Repair. Graco 313998S - HFR, Repair - Parts, 313998U - HFR, Repair - Parts, 313998S, 313998T - HFR, Repair - Parts

Add to my manuals
94 Pages

advertisement

Repair. Graco 313998S - HFR, Repair - Parts, 313998U - HFR, Repair - Parts, 313998S, 313998T - HFR, Repair - Parts | Manualzz

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 313998T

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

313998T 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

® dure, see page 26.

Cylinder

proce-

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 (24F516) into tube to fill cylinder.

5. With check valve arrow pointing away from the

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

6.

Install tubes into reservoir and install reservoir into holder.

26 313998T

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.

313998T 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 313998T

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

313998T 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 infor-

mation.

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

® dure, see page 26.

Cylinder

proce-

5.

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

Fluid Manifold Inlet

Pump Outlet

30

Pump Inlet

24C352_313998_4e1

313998T

Repair

313998T 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

11

705

744

721,

727 4 11

710

2

12

711

723

9

12

725

10

745

14

731

7

11

732

6

11

733 730 728

6

11

15

729

701

726

738

11

8

737

702

.30

1

+.01

-.00

702

5

11

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 medium strength threadlocker prior to assembly.

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 313998T

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.

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

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

See F IG . 8 on page 32.

1.

Perform

Shutdown procedure, see page 21.

2.

Remove Hydraulic Power Pack Shroud , see pro-

cedure 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.

313998T 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 313998T

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 procedure 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.

313998T 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 313998T

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

proce-

dure, 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).

313998T 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 313998T

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement

Table of contents