure Adjustment

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Logic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

230V, 1 Phase, No Heat . . . . . . . . . . . . . . . . . . 74

230V, 1 Phase, with Heat . . . . . . . . . . . . . . . . . 75

230V, 3 Phase, No Heat . . . . . . . . . . . . . . . . . . 77

230V, 3 Phase, with Heat . . . . . . . . . . . . . . . . . 78

400V, 3 Phase, No Heat . . . . . . . . . . . . . . . . . . 80

400V, 3 Phase, with Heat . . . . . . . . . . . . . . . . . 81

A (Red) Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

B (Blue) Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

DC Hydraulic Power Pack . . . . . . . . . . . . . . . . . 87

Motor Control Module (MCM) . . . . . . . . . . . . . . 88

Miscellaneous Power . . . . . . . . . . . . . . . . . . . . 90

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Motor Control Module Technical Data . . . . . . . . . 93

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 94

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 94

313998J

Related Manuals

Manuals are available at www.graco.com.

Component manuals in U.S. English:

System Manuals

313997 HFR Setup-Operation

Power Distribution Box Manual

3A0239 Power Distribution Boxes Instructions-Parts

Pumpline Manuals

3A0019

3A0020

Z-Series Chemical Pumps Instructions-Parts

HFR Hydraulic Actuator Instructions-Parts

Feed System Manuals

3A0238

3A0235

3A0395

3A1299

309572

3A0237

Dispense Head Hydraulic Power

Pack Instructions-Parts

Feed Supply Kits

Instructions-Parts

Stainless Steel Tank Feed Systems Instructions-Parts

Carbon Steel Tank Feed Systems

Instructions-Parts

Heated Hose, Instructions-Parts

Heated Hoses and Applicator Kits,

Instructions-Parts

Dispense Valve Manuals

313872

313536

312185

312752

312753

309550

309856

312666

EP

Gun

GX-16, Operation

MD2 Valve, Instructions-Parts

S-Head Operation-Parts

L-Head Operation-Parts

Fusion AP Gun

Fusion MP Gun

Fusion CS Gun

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

313998J

Related Manuals

3

4

Models

Models

See

Product Configurator on page 5 for detailed prod-

uct configuration information.

System

HFR,

Non-Heated

HFR,

Heated

Full Load

Peak Amps

Per Phase*

Voltage

(phase)

55 A

System

Watts†

Primary

Heater Watts

(per heater)

Max Flow

Rate ◆ ** lb/min (kg/min)

Approximate

Output per

Cycle (A+B)** gal. (liter)

Hydraulic

Pressure

Ratio**

Maximum

Fluid Working

Pressure ‡ psi (MPa, bar)

230V (1) 12,650

29 A 230V (3) 11,340

55 A ★ 400V (3) 12,650

116 A 230V (1) 26,680

-50 (22.7) 0.084

1.9:1

3000

(20.7, 207)

73 A 230V (3) 28,600

75 A ★ 400V (3) 28,600

6,000 50 (22.7) 0.084

1.9:1

3000

(20.7, 207)

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

** Values are dependent on installed pump size. Values shown are for largest available pump size.

† 210 ft (64 m) maximum heated hose length, including whip hose.

◆ Flow rate is independent of frequency 50/60 Hz.

approved.

‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of the hoses. If 2000 psi hoses were purchased and installed by Graco, the working pressure for the machine is already setup for the lower 2000 psi (13.8 MPa, 138 bar) working pressure by Graco. If the machine was pur-

chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see Adjust Motor

Control Module Selector Switch on page 34 for the procedure to setup the machine for higher rated hoses. The

change in working pressure is made by changing a rotary switch setting in the Motor Control Module. The minimum pressure rating for hoses is 2000 psi. Do not install hoses with a pressure rating lower than 2000 psi.

313998J

Product Configurator

HFR - A -

Ref.: 1

-

2

-

3

-

4

-

5

-

6

Product Configurator

An example of the product configurator would be the following configurator code.

HFR - A - 1 - 6 - AM - AM - D - AG

Ref.: 1 2 3 4 5 6

The following part number fields apply for the HFR part numbering configurator fields.

Ref. 1

1

2

Ref. 2

1

2

5

6

3

4

Part

Part

Base Unit

HFR Base Unit, Carbon Steel

HFR Base Unit, Stainless Steel

Voltage

230V, 1 phase;

No Heat

230V, 1 phase;

Maximum of Two 6 kW Primary Heater and One

Zone of Hose Heat

230V, 3 phase;

No Heat

230V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two

Zones of Hose Heat

400V, 3 phase;

No heat

400V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two

Zones of Hose Heat

Ref. 3

AJ

AK

AL

AM

AN

AP

AQ

AE

AF

AG

AH

AA

AB

AC

AD

Part B (Blue) Pump †

L010S1 10 cc Stainless Steel

L015S1 15 cc Stainless Steel

L020S1 20 cc Stainless Steel

L025S1 25 cc Stainless Steel

L030S1 30 cc Stainless Steel

L040S1 40 cc Stainless Steel

L050S1 50 cc Stainless Steel

L060S1 60 cc Stainless Steel

L080S1 80 cc Stainless Steel

L100S1 100 cc Stainless Steel

L120S1 120 cc Stainless Steel

L160S1 160 cc Stainless Steel

L005S1 5 cc Stainless Steel

L086S1 86 cc Stainless Steel

L065S1 65 cc Stainless Steel

Ref. 4 Part A (Red) Pump †

Code, Part, and Description for Ref. 4 are the same as Ref. 3

313998J 5

Product Configurator

6

Ref. 5

A

B

C

D

E

F

G

Ref. 6

NN

AA

AB

AC

AD

AE

AF

AG

AH

BA

BB

BC

BD

BE

BF

BG

BH

CA

CB

CC

CD

CE

Part

Part

Primary/Hose Heat

No Heat

A (Red) and B (Blue) Primary Heaters

A (Red) and B (Blue) Primary Heaters, One Zone of Hose Heat

A (Red) and B (Blue) Primary Heaters, A (Red) and B (Blue) Hose Heat

A (Red) and B (Blue) Hose Heat, Carbon Steel

A (Red) and B (Blue) Hose Heat, Stainless Steel

B (Blue) Primary Heaters, B (Blue) Hose Heat

B (Blue) Applicator Hose or High Volume/

Low Volume Hose Bundle Assembly

-No Hose

24D108 Dual Hose, 2:1, 1/4 x 3/8, 5 ft, Stainless Steel,

3500 psi

24D109 Dual Hose, 2:1, 1/4 x 3/8, 10 ft, Stainless Steel,

3500 psi

24D110 Dual Hose, 2:1, 1/4 x 3/8, 25 ft, Stainless Steel,

3500 psi

24D111 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D112 Dual Hose, 1:1, 3/8 x 3/8, 5 ft, Stainless Steel,

3500 psi

24D113 Dual Hose, 1:1, 3/8 x 3/8, 10 ft, Stainless Steel,

3500 psi

24D114 Dual Hose, 1:1, 3/8 x 3/8, 25 ft, Stainless Steel,

3500 psi

24D115 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D116 Dual Hose, 2:1, 1/4 x 3/8, 5 ft, Stainless Steel,

3500 psi

24D117 Dual Hose, 2:1, 1/4 x 3/8, 10 ft, Carbon Steel,

3500 psi

24D118 Dual Hose, 2:1, 1/4 x 3/8, 25 ft, Carbon Steel,

3500 psi

24D119 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D120 Dual Hose, 1:1, 3/8 x 3/8, 5 ft, Carbon Steel,

3500 psi

24D121 Dual Hose, 1:1, 3/8 x 3/8, 10 ft, Carbon Steel,

3500 psi

24D122 Dual Hose, 1:1, 3/8 x 3/8, 25 ft, Carbon Steel,

3500 psi

24D123 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E968 Single Hose, 1:1, 1/4 x 1/4, 10 ft, Carbon Steel,

2000 psi

24E963 Single Hose, 1:1, 1/4 x 1/4, 25 ft, Carbon Steel,

2000 psi

24E964 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

2000 psi

24D124 Single Hose, 2:1, 1/4 x 3/8, 25 ft, Carbon Steel,

2000 psi

24D125 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

2000 psi

CF 24E969 Single Hose, 1:1, 3/8 x 3/8, 10 ft, Carbon Steel,

2000 psi

CG 24D126 Single Hose, 1:1, 3/8 x 3/8, 25 ft, Carbon Steel,

2000 psi

CH 24D127 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

2000 psi

CJ 24E965 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

2000 psi

CK 24E966 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

3500 psi

CL 24D129 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

CM 24D131 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

CN 24E967 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

3500 psi

† Pump size listed is the combined volume dispensed in one extending stroke and one retracting stroke.

313998J

Product Configurator

Whip Hose Bundles

Part Description

24H076 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone

24H077 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone

24H078 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone

24H079 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone

24H080 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Single Zone

24H081 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone

24H082 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Dual Zone

24H083 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone

24H225 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H227 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Single Zone, 3500 psi

24H229 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H231 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Dual Zone, 3500 psi

24H233 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H235 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H237 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H239 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

Individual B (Blue) Heated Whip

Hose

Part Description

24E950 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24E952 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H086 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H088 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H090 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Single Zone, 3500 psi

24H092 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H094 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Dual Zone, 3500 psi

24H096 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

Individual A (Red) Heated Whip

Hose

Part Description

24E949 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24E951 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H085 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H087 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H089 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Single Zone, 3500 psi

24H091 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H093 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel,

Dual Zone, 3500 psi

24H095 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H224 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H226 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Single Zone, 3500 psi

24H228 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H230 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Dual Zone, 3500 psi

24H232 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H234 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H236 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H238 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

313998J 7

Product Configurator

8

Hoses

Part Description

24D111 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D115 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D119 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D123 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E964 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

2000 psi

24D125 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

2000 psi

24D127 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

2000 psi

24E965 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

2000 psi

24E966 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

3500 psi

24D129 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D131 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E967 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

3500 psi

B (Blue) Individual

Part Description

24E902 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

24E904 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi

24E906 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi

24E908 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi

24E910 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

24E912 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi

24E914 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi

24E916 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi

24E918 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

24E920 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi

24E922 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi

24E924 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi

24E926 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi

24E928 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi

24E930 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi

24E932 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi

24E934 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi

24E936 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi

24E938 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi

24E940 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi

24E942 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi

24E944 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi

24E946 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi

24E948 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi

262174 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

262176 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

262178 Unheated Hose, 25 ft, 1/4, Carbon Steel,

3500 psi

262180 Unheated Hose, 50 ft, 1/4, Carbon Steel,

3500 psi

262182 Unheated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

262184 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi

262186 Unheated Hose, 25 ft, 3/8, Carbon Steel,

3500 psi

262188 Unheated Hose, 50 ft, 3/8, Carbon Steel,

3500 psi

262190 Unheated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

262192 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi

262194 Unheated Hose, 25 ft, 1/2, Carbon Steel,

3500 psi

262196 Unheated Hose, 50 ft, 1/2, Carbon Steel,

3500 psi

262237 Unheated Hose, 5 ft, 1/4, Stainless Steel,

3500 psi

262239 Unheated Hose, 10 ft, 1/4, Stainless Steel,

3500 psi

262241 Unheated Hose, 25 ft, 1/4, Stainless Steel,

3500 psi

262243 Unheated Hose, 50 ft, 1/4, Stainless Steel,

3500 psi

262245 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi

262247 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi

262249 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi

262251 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi

262253 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi

262255 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi

262257 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi

262259 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi

313998J

A (Red) Individual

Part Description

24E901 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

24E903 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi

24E905 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi

24E907 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi

24E909 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

24E911 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi

24E913 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi

24E915 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi

24E917 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

24E919 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi

24E921 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi

24E923 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi

24E925 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi

24E927 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi

24E929 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi

24E931 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi

24E933 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi

24E935 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi

24E937 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi

24E939 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi

24E941 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi

24E943 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi

24E945 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi

24E947 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi

262173 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

262175 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

262177 Unheated Hose, 25 ft, 1/4, Carbon Steel,

3500 psi

262179 Unheated Hose, 50 ft, 1/4, Carbon Steel,

3500 psi

262181 Unheated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

262183 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi

262185 Unheated Hose, 25 ft, 3/8, Carbon Steel,

3500 psi

262187 Unheated Hose, 50 ft, 3/8, Carbon Steel,

3500 psi

262189 Unheated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

262191 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi

262193 Unheated Hose, 25 ft, 1/2, Carbon Steel,

3500 psi

262195 Unheated Hose, 50 ft, 1/2, Carbon Steel,

3500 psi

262236 Unheated Hose, 5 ft, 1/4, Stainless Steel,

3500 psi

313998J

Product Configurator

262238 Unheated Hose, 10 ft, 1/4, Stainless Steel,

3500 psi

262240 Unheated Hose, 25 ft, 1/4, Stainless Steel,

3500 psi

262242 Unheated Hose, 50 ft, 1/4, Stainless Steel,

3500 psi

262244 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi

262246 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi

262248 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi

262250 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi

262252 Unheated Hose, 5 ft, 1/2, Stainless Steel,

3500 psi

262254 Unheated Hose, 10 ft, 1/2, Stainless Steel,

3500 psi

262256 Unheated Hose, 25 ft, 1/2, Stainless Steel,

3500 psi

262258 Unheated Hose, 50 ft, 1/2, Stainless Steel,

3500 psi

9

Product Configurator

Hose Bundling Accessories

Part Description

24E953 Air Hose, 5 ft

15B280 Air Hose, 10 ft

15C624 Air Hose, 25 ft

15B295 Air Hose, 50 ft

24E900 Signal Cable, 5 pin, Male/Female, 2.0 meter

24E899 Signal Cable, 5 pin, Male/Female, 4.0 meter

24E898 Signal Cable, 5 pin, Male/Female, 8.5 meter

24E897 Signal Cable, 5 pin, Male/Female, 16.0 meter

24E896 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 2.0 meter

24E895 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 3.0 meter

24E894 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 8.0 meter

24E893 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 15.7 meter

24E954 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll

24E961 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll

261821 Wire Connector, 6AWG (4.11 mm)

24E955 Hose Lacing, 1500 ft (457.2 m) Roll

15B679 Hose Safety Label

Applicator

24K233

24K234

24E876

24E877

24E878

CS00RD

CS01RD

CS02RD

Part

24A084

24A085

24A086

24A090

24A092

24A093

24J187

246100

247007

246101

247019

246102

Description

L-Head 6/10 With Calibration Orifice

L-Head 10/14 With Calibration Orifice

L-Head 13/20 With Calibration Orifice

S-Head 6-625 With Calibration Orifice

S-Head 6-500 L/S With Calibration Orifice

S-Head 6-625 L/S With Calibration Orifice

GX-16, 24:1, Straight, Machine Mount

GX-16, 24:1, Left, Machine Mount

GX-16, No Orifice, Left, Machine Mount

GX-16, No Orifice, Straight, Machine Mount

GX-16, 24:1, Right, Machine Mount

GX-16, No Orifice, Right, Machine Mount

Fusion CS, 1:1 Only, 0.029

Fusion CS, 1:1 Only, 0.042

Fusion CS, 1:1 Only, 0.052

Fusion AP, 1:1 Only, 0.029

Fusion MP, 1:1 Only, 0.029

Fusion AP, 1:1 Only, 0.042

Fusion MP, 1:1 Only, 0.047

Fusion AP, 1:1 Only, 0.052

10

24D513

24D514

24D515

24D516

24D521

24D522

24D523

24D524

24D525

247025

24D500

24D501

24D502

24D503

24D504

24D505

24D509

24D510

24D511

24D512

24D526

24D530

24D531

24D532

24D533

24D534

24D535

24D536

24D537

24E505

257999

24C932

24C933

24C934

LC0058

LC0059

LC0060

LC0295

LC0296

Fusion MP, 1:1 Only, 0.057

Applicator, MD2, 1:1, Soft, Carbon Steel

Applicator, MD2, 1:1, Soft, Carbon Steel, Electric

Applicator, MD2, 1:1, Soft, Carbon Steel, Lever

Applicator, MD2, 1:1, Soft, Stainless Steel

Applicator, MD2, 1:1, Soft, Stainless Steel, Electric

Applicator, MD2, 1:1, Soft, Stainless Steel, Lever

Applicator, MD2, 1:1, Hard, Carbon Steel

Applicator, MD2, 1:1, Hard, Carbon Steel, Electric

Applicator, MD2, 1:1, Hard, Carbon Steel, Lever

Applicator, MD2, 1:1, Hard, Carbon Steel, Pneumatic

Applicator, MD2, 1:1, Hard, Stainless Steel

Applicator, MD2, 1:1, Hard, Stainless Steel, Electric

Applicator, MD2, 1:1, Hard, Stainless Steel, Lever

Applicator, MD2, 1:1, Hard, Stainless Steel,

Pneumatic

Applicator, MD2, 10:1, Soft, Carbon Steel

Applicator, MD2, 10:1, Soft, Carbon Steel, Electric

Applicator, MD2, 10:1, Soft, Carbon Steel, Lever

Applicator, MD2, 10:1, Soft, Stainless Steel

Applicator, MD2, 10:1, Soft, Stainless Steel, Electric

Applicator, MD2, 10:1, Soft, Stainless Steel,

Lever

Applicator, MD2, 10:1, Hard, Carbon Steel

Applicator, MD2, 10:1, Hard, Carbon Steel, Electric

Applicator, MD2, 10:1, Hard, Carbon Steel, Lever

Applicator, MD2, 10:1, Hard, Carbon Steel, Pneumatic

Applicator, MD2, 10:1, Hard, Stainless Steel

Applicator, MD2, 10:1, Hard, Stainless Steel,

Electric

Applicator, MD2, 10:1, Hard, Stainless Steel,

Lever

Applicator, MD2, 10:1, Hard, Stainless Steel,

Pneumatic

MD2 Orifice Adapter Kit

EP Pour Gun, Pistol Grip, 1/4 in. Purge Rod

EP Pour Gun, Machine mount, 1/4 in. Purge Rod

EP Pour Gun, Pistol Grip, 3/8 in. Purge Rod

EP Pour Gun, Machine Mount, 3/8 in. Purge Rod

Mixer Kit, (10) 3/8 in. x 24 Element with Shroud

Mixer Kit, (10) 3/8 in. x 36 Element with Shroud

Mixer Kit, (10) 3/8 in. Combo with Shroud

Mixer Kit, (10) 1/2 in. x 24 Element with Shroud

Mixer Kit, (10) 1/2 in. x 36 Element with Shroud

313998J

LC0079

LC0080

LC0081

LC0086

LC0087

LC0088

Mixer Pack, (50) 3/8 in. x 24 Element

Mixer Pack, (50) 3/8 in. x 24 Element

Mixer Pack, (50) 3/8 in. Combo Element

Mixer Pack, (250) 3/8 in. x 24 Element

Mixer Pack, (250) 3/8 in. x 36 Element

Mixer Pack, (250) 3/8 in. Combo Element

B (Blue) Applicator Orifice

S-Head and L-Head

4.20

4.50

5.00

5.50

6.00

6.50

7.00

Calibrate

1.70

1.80

1.90

2.00

2.50

3.00

3.50

4.00

0.25

0.45

0.5

0.75

0.8

0.85

1

1.1

1.2

1.25

Description Part

Calibrate 24A036

0.25

0.35

24A037

24A038

0.50

0.60

0.70

0.80

24A039

24A040

24A041

24A042

0.90

1.00

1.10

1.20

1.30

1.40

1.50

1.60

24A043

24A044

24A045

24A046

24A047

24A050

24A051

24A052

247761

247762

247763

247764

247765

247766

247767

247811

247848

248858

24A053

24A054

24A055

24A056

24A057

24A058

24A059

24A060

24A061

24A062

24A063

24A064

24A065

24A066

24A067

M0934A-4

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

L-Head Only

For Use With Applicator:

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

313998J

Product Configurator

GX-16

Description

257701

257702

257703

257704

257705

257706

257707

257708

257709

257710

257711

257712

257713

257714

257715

257716

257717

257718

257719

257720

257721

257722

257723

257724

24K682

3.6

4.2

5

5.6

1.9

2

2.4

3.2

1.3

1.4

1.5

1.6

1.65

1.7

1.75

1.8

247867

247868

247869

247870

247871

247872

247873

247874

247859

247860

247861

247862

247863

247864

247865

247866

Part

0.011 in. Orifice

0.013 in. Orifice

0.016 in. Orifice

0.018 in. Orifice

0.020 in. Orifice

0.022 in. Orifice

0.023 in. Orifice

0.024 in. Orifice

0.025 in. Orifice

0.026 in. Orifice

0.028 in. Orifice

0.029 in. Orifice

0.032 in. Orifice

0.035 in. Orifice

0.036 in. Orifice

0.038 in. Orifice

0.039 in. Orifice

0.040 in. Orifice

0.042 in. Orifice

0.043 in. Orifice

0.044 in. Orifice

0.049 in. Orifice

0.052 in. Orifice

0.061 in. Orifice

0.085 in. Orifice

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

EP

Gun

Description

Orifice Kit

0.51 mm Poly

Orifice

0.79 mm Poly

Orifice

1.19 mm Poly

Orifice

Part

24E250

For Use With Applicator:

EP 250, 6 Blue, 6 Red

24C751 EP 250 Poly Side Orifice, Std

24C752 EP 250 Poly Side Orifice, Std

24C753 EP 250 Poly Side Orifice, Std

11

Product Configurator

1.19 mm Poly

Orifice

1.52 mm Poly

Orifice

1.70 mm Poly

Orifice

2.18 mm Poly

Orifice

0.41 mm Poly

Orifice

0.61 mm Poly

Orifice

0.71 mm Poly

Orifice

0.89 mm Poly

Orifice

0.99 mm Poly

Orifice

1.07 mm Poly

Orifice

1.32 mm Poly

Orifice

1.40 mm Poly

Orifice

1.60 mm Poly

Orifice

1.85 mm Poly

Orifice

1.52 mm Poly

Orifice

1.70mm Poly

Orifice

2.18 mm Poly

Orifice

0.41 mm Poly

Orifice

0.61 mm Poly

Orifice

0.71 mm Poly

Orifice

0.89 mm Poly

Orifice

0.99 mm Poly

Orifice

1.07 mm Poly

Orifice

1.32 mm Poly

Orifice

1.40 mm Poly

Orifice

1.60 mm Poly

Orifice

1.85 mm Poly

Orifice

Orifice Kit

0.51 mm Poly

Orifice

0.79 mm Poly

Orifice

24C754 EP 250 Poly Side Orifice, Std

24C755 EP 250 Poly Side Orifice, Std

24C756 EP 250 Poly Side Orifice, Std

24C805 EP 250 Poly Side Orifice

24C806 EP 250 Poly Side Orifice

24C807 EP 250 Poly Side Orifice

24C808 EP 250 Poly Side Orifice

24C809 EP 250 Poly Side Orifice

24C810 EP 250 Poly Side Orifice

24C811 EP 250 Poly Side Orifice

24C812 EP 250 Poly Side Orifice

24C813 EP 250 Poly Side Orifice

24C815 EP 250 Poly Side Orifice

24E251 EP 375, 6 Blue, 6 Red

24C761 EP 375 Poly Side Orifice, Std

24C762 EP 375 Poly Side Orifice, Std

24C763 EP 375 Poly Side Orifice, Std

24C764 EP 375 Poly Side Orifice, Std

24C765 EP 375 Poly Side Orifice, Std

24C766 EP 375 Poly Side Orifice, Std

24C794 EP 375 Poly Side Orifice

24C795 EP 375 Poly Side Orifice

24C796 EP 375 Poly Side Orifice

24C797 EP 375 Poly Side Orifice

24C798 EP 375 Poly Side Orifice

24C799 EP 375 Poly Side Orifice

24C800 EP 375 Poly Side Orifice

24C801 EP 375 Poly Side Orifice

24C802 EP 375 Poly Side Orifice

24C804 EP 375 Poly Side Orifice

12

Iso A (Red) Applicator Orifice

S-Head and L-Head

The A (Red) applicator orifices for the S-Head and

L-Head are the same as the B (Blue) applicator orifices.

See page 11.

GX-16

Description

257701

257702

257703

257704

257705

257706

257707

257708

257709

257710

257711

257712

257713

257714

257715

257716

257717

257718

257719

257720

257721

257722

257723

257724

24K682

Part

0.011 in. Orifice

0.013 in. Orifice

0.016 in. Orifice

0.018 in. Orifice

0.020 in. Orifice

0.022 in. Orifice

0.023 in. Orifice

0.024 in. Orifice

0.025 in. Orifice

0.026 in. Orifice

0.028 in. Orifice

0.029 in. Orifice

0.032 in. Orifice

0.035 in. Orifice

0.036 in. Orifice

0.038 in. Orifice

0.039 in. Orifice

0.040 in. Orifice

0.042 in. Orifice

0.043 in. Orifice

0.044 in. Orifice

0.049 in. Orifice

0.052 in. Orifice

0.061 in. Orifice

0.085 in. Orifice

EP Gun

Description

0.51 mm Iso Orifice

0.79 mm Iso Orifice

1.19 mm Iso Orifice

1.52 mm Iso Orifice

1.70mm Iso Orifice

2.18 mm Iso Orifice

0.41 mm Iso Orifice

0.61 mm Iso Orifice

Part

24D223

For Use With Applicator:

EP 250 Iso Side Orifice, Std

24D224 EP 250 Iso Side Orifice, Std

24D225 EP 250 Iso Side Orifice, Std

24D226 EP 250 Iso Side Orifice, Std

24D227 EP 250 Iso Side Orifice, Std

24D228 EP 250 Iso Side Orifice, Std

24D229 EP 250 Iso Side Orifice

24D230 EP 250 Iso Side Orifice

313998J

0.71 mm Iso Orifice

0.89 mm Iso Orifice

0.99 mm Iso Orifice

1.07 mm Iso Orifice

1.32 mm Iso Orifice

1.40 mm Iso Orifice

1.60 mm Iso Orifice

1.85 mm Iso Orifice

0.51 mm Iso Orifice

0.79 mm Iso Orifice

1.19 mm Iso Orifice

1.52 mm Iso Orifice

1.70 mm Iso Orifice

2.18 mm Iso Orifice

0.41 mm Iso Orifice

0.61 mm Iso Orifice

0.71 mm Iso Orifice

0.89 mm Iso Orifice

0.99 mm Iso Orifice

1.07 mm Iso Orifice

1.32 mm Iso Orifice

1.40 mm Iso Orifice

1.60 mm Iso Orifice

1.85 mm Iso Orifice

24D231 EP 250 Iso Side Orifice

24D232 EP 250 Iso Side Orifice

24D233 EP 250 Iso Side Orifice

24D234 EP 250 Iso Side Orifice

24D235 EP 250 Iso Side Orifice

24D236 EP 250 Iso Side Orifice

24D237 EP 250 Iso Side Orifice

24D238 EP 250 Iso Side Orifice

24D239 EP 375 Iso Side Orifice, Std

24D240 EP 375 Iso Side Orifice, Std

24D241 EP 375 Iso Side Orifice, Std

24D242 EP 375 Iso Side Orifice, Std

24D243 EP 375 Iso Side Orifice, Std

24D244 EP 375 Iso Side Orifice, Std

24D245 EP 375 Iso Side Orifice

24D246 EP 375 Iso Side Orifice

24D247 EP 375 Iso Side Orifice

24D248 EP 375 Iso Side Orifice

24D249 EP 375 Iso Side Orifice

24D250 EP 375 Iso Side Orifice

24D251 EP 375 Iso Side Orifice

24D252 EP 375 Iso Side Orifice

24D253 EP 375 Iso Side Orifice

24D254 EP 375 Iso Side Orifice

Product Configurator

AC Power Pack with

S-Head/L-Head Hoses, Optional

Boom

Part Description

24D829 230V, Boom, L-Head Hoses

24D830 230V, Boom, S-Head Hoses

24D834 400V, Boom, L-Head Hoses

24D835 400V, Boom, S-Head Hoses

24D831 230V, L-Head Hoses, No Boom

24D832 230V, S-Head Hoses, No Boom

24D836 400V, L-Head Hoses, No Boom

24D837 400V, S-Head Hoses, No Boom

24F297 230V, L-Head Application, No Boom, No Hoses

24J912 230V, S-Head Application, No Boom, No Hoses

24F298 400V, L-Head Application, No Boom, No Hoses

24J913 230V, S-Head Application, No Boom, No Hoses

257798 Power Pack GX-16 Connection Kit

24E347 Hydraulic Power Pack Level Sensor Kit

24C872 Hydraulic Power Pack Pressure Gauge Kit

24E348 Hydraulic Power Pack Temperature Sensor

124217 Power Pack Accumulator Charging kit

Dispense Valve Interface Kit

Part Description

24C757 MD2 Valve Solenoid, Machine Mount

24D160 MD2 Valve Solenoid, Remote Mount

24D161 Auto-Fusion Solenoid for Fusion Dispense Valve

24C067 Fusion Gun Pressure Adjust Kit

313998J 13

Product Configurator

Flow Meters

Flow Meter Electronics (Necessary)

Part Description

24J318 Flow Meter Electronics Kit

“A” and “B” Side Flow Meter (One for each side)

Part Description

24J319 S3000 Flow Meter Kit

(0.01 to 0.53 gpm, 50 to 2000 cc per min)

(1 to 1000 cps)

24J320 G3000 Flow Meter Kit

(0.02 to 1.0 gpm, 75 to 3800 cc per min)

(20 to 3000 cps)

24J321 G3000HR Flow Meter Kit

(0.01 to 0.5 gpm, 38 to 1900 cc per min)

(20 to 3000 cps)

24J322 HG6000 Flow Meter Kit

(0.013 to 6.0 gpm, 50 to 22,700 cc per min)

(30 to 1,000,000 cps)

24J323 HG6000HR Flow Meter Kit

(0.007 to 2.0 gpm, 25 to 7571 cc per min)

(30 to 1,000,000,cps)

Flow Meter Calibration Kit (per applicator)

Part Description

24J324 L-Head Flow Meter Calibration Kit

24J325 S-Head Flow Meter Calibration Kit

24J326 P2 Flow Meter Calibration Kit

24J357 GX-16 Flow Meter Calibration Kit

24F227 EP/Fusion Flow Meter Calibration Kit

255247 MD2 1:1 Flow Meter Calibration Kit

255245 MD2 10:1 Flow Meter Calibration Kit

Pump Feed Kits

Part Description

246081 2:1 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246369 H515 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246375 H716 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

24D328 H1050 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

257769

High-Flo

®

(Air/Fluid) Carbon Steel Complete

Supply Pump Kit

24D091 2:1 (Air/Fluid) Stainless Steel Complete Supply

Pump Kit

14

24D092 H515 (Air/Fluid) Stainless Steel Complete Supply

Pump Kit

24D093 H716 (Air/Fluid) Stainless Steel Complete Supply

Pump Kit

24D094 H1050 (Air/Fluid) Stainless Steel Complete Supply Pump Kit

24D095 5:1 Monarch 55G Stainless Steel Complete Supply Pump Kit

24D096 5:1 Monarch 5G Stainless Steel Complete Supply

Pump Kit

257777 High-Flo Stainless Steel Complete Supply Pump

Kit

246366

Husky

515 Pump, Drum with Riser Tube

246367 Husky 716 Pump, Drum with Riser Tube

24D329 Husky 1050 Pump, Drum with Riser Tube

233052 Husky 515 Diaphragm Pump, Drum with Riser

Tube

233057 Husky 716 Diaphragm Pump, Drum with Riser

Tube

24D097 Husky 1050 SS Pump, Drum with Riser Tube

295616 2:1 (Air/Fluid) Stainless Steel Supply Pumps with

Riser Tubes

24D098 5:1 Monarch, 5G, Stainless Steel Supply Pumps with Riser Tubes

24D099 5:1 Monarch, 55G, Stainless Steel Supply Pumps with Riser Tubes

246481 Husky 515 Pump with Carbon Steel Fluid Plumbing

246482 Husky 716 Pump with Carbon Steel Fluid Plumbing

24D332 Husky 1050 Pump with Carbon Steel Fluid

Plumbing

246898 2:1 Supply Pump with Carbon Steel Fluid Plumbing

24D100 Husky 515 Pump with Stainless Steel Fluid

Plumbing

24D101 Husky 716 Pump with Stainless Steel Fluid

Plumbing

24D102 Husky 1050 Pump with Stainless Steel Fluid

Plumbing

24D103 2:1 Supply Pump with Stainless Steel Fluid

Plumbing

24D104 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24D105 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24E396 One 2:1 T-2 Pump, Carbon Steel

24E397 One 2:1 T-2 Pump, Stainless Steel

24E398 One Monarch 5:1 Pump, 5G

24E399 One Monarch 5:1 Pump, 55G

246419 Carbon Steel Riser Tube Assembly

246477 Carbon Steel Return Tube

246483 Air Supply for Feed Pump and Gun

313998J

Product Configurator

247616 Desiccant Dryer

15C381 Desiccant Dryer Cartridge

233048 Drum Pump Accessory Kit

24D106 Stainless Steel Return Tube Accessory Kit

24D107 Stainless Steel Circulation Accessory

24E379 Carbon Steel Circulation Accessory Kit

244053 26 sq. in., 60 mesh, Stainless Steel Fluid Filter

116178 26 sq. in., 30 mesh, Stainless Steel Fluid Filter

Element

116179 26 sq. in., 60 mesh, Stainless Steel Fluid Filter

Element

116180 26 sq. in., 100 mesh, Stainless Steel Fluid Filter

Element

116181 26 sq. in., 200 mesh, Stainless Steel Fluid Filter

Element

213058 36 sq. in., 60 mesh, Carbon Steel Fluid Filter

108106 36 sq. in., 30 mesh, Carbon Steel Fluid Filter Element

108107 36 sq. in., 60 mesh, Carbon Steel Fluid Filter Element

108108 36 sq. in., 100 mesh, Carbon Steel Fluid Filter

Element

108109 36 sq. in., 150 mesh, Carbon Steel Fluid Filter

Element

108110 36 sq. in., 200 mesh, Carbon Steel Fluid Filter

Element

B (Blue) and A (Red) Feed Tanks

Part Description

24D562 38L Tank, No Agitation, Chiller, Desiccant, 2

Level Sensors

24D564 38L Tank, Agitation, Chiller, Desiccant, 2 Level

Sensors

24D565 75L Tank, No Agitation, Chiller, Desiccant, 2

Level Sensors

24C317 75L Tank, Agitation, Chiller, Desiccant, 2 Level

Sensors

24D568 38L Tank, No Agitation, No Level Sensors

24D569 38L Tank, No Agitation, 2 Level Sensors

24D570 38L Tank, Agitation, 2 Level Sensors

24D571 38L Tank, Agitation, Slinger Plate, 2 Level Sensors

24D572 38L Tank, Agitation, Slinger Plate, Heat, Insulation, 2 Level Sensors

24D573 38L Tank, Agitation, Heat, Insulation, 2 Level

Sensors

24D574 75L Tank, No Agitation, No Level Sensors

24D575 75L Tank, No Agitation, 2 Level Sensors

24D576 75L Tank, Agitation, 2 Level Sensors

24D577 75L Tank, Agitation, Slinger Plate, 2 Level Sensors

24D578 75L Tank, Agitation, Slinger Plate, Heat, Insulation, 2 Level Sensors

24D579 75L Tank, Agitation, Heat, Insulation, 2 Level

Sensors

257757 Insulator Blanket for 38L Tank

257758 Insulator Blanket for 75L Tank

257770 Refill Kit For Customer Supplied Feed System

257778 Nitrogen Kit For 1 Tank

257779 Nitrogen Kit For 2 Tanks

257916 Vacuum Pump Kit, 6.9 cfm, 1st, 230V, 1 phase

24D271 3rd Level Sensor Prox Switch Option

LC0097 Desiccant Dryer, 3/8 in. Npt With Adapter And

Cartridge

LC0098 Desiccant Dryer Refill Cartridge

24G952 20gal (75L) Carbon Steel Tank, 2 Level Sensors

24G953 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator

24G955 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator

24G956 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Chiller Control Valve, Heat Exchanger

24G957 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator, Chiller Control Valve, Heat Exchanger

24G959 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator, Chiller Control

Valve, Heat Exchanger

24J209 20gal (75L) Stainless Steel Tank, 3 Level Sensors, Insulated

24J707 20gal (75L) Carbon Steel Tank, 3 Level Sensors,

Insulated

24J243 2gal (7.6L) Stainless Steel Tank

313998J 15

Product Configurator

Additional Accessories

Miscellaneous

Part Description

24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level

Sensor

24C873 Hydraulic Power Pack Manifold Oil Temperature

Sensor

257543 Caster Kit

24F516 IsoGuard Select fluid, 6 quarts

121728 Extension Cable for Advanced Display Module,

4 meter,

255244 Foot Switch with Guard and 4 meter Cable

24F227

EP and Fusion

®

Gun Ratio Check

24F235 25 ft hose extensions for L-Head applicator; material, hydraulic, and signal cables

24F236 50 ft hose extensions for L-Head applicator; material, hydraulic, and signal cables

24F237 25 ft hose extensions for S-Head applicator; material, hydraulic, and signal cable

24F238 50 ft hose extensions for S-Head applicator; material, hydraulic, and signal cable

24K206 Nip Sensor Kit

24H019 Air Inlet Filter for Hydraulic Power Pack

Communications Gateway Module (CGM)

The HFR Communication Gateway Module allows the user to control an HFR through an external control device such as a PLC. The DGM operates in conjunction with the existing Advanced Display Module (ADM) such that both devices can be used to control the machine. See HFR Communication Gateway Module manual for more information

Part Description

24J415 CGM Mounting KIt (Required)

CGMDN0 GCA Gateway Module, DeviceNet Fieldbus

CGMEP0 GCA Gateway Module, EtherNet/IP Fieldbus

CGMPB0 GCA Gateway Module, PROFIBUS Fieldbus

CGMPN0 GCA Gateway Module, PROFINET Fieldbus

Discrete Gateway Module (DGM)

The HFR Discrete Gateway Module allows the user to control an HFR through multiple external control devices such as contact blocks or relays. The DGM operates in conjunction with the existing Advanced Display Module

(ADM) such that both devices can be used to control the machine. See HFR Communication Gateway Module manual for more information

Part Description

24F843 Single DGM Cube with Board

24F844 Two DGM Cubes with Board

24G830 Single DGM Cube

16 313998J

Warnings

+

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

313998J 17

Warnings

18

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately.

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

313998J

Important Two-Component Material Information

WARNING

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

Important Two-Component Material Information

Isocyanate Conditions Keep Components A (Red) and

B (Blue) Separate

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material

MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (Red) and component B (Blue) parts.

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

313998J 19

A (Red) and B (Blue) Components

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture

(such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the IsoGuard Select cylinder filled with Iso-

Guard Select, part 24F516. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for

ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Foam Resins with 245 fa

Blowing Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A (Red) side, but some use ISO on the B (Blue) side. See the following section.

A (Red) and B (Blue) Components

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

Be aware that when standing in front of the manifold on proportioner:

• Component A (Red) is on the left side.

• Component B (Blue) is on the right side.

For all machines:

• The A (Red) side is intended for ISO, hardeners, and catalysts.

• If one of the materials is moisture-sensitive that material should always be on the A (Red) side.

• The B (Blue) side is intended for polyols, resins, and bases.

NOTE: For machines with material volume ratios other than 1:1, the higher volume side is typically the B (Blue) side.

20 313998J

Shutdown

1.

Park pumps.

a.

From the Home screen, press

Standby mode.

and select b.

Press . Material will dispense. Pump will park automatically. Once pump is parked, pump will stop moving.

If a dispense gun with a trigger is installed, pulling the trigger will begin a park operation.

Material will dispense. Continue pulling the trigger until the pump stops moving.

2.

Press the power key on the ADM

3.

Turn main power switch (MP) to OFF position.

4.

Close A (Red) and B (Blue) side fluid supply valves

(FV).

FV ti9883a1

5.

Perform Pressure Relief Procedure on page 22.

6.

Shut down feed pumps as required. See feed pump manual.

313998J

Shutdown

21

Pressure Relief Procedure

Pressure Relief Procedure

1.

Shut off feed pumps and agitator, if used.

2.

Turn PRESSURE RELIEF/DISPENSE valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

Route fluid to waste containers or supply tanks.

Ensure gauges drop to 0.

.

SA

SB ti9879a1

3.

For models with an EP Gun installed, engage gun safety lock.

4.

Relieve pressure in EP Gun or dispense valve. See related manual.

22 313998J

Flushing

Flushing

Flush equipment only in a well-ventilated area. Do not dispense flammable fluids. Do not turn on heaters while flushing with flammable solvents.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common solvents. Use only moisture-free solvents. See

Technical Data on page 92 for wetted components.

See solvent manufacturers information for material compatibility.

• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/DIS-

PENSE valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

SA

. Flush through bleed

SB

N

N ti9880a1

• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water. See

Important Two-Component Material Information on page 19.

313998J 23

Repair

Repair

Pumpline

See Z-Series Chemical Pumps manual, HFR Hydraulic

Driver manuals for more detailed pumpline repair information.

Remove Chemical Pumps

5.

Disconnect the chemical pump inlet and outlet fluid lines. Do not disconnect the fluid manifold inlet line or the fluid line connections at the heater.

Fluid Manifold Inlet

Pump Outlet

This procedure removes the chemical pumps so that replacement parts can be installed. See Z-Series Chemical Pumps manual for replacement parts installation procedure.

1.

For models with heat, turn off all heat including heated hoses and primary heaters.

2.

Flush system, see page 23.

3.

Perform

Shutdown , see page 21.

4.

Remove the front pump shroud.

Pump Inlet

24C352_313998_4g1

24 313998J

Repair

6.

Unthread smaller cylinder from hydraulic driver and slide inside larger cylinder. Use punch slots in lube cylinder to aid rotation if necessary. See F IG . 1.

Lube Cylinder Outlet Fitting

Punch Slot (same on opposite side)

8.

Remove coupler from the A and B side pump shafts.

See F IG . 2.

9.

Unscrew LVDT sensor assembly and spool assembly from pump outlet housing. Wipe off spool

assembly. See F IG . 2.

10. Remove three nuts securing pump to tie rods. See

F IG . 2.

24C352_313998_2g1

Lube Cylinder Inlet Fitting (behind cylinder)

F IG . 1: Lube Cylinder

7.

Remove two shoulder bolts from LVDT collar then

remove collar from B side pump shaft. See F IG . 2.

Pump Outlet Housing

LVDT Sensor Assembly

(behind pump)

LVDT Spool Assembly

LVDT Collar

F IG . 2

Coupler

24C352_313998_2g1

Nuts

313998J 25

Repair

Install Chemical Pumps

Reconnect or install a different size chemical pump to achieve desired ratio.

1.

Install ISO lube cylinder on A side pump. Apply light coating of lubricant on o-rings on outside of small cylinder.

2.

Install nuts on tie rods after the pumps have been installed. Torque to 50-60 ft-lb (68-81 N•m).

3.

Install coupler on A and B side pump shafts.

4.

Install LVDT Assembly.

a.

Apply a very light coat of hydraulic oil on LVDT sensor tube and install through pump outlet housing. Install spool assembly.

b.

Install LVDT collar on coupler and pump shaft.

Ensure that the split on the LVDT collar does not ride in the spool assembly.

c.

Apply thread sealant to shoulder bolts then install in LVDT collar. Torque to 40-50 in-lb

(4.5-5.6 N•m).

5.

After the IsoGuard Select cylinder has been installed on the A side pump, apply pipe sealant on cylinder outlet fitting.

6.

Perform

Prime IsoGuard Select

®

Cylinder

proce-

dure, see page 26.

7.

Reconnect inlet and outlet fluid lines.

Prime IsoGuard Select

®

Cylinder

F IG . 3: IsoGuard Select System

24C352_313998_8g1

Ensure that the IsoGuard Select cylinder outlet faces upward for air to exhaust.

1.

Install IsoGuard Select cylinder inlet fitting and inlet tube into bottom of cylinder. The inlet tube is the tube with a check valve installed in it which points in the direction of flow towards the IsoGuard Select cylinder.

2.

Install IsoGuard Select cylinder outlet fitting and outlet tube into top of cylinder. The outlet tube is the tube with a check valve installed in it which points in the direction of flow away from the IsoGuard Select cylinder.

3.

Remove check valve from end of outlet tube.

4.

Use funnel to pour IsoGuard Select into tube to fill cylinder.

5.

With check valve arrow pointing away from the Iso-

Guard Select cylinder, install check valve in end of outlet tube.

6.

Install tubes into reservoir and install reservoir into holder.

26 313998J

Repair

Remove HFR Hydraulic Driver

155

156

124

125

155

156

180

188

F IG . 4

112

111 104

24C352_313998_5g1

This procedure removes the HFR Hydraulic Driver so replacement parts can be installed. See HFR Hydraulic

Driver manual for replacement parts installation procedure.

1.

Perform Remove Chemical Pumps

procedure, see

page 24.

2.

Disconnect the fluid manifold inlet lines. Do not disconnect the fluid line connections at the heater.

Fluid Manifold Inlet

4.

See F IG . 4. Remove four nuts (188) securing

hydraulic driver to hydraulic power pack. This will also loosen manifold plate (104) from hydraulic driver. Remove manifold plate. Remove hydraulic driver.

Install HFR Hydraulic Driver

This procedure installs the hydraulic driver after replacement parts have been installed and actuator has been reassembled. See HFR Hydraulic Driver manual for replacement parts installation procedure.

1.

Hang the hydraulic driver on the studs. Verify o-rings between driver and hydraulic power pack are installed and lubricated. Secure the driver with nuts and washer at bottom-left and top-right corners.

2.

Install manifold bracket. Secure at top-left and bottom-right corners.

3.

Install pump support brackets, torque to 300 in-lb

(33.9 N•m). This will also install manifold plate (104) to hydraulic driver.

4.

Connect fluid manifold inlet lines.

5.

Perform Install Chemical Pumps procedure, see page 26.

24C352_313998_4e1

3.

Remove pump support brackets. Each bracket is secured with three screws at the base frame and two screws at the manifold bracket.

313998J 27

Repair

Remove PowerHouse Pumpline

4.

Remove lube cylinder inlet and outlet fittings. Let cylinder drain.

Punch Slot (same on opposite side)

Lube Cylinder Outlet Fitting

The Hydraulic Power Pack must be removed to perform some Hydraulic Power Pack repair procedures. In order to remove the Hydraulic Power Pack, the PowerHouse

pumpline must be removed. See Hydraulic Power

Pack Repair starting on page 32 for more information.

1.

Perform

Shutdown procedure, see page 21.

2.

Flush the system, see page 23.

3.

Disconnect the chemical pump inlet, pump outlet, and fluid manifold inlet lines. Do not disconnect the fluid line connections at the heater.

Fluid Manifold Inlet

Pump Outlet

24C352_313998_8e1

Lube Cylinder Inlet Fitting

F IG . 5: Lube Cylinder, Viewed from Rear Left of

Machine

5.

See F IG . 6. Remove four screws (107) securing pumpline to hydraulic power pack. This will also loosen manifold plate (104) from hydraulic driver.

111 104

Pump Inlet

24C352_313998_4e1

155

156

124

125

155

156

180

188

F IG . 6

112

24C352_313998_5g1

28 313998J

6.

While supporting the pumpline, remove the three bolts on each side of the machine securing the pump support brackets to the machine base. See

F IG . 7. Remove pumpline.

F IG . 7

24C352_313998_4e1

Repair

313998J 29

Repair

Install PowerHouse Pumpline

The Hydraulic Power Pack must be removed to perform some Hydraulic Power Pack repair procedures. In order to remove the Hydraulic Power Pack, the PowerHouse pumpline must be removed. This procedure is for installing the PowerHouse pumpline at the end of the Hydraulic Power Pack Repair procedure. See

Hydraulic Power

Pack Repair starting on page 32 for more information.

1.

While supporting the pumpline, install the three bolts on each side of the machine securing the pump support brackets to the machine base. See

F IG . 7. Torque to 150 in-lb (16.9 N•m).

2.

See F IG . 6. Align manifold plate (104) with hydraulic driver. Align hydraulic driver with hydraulic power pack. Install four screws (107) securing hydraulic driver to hydraulic power pack. This will also install manifold plate (104) to hydraulic driver. Torque to

300 in-lb (33.9 N•m).

3.

Install lube cylinder inlet and outlet fittings. See F IG .

5. Apply thread sealant to threads.

4.

Perform

Prime IsoGuard Select

®

Cylinder

proce-

dure, see page 26.

5.

Connect the chemical pump inlet, pump outlet, and fluid manifold inlet lines.

Fluid Manifold Inlet

Pump Outlet

30

Pump Inlet

24C352_313998_4e1

313998J

Repair

313998J 31

Repair

704

3

11

714

10

2

709

12

2

712

12

713

10

708 3 11

724

9

13

Hydraulic Power Pack Repair

735

8 11

715

2

12

716

10

734

26

721, 722

5 11

746

11

718

717

2

12

719

706 5

705

710

2

12

711

744

721,

727 4 11

723

9

12

725

10

745

14

731

7

11

732

6

11

733 730 728

6

11

15

729

701

702

726

738

11

8

737

702

.30

1

+.01

-.00

707

257442_3A0998_1j

731

24

720

1

Assemble coupler to specified dimensions prior to mounting assembly to housing.

2

Torque to 40 ft-lb (54 N•m).

3

Torque to 35 ft-lb (47 N•m).

4

Torque to 20 ft-lb (27 N•m).

5

Torque to 15 ft-lb (20 N•m).

6

Torque to 10 ft-lb (14 N•m).

7

Torque to 58 in-lb (6.5 N•m).

F IG . 8: Hydraulic DC Power Pack

702 1

8

Torque to 34 in-lb (3.8 N•m).

9

Torque 1/4 turn past hand-tight.

10 Apply PTFE tape on installation end only.

11 Apply sealant to threads.

12 Apply light coating of lubricant to seals.

13 Fill reservoir with hydraulic fluid.

14 Orient with airflow arrow pointing toward mounting bracket.

15 Prior to installing Ref. 728 into Ref. 726, install Ref. 729 into Ref. 728 and adjust head 1/8 in. from surface.

24 Align fan plug as shown.

26 Apply thermal lubricant to contact side.

32 313998J

Repair

Remove Hydraulic Power Pack Shroud

1.

Remove four screws from base of shroud.

2.

Lift shroud off of Hydraulic Power Pack.

Install Hydraulic Power Pack Shroud

NOTICE

Do not over-torque any item that threads into the hydraulic tank. This will strip the threads and require tank replacement.

3.

Remove four screws (732) connecting fan to mounting plate.

4.

Remove fan and install new fan.

5.

Install four screws (732) connecting fan to Motor and Motor Control Module.

6.

Install Hydraulic Power Pack Shroud , see proce-

dure on this page.

Remove Motor Control Module

1.

Place shroud on top of Hydraulic Power Pack.

2.

Install four screws securing shroud to hydraulic tank.

Replace Hydraulic Filter

Filter is located at right rear of hydraulic power pack.

See F IG . 8 on page 32.

NOTICE

If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result.

1.

Perform Shutdown procedure, see page 21.

2.

Use compressed air to remove any loose debris around the hydraulic filter.

3.

Remove new filter from wrapping.

4.

Apply a light coat of hydraulic fluid to the o-ring on the face of the hydraulic filter.

5.

Being careful not to allow any debris into the hydraulic tank remove old filter from tank then quickly install new filter.

Replace Fan

See F IG . 8 on page 32.

1.

Perform Shutdown procedure, see page 21.

2.

Remove Hydraulic Power Pack Shroud

, see procedure on this page.

3.

Remove four screws (732) connecting fan to Motor and Motor Control Module. Remove fan and mounting plate.

4.

Note the location of each Motor Control Module cable then remove all electrical cables on the left and right sides of the Motor Control Module.

5.

Remove six screws (729) securing Motor Control

Module in place.

6.

Slowly and carefully slide the Motor Control Module up until the cable on the bottom of the Motor Control

Module can be accessed and removed. Disconnect the cable.

7.

Slide the Motor Control Module up and remove.

See F IG . 8 on page 32.

1.

Perform Shutdown procedure, see page 21.

2.

Remove Hydraulic Power Pack Shroud

, see procedure on this page.

313998J 33

Repair

Adjust Motor Control Module Selector

Switch

NOTICE

If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the

Motor Control Module or damage may occur.

The Motor Control Module uses an 8-position selector switch (S) to set system maximum working pressure.

See F IG . 9.

The system can be configured to run in two pressure ranges:

• 0-3000 psi (0-20.7 MPA, 0-207 bar): For systems will all components rated to 3000 psi maximum working pressure or higher.

• 0-2000 psi (0-13.8 MPA, 0-138 bar): For systems with one or more component rated less than

3000 psi maximum working pressure. For example, if the dispense valve is rated to 2500 psi, then the

0-2000 psi range must be used.

NOTE: The Motor Control Module selector switch (S) position #1 sets the system to 2000 psi maximum working pressure. Selector switch position #3 sets the system to 3000 psi maximum working pressure.

The factory setting for the Motor Control Module selector switch is position #1 to set the machine to 2000 psi if the machine is shipped with no hoses or hoses rated to

2000 psi maximum working pressure. If the machine is shipped with hoses rated to 3000 psi maximum working pressure or higher then the factory setting for the selector switch is position #3 to set the machine to 3000 psi.

The selector switch position will be properly set at the factory for new systems. When a motor control module is replaced, the selector switch must be set to the correct setting by the user prior to initial startup.

To change the maximum working pressure rating of the system in the field, all outlet components including hoses and dispense valve must be rated at or above the new system maximum working pressure rating. For example, if the new system rating will be 3000 psi, all system components must be rated to at least 3000 psi maximum working pressure.

• Do not install components rated to less than the highest pressure in the selected pressure range.

For example, if the 0-2000 psi range is selected do not install items rated less than 2000 psi. If the

0-3000 psi range is selected do not install items rated less than 3000 psi. Doing so may lead to overpressurization and ruptured components.

• High-pressure fluid from ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

To set the Motor Control Module selector switch:

1.

Turn machine power off.

2.

Remove the access cover (D). See F IG . 9.

3.

Set the selector switch (S).

4.

Install access cover (D).

F IG . 9

257396_3b9905_04b

D

S

34 313998J

Repair

Install Motor Control Module

This procedure starts assuming that the old Motor Control Module is removed from the machine. See

Remove

Motor Control Module procedure, see page 33.

See F IG . 8 on page 32.

1.

Perform Adjust Motor Control Module Selector

Switch procedure on page 34.

NOTICE

Motor Control Module selector switch position must be set prior to startup of Motor Control Module or damage may occur.

2.

Slide the Motor Control Module into the slot.

3.

Attach the cable on the bottom of the Motor Control

Module.

4.

Install the six screws (729) securing Motor Control

Module in place.

5.

Install electrical cables on left and right sides of the

Motor Control Module.

6.

Install four screws (732) connecting fan to Motor and Motor Control Module. Install fan and mounting plate.

7.

Install Hydraulic Power Pack Shroud

, see proce-

dure on page 33.

Remove Hydraulic Power Pack

This procedure removes the hydraulic power pack from the machine as a single unit to enable further disassembly. User must purchase three 5/16-18 eye-bolts capable of holding 300 lb to perform this procedure.

See F IG . 8 on page 32.

1.

Perform Shutdown procedure, see page 21.

2.

Perform Remove Hydraulic Power Pack Shroud

,

see procedure on page 33.

3.

Perform Remove Motor Control Module

proce-

dure, see page 33.

4.

Perform Remove PowerHouse Pumpline

proce-

dure, see page 28.

5.

Disconnect heat exchanger inlet hose and fitting from elbow fitting (617). Disconnect heat exchanger outlet hose and fitting from elbow fitting (025).

6.

Remove the two bolts (746) from the fluid housing (703) and replace each with a strong

5/16-18 thread eye-bolt. Install a third strong

5/16-18 eye-bolt as indicated. See F IG

. 10. See F IG .

8 on page 32 for full hydraulic power pack view.

703 746

746

Install third eye-bolt here

F IG . 10

257442_313998_1j1

The hydraulic power pack weighs up to 300 lb. To avoid serious injury due the hydraulic power pack falling, secure the hydraulic lift when raising the hydraulic power pack.

7.

Run a rope through the three eye-bolts and between the motor and the Motor Control Module. Secure to a hydraulic lift.

8.

Remove the four bolts (604) and washers (603) securing the tank to the electrical enclosure. See

Power Pack Module on page 52.

9.

Lift the hydraulic power pack and place on a sturdy location capable of supporting up to 300 lbs.

NOTICE

If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result.

313998J 35

Repair

Install Hydraulic Power Pack Replace Tank Gasket, Tank

NOTICE

If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result.

NOTICE

Do not over-torque any item that threads into the hydraulic tank. This will strip the threads and require tank replacement.

This procedure assumes the Hydraulic Power Pack has been removed from the machine and is assembled except for the Motor Control Module.

See F IG . 8 on page 32.

1.

Run a rope through the three eye-bolts and between the Motor and the Motor Control Module. Secure to a hydraulic lift.

2.

Lift the Hydraulic Power Pack and place onto the electronic enclosure.

3.

Align the holes with the tank then install finger-tight the four bolts (604) and washers (603) securing the tank to the electrical enclosure. Torque to 10 ft-lb

(14 N•m).

4.

Remove rope and lift.

5.

Remove eye-bolts. Install original bolts (746) into

fluid housing (703). See F IG . 10.

6.

Perform Install PowerHouse Pumpline procedure, see page 30.

7.

Perform

Install Motor Control Module procedure, see page 35.

8.

Connect heat exchanger inlet hose and fitting to elbow fitting (617). Connect heat exchanger outlet hose and fitting to elbow fitting located on rear right

face of tank. See Power Pack Module on page 52.

See F IG . 8 on page 32.

1.

Perform

Remove Hydraulic Power Pack

proce-

dure, see page 35.

2.

Remove hex head cap screws (722) securing hydraulic housing (703) to tank (720). Carefully remove motor (701) and hydraulic housing assembly from tank.

3.

Remove tank gasket. If tank is damaged, replace tank.

4.

Install thrust washers (721) onto hex head cap screws (022). Apply pipe sealant to threads of screws. Align tank gasket (719), hydraulic housing, and tank (720) then install screws. Torque to

15 ft-lb (20 N•m).

5.

Perform

Install Hydraulic Power Pack

procedure,

see page 36.

Remove Motor

NOTICE

Do not over-torque any item that threads into the hydraulic tank. This will strip the threads and require tank replacement.

See F IG . 8 on page 32.

1.

Perform

Remove Hydraulic Power Pack

proce-

dure, see page 35.

2.

Remove four hex head cap screws (722) securing hydraulic housing (703) and motor (701) to tank (020). Carefully remove motor and hydraulic housing assembly from tank.

3.

Remove four hex head cap screws (727) connecting mounting bracket (726) to motor.

4.

Remove four socket head cap screws (704) securing motor to hydraulic housing. Carefully remove motor from hydraulic housing.

36 313998J

Repair

5.

Loosen set screw for motor coupler (702) then remove motor coupler.

Install Motor

Remove Hydraulic Gear Pump

See F IG . 8 on page 32.

1.

Use four hex head cap screws (727) and thrust washers (721) to install Motor Control Module mounting bracket (726) onto motor (701).

2.

Install motor coupler (702) onto motor (701). Coupler must be 0.65-0.67 in. from the face of the motor. Torque motor coupler set screw to 15 ft-lb

(20 N•m).

3.

Install spider coupler (707) into motor coupler.

4.

Use four socket head cap screws (704) to attach hydraulic housing (703) to motor. Be sure to align teeth of gear coupler with the teeth of the motor coupler. Apply pipe sealant to threads of screws. Torque to 35 ft lb (47 N•m).

NOTICE

Do not over-torque any item that threads into the hydraulic tank. This will strip the threads and require tank replacement.

See F IG . 8 on page 32.

1.

Perform Remove Hydraulic Power Pack procedure, see page 35.

2.

Remove hex head cap screws (722) securing hydraulic housing (703) to tank. Carefully remove motor (701) and hydraulic housing assembly.

3.

Remove tube (711).

4.

Remove elbow fittings (710, 712) from gear pump (705).

5.

Remove two hex head cap screws (708) securing gear pump to hydraulic housing.

6.

Remove spider coupler (707).

7.

Loosen set screw for gear coupler (706) then remove gear coupler from gear pump.

Install Hydraulic Gear Pump

5.

Install thrust washers (721) onto hex head cap screws (722). Apply pipe sealant to threads of screws. Align tank gasket (719), hydraulic housing, and tank (720) then install screws. Torque to 15 ft-lb

(20 N•m).

6.

Perform Install Hydraulic Power Pack procedure, see page 36.

See F IG . 8 on page 32.

1.

Install gear coupler (706) onto gear pump (705).

Coupler must be 0.12 to 0.13 in. from the face of the gear pump. Torque gear coupler set screw to 15 ft-lb

(20 N•m).

2.

Install spider coupler (707) into gear coupler.

3.

Use two hex head cap screws (708) to attach gear pump to hydraulic housing. Be sure to align teeth of gear coupler with the teeth of the motor coupler.

Torque screws to 35 ft-lb (47 N•m).

4.

Apply a light coat of lubricant to seals of elbow fittings (710, 712). Install elbow fittings into gear

pump. See F IG . 8 on page 32. for fitting alignment.

Torque both fittings to 40 ft-lb (54 N•m).

313998J 37

Repair

5.

Apply a light coating of lubricant to seals of tube (711). Install tube (711) onto elbow fitting (710) and straight fitting (709). Hand-tighten then use wrench to tighten 90 degrees further.

NOTICE

Do not over-torque any item that threads into the hydraulic tank. This will strip the threads and require tank replacement.

6.

Install thrust washers (721) onto hex head cap screws (722). Apply pipe sealant to threads of screws. Align tank gasket (719), hydraulic housing, and tank (720) then install screws. Torque to 15 ft-lb

(20 N•m).

7.

Perform

Install Hydraulic Power Pack

procedure,

see page 36.

38 313998J

Parts

Base Machine

175

127

193

Parts

110

123

147

112

F IG . 11: Base Machine, Image 1 of 6

313998J

24C352_313998_7

39

Parts

155

156

124

125

155

156

180

188 1

112 2

111

187

1

Torque to 300 in-lb (34 N•m).

2

Torque to 79 in-lb (8.9 N•m).

3

Torque to 62 in-lb (7.0 N•m).

4

Torque to 150 in-lb (17 N•m).

104

105, 150

171

110

189

3

151, 165

24C352_313998_5g

See Power Distribution

Box manual

110

4

F IG . 12: Base Machine, Image 2 of 6

24C352_313998_3g1

40

24C352_313998_6g1

103

313998J

157

115

114

121

158

154

110

Parts

132

1

24C352_313998_8g

161

102

101

F IG . 13: Base Machine, Image 3 of 6

1

Torque to 40-50 ft-lb (54-68 N•m).

176

129

128

130

110

108

313998J 41

Parts

152, 153

168

110

160

146

116, 117

118, 119, 120

168

132 3

109

110

163 2

162 1

F IG . 14: Base Machine, Image 4 of 6

1

Apply sealant to pipe threads.

2

Do not apply sealant to threads.

3

Torque to 40-50 ft-lb (54-68 N•m).

42

24C352_313998_4g

313998J

Parts

132 7

166

183

153

143 2

141 3

131 1

106

131 1

139

136 6

135 6

134

144, 145

4

183

153

166

132

7

122

4

133

144, 145 4

135

6

126

167

156

143 2

24C352_313998_9e

126

122

4

140

5

142

1

Torque to 50-60 ft-lb (68-81 N•m).

2

Torque to 40-50 ft-lb (54-68 N•m).

3

Assemble to orientation shown.

4

Apply sealant to pipe threads.

5

Apply a very thin coating of lubricant to the sensor tube.

6

Apply a thin coating of lubricant.

7

Snug only enough to hold pump module in place until final torque is applied later in assembly.

F IG . 15: Base Machine, Image 5 of 6

313998J 43

Parts

195

196

194

F IG . 16: Base Machine, Image 6 of 6

24C352_313998_11

44 313998J

Parts

112

114

115

116

117

118

119

120

121

122

Ref

101

102

103

104

105

106

107

108

109

110

111

Part

112395

24E170

103413

258771

16E281

123

124

125

126

111800

255629

289999

113796

24E647

255235

120060

122168

110755

100016

121253

24E451

123111

C20487

24C234

117502

16A361

117677

16A362

255159

134

135

136

139

140

141

142

143

144

127

128

129

130

131

132

133

24B855

297216

295187

258707

15X519

101712

15Y596

15Y595

C20278

122892

125966

258669

16A509

258704

119999

191892

Description

MODULE, power pack, enclosure, assy

FRAME, pallet

SCREW, cap, flange head

BRACKET, manifold

PACKING, o-ring

DRIVER, hydraulic, horizontal

STUD, threaded, 3/8-16 x 6.0 long

BRACKET, pump, left

BRACKET, pump, right

SCREW, cap, hex head

MANIFOLD, inlet, fluid, h-controller

MANIFOLD, fluid, sst

SCREW, flanged, hex hd

BRACKET, ADM mounting

BRACKET, mounting, assembly

CLIP, speed, tubular

RIVET, aluminum

WASHER, plain

WASHER, lock

KNOB, display adj.

MODULE, ADM, w/ USB

FITTING, nipple, hex, 3/4 NPT, 3k, ss

FITTING, nipple, hex

COVER, shroud, front

FITTING, reducer #5 x #8 (JIC)

FITTING, reducer, #5 x #8 (JIC), sst

FITTING, reducer #6 x #10 (JIC)

FITTING, reducer, #6x #10 (JIC), sst

KIT, assembly, pair, inlet

KIT, pair, inlet, sst, no filter

COVER, assembly

BRACKET, reservoir, lube

SCREW, machine, ph, 8 x 3/8

RESERVOIR, bottle, assembly

ROD, tie, 12 lng, 5/8-11 unc

NUT, lock

HOUSING, iso lube, telescoping

HOUSING, iso lube, telescoping

PACKING, o-ring

O-RING, fluoroelastomer, 038

CLIP, hairpin

SENSOR, assembly

COLLAR, sensor, lvdt

SPOOL, assembly, lvdt

BOLT, shoulder

FITTING, elbow, street, 90 deg

313998J

1

2

1

1

2

1

1

1

2

6

1

1

6

1

1

2

1

1

2

2

1

1

4

1

1

Quantity

BASE, fixed ratio, non-stainless

1

BASE, fixed ratio, stainless

1

1

1

1

4

1

2

1

5

15

1

1

1

1

4

15

1

2

1

5

1

1

2

2

1

1

1

4

1

1

2

2

1

1

1

1

1

1

1

1

2

1

1

2

1

1

1

2

6

1

1

6

1

2

1

1

45

Parts

Ref Part

145 116746

146 24C235

147 24C153

150 123313

151 123366

152 16A093

153 121399

154 121002

155 205447

156 054826

157 123798

Description

FITTING, barbed, plated

COVER, pump

COVER, heat exchanger

VALVE, directional, hydraulic

SCREW, shc, 10-24 x 1.125, s

SENSOR, pressure, fluid outlet

PACKING, o-ring 012 fx75

CABLE, can, female / female 1.5m

COUPLING, hose

TUBE, plastic

CABLE, m8, 4-pin, mf, 1m, molded

158 120999 RESISTOR, terminal, turck rke 57-tr2

160 15H108

▲ LABEL, pinch point

161 COVER, enclosure, slotted, asmbly

162 122970

163 123140

164

165

166 121312

123108

167 123112

168 121581

170 054175

171

173 24F516

174

FITTING, adapter, JIC (08) x sae (08), m

FITTING, cap, 1/2 JIC , cs

SEALANT, pipe, sst

SEALANT, anaerobic

FITTING, elbow, sae x JIC

FITTING, elbow, 3/4 sae x 1/2 JIC, sst

FITTING, t, 1/4 tube, prestolock, brass

HARNESS, I/O, M12 x M12

TUBE, nylon, rd

LUBRICANT, grease

FLUID, ISO-Guard Select, 6 qt.

LABEL, identification

175 LABEL, HFR metering system

176 15M511

LABEL, warning, eng/span/fre

177 FLUID, hydraulic (gallon)

178 117792 GUN, grease, 3 oz

179 117773

180 555621

181 15V551

187 16E277

188 U90126

189 071019

193 124804

194 15U075

195 24H018

196 16G251

199 16H821

LUBRICANT, grease, food grade

WASHER, 3/8 plain flat

SHIELD, membrane, ADM

BUSHING, flanged, 1.0 x 1.25 x 1.0

NUT, hex, 3/8-16, ms, gr8

ADHESIVE, anaerobic

SCREW, hex, slotted

SCREW, cap, bh, 8-32 x 0.37

FILTER, air

HOUSING, filter

TOKEN, software upgrade

† See Z-Series Chemical Pumps manual for parts information.

▲ Replacement Danger and Warning labels, tags and cards are available at no cost.

0.100

4

4

1

1

4

9

1

1

1

4

4

1

Quantity

BASE, fixed ratio, non-stainless

2

BASE, fixed ratio, stainless

2

1

2

2

4

1

4

1

1

10

1

1

1

10

1

1

1

1

2

2

4

1

4

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

2

1

1

1

0.100

4

4

1

1

4

9

1

1

1

4

4

1

46 313998J

Base Machine Sub-Assemblies

HFR Hydraulic Driver 258771

See the HFR Hydraulic Driver manual 3A0020 for parts information.

Z-Series Chemical Pumps

See the Z-Series Chemical Pumps manual for parts information.

Power Distribution Boxes

See the Power Distribution Boxes manual for parts information.

Parts

313998J 47

Parts

Non-Stainless Steel Fluid Manifold 255629,

Stainless Steel Fluid Manifold 289999

2 308

1

3

302

314

302b

2

302a

306 3

318

303

315

304

307 3

301

4 312

4 313

317

255629_313998_1a

314

1 Torque to 355-395 in-lb (40.1-44.6 N•m)

2

Apply sealant (113500) to threads.

3

Valve must be closed with handle position as shown on drawing.

4 Adapter fittings for hoses are included in base machine parts. See

Base Machine starting on page 39 for part numbers.

**Apply PTFE or thread sealant to tapered threads.

48 313998J

Ref

301

Assembly

255629

247837

302† 247824

Part

Assembly

289999

24E307

24E306

302a† 158674

302b† 247779

303

304

102814

162453

158674

247779

112941

166846

306

307

247788

247789

308† 112309

312 117556

313

314

315

117557

121312

100840

247788

247789

112309

123106

123107

123108

166866

317

318†

189285

150829

189285

150829

Description

MANIFOLD, fluid

Qt y

VALVE, drain cartridge

. O-RING

. SEAL, seat, valve

GAUGE, pressure, fluid 2

FITTING, 1/4 npsm x 1/4 npt 2

1

1

1

2

HANDLE, red

HANDLE, blue

1

1

NUT, hex, jam

NIPPLE, #8 JIC x 1/2 npt

NIPPLE, #10 JIC x 1/2 npt

ELBOW, 90 degrees

ELBOW, street, 1/4 npsm x

1/4 npt

LABEL, caution

SPRING, compression

1

2

1

2

2

1

2

Replacement Warning labels, signs, tags, and cards are available at no cost.

† Included in the following complete valve kits*:

Assembly 255629

A (Red) Valve Kit (left/red handle) 255149.

B (Blue) Valve Kit (right/blue handle) 255150.

Valve Set Kit (both handles and grease gun) 255148.

Assembly 289999:

A (Red) Valve Kit (left/red handle) 24E309.

B (Blue) Valve Kit (right/blue handle) 24E310.

Valve Set Kit (both handles and grease gun) 24E308.

* Complete valve kits also include thread sealant.

(Purchase kits separately).

Parts

313998J 49

Parts

Non-SST Fluid Inlet Assemblies, 255159

A Side Shown

401

405

406

412

414

413

402

401

404

403

407

408

409

410 ti9841a1

** Apply sealant to all non-swivel fittings.

Ref Part Description

401 118459 UNION, swivel; 3/4 npt(m) 3/4

402

403 npsm(f)

VALVE, ball; 3/4 npt (FBE)

NIPPLE; 3/4 npt

404 247503 MANIFOLD, strainer, inlet

405 102124 THERMOMETER, dial

406 120300 GAUGE, pressure, fluid

407 180199 ELEMENT, filter; 20 mesh (standard)

408 15H200 GASKET, strainer; PTFE

409 15H199 PLUG, strainer

410 PLUG, pipe; 3/8 npt

411 296178 UNION, swivel; 3/4 npt(m) x 1/2 npt(f); A side only

412 15D757 HOUSING, thermometer

413 253481 GUARD, gauge

414 111800 SCREW, cap, hex hd, 5/16-18 x

415

5/8 in. (16 mm)

SEALANT, pipe, sst

Qty

3

2

2

2

2

2

2

2

1

2

2

2

2

4

1

50 313998J

SST Fluid Inlet Assemblies

501

B (Blue) Side Assembly shown,

A (Red) Assembly also included

503

502

508

504

501, 512

** Apply sealant and tape to all non-swiveling threads.

24D285_313998_1a

506

507

505,

509

Ref Part

501 112268

502 512485

503 123111

504 501118

505 102124

506 120300

507 500352

508 516308

509 15D757

510

511

512 123980

Description

SWIVEL, union

VALVE, ball, sst

FITTING, nipple, hex, 3/4npt,

3k, ss

FITTING, tee

THERMOMETER, dial

GAUGE, press, fluid,

(waterborne)

BUSHING, hex hd, sst

FITTING, bushing, reducer, sst

HOUSING, thermometer, viscon hp

SEALANT, pipe, sst

TAPE, tfe, sealant

FITTING, straight, swivel, 1/2 x 3/4, FM, sst

Qty

3

2

4

2

2

2

4

2

2

1

1

1

Parts

313998J 51

Parts

Power Pack Module

608

609 607

604

1

2

603

606

605

24C273_313998_1d 610

1 Torque to 10 ft-lb (14 N•m).

2 Apply sealant to threads.

24C273_313998_2d

601

Ref Part Description

601

602

ENCLOSURE, frame, painted

MODULE, hydraulic power

603 U90205 WASHER, flat, 3/8, 0.41 x 1.25 x 0.13, ms

604 802277 SCREW, machine (matrix)

605 COVER, enclosure, heat exch, assy

606 111800 SCREW, cap, btn hd (matrix)

607 15Y935 TUBE, heat exchanger, outlet

608 24C621 HOSE, heat exchanger, inlet

609 123528 FITTING, elb, swvl, 45, jic08, fm, 6k

610 24C518 CORD, fan, heat exch, mcm

611 SEALANT, anaerobic

612 189930

LABEL, caution, electric shock (not shown)

613 15H108 ▲ LABEL, pinch point (not shown)

Replacement Danger and Warning labels, tags and cards are available at no cost.

1

1

2

1

1

1

2

1

Qty

1

1

4

4

1

52 313998J

Parts

313998J 53

Parts

Power Pack Module Sub-Assemblies

704

3

11

714

10

2

709

12

2

712

12

713

10

708 3 11

724

9

13

Hydraulic DC Power Pack Module

735

8 11

715

2

12

734

26

703

721, 722

5 11

746

11

716

10

718

717

2

12

719

706 5

705

710

2

12

711

744

721,

727

4 11

723

9

12

725

10

745

14

731

7

11

732

6

11

733 730 728

6

11

15

729

701

726

702

738

11

8

737

706

.30

1

+.01

-.00

707

_313998_1j

731

24

720

748, 749

1

Assemble coupler to specified dimensions prior to mounting assembly to housing.

2

Torque to 40 ft-lb (54 N•m).

3

Torque to 35 ft-lb (47 N•m).

4

Torque to 20 ft-lb (27 N•m).

5

Torque to 15 ft-lb (20 N•m).

6

Torque to 10 ft-lb (14 N•m).

7

Torque to 58 in-lb (6.5 N•m).

F IG . 17: Hydraulic DC Power Pack

736

702 1

8

Torque to 34 in-lb (3.8 N•m).

9

Torque 1/4 turn past hand-tight.

10 Apply PTFE tape on installation end only.

11 Apply sealant to threads.

12 Apply light coating of lubricant to seals.

13 Fill reservoir with hydraulic fluid.

14 Orient with airflow arrow pointing toward mounting bracket.

15 Prior to installing Ref. 728 into Ref. 726, install Ref. 729 into Ref. 728 and adjust head 1/8 in. from surface.

24 Align fan plug as shown.

26 Apply thermal lubricant to contact side.

54 313998J

Parts

Ref Part Description

701 24C719 MOTOR, power connector, assembly

702 16A951 COUPLER, motor

703 15W772 HOUSING, machined.hydraulic, module

704 123338 SCREW, shc, 3/8-16 x 2.75, s(matrix)

705 122295 PUMP, gear, hydraulic, h39

706 16A952 COUPLER, pump

707 16A953 COUPLER, spider

708 123942 SCREW, cap, hex hd (matrix)

709 15T939 FITTING, straight, jic8 x sae8

710 122520 FITTING, elbow, male, sae x jic

711 15W798 TUBE, pump to tube outlet

712 122606 FITTING, elbow, male, female

713 100627 NIPPLE, short

714 101353 FITTING, nipple, pipe

715 122527 VALVE, relief, t-10a cavity, 0-25g

716 100721 PLUG, pipe

717 121312 FITTING, elbow, sae x jic

718 101754 PLUG, pipe

719 15X622 GASKET, housing, to, tank

720 RESERVOIR, assembly, 8 gallon

721 101971 WASHER, thrust

722 111302 SCREW, cap, hex hd (matrix)

723 15J937 FILTER, oil, 18-23 psi bypass

724 116915 CAP, breather filler

725 121486 FITTING, elbow, male, 1/2jic x 1/2npt

726 15Y912 BRACKET, mcm mounting

727 100057 SCREW, cap hex hd (matrix)

728 257396 MODULE, motor control

729 101550 SCREW, cap, sch (matrix)

730 PLATE, mounting, fan

731 122301 FAN, 220v

732 112310 SCREW, cap, sch (matrix)

733 100644 SCREW, cap, sch (matrix)

734 123367 HARNESS, m8 x thermal switch, 4-pin

735 102410 SCREW, cap soc hd (matrix)

736 FLUID, hydraulic (gallon)

737 123303 HARNESS, m12

738 295709 SCREW, soc.hd (matrix)

739 LUBRICANT, grease

740 SEALANT, pipe, sst

741 SEALANT, pipe, sst

743 189285

LABEL, caution

744 121208 ▲ LABEL, hot surface

745 15H108

LABEL, pinch point

746 109468 SCREW, cap, hex head

747 LUBRICANT, thermal

748 123601 CLAMP, wire, harness, nylon, 3/4

749 103833 SCREW, mach, crbh

Replacement Danger and Warning labels, tags and cards are available at no cost.

4

1

7

1

1

1

1

4

4

1

1

1

1

1

1

1

1

1

1

2

1

1

Qty

1

1

1

1

1

4

1

1

2

1

1

1

1

4

1

1

5

5

8

2

1

1

8

2

1

1

313998J 55

Parts

Heat Exchanger Assembly

805

808 3 5

807

802

801

806 4 5

804

257931_313998_2f

7

257931_313998_1f

805 1 2

1 Torque to 65 ft-lb (88 N•m).

2

Apply lubricant to o-rings before assembling.

3

Torque to 8 ft-lb (11 N•m).

4 Torque to 2.5 ft-lb (3.4 N•m).

803

5 Apply sealant to threads.

6

Orient fan with airflow arrow pointing toward cover.

7

Align fan plug as shown.

Ref Part Description

801 257967 COVER, enclosure, heat exch,

802

803

804

15X621

122300

122301 painted

GASKET, fan, mounting

EXCHANGER, heat, m-4

FAN, 220v

805 122842 FITTING, elbow, sae x jic

806 15U075 SCREW, cap, bh, 8-32 x

807 110755

.37(matrix)

WASHER, plain 4

808 100022 SCREW, cap, hex hd (matrix) 4

810

811

LUBRICANT, thread

SEALANT, anaerobic

1

1

1

1

1

2

8

Qty

1

56 313998J

Parts

Heater Options

9

10

10

922 910 908 913 914 929 930 919 918 920

5

917

904

931

902

908

9

916

6

925

903

24C327_313998_1L

932

901

909

906

904

908 9

905

908 9

926

912

10

911

10

1

Assembly NPT portion of Ref. 938 into Ref.

907. Tighten to tight minus 1 turn approximately. Insert Ref. 933 into Ref. 938 an tighten while holding against heater element. Tighten ferrule to 21-25 ft-lb

(28-34 N•m). Hold NPT portion to prevent tightening.

2

Tighten NPT thread at least one turn after

RTD has been tightened.

3

Apply thermal lubricant when assembling

Ref. 934.

F IG . 18: Heater Options, Image 1 of 4

6

7

4

Apply oxide inhibitor to bare ends of wires and to ferrule ends.

5

Apply oxide inhibitor included in Ref. 917 to bare ends of wires and to ferrule ends.

Torque to 16 in-lb (1.8 N•m).

Connect to Ref. 920 through extension cable.

8

Choose adapter and swivel fitting from kit based on hose size.

9

Torque to 17 ft-lb (23 N•m).

10 Apply lubricant to threads of tube fitting and torque to 21 ft-lb (28 N•m).

12 Apply sealant and tape to all non-swiveling and non-o-ring threads.

313998J 57

Parts

927

928

938

2 12 1

933 1

934 3

935

907

921 4

Non-Heated Models Only

905

24C327_313998_1L

Ref. 924, 258757 shown

905

915

24C327_313998_2L

F IG . 19: Heater Options, Image 2 of 4

7

8

8

24C327_313997_9f

58 313998J

Quantity

Parts

Ref

901

902

Part Description

MODULE, panel, pwr, heat, hose, pr, lv

MODULE, panel, pwr, heat, hose, lv

MODULE, panel, pwr, heat, pri, lv

MODULE, panel, pwr, heat, hose, pr, hv

MODULE, panel, pwr, heat, hose, hv

MODULE, panel, pwr, heat, pri, hv

MODULE, panel, pwr, no heat, hv

903 115942 NUT, hex, flange head

904 253192 BRACKET, painted, heater mount, poly

905 167002 INSULATOR, heat

906 113796 SCREW, flanged, hex hd (matrix)

907 24C426 HEATER, assy, 6kw, 1-zone, rtd, s

908 111800 SCREW, cap, hex hd (matrix)

909 255360 COVER, wire, heater, painted

910 253196 COVER, painted, heater, poly, h-25

911 16A104 TUBE, fluid, a, inlet, heater, ams

912 16A105 TUBE, fluid, a, outlet, heater, ams

913 16A106 TUBE, fluid, b, inlet, heater, ams

914 16A107 TUBE, fluid, b, outlet, heater, ams

915 16A108 TUBE, fluid, no heater, ams

916 24C418 MODULE, transformer, assy, hv

917 261821 CONNECTOR, wire, 6awg

918 24C314 HARNESS, wire, hptcm, hoseheat, fixed

919 24C312 HARNESS, wire, hptcm, heater, fixed

920 122242 CABLE, m8, 4-pin, mf, 2.5m, mold

921 255716 KIT, heater wire connector

922 189285 ▲ LABEL, caution

923 FLUID, oxide inhibitor

924 258756 KIT, fts, rtd, dual hose, sst

258757 KIT, fts, rtd, dual hose

258758 KIT, fts, rtd, single hose

925 24C779 MODULE, transformer, assy, lv

1

1

2

16

2

2

4

4

6

2

1

1

1

1

1

1

2

1

2

1

2

2

1

2

1

1

2

14

2

2

4

4

6

2

1

1

1

1

2

1

1

1

1

2

1

1

1

1

1

6

4

2

2

2

1

2

1

1

1

1

1

1

6

4

2

2

2

1

2

1

1

2

1

2

1

1

2

12

2

2

4

4

6

2

1

1

1

1

1

1

1

8

2

2

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

2

313998J 59

Parts

Quantity

Ref Part Description

926 123398 PLUG, hole, 1.5"dia

123589 BUSHING, wire protector, snap-in

927 100028 WASHER, lock

928 113783 SCREW, machine, pn hd (matrix)

929 103361 BUSHING, snap

930 114269 GROMMET, rubber

931 121002 CABLE, can, female / female 1.5m

932 122487 CABLE, can, male-female, 1.5m

933 124262 SENSOR, rtd, 1 k ohm, 5 ft, 4 pin, tip sensor

934 123408 HARNESS, m8 x thermal switch, 3-pin

935 100518 SCREW, mach, pnhd (matrix)

936

937

LUBRICANT, thermal

LUBRICANT, thread

938 123325 FITTING, compression, 1/8npt, ss

939 SEALANT, pipe, sst

940 TAPE, tfe, sealant

▲ Replacement Danger and Warning labels, tags and cards are available at no cost.

2

1

1

1

1

2

4

1

2

2

1

2

2

2

2

2 2

2

1

1

1

1

2

4

1

2

2

1

2

2

2

2

1

1

1

1

1 1

2

1

1

1

1

1

1

1

2

1

1

2

1

1

1

2

1

1

1

1

2

4

1

2

2

1

2

2

2

2

1

60 313998J

Parts

24J707 Shown

1342

10

1313

10

1314

1341

1302

1303

1331

1301

1332

9

Torque to 17 ft-lb (23 N•m).

10 Apply lubricant to threads of tube fitting and torque to 21 ft-lb (28 N•m).

F IG . 20: Heater Options, Image 3 of 4

1341

313998J

1311

10

1312

10

1342 ti17873a

61

Parts

1348

1350

1346

1347

1345

1344

1343

1334

1354

1308

9

1351

1354

1349

1353

1346

1347 ti17874a

1344

1345

1343

F IG . 21: Heater Options, Image 4 of 4

62 313998J

Quantity

Parts

Ref Part

1318 24C314

1319 24C312

1320 122242

1321 255716

1322 189285

1323 261843

1324 258756

258758

24G976

1325 24C779

1327 100028

1328 113783

1329 103361

1330 114269

1331 121002

1332 122487

1334 123408

1335 100518

1336 073019

1301 24C336

24C338

1302 24C332

24C334

1303 115942

1304 253192

1305 167002

1306 113796

1307 24C426

1308 111800

1309 255360

1310 253196

1311 16A104

16H486

1312 16A105

16H485

1313 16G338

1314 16G339

1316 24C418

1317 261821

Description

MODULE, panel, pwr, heat, hose, pr, lv

MODULE, panel, pwr, heat, pri, lv

MODULE, panel, pwr, heat, hose, pr, hv

MODULE, panel, pwr, heat, pri, hv

NUT, hex, flange head

BRACKET, painted, heater mount, poly

INSULATOR, heat

SCREW, flanged, hex hd

HEATER, assy, 6kw, 1-zone, rtd, s

SCREW, cap, hex hd

COVER, wire, heater, painted

COVER, painted, heater, poly, h-25

TUBE, fluid, a, inlet, heater, ams

TUBE, fluid, outlet

TUBE, fluid, a, outlet, heater, ams

TUBE, fluid, inlet

TUBE, fluid, b, inlet, heater, visc

TUBE, fluid, b, outlet, heater, vis

MODULE, transformer, assy, hv

CONNECTOR, wire, 6awg

HARNESS, wire, hptcm, hoseheat, fixed

HARNESS, wire, hptcm, heater, fixed

CABLE, m8, 4-pin, mf, 2.5m, mold

KIT, heater wire connector

LABEL, caution

FLUID, oxide inhibitor

KIT, fts, rtd, dual hose, sst

KIT, fts, rtd, single hose

KIT, fts, rtd, single hose, 1/2-2

MODULE, transformer, assy, lv

WASHER, lock

SCREW, machine, pn hd)

BUSHING, snap

GROMMET, rubber

CABLE, can, female / female 1.5m

CABLE, can, male-female, 1.5m

HARNESS, m8 x thermal switch, 3-pin

SCREW, mach, pnhd

LUBRICANT, thermal

313998J

1

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

10

1

1

1

1

6

1

2

2

1

1

10

1

1

1

1

6

1

2

2

1

1

1

1

1

1

1

1

1

1

14

1

1

1

2

2

6

1

1

2

1

2

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

2

1

1

2

1

1

6

8

1

1

1

1

1

1

1

2

1

1

1

6

10 12

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

2

2

1

1

1

1

1

2

1

1

1

6

63

Parts

Quantity

Ref Part

1337 070268

1338 123325

1339 070408

1340 070274

1341 24J537

1342 24J787

1343 124813

1344 124814

1345 262120

1346 124586

1347 124885

1348 124956

1349 124955

1350 124909

1351 123798

1353 124957

1354 24J142

1355 114225

1356 105676

Description

LUBRICANT, thread

FITTING, compression, 1/8npt, ss

SEALANT, pipe, sst

TAPE, tfe, sealant

BRACKET, heater, viscon, hfr, painted

HEATER, sst

FITTING, elbw, 90, jic08x1/4npt

FITTING, rducr, 1/2nptx1/4npt

SENSOR, fluid temp rtd

COUPLING, hex, 1/2npt

FITTING, elbow, 90, jic(08)x1/2npt

FITTING, elbow, 45 deg, 3/4 conduit

CONDUIT, 3/4, gray seal tite

WASHER, reducer, 1in-3/4in

CABLE, m8, 4-pin, mf, 1m, molded

FITTING, elbow, 90 deg, conduit

HARNESS, wire, hptcm, heater, fixed

TRIM, edge protection

SCREW, mach, pnh

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

0.330 0.670 0.670

1 1 1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

2

2

2

2

1

1

2

2

2

2

2

2

2

4

1

2

2

2

2

2

1

1

2

2

2

2

2

2

2

4

2

1

2

2

2

2

2

1

1

2

2

2

2

2

2

2

4

2

64 313998J

Parts

Heater Sub-Assemblies

Heat Power Panel Module

1004, 1006

1

1004, 1006 1

1 Tie wires at this point.

2 Torque connector screws to 16 in-lb

(1.8 N•m).

1007

1004,

1006

1

1005,

1006

1010

1009

1011

1008

24C332_313998_8f

1002

1015

1016

24C332_313998_7f

F IG . 22: Heat Power Panel Modules

313998J

24C332_313998_3f

1003

1014

2

1012

1005, 1006

1001

24C332_313998_1f

65

Parts

1005, 1006 1004, 1006 1

1 Tie wires at this point.

2 Torque connector screws to 16 in-lb

(1.8 N•m).

1004,

1006

1007

1004,

1006

1

24C332_313998_6f

1008 1010 1009

1

1011

1004, 1006

1005, 1006

1002

1015

1016

24C332_313998_4f

24C332_313998_7f

F IG . 23: Heat Power Panel Modules

66

1003

24C332_313998_4f

1014 2

1012

313998J

Parts

Quantity

Ref Part Description

1001 PANEL, electric, heat

1002 255774 MODULE, high power temp, gca

1003 MODULE, assy, pwr, heat, hose, pri, hv

MODULE, assy, pwr, heat, hose, hv

MODULE, assy, pwr, heat, pri, hv

MODULE, assy, pwr, no heat, hv

MODULE, assy, pwr, heat, hose, pri, lv

MODULE, assy, pwr, heat, hose, lv

MODULE, assy, pwr, heat, pri, lv

MODULE, assy, pwr, no heat, lv

1004 123452 HOLDER, anchor, wire tie, nylon

1005 116876 WASHER, flat

1006 103833 SCREW, mach, crbh (matrix)

1007 125306 CABLE, can, female / female 0.5m

1008 100021 SCREW, cap hex hd (matrix)

1009 100028 WASHER, lock

1010 100015 NUT, hex mscr

1011 24C311 HARNESS, wire, pdb, ground

1012 24C318 HARNESS, wire, pdb, terminal

1014 24C304 HARNESS, wire, pdb, inline heater

1015 15R535 BRACKET, mounting, GCA high power

1016 117831 SCREW, mach., pan hd (matrix)

1

2

1

2

1

1

1

2

2

5

4

9

1

4

8

1

1

1

2

4

2

1

1

1

2

1

5

3

8

1

1

1

1 1

2

1

1

2

4

2

1

1

1

2

1

4

3

7

2

1

1

1

2

4

2

6

2

1

1

1

2

2

5

4

9

1

4

8

1

1

1

1

1

1

2

4

2

1

1

1

2

1

5

3

8

1

2

4

2

1

1

1

2

1

4

3

7

1

4

2

6

2

1

1

1

2

313998J 67

Parts

Heater 24C426

1101

1105

2

6

1104

3

6

1107 6

1106 5

24C106_313998_1g

1119

1108

1102 1

1110

1

Torque to 120 ft-lb (163 N•m)

2

Torque to 23 ft-lb (31 N•m)

3 Torque to 40 ft-lb (54 N•m)

5

Apply sealant and tape to all non-swiveling threads and non-o-ring threads.

6

Apply lubricant to o-rings before assembling into heater.

Ref Part

1101 15J090

1102 15H302

1103 15H305

1104 121309

1105 15H304

1106 15H306

1107 120336

1108 15B140

1110 15B135

1114

1115

1117

1119 295607

Description

HEATER, machined, 1 zone, 3500 psi

FITTING, reducer 1-3/16 saex1/2npt

FITTING, plug hollow hex 1-3/16 sae

FITTING, adapter, sae-orb x jic

FITTING, plug 9/16 sae

ADAPTER, thermocouple, 9/16 x 1/8

O-RING, packing

HEATER, immersion (1500W 230V)

MIXER, immersion heater

SEALANT, pipe, sst

TAPE, tfe, sealant

LUBRICANT, thread

PLUG, hex

1

1

1

4

1

1

4

Qty

1

4

3

1

4

2

68

1105

2

6

1103

1

6

313998J

Parts

313998J 69

Parts

Heater 24J787

1408

1409

1435

1416

1422

1427

1428

1421

1426

1410

1411

1408

1429

1430

1431

1412

70 ti17875a

1403

1402

1412

1433

1410

1423

1401

1409

1407

1405

1434

1409

1404

1406

1404

1417

1418

1419

1420

313998J

Parts

Ref Part

1401† ---

1402

1403

15A990

15A811

Description

BLOCK, heater, machined

GASKET, heater

COVER, heater controls, bottom

1404

1405

1406

1407

15A991

15A809

15A810

15B625

GASKET, heater

ENCLOSURE, controls, heater

COVER, heater controls, top

LABEL, plate, warning

1408

1409

1410

1411

1412† 117344 FITTING, tube, compression

1413

172953 LABEL, designation

1414

1415

1416

111962

100055

107542

117367

111307

SCREW, cap, button hd

SCREW, drive, #6

WASHER, lock, spring

SCREW, shcs, m8x18

WASHER, lock, external

116343 SCREW, ground 1

15B828 HOUSING, light, heater, viscon hp 1

1

1

10

10

10

6

2

1417

1418

1419

1420

106216

15B827

103338

117483

NUT, lock

LENS, light, glass

PACKING, o-ring

SCREW, jam, socket

1

1

1

1

1

1

2

1

1

1

Qty

1

1421

1422

1423

1424

1425

1426

1427

1428

111802

112731

109114

100166

102360

15U075

555388

100079

SCREW, cap, hex hd

NUT, hex, flanged

SCREW, cap, sch

NUT, full hex

WASHER, flat

SCREW, cap, bh, 8-32 x .37

NUT, # 8-32 hex

WASHER, lock, spring

1429

1430

108674 THERMOSTAT

105676 SCREW, mach, pnh

1431 073019 LUBRICANT, thermal

1432 235524 WIRE, assy

1433 ▲ 177922 TAG, warning

1434

16K138 LABEL, brand, viscon hp, nvh

1435 ▲ 15B623 LABEL, plate, des, viscon hp

1442

15B777 LABEL, warning, viscon hp

1443 ▲ 15B819 LABEL, warning, viscon hp

1

1

1

1

1

1

1

2

1

2

2

4

2

4

4

1

1

Replacement Danger and Warning labels, tags and cards are available at no cost.

--- Not for individual sale

† Items available for purchase in kit 24K290

313998J 71

Kits

Kits

DC Power Pack Pressure Adjustment Kit, 24C067

This kit provides a release for excess pressure in the hydraulic system. It must be installed if a Fusion or P2 gun is used.

2

1204 1

1203

1201

1202

4 Torque to 23 in-lb (2.6 N•m).

5 Part is reference number 15 in hydraulic power

pack assembly. See Hydraulic DC Power Pack

Module on page 54.

Ref Part

1201 15H204

1202 15H512

1203 15Y370

1204 116624

Description

KNOB, pressure adjustment

LABEL, control, H25

ADAPTER, pressure relief

SCREW, set, socket head

Qty

1

1

1

1

72 313998J

Kits

DC Power Pack Hydraulic

Pressure Adjustment Setup

This procedure requires running the machine with the hydraulic power pack shroud removed. Be sure to avoid contact with the fan while the machine is on.

This kit provides a release for excess pressure in the hydraulic system. It must be installed if a Fusion or P2 gun is used.

1.

Perform Shutdown on page 21.

2.

Remove Hydraulic Power Pack Shroud , page 33.

3.

Install pressure relief kit 24C067.

NOTE: Prior to installing pressure adjustment knob (1201), use a 9/16 in. wrench to back the jam nut (1203) all the way out until it stops.

4.

Turn the pressure adjustment knob (1201) clockwise until it stops.

5.

Turn the pressure adjustment knob counter-clockwise two full turns.

6.

Turn main power switch to ON position.

7.

Setup the machine to spray in Operator mode. See

HFR operation manual 313997 if necessary.

8.

While watching the ADM and listening to the motor, begin spraying material.

NOTE: If the ADM displays an overpressure situation, the relief pressure is set too high.

NOTE: If it sounds like the motor is spinning too fast and/or it sounds like hydraulic fluid is being dumped back to the tank, the relief pressure is set too low.

9.

If the relief pressure is set too high: Clear the over pressure warning on the ADM then turn the pressure adjustment knob counterclockwise 1/4 turn. See HFR operation manual 313997 if necessary.

If the relief pressure is set too low: Turn the pressure adjustment knob clockwise 1/4 turn.

10. Repeat the previous two steps until the relief pressure is correctly set.

313998J 73

Logic Drawings

Logic Drawings

230V, 1 Phase, No Heat

126

127

128

129

130

131

132

133

134

135

136

137

117

118

119

120

121

122

123

124

125

138

139

140

141

142

143

144

145

146

147

148

149

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

230V/

1PH/

50-60HZ

1L1

1L1

1L2

1L2

1L1

1L2

1L1

1L2

1

CB1A

63A

CB5

5A

1080

1100

1340

1360 1360

1360

1340

1340

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C515

BLK

WHT

1080

1100

PG105

1

GND

L1

L2

L3

331

MCM

B VOLUME

HARNESS

24C318

1390 BR

1400 BL

POWER

SUPPLY

121808

1340

PG133

1360

1

755

MISC

B VOLUME

CAN SPLITTER

123466

176

177

178

179

180

181

182

183

184

185

186

187

167

168

169

170

171

172

173

174

175

188

189

190

191

192

193

194

195

196

197

198

199

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

F IG . 24: 230V, 1 Phase, No Heat Logic Drawing; Page 1 of 1

74 313998J

Logic Drawings

230V, 1 Phase, with Heat

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

100

101

102

103

104

105

106

107

108

109

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

230V/

1PH/

50-60HZ

1L1

1L1

1L1

1L1

1L1

151

1L1

1L2

1L2

1L2

1L2

1L2

151

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1

CB1A

63A

CB2

40A

CB3

15A

CB4

40A

CB5

5A

1080

1100

1160

1180

1220

1240

1280

1300

1340

1360 1360

1360

1340

1340

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C515

BLK

WHT

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1080

1100

PG105

GND

L1

L2

L3

1160

PG116

1180

1

1

331

MCM

B VOLUME

511

PRIMARY HT

B VOLUME

1220

PG121

1240

1

TANK

B VOLUME

1280

PG127

1300

1

580

HOSE HT

B VOLUME

1340

PG133

1360

1

755

MISC

B VOLUME

1390 BR

1400 BL

POWER

SUPPLY

121808

CAN SPLITTER

123466

F

IG

. 25: 230V, 1 Phase, with Heat Logic Drawing; Page 1 of 2

313998J 75

Logic Drawings

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

159

160

161

162

163

164

165

166

167

168

169

170

171

172

150

151

152

153

154

155

156

157

158

1L1

148

1L2

148

1L1

1L1

1L1

1L1

1L2

1L2

1L2

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1660

1680

CB9

40A

1720

1740

CB8

15A

CB7

40A

1780

1800

1840

1860

CB6

5A

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1660

PG166

1680

2

649

PRIMARY HT

A VOLUME

1720

PG172

1740

2

TANK

A VOLUME

1780

PG178

1800

2

718

HOSE HT

A VOLUME

1840

PG184

1860

2

824

MISC

A VOLUME

F IG . 26: 230V, 1 Phase, with Heat Logic Drawing; Page 2 of 2

76 313998J

Logic Drawings

230V, 3 Phase, No Heat

121

122

123

124

125

126

127

128

129

134

135

136

137

138

130

131

132

133

144

145

146

147

139

140

141

142

143

148

149

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

230V/

3PH/

50-60HZ

1L1

1L1

1L2

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1

CB1

30A

CB5

5A

1080

1100

1120

1340

1360 1360

1360

1340

1340

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C516

BLK

RED

WHT

1080

1100

1120

PG105

GND

L1

L2

L3

1

331

MCM

B VOLUME

HARNESS

24C318

1390 BR

1400 BL

POWER

SUPPLY

121808

1

1340

1360

PG133

755

MISC

B VOLUME

CAN SPLITTER

123466

F

IG

. 27: 230V, 3 Phase, No Heat Logic Drawing; Page 1 of 1

313998J 77

Logic Drawings

230V, 3 Phase, with Heat

119

120

121

122

123

124

125

126

127

128

129

130

131

132

110

111

112

113

114

115

116

117

118

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

100

101

102

103

104

105

106

107

108

109

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

230V/

3PH/

50-60HZ

1L1

1L1

1L1

1L1

151

1L1

1L2

1L2

1L2

151

1L2

1L3

1L3

1L3

1L3

151

1L3

1L1

1L2

1L3

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1

CB1

30A

CB2

40A

CB3

15A

CB4

40A

CB5

5A

1080

1100

1120

1160

1180

1220

1240

1280

1300

1340

1360 1360

1360

1340

1340

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C516

BLK

RED

WHT

HARNESS

24C304

1

1080

1100

1120

PG105

GND

L1

L2

L3

1160

PG116

1180

1

331

MCM

B VOLUME

511

PRIMARY HT

B VOLUME

HARNESS

24C517

HARNESS

24C303

1220

PG121

1240

1

TANK

B VOLUME

1280

PG127

1300

1

580

HOSE HT

B VOLUME

HARNESS

24C318

1340

PG133

1360

1

755

MISC

B VOLUME

1390 BR

1400 BL

POWER

SUPPLY

121808

CAN SPLITTER

123466

F

IG

. 28: 230V, 3 Phase, with Heat Logic Drawing; Page 1 of 2

78 313998J

Logic Drawings

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

150

151

152

153

154

155

156

157

158

159

160

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

1L1

148

1L2

148

1L3

148

1L1

1L1

1L2

1L2

1L2

1L3

1L3

1L3

1L2

1L1

1L3

1L2

1L1

1L3

1L2

30A

CB9

40A

1660

1680

1720

1740

CB8

15A

1780

1800

CB7

40A

1840

1860

CB6

5A

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1660

1680

PG166

2

649

PRIMARY HT

A VOLUME

1720

1740

PG172

2

TANK

A VOLUME

1780

PG178

1800

2

718

HOSE HT

A VOLUME

1840

1860

PG184

2

824

MISC

A VOLUME

F IG . 29: 230V, 3 Phase, with Heat Logic Drawing; Page 2 of 2

313998J 79

Logic Drawings

400V, 3 Phase, No Heat

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

110

111

112

113

114

115

116

117

118

119

100

101

102

103

104

105

106

107

108

109

146

147

148

149

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

400V/

3PH/

50-60HZ

1L1

1L1

1N

1N

1L1

1L1

1N

1N

1

CB1A

63A

CB5

5A

1081

1101

1340

1360 1360

1360

POWER

FILTER

L1/P

L2/N

1340

1340

GND

1080

1100

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C515

BLK

WHT

HARNESS

24C318

1390 BR

1400 BL

POWER

SUPPLY

121808

1

1080

1100

PG105

GND

L1

L2

L3

331

MCM

B VOLUME

1

1340

PG133

1360

755

MISC

B VOLUME

CAN SPLITTER

123466

F

IG

. 30: 400V, 3 Phase, No Heat Logic Drawing; Page 1 of 1

80 313998J

Logic Drawings

400V, 3 Phase, with Heat

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

100

101

102

103

104

105

106

107

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

400V/

3PH/

50-60HZ

1L1

1L1

1L1

1L2

1L2

151

1L2

151

1L3

1N

1N

1N

1N

1N

151

1N

1L1

1N

1L1

1N

1L1

1N

1L2

1N

1L2

1N

1

CB1A

63A

CB2

40A

CB3

15A

CB4

40A

CB5

5A

1081

1101

1160

1180

1220

1240

1280

1300

1340

1360

POWER

FILTER

1360

1360

L1/P

L2/N

1340

1340

GND

1080

1100

POWER

FILTER

L1/P

L2/N

GND

HARNESS

24C515

BLK

WHT

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1390 BR

1400 BL

POWER

SUPPLY

121808

1

1080

1100

PG105

GND

L1

L2

L3

331

MCM

B VOLUME

1160

PG116

1180

1

511

PRIMARY HT

B VOLUME

1220

PG121

1240

1

TANK

B VOLUME

1280

PG127

1300

1

580

HOSE HT

B VOLUME

1340

PG133

1360

1

755

MISC

B VOLUME

CAN SPLITTER

123466

F

IG

. 31: 400V, 3 Phase, with Heat Logic Drawing; Page 1 of 2

313998J 81

Logic Drawings

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

150

151

152

153

154

155

156

157

158

159

160

161

162

163

1L2

148

1L3

148

1N

148

1L2

1L3

1L3

1N

1N

1N

1N

1L3

1N

1L3

1N

1L2

1N

1L2

1N

CB9

40A

1660

1680

1720

1740

CB8

15A

1780

1800

CB7

40A

1840

1860

CB6

5A

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1660

PG166

1680

2

649

PRIMARY HT

A VOLUME

1720

PG172

1740

2

TANK

A VOLUME

1780

PG178

1800

2

718

HOSE HT

A VOLUME

1840

PG184

1860

2

824

MISC

A VOLUME

F IG . 32: 400V, 3 Phase, with Heat Logic Drawing; Page 2 of 2

82 313998J

Logic Drawings

A (Red) Heat

658

659

660

661

662

663

650

651

652

653

654

655

656

657

664

665

666

667

668

669

675

676

677

678

679

680

681

682

670

671

672

673

674

628

629

630

631

632

633

634

635

622

623

624

625

626

627

614

615

616

617

618

619

620

621

642

643

644

645

646

647

648

649

636

637

638

639

640

641

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

PRIMARY HT

LOW VOLUME

HARNESS

24C265

167

BRN

PG166

6400

1660

1680

A1+

CR642

3

1

CON863

A2-

4

2

6420

BLU

HARNESS

24C267

6490

6500

CAN COMM PORT

CAN COMM PORT

HARNESS

16A522

M8 3 PIN

MALE

+24VDC

1

SIGNAL

4

3

2 4

PG646

5

GND

2

A - RED

HPTCM PRIMARY LOW VOLUME

M12 5 PIN

MALE

3

5

6

2

1

1

2

3

4

5

2

M8 4 PIN

FEMALE

1

2

3

4

M12 5 PIN

MALE

1

2

3

4

5

M8 3 PIN

FEMALE

1

4

3

5

6

4

1

M8 3 PIN

FEMALE

1

4

3

3

M8 4 PIN

MALE

1

2

3

4

EXC

SIGNAL

2

2

M8 3 PIN

MALE

1

4

3

EXC

SIGNAL

1

2

PG647

6480

6520

3 2

HARNESS

VR 24C313

FR 24C312

PRIMARY TEMP

PRIMARY TEMP

OTS628

6520

6520

6520

6520

RTD618

DB-1 PRIMARY HEATER

SEE CONFIGURATION

6480

6480

6480

6480

F

IG

. 33: A (Red) Heat Logic Drawing, Page 1 of 2

313998J 83

Logic Drawings

709

710

711

712

713

714

715

716

703

704

705

706

707

708

723

724

725

726

727

728

729

730

731

732

733

734

735

736

717

718

719

720

721

722

737

738

739

740

741

742

743

744

745

746

747

748

749

750

751

683

684

685

686

687

688

689

690

691

692

693

694

695

696

697

698

699

700

701

702

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

HOSE HT

LOW VOLUME

179

BRN

PG178

7090

1780

1800

HARNESS

24C274

A1+

CR711

3

1

CON-869

A2-

4

2

CAN COMM PORT

CAN COMM PORT

7110

BLU

7170

HARNESS

16A522

M8 3 PIN

MALE

+24VDC

1

4

SIGNAL

3

4

PG715

2

CB718

5

GND

PG728

2

2

A - RED

HPTCM HOSE LOW VOLUME

M12 5 PIN

MALE 3

5

6

2

1

1

2

3

4

5

2

M12 5 PIN

MALE

3

4

5

1

2

M8 3 PIN

FEMALE

1

4

3

5

7290

7310

7330

7350

6

4

1

PRIMARY

SECONDARY

M8 4 PIN

FEMALE

1

2

3

4

M8 3 PIN

FEMALE

1

4

3

TRANS1

24C418

3

M8 4 PIN

MALE

1

2

3

4

EXC

SIGNAL

2

2

PG716

7172

7210

3 2

HARNESS

VR 24C315

FR 24C314

HOSE TEMP

RTD688

HOSE HEATER

SEE CONFIGURATION

F IG . 34: A (Red) Heat Logic Drawing, Page 2 of 2

84 313998J

Logic Drawings

B (Blue) Heat

517

518

519

520

521

522

512

513

514

515

516

523

524

525

526

527

528

529

530

531

532

533

534

535

536

537

538

539

540

541

542

543

544

481

482

483

484

485

486

487

488

489

490

491

476

477

478

479

480

498

499

500

501

502

503

504

505

506

507

508

509

510

511

492

493

494

495

496

497

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

PRIMARY HT

HI VOLUME

HARNESS

24C265

117

BRN

5020

PG116

1160

1180

A1+

CR504

3

1

CON794

A2-

4

2

5040

BLU

HARNESS

24C267

5110

5120

CAN COMM PORT

CAN COMM PORT

HARNESS

16A522

M8 3 PIN

MALE

+24VDC

SIGNAL

1

4

3

1

4

PG509

5

GND

1

B - BLUE

HPTCM PRIMARY HI VOLUME

M12 5 PIN

MALE 3

5

6

2

1

3

4

5

1

2

2

M12 5 PIN

MALE

1

2

3

4

5

M8 3 PIN

FEMALE

1

4

3

5

6

4

1

M8 4 PIN

FEMALE

1

2

3

4

M8 3 PIN

FEMALE

1

4

3

3

M8 4 PIN

MALE

1

2

3

4

EXC

SIGNAL

2 1

M8 3 PIN

MALE

1

4

3

EXC

SIGNAL

1

1

PG508

5100

PRIMARY TEMP

RTD480

PRIMARY TEMP

OTS490

DB-1

PRIMARY HEATER

SEE CONFIGURATION

5100

5100

5100

5100

5140

1

3

HARNESS

VR 24C313

FR 24C312

5140

5140

5140

5140

F

IG

. 35: B (Blue) Heat Logic Drawing, Page 1 of 2

313998J 85

Logic Drawings

573

574

575

576

577

578

579

580

567

568

569

570

571

572

581

582

583

584

585

586

587

588

589

590

591

601

602

603

604

605

606

607

608

609

610

611

612

613

592

593

594

595

596

597

598

599

600

559

560

561

562

563

564

565

566

553

554

555

556

557

558

545

546

547

548

549

550

551

552

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

HOSE HT

HI VOLUME

HARNESS

24C263

129

BRN

5710

PG127

1280

1300

HARNESS

24C274

A1+

CR573

3

1

A2-

4

2

CON800

CAN COMM PORT

CAN COMM PORT

5730

BLU

5790

HARNESS

16A522

M8 3 PIN

MALE

+24VDC

1

4

SIGNAL

3

4

PG578

1

CB579

5

GND

PG590

1

1

B - BLUE

HPTCM HOSE HI VOLUME

M12 5 PIN

MALE 3

5

6

2

1

2

3

4

5

1

2

M12 5 PIN

MALE

3

4

5

1

2

M8 3 PIN

FEMALE

1

4

3

5

5910

5930

5950

5970

6

4

1

PRIMARY

SECONDARY

M8 4 PIN

FEMALE

1

2

3

4

M8 3 PIN

FEMALE

1

4

3

3

TRANS1

24C418

M8 4 PIN

MALE

1

2

3

4

EXC

SIGNAL

2

1

PG577

5792

5830

3 1

HARNESS

VR 24C315

FR 24C314

HOSE TEMP

RTD550

HOSE HEATER

SEE CONFIGURATION

F IG . 36: B (Blue) Heat Logic Drawing, Page 2 of 2

86 313998J

Logic Drawings

DC Hydraulic Power Pack

924

925

926

927

928

929

930

931

932

933

934

935

936

937

938

939

940

941

942

943

944

945

946

947

948

949

950

951

952

953

954

955

956

957

958

890

891

892

893

894

895

896

897

898

899

900

901

902

903

904

905

906

907

908

909

910

911

912

913

914

915

916

917

918

919

920

921

922

923

'A' RED

ISO LUBE

PUMP

LOCATED ON THE MAIN

HYDRAULIC POWER PACK

HV SOL234

LV SOL372

A

T P

B A

OIL TEMP

RTD OPTIONAL

HV RTD290

LV RTD428

OIL LEVEL

SENSOR

OPTIONAL

HV PX262

LV PX400

PRESSURE

GAUGE

OPTIONAL

PRESSURE

RELIEF

VALVE

B

HV SOL241

LV SOL378

123313

HYDRAULIC CYLINDER

PUMP POSITION

+5 VDC GND

SIGNAL

FIXED RATIO

MACHINE FRONT

FACING PUMPS

HV LPT280

LV LPT416

'B' BLUE

B

A GND

+5 VDC

VARIABLE RATIO

VERTICAL PUMP

SIGNAL

OIL OVERTEMP

SWITCH

HV OTS264

LV OTS402

MCM FAN

HV M772

LV M841

HYD. FAN

HV M762

LV M831

M

HV M310

LV M450

PUMP

COOLER

FILTER

15J437

F

IG

. 37: DC Hydraulic Power Pack Logic Drawing, Page 1 of 1

313998J 87

Logic Drawings

Motor Control Module (MCM)

223

224

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

240

241

242

243

244

245

246

247

248

249

250

251

252

253

254

255

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

256

257

258

259

260

261

262

263

264

265

266

267

268

2A

1

2B

1

2C

1

3

3

LOCATED ON THE HYDRAULIC

POWER PACK - FIXED RATIO

3

5

6

2

3

5

6

2

START

PB235

0X

SOL240

DISPENSE

GUN

START

FS247

HYD-OIL

LO-LVL

PX262

121061

1

1 POS 1 = 2000psi

(DEFAULT)

POS 3 = 3000psi

2

3

4

5

2

3

4

5

2

3

4

1

1

1

CAN COMM PORT

CAN COMM PORT

M12 5 PIN

MALE

M12 5 PIN

MALE

1

2

3

4

5

M8 4 PIN

FEMALE

1

2

3

4

1

2

3

4

5

3

5

6

2

1

SWITCH POSITION

SHOWN FOR

REF ONLY

9

M12 5 PIN

FEMALE

3

4

5

1

2

B-CODE

1

8

B-CODE

M12 5 PIN

FEMALE

3

4

5

1

2

10

M12 5 PIN

MALE

3

4

5

1

2

+5VDC

-SIG

DC COM

+SIG

SHLD

9

M12 5 PIN

MALE

3

4

5

1

2

1

+5VDC

-SIG

DC COM

+SIG

SHLD

8

1

HARNESS

123303

HARNESS

123303

SIGNAL

M12 5 PIN

MALE

+24VDC

COMMON

SIGNAL

SIGNAL

1

2

3

4

5

2

1

M12 5 PIN

FEMALE

1

2

3

4

5

2

7

M12 5 PIN

FEMALE

1 ss

2

3

4

5

M12 5 PIN

MALE

3

4

5

1

2

SIGNAL

SIGNAL

COMMON

SIGNAL

SIGNAL

7

1

PRESS XDUCER

FIXED RATIO ONLY

RED 'A' VOLUME

PRESS XDUCER

BLUE 'B' VOLUME

2

1

3

4

2

1

3

4

5

VALVE ASSY

123313

SOL234

PUMP

LEFT

3

4

2

1

5

SOL241

PUMP

RIGHT

DISPENSE SIGNAL

TO HYDRAULIC

DISP. HEAD FCM

SIGNAL

DC COM

7A

1

7B

1

7C

1

OIL TEMP

HI

OTS264

123367

F

IG

. 38: Motor Control Module (MCM) Logic Drawing, Page 1 of 2

88 313998J

285

286

287

288

289

290

291

292

293

280

281

282

283

284

294

295

296

297

298

299

300

301

302

303

269

270

271

272

273

274

275

276

277

278

279

304

305

306

307

308

309

310

311

312

313

314

315

316

317

332

333

334

335

336

327

328

329

330

331

337

318

319

320

321

322

323

324

325

326

OIL TEMP

RTD290

OPTION

EXC

M8 4 PIN

MALE

SIGNAL

1

2

3

4

3

1

M8 4 PIN

FEMALE

1

2

3

4

3

6

5

M8 4 PIN

FEMALE

1

2

3

4

M8 4 PIN

FEMALE

1

2

3

4

15 PIN DSUB

FEMALE

M8 4 PIN

MALE

1

2

3

4

EXC

SHLD

COMMON

SIGNAL

6

1

M8 4 PIN

MALE

1

2

3

4

5

15 PIN DSUB

MALE

EXC

SIGNAL

1

LPT280

258669

PUMP POSITION

MOTOR TEMP

RTD292

M310

ENCODER

11

12

PG105

3 PHASE

GND L1 L2 L3

13

12

1

HARNESS

24C516

109

GND

13

1

L3

11

BLK

1

RED

L2

L1

BLU

MOTOR

PG105

1 PHASE

GND L1 L2 L3

HARNESS

24C515

109

Logic Drawings

F IG . 39: Motor Control Module (MCM) Logic Drawing, Page 2 of 2

313998J 89

Logic Drawings

Miscellaneous Power

778

779

784

785

786

787

780

781

782

783

792

793

794

795

796

788

789

790

791

802

803

804

805

797

798

799

800

801

806

807

808

809

810

811

812

813

814

815

816

817

818

819

820

774

775

776

777

769

770

771

772

773

760

761

762

763

764

765

766

767

768

752

753

754

755

756

757

758

759

MISC B - BLUE

HI VOLUME

135

1

PG133

1340

1360

1340

1360

1340

1360

1340

1340

1360

1360

HARNESS

24C518

HARNESS

24C518

1

2

1

2

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

FOR FIXED OR VARIABLE

RATIO

TERMINAL STRIP MOUNTED

ON BACKPANEL

11 14

7940

CR504

11 14

8000

CR573

A1

1

2

1

2

CON794

A1

CON800

M762

MOTOR

FAN

HYD

HEAT

EXCH'R

M772

MOTOR

FAN

MCM

A2

A2

BL

BR

230VAC POWER TO THE FAN

MOTOR

230VAC POWER TO THE FAN

MOTOR

HYD

VALVE

ASSY

SOL234

SOL241

USED ONLY WITH PRIMARY HEAT

OPTION

USED ONLY WITH HOSE HEAT

OPTION

F

IG

. 40: Miscellaneous Power Logic Drawing, Page 1 of 2

230VAC POWER TO THE

HYDRAULIC POWER VALVE

90 313998J

Logic Drawings

843

844

845

846

838

839

840

841

842

829

830

831

832

833

834

835

836

837

847

848

853

854

855

856

849

850

851

852

825

826

827

828

821

822

823

824

857

858

859

860

861

862

863

864

865

866

867

868

869

870

871

872

873

874

875

876

877

878

879

880

881

882

883

884

885

886

887

888

889

MISC A - RED

LOW VOLUME

185

2

PG184

1840

1860

1840

1860

1840

1860

1840

1840

1860

1860

HARNESS

24C518

HARNESS

24C518

1

2

1

2

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

FOR VARIABLE RATIO ONLY

TERMINAL STRIP MOUNTED

ON BACKPANEL

11 14

8630

CR642

11 14

8690

CR711

A1

1

2

1

2

CON863

A1

CON869

M831

MOTOR

FAN

HYD

HEAT

EXCH'R

M841

MOTOR

FAN

MCM

A2

A2

BL

BR

F

IG

. 41: Miscellaneous Power Logic Drawing, Page 2 of 2

230VAC POWER TO THE FAN

MOTOR

230VAC POWER TO THE FAN

MOTOR

HYD

VALVE

ASSY

SOL372

SOL378

USED ONLY WITH PRIMARY HEAT

OPTION

USED ONLY WITH HOSE HEAT

OPTION

230VAC POWER TO THE

HYDRAULIC POWER VALVE

313998J 91

Technical Data

Technical Data

Maximum Fluid Working Pressure . . . 3000 psi (20.7 MPa, 207 bar)

Maximum Fluid Temperature . . . . . . . 190°F (88°C)

Fluid Inlet Feed Pressure Range . . . . 50 psi (0.35 MPa, 3.5 bar) to 250 psi (1.75 MPa, 17.5 bar)

Fluid Inlets . . . . . . . . . . . . . . . . . . . . .

Component A (Red): 1/2 npt(f)

Component B (Blue): 3/4 npt(f)

Fluid Outlets. . . . . . . . . . . . . . . . . . . .

Component A (Red): #8 (1/2 in.) JIC (3/4-16 unf), with #5 (5/16 in.) JIC adapter

Component B (Blue): #10 (5/8 in.) JIC (7/8-14 unf), with #6 (3/8 in.) JIC adapter

Fluid Circulation Ports . . . . . . . . . . . . 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum

Line Voltage Requirement . . . . . . . . .

230V / 1 phase and 230V / 3 phase Models: 195-264V, 50/60 Hz

400V / 3 phase: 360-440V, 50/60 Hz

Amperage Requirement. . . . . . . . . . . See

Models on page 4

Sound Power . . . . . . . . . . . . . . . . . . . 93 dB

Heater Power

(A (Red) and B (Blue) heaters total, no hose, Heated HFR Models only). . 12 kW

Hydraulic reservoir capacity. . . . . . . . 8 gal. (30 liters)

Recommended hydraulic fluid . . . . . . Citgo A/W Hydraulic Oil, ISO Grade 46

Weight . . . . . . . . . . . . . . . . . . . . . . . .

Units with 12 kW Heaters: 868 lb (394 kg)

Units without heaters: 634 lb (288 kg)

Wetted Parts . . . . . . . . . . . . . . . . . . . Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome, fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically resistant o-rings

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

92 313998J

Motor Control Module Technical Data

Motor Control Module Technical Data

Input Specifications

Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-264 Vac, line-to-line

Input Line Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single or Three Phase

Input Line Frequency . . . . . . . . . . . . . . . . . . . . . . . . .

50/60 Hz

Input Current per Phase. . . . . . . . . . . . . . . . . . . . . . .

25A (three-phase), 50A (single-phase)

Maximum Branch Circuit Protection Rating: . . . . . . .

30A (three-phase), 63A (single-phase)

Short Circuit Current Rating. . . . . . . . . . . . . . . . . . . .

5 kA

Output Specifications

Output Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .

0-264 Vac

Output Line Phasing . . . . . . . . . . . . . . . . . . . . . . . . .

Three Phase

Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-30A

Output Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200% for 0.2 seconds

DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 Vdc, Class 2, Graco-provided power supply

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type 1

Max Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . .

50°C (122°F)

Overtemperature protection is provided to protect from motor overload.

Current limit, set via the software, is provided as a secondary protection from motor overload.

All installations and wiring must comply with NEC and local electrical codes.

313998J 93

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED

TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 313998

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised 12/2011

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