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.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information and maximum
working pressure.
313998S
EN
ti19598a
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
Motor Control Module (MCM) ..............88
Miscellaneous Power ....................90
Technical Data ............................92
Motor Control Module Technical Data .........93
Graco Standard Warranty ...................94
Graco Information .........................94
.................87
2313998S
Related Manuals
Manuals are available at www.graco.com.
Component manuals in U.S. English:
System Manuals
313997HFR Setup-Operation
Power Distribution Box Manual
3A0239Power Distribution Boxes Instruc-
tions-Parts
Pumpline Manuals
3A0019Z-Series Chemical Pumps Instruc-
tions-Parts
3A0020HFR Hydraulic Actuator Instruc-
tions-Parts
Feed System Manuals
Related Manuals
3A0238Dispense Head Hydraulic Power
Pack Instructions-Parts
3A0235Feed Supply Kits
Instructions-Parts
3A0395Stainless Steel Tank Feed Sys-
tems Instructions-Parts
3A1299Carbon Steel Tank Feed Systems
Instructions-Parts
309572Heated Hose, Instructions-Parts
3A0237Heated Hoses and Applicator Kits,
Instructions-Parts
Dispense Valve Manuals
313872
313536GX-16, Operation
312185MD2 Valve, Instructions-Parts
312752S-Head Operation-Parts
312753L-Head Operation-Parts
309550
309856Fusion MP Gun
312666Fusion CS Gun
EP™Gun
Fusion®AP Gun
Accessory Manuals
3A1149HFR Discrete Gateway Module
Kits Manual
313998S3
Models
Models
See Product Configurator on page 5 for detailed product configuration information.
Maximum
Fluid Working
Pressure ‡
psi (MPa, bar)
System
Full Load
PeakAmps
Per Phase*
Voltage
(phase)
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**
55 A230V (1)12,650
HFR,
Non-Heated
29 A230V (3)11,340
--50 (22.7)0.0841.9:1
3000
(20.7, 207)
55 A ★✖400V (3)12,650
116 A230V (1)26,680
HFR,
Heated
73 A230V (3)28,600
6,00050 (22.7)0.0841.9:1
3000
(20.7, 207)
75 A ★✖400V (3)28,600
*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 purchased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see Adjust MotorControl 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.
✖ See 400 V Power Requirements.
400 V Power Requirements
•400 V systems are intended for International voltage
requirements. Not for voltage requirements in North
America.
•If a 400 volt configuration is operated in North America, a special transformer rated for 400 V (“Y” configuration (4 wire)) may be required.
•North America mostly employs a 3 wire or Delta
configuration. The two configurations are not interchangeable.
4313998S
Product Configurator
HFR-A------
Product Configurator
Ref.:123456
Configurator Revision
Base
Voltage
B (Blue) Pump
A (Red) Pump
Primary/Hose Heat
An example of the product configurator would be the following configurator code.
HFR- A - 1 - 6 - AM - AM - D - AG
Ref.:123456
Configurator Revision
Base
Voltage
B (Blue) Pump
A (Red) Pump
Primary/Hose Heat
Hose Bundle Assembly
High Volume/Low Volume
High Volume/Low Volume
The following part number fields apply for the HFR part numbering configurator fields.
Ref. 1PartBase Unit
1HFR Base Unit, Carbon Steel
2HFR Base Unit, Stainless Steel
Ref. 2PartVoltage
1230V, 1 phase;
No Heat
2230V, 1 phase;
Maximum of Two 6 kW Primary Heater and One
Zone of Hose Heat
3230V, 3 phase;
No Heat
4230V, 3 phase;
Maximum of Two 6 kW Primary Heaters and Two
Zones of Hose Heat
5400V, 3 phase;
No heat
6400V, 3 phase;
Maximum of Two 6 kW Primary Heaters and Two
Zones of Hose Heat
Ref. 3PartB (Blue) Pump †
AAL010S1 10 cc Stainless Steel
ABL015S1 15 cc Stainless Steel
ACL020S1 20 cc Stainless Steel
ADL025S1 25 cc Stainless Steel
AEL030S1 30 cc Stainless Steel
AFL040S1 40 cc Stainless Steel
AGL050S1 50 cc Stainless Steel
AHL060S1 60 cc Stainless Steel
AJL080S1 80 cc Stainless Steel
AKL100S1 100 cc Stainless Steel
ALL120S1 120 cc Stainless Steel
AML160S1 160 cc Stainless Steel
ANL005S1 5 cc Stainless Steel
APL086S1 86 cc Stainless Steel
AQL065S1 65 cc Stainless Steel
Ref. 4PartA (Red) Pump †
Code, Part, and Description for Ref. 4 are the same as Ref. 3
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
NOTE: When selecting an applicator, if an applicator is
chosen which does not have a signal communicating to
the HFR, then the sizes of the A and B pumps added
together must be greater or equal to 120 cc. For example: A (red) pump size = 20 cc, B (blue) pump size = 100
cc, 20 cc + 100 cc = 120 cc. Since the pump sizes combined = 120 cc, an applicator may be selected which
does not have a signal communicating to the HFR.
PartDescription
24A084L-Head 6/10 With Calibration Orifice
24A085L-Head 10/14 With Calibration Orifice
24A086L-Head 13/20 With Calibration Orifice
24A090S-Head 6-625 With Calibration Orifice
24A092S-Head 6-500 L/S With Calibration Orifice
24A093S-Head 6-625 L/S With Calibration Orifice
24J187GX-16, 24:1, Straight, Machine Mount
24K233GX-16, 24:1, Left, Machine Mount
24K234GX-16, No Orifice, Left, Machine Mount
24E876GX-16, No Orifice, Straight, Machine Mount
24E877GX-16, 24:1, Right, Machine Mount
24E878GX-16, No Orifice, Right, Machine Mount
CS00RDFusion CS, 1:1 Only, 0.029
CS01RDFusion CS, 1:1 Only, 0.042
CS02RDFusion CS, 1:1 Only, 0.052
246100Fusion AP, 1:1 Only, 0.029
247007Fusion MP, 1:1 Only, 0.029
246101Fusion AP, 1:1 Only, 0.042
247019Fusion MP, 1:1 Only, 0.047
246102Fusion AP, 1:1 Only, 0.052
247025Fusion MP, 1:1 Only, 0.057
24D500Applicator, MD2, 1:1, Soft, Carbon Steel
24D501Applicator, MD2, 1:1, Soft, Carbon Steel, Electric
24D502Applicator, MD2, 1:1, Soft, Carbon Steel, Lever
24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level
Sensor
24C873 Hydraulic Power Pack Manifold Oil Temperature
Sensor
24P090 Mobile Pallet Base with Casters
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
24F235 25 ft hose extensions for L-Head applicator;
24F236 50 ft hose extensions for L-Head applicator;
24F237 25 ft hose extensions for S-Head applicator;
24F238 50 ft hose extensions for S-Head applicator;
24K206 Nip Sensor Kit
24H019 Air Inlet Filter for Hydraulic Power Pack
EP and Fusion®Gun Ratio Check
material, hydraulic, and signal cables
material, hydraulic, and signal cables
material, hydraulic, and signal cable
material, hydraulic, and signal cable
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
PartDescription
24F843 Single DGM Cube with Board
24F844 Two DGM Cubes with Board
24G830 Single DGM Cube
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
PartDescription
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
16313998S
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 elec-
tric 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.
313998S17
Warnings
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.
18313998S
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
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
Keep Components A (Red) and
B (Blue) Separate
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.
313998S19
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
IsoGuard 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.
20313998S
Shutdown
1. Park pumps.
a. From the Home screen, pressand select
Standby mode.
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.
Shutdown
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
5. Perform Pressure Relief Procedure on page 22.
6. Shut down feed pumps as required. See feed pump
manual.
ti9883a1
313998S21
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.
22313998S
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.
Flushing
•To flush feed hoses, pumps, and heaters separately
from heated hoses, set PRESSURE RELIEF/DISPENSE valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION. Flush through bleed
lines (N).
SA
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.
313998S23
Repair
Repair
Pumpline
See Z-Series Chemical Pumps manual, HFR Hydraulic
Driver manuals for more detailed pumpline repair information.
Remove Chemical Pumps
This procedure removes the chemical pumps so that
replacement par ts 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.
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
24C352_313998_4g1
Pump Inlet
24313998S
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 FIG.1.
Lube Cylinder Outlet Fitting
Punch Slot (same on opposite side)
24C352_313998_2g1
Lube Cylinder Inlet Fitting (behind cylinder)
8. Remove coupler from the A and B side pump shafts.
See FIG.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.
FIG. 1: Lube Cylinder
7. Remove two shoulder bolts from LVDT collar then
remove collar from B side pump shaft. See FIG.2.
Pump Outlet Housing
LVDT Sensor Assembly
(behind pump)
LVDT Spool Assembly
24C352_313998_2g1
LVDT Collar
Coupler
Nuts
FIG.2
313998S25
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 procedure, see page 26.
7. Reconnect inlet and outlet fluid lines.
Prime IsoGuard Select®Cylinder
24C352_313998_8g1
FIG. 3: IsoGuard Select System
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.
26313998S
Repair
Remove HFR Hydraulic Driver
155
156
124
125
155
156
180
188
112
FIG.4
111
24C352_313998_5g1
4. See FIG. 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
104
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.
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
24C352_313998_4e1
5. Perform Install Chemical Pumps procedure, see
page 26.
3. Remove pump support brackets. Each bracket is
secured with three screws at the base frame and
two screws at the manifold bracket.
313998S27
Repair
Remove 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. See Hydraulic PowerPack 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
4. Remove lube cylinder inlet and outlet fittings. Let
cylinder drain.
Punch Slot (same on opposite side)
Lube Cylinder Outlet Fitting
24C352_313998_8e1
Lube Cylinder Inlet Fitting
FIG. 5: Lube Cylinder, Viewed from Rear Left of
Machine
Pump Inlet
24C352_313998_4e1
5. See FIG. 6. Remove four screws (107) securing
pumpline to hydraulic power pack. This will also
loosen manifold plate (104) from hydraulic driver.
155
111
104
156
124
125
155
156
180
188
112
24C352_313998_5g1
FIG.6
28313998S
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
FIG. 7. Remove pumpline.
Repair
FIG.7
24C352_313998_4e1
313998S29
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