Graco 313998S User Manual

Page 1

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.

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

ti19598a

Page 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

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

2 313998S

Page 3

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 Instruc-

tions-Parts

Pumpline Manuals

3A0019 Z-Series Chemical Pumps Instruc-

tions-Parts

3A0020 HFR Hydraulic Actuator Instruc-

tions-Parts

Feed System Manuals

Related Manuals

3A0238 Dispense Head Hydraulic Power

Pack Instructions-Parts

3A0235 Feed Supply Kits

Instructions-Parts

3A0395 Stainless Steel Tank Feed Sys-

tems Instructions-Parts

3A1299 Carbon Steel Tank Feed Systems

Instructions-Parts

309572 Heated Hose, Instructions-Parts

3A0237 Heated Hoses and Applicator Kits,

Instructions-Parts

Dispense Valve Manuals

313872

313536 GX-16, Operation

312185 MD2 Valve, Instructions-Parts

312752 S-Head Operation-Parts

312753 L-Head Operation-Parts

309550

309856 Fusion MP Gun

312666 Fusion CS Gun

EP™Gun

Fusion®AP Gun

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

313998S 3

Page 4

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 A 230V (1) 12,650 HFR, Non-Heated

29 A 230V (3) 11,340

-- 50 (22.7) 0.084 1.9:1

3000

(20.7, 207)

55 A ★✖ 400V (3) 12,650

116 A 230V (1) 26,680 HFR, Heated

73 A 230V (3) 28,600

6,000 50 (22.7) 0.084 1.9:1

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 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.

✖ 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.

4 313998S

Page 5

Product Configurator

HFR-A------

Product Configurator

Ref.: 1 2 3 4 5 6

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.: 1 2 3 4 5 6

Configurator Revision

Base

Voltage

B (Blue) Pump

A (Red) Pump

Primary/Hose Heat

Hose Bundle Assembly

High Volume/Low Volume

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

Ref. 1 Part Base Unit

1 HFR Base Unit, Carbon Steel

2 HFR Base Unit, Stainless Steel

Ref. 2 Part Voltage

1 230V, 1 phase;

No Heat

2 230V, 1 phase;

Maximum of Two 6 kW Primary Heater and One Zone of Hose Heat

3 230V, 3 phase;

No Heat

4 230V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two Zones of Hose Heat

5 400V, 3 phase;

No heat

6 400V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two Zones of Hose Heat

Ref. 3 Part B (Blue) Pump †

AA L010S1 10 cc Stainless Steel

AB L015S1 15 cc Stainless Steel

AC L020S1 20 cc Stainless Steel

AD L025S1 25 cc Stainless Steel

AE L030S1 30 cc Stainless Steel

AF L040S1 40 cc Stainless Steel

AG L050S1 50 cc Stainless Steel

AH L060S1 60 cc Stainless Steel

AJ L080S1 80 cc Stainless Steel

AK L100S1 100 cc Stainless Steel

AL L120S1 120 cc Stainless Steel

AM L160S1 160 cc Stainless Steel

AN L005S1 5 cc Stainless Steel

AP L086S1 86 cc Stainless Steel

AQ L065S1 65 cc Stainless Steel

Ref. 4 Part A (Red) Pump †

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

313998S 5

Page 6

Product Configurator

Ref. 5 Part Primary/Hose Heat

A No Heat

B A (Red) and B (Blue) Primary Heaters

C A (Red) and B (Blue) Primary Heaters, One Zone

of Hose Heat

D A (Red) and B (Blue) Primary Heaters, A (Red)

and B (Blue) Hose Heat

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

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

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

B (Blue) Applicator Hose or High Volume/

Ref. 6 Part

-- No Hose

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Low Volume Hose Bundle Assembly

3500 psi

2000 psi

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

2000 psi

24D126 Single Hose, 1:1, 3/8 x 3/8, 25 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

† Pump size listed is the combined volume dispensed

in one extending stroke and one retracting stroke.

6 313998S

Page 7

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

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

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 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

313998S 7

Page 8

Product Configurator

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

8 313998S

Page 9

Product Configurator

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

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

313998S 9

Page 10

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

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.

Part Description

24A084 L-Head 6/10 With Calibration Orifice

24A085 L-Head 10/14 With Calibration Orifice

24A086 L-Head 13/20 With Calibration Orifice

24A090 S-Head 6-625 With Calibration Orifice

24A092 S-Head 6-500 L/S With Calibration Orifice

24A093 S-Head 6-625 L/S With Calibration Orifice

24J187 GX-16, 24:1, Straight, Machine Mount

24K233 GX-16, 24:1, Left, Machine Mount

24K234 GX-16, No Orifice, Left, Machine Mount

24E876 GX-16, No Orifice, Straight, Machine Mount

24E877 GX-16, 24:1, Right, Machine Mount

24E878 GX-16, No Orifice, Right, Machine Mount

CS00RD Fusion CS, 1:1 Only, 0.029

CS01RD Fusion CS, 1:1 Only, 0.042

CS02RD Fusion CS, 1:1 Only, 0.052

246100 Fusion AP, 1:1 Only, 0.029

247007 Fusion MP, 1:1 Only, 0.029

246101 Fusion AP, 1:1 Only, 0.042

247019 Fusion MP, 1:1 Only, 0.047

246102 Fusion AP, 1:1 Only, 0.052

247025 Fusion MP, 1:1 Only, 0.057

24D500 Applicator, MD2, 1:1, Soft, Carbon Steel

24D501 Applicator, MD2, 1:1, Soft, Carbon Steel, Electric

24D502 Applicator, MD2, 1:1, Soft, Carbon Steel, Lever

24D503 Applicator, MD2, 1:1, Soft, Stainless Steel

24D504 Applicator, MD2, 1:1, Soft, Stainless Steel, Elec-

tric

24D505 Applicator, MD2, 1:1, Soft, Stainless Steel, Lever

24D509 Applicator, MD2, 1:1, Hard, Carbon Steel

24D510 Applicator, MD2, 1:1, Hard, Carbon Steel, Electric

24D511 Applicator, MD2, 1:1, Hard, Carbon Steel, Lever

24D512 Applicator, MD2, 1:1, Hard, Carbon Steel, Pneu-

matic

24D513 Applicator, MD2, 1:1, Hard, Stainless Steel

24D514 Applicator, MD2, 1:1, Hard, Stainless Steel, Elec-

tric

24D515 Applicator, MD2, 1:1, Hard, Stainless Steel, Lever

24D516 Applicator, MD2, 1:1, Hard, Stainless Steel,

Pneumatic

24D521 Applicator, MD2, 10:1, Soft, Carbon Steel

24D522 Applicator, MD2, 10:1, Soft, Carbon Steel, Elec-

tric

24D523 Applicator, MD2, 10:1, Soft, Carbon Steel, Lever

24D524 Applicator, MD2, 10:1, Soft, Stainless Steel

24D525 Applicator, MD2, 10:1, Soft, Stainless Steel, Elec-

tric

24D526 Applicator, MD2, 10:1, Soft, Stainless Steel,

Lever

24D530 Applicator, MD2, 10:1, Hard, Carbon Steel

24D531 Applicator, MD2, 10:1, Hard, Carbon Steel, Elec-

tric

24D532 Applicator, MD2, 10:1, Hard, Carbon Steel, Lever

24D533 Applicator, MD2, 10:1, Hard, Carbon Steel, Pneu-

matic

24D534 Applicator, MD2, 10:1, Hard, Stainless Steel

24D535 Applicator, MD2, 10:1, Hard, Stainless Steel,

Electric

24D536 Applicator, MD2, 10:1, Hard, Stainless Steel,

Lever

24D537 Applicator, MD2, 10:1, Hard, Stainless Steel,

Pneumatic

24E505 MD2 Orifice Adapter Kit

257999 EP Pour Gun, Pistol Grip, 1/4 in. Purge Rod

24C932 EP Pour Gun, Machine mount, 1/4 in. Purge Rod

10 313998S

Page 11

Product Configurator

24C933 EP Pour Gun, Pistol Grip, 3/8 in. Purge Rod

24C934 EP Pour Gun, Machine Mount, 3/8 in. Purge Rod

LC0058 Mixer Kit, (10) 3/8 in. x 24 Element with Shroud

LC0059 Mixer Kit, (10) 3/8 in. x 36 Element with Shroud

LC0060 Mixer Kit, (10) 3/8 in. Combo with Shroud

LC0295 Mixer Kit, (10) 1/2 in. x 24 Element with Shroud

LC0296 Mixer Kit, (10) 1/2 in. x 36 Element with Shroud

LC0079 Mixer Pack, (50) 3/8 in. x 24 Element

LC0080 Mixer Pack, (50) 3/8 in. x 24 Element

LC0081 Mixer Pack, (50) 3/8 in. Combo Element

LC0086 Mixer Pack, (250) 3/8 in. x 24 Element

LC0087 Mixer Pack, (250) 3/8 in. x 36 Element

LC0088 Mixer Pack, (250) 3/8 in. Combo Element

B (Blue) Applicator Orifice

S-Head and L-Head

Description Part For Use With Applicator:

Calibrate 24A036 S-Head Only

0.25 24A037 S-Head Only

0.35 24A038 S-Head Only

0.50 24A039 S-Head Only

0.60 24A040 S-Head Only

0.70 24A041 S-Head Only

0.80 24A042 S-Head Only

0.90 24A043 S-Head Only

1.00 24A044 S-Head Only

1.10 24A045 S-Head Only

1.20 24A046 S-Head Only

1.30 24A047 S-Head Only

1.40 24A050 S-Head Only

1.50 24A051 S-Head Only

1.60 24A052 S-Head Only

1.70 24A053 S-Head Only

1.80 24A054 S-Head Only

1.90 24A055 S-Head Only

2.00 24A056 S-Head Only

2.50 24A057 S-Head Only

3.00 24A058 S-Head Only

3.50 24A059 S-Head Only

4.00 24A060 S-Head Only

4.20 24A061 S-Head Only

4.50 24A062 S-Head Only

5.00 24A063 S-Head Only

5.50 24A064 S-Head Only

6.00 24A065 S-Head Only

6.50 24A066 S-Head Only

7.00 24A067 S-Head Only

Calibrate M0934A-4 L-Head Only

0.25 247761 L-Head Only

0.45 247762 L-Head Only

0.5 247763 L-Head Only

0.75 247764 L-Head Only

0.8 247765 L-Head Only

0.85 247766 L-Head Only

1 247767 L-Head Only

1.1 247811 L-Head Only

1.2 247848 L-Head Only

1.25 248858 L-Head Only

1.3 247859 L-Head Only

1.4 247860 L-Head Only

1.5 247861 L-Head Only

1.6 247862 L-Head Only

1.65 247863 L-Head Only

1.7 247864 L-Head Only

1.75 247865 L-Head Only

1.8 247866 L-Head Only

1.9 247867 L-Head Only

2 247868 L-Head Only

2.4 247869 L-Head Only

3.2 247870 L-Head Only

3.6 247871 L-Head Only

4.2 247872 L-Head Only

5 247873 L-Head Only

5.6 247874 L-Head Only

GX-16

Description Part

257701 0.011 in. Orifice

257702 0.013 in. Orifice

257703 0.016 in. Orifice

257704 0.018 in. Orifice

257705 0.020 in. Orifice

257706 0.022 in. Orifice

257707 0.023 in. Orifice

257708 0.024 in. Orifice

257709 0.025 in. Orifice

257710 0.026 in. Orifice

257711 0.028 in. Orifice

257712 0.029 in. Orifice

257713 0.032 in. Orifice

257714 0.035 in. Orifice

257715 0.036 in. Orifice

257716 0.038 in. Orifice

257717 0.039 in. Orifice

257718 0.040 in. Orifice

257719 0.042 in. Orifice

257720 0.043 in. Orifice

257721 0.044 in. Orifice

257722 0.049 in. Orifice

257723 0.052 in. Orifice

257724 0.061 in. Orifice

24K682 0.085 in. Orifice

313998S 11

Page 12

Product Configurator

EP™Gun

Description Part For Use With Applicator:

Orifice Kit 24E250 EP 250, 6 Blue, 6 Red

0.51 mm Poly Orifice

0.79 mm Poly Orifice

1.19 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 24E251 EP 375, 6 Blue, 6 Red

0.51 mm Poly Orifice

0.79 mm Poly Orifice

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

24C751 EP 250 Poly Side Orifice, Std

24C752 EP 250 Poly Side Orifice, Std

24C753 EP 250 Poly Side Orifice, Std

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

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

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

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

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 Part

257701 0.011 in. Orifice

257702 0.013 in. Orifice

257703 0.016 in. Orifice

257704 0.018 in. Orifice

257705 0.020 in. Orifice

257706 0.022 in. Orifice

257707 0.023 in. Orifice

257708 0.024 in. Orifice

257709 0.025 in. Orifice

257710 0.026 in. Orifice

257711 0.028 in. Orifice

257712 0.029 in. Orifice

257713 0.032 in. Orifice

257714 0.035 in. Orifice

257715 0.036 in. Orifice

257716 0.038 in. Orifice

257717 0.039 in. Orifice

257718 0.040 in. Orifice

257719 0.042 in. Orifice

257720 0.043 in. Orifice

257721 0.044 in. Orifice

257722 0.049 in. Orifice

257723 0.052 in. Orifice

257724 0.061 in. Orifice

24K682 0.085 in. Orifice

12 313998S

Page 13

Product Configurator

EP Gun

Description Part For Use With Applicator:

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

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

24D223 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

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

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

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

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

313998S 13

Page 14

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

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

High-Flo®(Air/Fluid) Carbon Steel Complete Supply Pump Kit

Pump Kit

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 Sup-

ply Pump Kit

24D095 5:1 Monarch 55G Stainless Steel Complete Sup-

ply Pump Kit

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

Pump Kit

257777 High-Flo Stainless Steel Complete Supply Pump

Kit

246366

246367 Husky 716 Pump, Drum with Riser Tube

24D329 Husky 1050 Pump, Drum with Riser Tube

233052 Husky 515 Diaphragm Pump, Drum with Riser

233057 Husky 716 Diaphragm Pump, Drum with Riser

24D097 Husky 1050 SS Pump, Drum with Riser Tube

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

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

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

246481 Husky 515 Pump with Carbon Steel Fluid Plumb-

246482 Husky 716 Pump with Carbon Steel Fluid Plumb-

24D332 Husky 1050 Pump with Carbon Steel Fluid

246898 2:1 Supply Pump with Carbon Steel Fluid Plumb-

24D100 Husky 515 Pump with Stainless Steel Fluid

24D101 Husky 716 Pump with Stainless Steel Fluid

24D102 Husky 1050 Pump with Stainless Steel Fluid

24D103 2:1 Supply Pump with Stainless Steel Fluid

24D104 5:1 Monarch Pump with Stainless Steel Fluid

24D105 5:1 Monarch Pump with Stainless Steel Fluid

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

Husky™515 Pump, Drum with Riser Tube

Tube

Riser Tubes

with Riser Tubes

ing

Plumbing

ing

Plumbing

14 313998S

Page 15

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 Ele-

ment

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

ment

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 Sen-

sors

24D572 38L Tank, Agitation, Slinger Plate, Heat, Insula-

tion, 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 Sen-

sors

24D578 75L Tank, Agitation, Slinger Plate, Heat, Insula-

tion, 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 Sen-

sors, Insulated

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

Insulated

24J243 2gal (7.6L) Stainless Steel Tank

313998S 15

Page 16

Product Configurator

Additional Accessories

Miscellaneous

Part Description

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 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

Part Description

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

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

16 313998S

Page 17

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.

313998S 17

Page 18

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.

18 313998S

Page 19

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.

313998S 19

Page 20

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.

20 313998S

Page 21

Shutdown

1. Park pumps.

a. From the Home screen, press and 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).

5. Perform Pressure Relief Procedure on page 22.

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

ti9883a1

313998S 21

Page 22

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.

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 313998S

Page 23

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).

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.

313998S 23

Page 24

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

24 313998S

Page 25

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

313998S 25

Page 26

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.

26 313998S

Page 27

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.

313998S 27

Page 28

Repair

Remove PowerHouse Pumpline

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

28 313998S

Page 29

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

313998S 29

Page 30

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

2. See FIG. 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 FIG.

5. Apply thread sealant to threads.

4. Perform Prime IsoGuard Select®Cylinder procedure, see page 26.

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

Fluid Manifold Inlet

Pump Outlet

24C352_313998_4e1

Pump Inlet

30 313998S

Page 31

Repair

313998S 31

Page 32

Repair

Hydraulic Power Pack Repair

715

716

704

714

709

712

713

708

724

735

11 26

734

721, 722

746

728

730733732731745

729

718

717

719

706

705

710

711

723

725

721, 727

744

737

726

701

738

707

702

257442_3A0998_1j

702

720

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

Torque to 40 ft-lb (54 N•m).

Torque to 35 ft-lb (47 N•m).

Torque to 20 ft-lb (27 N•m).

Torque to 15 ft-lb (20 N•m).

Torque to 10 ft-lb (14 N•m).

Torque to 58 in-lb (6.5 N•m).

+.00

.45

-.02

702

Torque to 34 in-lb (3.8 N•m).

Torque 1/4 turn past hand-tight.

Apply PTFE tape on installation end only.

Apply medium strength threadlocker prior to assembly.

Apply light coating of lubricant to seals.

Fill reservoir with hydraulic fluid.

+.01

.30

-.00

Orient with airflow arrow pointing toward mounting bracket.

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

Align fan plug as shown.

Apply thermal lubricant to contact side.

731

FIG. 8: Hydraulic DC Power Pack

32 313998S

Page 33

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 FIG. 8 on page 32.

NOTICE

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

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 procedure on this page.

Remove Motor Control Module

See FIG. 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.

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 FIG. 8 on page 32.

1. Perform Shutdown procedure, see page 21.

2. Remove Hydraulic Power Pack Shroud, see procedure on this page.

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.

313998S 33

Page 34

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 FIG.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.

• 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).

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.

257396_3b9905_04b

FIG.9

34 313998S

Page 35

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 FIG. 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.

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 FIG. 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 procedure, 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 FIG. 10. See FIG. 8 on page 32 for full hydraulic power pack view.

703 746

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

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.

NOTICE

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

746

257442_313998_1j1

Install third eye-bolt here

FIG.10

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.

313998S 35

Page 36

Repair

Install Hydraulic Power Pack

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 FIG. 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.

Replace Tank Gasket, Tank

See FIG. 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 (720). Carefully remove motor (701) and hydraulic housing assembly from tank.

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

NOTICE

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

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

5. Remove eye-bolts. Install original bolts (746) into fluid housing (703). See FIG. 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.

36 313998S

See FIG. 8 on page 32.

1. Perform Remove Hydraulic Power Pack procedure, 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.

Page 37

Repair

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

Install Motor

See FIG. 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).

Remove Hydraulic Gear Pump

See FIG. 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.

NOTICE

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

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.

Install Hydraulic Gear Pump

See FIG. 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 FIG. 8 on page 32. for fitting alignment. Torque both fittings to 40 ft-lb (54 N•m).

313998S 37

Page 38

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 313998S

Page 39

Parts

Base Machine

Parts

175

127

110

123

193

ti19598a

147

112

FIG. 11: Base Machine, Image 1 of 6

313998S 39

Page 40

Parts

155

156

124

125

155 156 180

188

112

151, 165

111

104

105, 150

171

110

189

187

Torque to 300 in-lb (34 N•m).

Torque to 79 in-lb (8.9 N•m).

Torque to 62 in-lb (7.0 N•m).

Torque to 150 in-lb (17 N•m).

ti19600a

See Power Distribution

Box manual

110

ti19601a

FIG. 12: Base Machine, Image 2 of 6

40 313998S

Page 41

115

114

121

Parts

157

ti19603a

158

154

110

132

108

130

128

161

102

110

Torque to 40-50 ft-lb (54-68 N•m).

IsoGuard Select fluid, 24F516.

Torque to 17 ft-lb (23 N•m).

101

176

129

FIG. 13: Base Machine, Image 3 of 6

313998S 41

Page 42

Parts

116, 117

132

152, 153

118, 119, 120

168

110

160

146

168

109

110

ti19604a

163

162

Apply sealant to pipe threads.

Do not apply sealant to threads.

Torque to 40-50 ft-lb (54-68 N•m).

FIG. 14: Base Machine, Image 4 of 6

42 313998S

Page 43

132

Parts

†

132

166

183

131

135

136

†

144, 145

134

153

139

106

131

141

†

183

166

153

†

143

†

135

156

133

144, 145

122

126

143

122

24C352_313998_9e

142

140

Torque to 50-60 ft-lb (68-81 N•m).

Torque to 40-50 ft-lb (54-68 N•m).

Assemble to orientation shown.

Apply sealant to pipe threads.

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

Apply a thin coating of lubricant.

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

167

FIG. 15: Base Machine, Image 5 of 6

313998S 43

Page 44

Parts

195

196

194

FIG. 16: Base Machine, Image 6 of 6

24C352_313998_11

44 313998S

Page 45

Quantity

BASE,

fixed ratio,

Ref Part Description

101 MODULE, power pack, enclosure, assy 1 1 102 24M024 BRACKET, anchor 4 4 104 24E170 BRACKET, manifold 1 1 105 103413 PACKING, o-ring 2 2 106 258771 DRIVER, hydraulic, horizontal 1 1 107 16E281 STUD, threaded, 3/8-16 x 6.0 long 4 4 108 BRACKET, pump, left 1 1 109 BRACKET, pump, right 1 1 110 111800 SCREW, cap, hex head 23 23 111 255629 MANIFOLD, inlet, fluid, h-controller 1

289999 MANIFOLD, fluid, sst 1 112 113796 SCREW, flanged, hex hd 4 4 114 24E647 BRACKET, ADM mounting 1 1 115 255235 BRACKET, mounting, assembly 1 1 116 120060 CLIP, speed, tubular 2 2 117 122168 RIVET, aluminum 2 2 118 110755 WASHER, plain 1 1 119 100016 WASHER, lock 1 1 120 121253 KNOB, display adj. 1 1 121 24E451 MODULE, ADM, w/ USB 1 1 122 123111 FITTING, nipple, hex, 3/4 NPT, 3k, ss 2

C20487 FITTING, nipple, hex 2 123 24C234 COVER, shroud, front 1 1 124 117502 FITTING, reducer #5 x #8 (JIC) 1

16A361 FITTING, reducer, #5 x #8 (JIC), sst 1 125 117677 FITTING, reducer #6 x #10 (JIC) 1

16A362 FITTING, reducer, #6x #10 (JIC), sst 1 126 255159 KIT, assembly, pair, inlet 1

KIT, pair, inlet, sst, no filter 1 127 24B855 COVER, assembly 1 1 128 297216 BRACKET, reservoir, lube 1 1 129 295187 SCREW, machine, ph,8x3/8 2 2 130 258707 RESERVOIR, bottle, assembly 1 1 131 15X519 ROD, tie, 12 lng, 5/8-11 unc 6 6 132 101712 NUT, lock 6 6 133 15Y596 HOUSING, iso lube, telescoping 1 1 134 15Y595 HOUSING, iso lube, telescoping 1 1 135 C20278 PACKING, o-ring 2 2 136 122892 O-RING, fluoroelastomer, 038 1 1 139 125966 CLIP, hairpin 1 1 140 258669 SENSOR, assembly 1 1 141 16A509 COLLAR, sensor, lvdt 1 1 142 258704 SPOOL, assembly, lvdt 1 1 143 119999 BOLT, shoulder 2 2 144 191892 FITTING, elbow, street, 90 deg 2 2 145 116746 FITTING, barbed, plated 2 2

non-stainless

BASE,

fixed ratio,

stainless

Parts

313998S 45

Page 46

Parts

Quantity

BASE,

fixed ratio,

Ref Part Description

146 24C235 COVER, pump 1 1 147 24C153 COVER, heat exchanger 1 1 150 123313 VALVE, directional, hydraulic 1 1 151 123366 SCREW, shc, 10-24 x 1.125, s 4 4 152 16A093 SENSOR, pressure, fluid outlet 2 2 153 121399 PACKING, o-ring 012 fx75 4 4 154 121002 CABLE, can, female / female 1.5m 1 1 155 205447 COUPLING, hose 2 2 156 054826 TUBE, plastic 10 10 157 123798 CABLE, m8, 4-pin, mf, 1m, molded 1 1 158 120999 RESISTOR, terminal, turck rke 57-tr2 1 1 160

161 COVER, enclosure, slotted, assembly 1 1 162 122970 FITTING, adapter, JIC (08) x sae (08), m 1 1 163 123140 FITTING, cap, 1/2 JIC, cs 1 1 164 SEALANT, pipe, sst 1 1 165 SEALANT, anaerobic 1 1 166 121312 FITTING, elbow, sae x JIC 2

167 123112 FITTING, t, 1/4 tube, prestolock, brass 1 1 168 121581 HARNESS, I/O, M12 x M12 1 1 170 054175 TUBE, nylon, rd 5 5 171 LUBRICANT, grease 1 1 173 24F516 FLUID, ISO-Guard Select, 6 qt. 1 1 174 LABEL, identification 1 1 175

176

177 FLUID, hydraulic (gallon) 9 9 178 117792 GUN, grease, 3 oz 1 1 179 117773 LUBRICANT, grease, food grade 1 1 180 555621 WASHER, 3/8 plain flat 4 4 181 15V551 SHIELD, membrane, ADM 0.100 0.100 187 16E277 BUSHING, flanged, 1.0 x 1.25 x 1.0 4 4 188 U90126 NUT, hex, 3/8-16, ms, gr8 4 4 189 071019 ADHESIVE, anaerobic 1 1 193 124804 SCREW, hex, slotted 4 4 194 15U075 SCREW, cap, bh, 8-32 x 0.37 4 4 195 24H018 FILTER, air 1 1 196 16G251 HOUSING, filter 1 1 199 16H821 TOKEN, software upgrade 1 1

15H108▲

123108 FITTING, elbow, 3/4 sae x 1/2 JIC, sst 2

15M511▲

LABEL, pinch point 1 1

LABEL, HFR metering system

LABEL, warning, eng/span/fre 1 1

non-stainless

1 1

BASE,

fixed ratio,

stainless

† See Z-Series Chemical Pumps manual for parts

information.

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

46 313998S

Page 47

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

313998S 47

Page 48

Parts

Non-Stainless Steel Fluid Manifold 255629, Stainless Steel Fluid Manifold 289999 Aluminum Manifold with Stainless Steel Fittings, 24P166

308

318

306

304

314

315

1 3

302b

302

302a

303

301

312

313

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

Apply sealant (113500) to threads.

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

Adapter fittings for hoses are included in base machine parts. See Base Machine starting on page 39 for part numbers.

For assembly 24P166, replace o-ring that comes standard with item 302.

317

255629_313998_1a

307

314

**Apply PTFE or thread sealant to tapered threads.

48 313998S

Page 49

Part

Ref

Assembly 255629

Assembly 289999

Assembly 24P166

Description

301 247837 24E307 255228 MANIFOLD, fluid 1 302† 247824 24E306 24E306** VALVE, drain cartridge 2 .302a 158674† 158674† 556560** . O-RING 1 302b† 247779 247779 247779 . SEAL, seat, valve 1 303 102814 112941 112941 GAUGE, pressure, fluid 2 304 162453 166846 166846 FITTING 2 306 247788 247788 247788 HANDLE, red 1 307 247789 247789 247789 HANDLE, blue 1 308† 112309 112309 112309 NUT, hex, jam 2 312 117556 123106 123106 NIPPLE, #8 JIC x 1/2 npt 1 313 117557 123107 123107 NIPPLE, #10 JIC x 1/2 npt 1 314 121312 123108 126565 ELBOW, 90 degrees 2 315 100840 166866 166866 ELBOW, street, 1/4 npsm x

1/4 npt 317▲ 189285 189285 189285 LABEL, caution 1 318† 150829 150829 150829 SPRING, compression 2

Parts

▲ 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).

** When replacing item 302, item 302a must be

ordered to replace the standard o-ring that comes with item 302.

313998S 49

Page 50

Parts

Non-SST Fluid Inlet Assemblies, 255159 Aluminum Fluid Inlet Assemblies with Stainless Steel Fittings, 24P167

A Side Shown

401

413

412

402

403

404

407

405

406

414

** Apply sealant to all non-swivel fittings.

410

408

409

ti9841a1

Part

Ref

Assembly 255159

Assembly 24P167

Description Qty

401 118459 112268 UNION, swivel; 3/4 npt(m) 3/4 npsm(f) 3

402 --- --- VALVE, ball; 3/4 npt (FBE) 2

403 --- --- NIPPLE; 3/4 npt 2

404 247503 247503 MANIFOLD, strainer, inlet 2

405 102124 102124 THERMOMETER, dial 2

406 120300 120300 GAUGE, pressure, fluid 2

407 180199 180199 ELEMENT, filter; 20 mesh (standard) 2

408 15H200 15H200 GASKET, strainer; PTFE 2

409 15H199 15H199 PLUG, strainer 2

410 --- --- PLUG, pipe; 3/8 npt 2

411 296178 123980 UNION, swivel; 3/4 npt(m) x 1/2 npt(f); A side only 1

412 15D757 15D757 HOUSING, thermometer 2

413 253481 253481 GUARD, gauge 2

414 111800 111800 SCREW, cap, hex hd, 5/16-18 x 5/8 in. (16 mm) 4

415 --- --- SEALANT, pipe, sst 1

401, 411

--- Not available for individual sale.

50 313998S

Page 51

SST Fluid Inlet Assemblies

B (Blue) Side Assembly shown, A (Red) Assembly also included

502

Parts

501

505, 509

503

507

506

508

504

501, 512

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

Ref Part Description Qty

501 112268 SWIVEL, union 3 502 512485 VALVE, ball, sst 2 503 123111 FITTING, nipple, hex, 3/4npt,

3k, ss 504 501118 FITTING, tee 4 505 102124 THERMOMETER, dial 2 506 120300 GAUGE, press, fluid,

(waterborne) 507 500352 BUSHING, hex hd, sst 2 508 516308 FITTING, bushing, reducer,

sst 509 15D757 HOUSING, thermometer,

Viscon®hp 510 SEALANT, pipe, sst 1 511 TAPE, tfe, sealant 1 512 123980 FITTING, straight, swivel, 1/2

x 3/4, FM, sst

24D285_313998_1a

313998S 51

Page 52

Parts

Power Pack Module

606

608

605

609

24C273_313998_1d

Torque to 10 ft-lb (14 N•m).

Apply sealant to threads.

604

603

610

1 2

24C273_313998_2d

607

601

Ref Part Description Qty

601 ENCLOSURE, frame, painted 602 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)

1 1 4 4 1 2 1 1 1 2 1 1 1

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

52 313998S

Page 53

Parts

313998S 53

Page 54

Parts

Power Pack Module Sub-Assemblies

Hydraulic DC Power Pack Module

715

716

704

714

709

712

713

708

724

735

11 26

734

703

721, 722

746

728

730733732731745

729

718

717

719

706

705

710

711

723

725

721, 727

744

737

726

701

738

707

702

_313998_1j

706

720

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

Torque to 40 ft-lb (54 N•m).

Torque to 35 ft-lb (47 N•m).

Torque to 20 ft-lb (27 N•m).

Torque to 15 ft-lb (20 N•m).

Torque to 10 ft-lb (14 N•m).

Torque to 58 in-lb (6.5 N•m).

748, 749

736

.45

702

Torque to 34 in-lb (3.8 N•m).

Torque 1/4 turn past hand-tight.

Apply PTFE tape on installation end only.

Apply medium strength threadlocker prior to assembly.

Apply light coating of lubricant to seals.

Fill reservoir with hydraulic fluid.

+.00

-.02

+.01

.30

-.00

Orient with airflow arrow pointing toward mounting bracket.

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

Align fan plug as shown.

Apply thermal lubricant to contact side.

731

FIG. 17: Hydraulic DC Power Pack

54 313998S

Page 55

Parts

Ref Part Description Qty

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 115597 NIPPLE 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.

1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 4 1 7 1 1 8 2 1 1 8 2 4 1 1 1 1 1 1 2 1 5 5

313998S 55

Page 56

Parts

Heat Exchanger Assembly

257931_313998_2f

801

806

4 5

804

802

3 5

808

805

807

803

805

257931_313998_1f

1 2

Torque to 65 ft-lb (88 N•m).

Apply lubricant to o-rings before assembling.

Torque to 8 ft-lb (11 N•m).

Torque to 2.5 ft-lb (3.4 N•m).

Ref Part Description Qty

801 257967 COVER, enclosure, heat exch,

painted 802 15X621 GASKET, fan, mounting 1 803 122300 EXCHANGER, heat, m-4 1 804 122301 FAN, 220v 1 805 122842 FITTING, elbow, sae x jic 2 806 15U075 SCREW, cap, bh, 8-32 x

.37(matrix) 807 110755 WASHER, plain 4 808 100022 SCREW, cap, hex hd (matrix) 4 810 LUBRICANT, thread 1 811 SEALANT, anaerobic 1

Apply sealant to threads.

Orient fan with airflow arrow pointing toward cover.

Align fan plug as shown.

56 313998S

Page 57

Heater Options

Parts

922 910 908 913 914

904

931

902

908

24C327_313998_1L

929 930

916

925

918919 917

920

926

912

911

903

932

901

909

906

904

908

905

908

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.

Tighten NPT thread at least one turn after RTD has been tightened.

Apply thermal lubricant when assembling Ref. 934.

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

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.

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

Torque to 17 ft-lb (23 N•m).

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

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

FIG. 18: Heater Options, Image 1 of 4

313998S 57

Page 58

Parts

927

928

938

933

934

905

935

907

921

Non-Heated Models Only

24C327_313998_2L

915

24C327_313998_1L

Ref. 924, 258757 shown

905

24C327_313997_9f

FIG. 19: Heater Options, Image 2 of 4

58 313998S

Page 59

Quantity

Parts

Ref Part Description

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

A (Red) and B (Blue) Hose Heat

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

One Zone of Hose Heat

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

Stainless Steel

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

Carbon Steel

A (Red) and B (Blue) Primary Heaters

B (Blue) Primary Heaters,

B (Blue) Hose Heat

901 MODULE, panel, pwr, heat, hose, pr, lv 1 1

MODULE, panel, pwr, heat, hose, lv 1 1 MODULE, panel, pwr, heat, pri, lv 1

902 MODULE, panel, pwr, heat, hose, pr, hv 1 1

MODULE, panel, pwr, heat, hose, hv 1 1 MODULE, panel, pwr, heat, pri, hv 1 1

MODULE, panel, pwr, no heat, hv 1 903 115942 NUT, hex, flange head 6 6 6 6 6 3 3 904 253192 BRACKET, painted, heater mount, poly 2 2 2 1 905 167002 INSULATOR, heat 4 4 4 2 906 113796 SCREW, flanged, hex hd (matrix) 4 4 4 2 907 24C426 HEATER, assy, 6kw, 1-zone, rtd, s 2 2 2 1 908 111800 SCREW, cap, hex hd (matrix) 16 14 4 4 12 8 909 255360 COVER, wire, heater, painted 2 2 2 1 910 253196 COVER, painted, heater, poly, h-25 2 2 2 1 911 16A104 TUBE, fluid, a, inlet, heater, ams 1 1 1 912 16A105 TUBE, fluid, a, outlet, heater, ams 1 1 1 913 16A106 TUBE, fluid, b, inlet, heater, ams 1 1 1 1 914 16A107 TUBE, fluid, b, outlet, heater, ams 1 1 1 1 915 16A108 TUBE, fluid, no heater, ams 2 2 1 2 916 24C418 MODULE, transformer, assy, hv 1 1 1 1 1 917 261821 CONNECTOR, wire, 6awg 2 1 2 2 1 918 24C314 HARNESS, wire, hptcm, hoseheat, fixed 2 1 2 2 1 919 24C312 HARNESS, wire, hptcm, heater, fixed 2 2 2 1 920 122242 CABLE, m8, 4-pin, mf, 2.5m, mold 2 1 2 2 1 921 255716 KIT, heater wire connector 1 1 1 1 922 189285▲ LABEL, caution 2 2 2 1 923 FLUID, oxide inhibitor 1 1 1 1 924 258756 KIT, fts, rtd, dual hose, sst 1

258757 KIT, fts, rtd, dual hose 1 1 258758 KIT, fts, rtd, single hose 1 1

925 24C779 MODULE, transformer, assy, lv 1 1 1

No Heat

313998S 59

Page 60

Parts

Quantity

Ref Part Description

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

A (Red) and B (Blue) Hose Heat

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

One Zone of Hose Heat

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

Stainless Steel

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

Carbon Steel

A (Red) and B (Blue) Primary Heaters

B (Blue) Primary Heaters,

B (Blue) Hose Heat

926 123398 PLUG, hole, 1.5"dia 2 2 2

123589 BUSHING, wire protector, snap-in 2 2 2 2 927 100028 WASHER, lock 2 2 2 1 928 113783 SCREW, machine, pn hd (matrix) 2 2 2 1 929 103361 BUSHING, snap 2 2 2 1 930 114269 GROMMET, rubber 2 2 2 1 931 121002 CABLE, can, female / female 1.5m 1 1 1 1 1 1 932 122487 CABLE, can, male-female, 1.5m 1 1 1 1 1 933 124262 SENSOR, rtd, 1 k ohm, 5 ft, 4 pin, tip

2 2 2 1

sensor 934 123408 HARNESS, m8 x thermal switch, 3-pin 2 2 2 1 935 100518 SCREW, mach, pnhd (matrix) 4 4 4 2 936 LUBRICANT, thermal 1 1 1 1 937 LUBRICANT, thread 1 1 1 1 1 1 1 938 123325 FITTING, compression, 1/8npt, ss 2 2 2 1 939 SEALANT, pipe, sst 1 1 1 1 940 TAPE, tfe, sealant 1 1 1 1

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

No Heat

60 313998S

Page 61

1342

1314

Parts

24J707 Shown

1313

1341

1302

1303

1331

Torque to 17 ft-lb (23 N•m).

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

FIG. 20: Heater Options, Image 3 of 4

1301 1332

1341

1311

1312

1342

ti17873a

313998S 61

Page 62

Parts

1345

1344

1348 1350

1346

1347

1343

1354

1334

1308

FIG. 21: Heater Options, Image 4 of 4

1351

1343

1345

1344

1354

1349

1353

1346

1347

ti17874a

62 313998S

Page 63

Quantity

Parts

Ref Part Description

24G617, HEATER, fix, pr,

1hose, 1fts, viscon

24J105, HEATER, fix, pr, 1

viscon, 1 std

24J106, HEATER, fix, pr, 1

vis, 1 std, 2 hose

24J107, HEATER, fix, pr,

2viscon

24J108, HEATER, fix, pr, 2

viscon, 1 hose

1301 24C336 MODULE, panel, pwr, heat, hose, pr, lv 1 1 1 1

24C338 MODULE, panel, pwr, heat, pri, lv 1 1

1302 24C332 MODULE, panel, pwr, heat, hose, pr, hv 1 1

24C334 MODULE, panel, pwr, heat, pri, hv 1 1 1 1 1303 115942 NUT, hex, flange head 6 6 6 6 6 6 1304 253192 BRACKET, painted, heater mount, poly 1 1 1 1305 167002 INSULATOR, heat 2 2 2 1306 113796 SCREW, flanged, hex hd 2 2 2 1307 24C426 HEATER, assy, 6kw, 1-zone, r td, s 1 1 1 1308 111800 SCREW, cap, hex hd 10 10 14 8 10 12 1309 255360 COVER, wire, heater, painted 1 1 1 1310 253196 COVER, painted, heater, poly, h-25 1 1 1 1311 16A104 TUBE, fluid, a, inlet, heater, ams 1 1 1

16H486 TUBE, fluid, outlet 1 1 1 1312 16A105 TUBE, fluid, a, outlet, heater, ams 1 1 1

16H485 TUBE, fluid, inlet 1 1 1 1313 16G338 TUBE, fluid, b, inlet, heater, visc 1 1 1 1 1 1 1314 16G339 TUBE, fluid, b, outlet, heater, vis 1 1 1 1 1 1 1316 24C418 MODULE, transformer, assy, hv 1 1 1 1 1317 261821 CONNECTOR, wire, 6awg 1 2 1 2 1318 24C314 HARNESS, wire, hptcm, hoseheat, fixed 1 2 1 2 1319 24C312 HARNESS, wire, hptcm, heater, fixed 1 1 1 1320 122242 CABLE, m8, 4-pin, mf, 2.5m, mold 1 2 1 2 1321 255716 KIT, heater wire connector 1 1 1 1322 189285 LABEL, caution 1 1 1 1323 261843 FLUID, oxide inhibitor 1 1 1 1 1 1 1324 258756 KIT, fts, rtd, dual hose, sst 1 1

258758 KIT, fts, rtd, single hose 1

24G976 KIT, fts, rtd, single hose, 1/2-2 1 1325 24C779 MODULE, transformer, assy, lv 1 1 1327 100028 WASHER, lock 1 1 1 1328 113783 SCREW, machine, pn hd) 1 1 1 1329 103361 BUSHING, snap 1 1 1 1330 114269 GROMMET, rubber 1 1 1 1331 121002 CABLE, can, female / female 1.5m 1 1 1 1 1 1 1332 122487 CABLE, can, male-female, 1.5m 1 1 1 1 1 1 1334 123408 HARNESS, m8 x thermal switch, 3-pin 2 2 2 2 2 2 1335 100518 SCREW, mach, pnhd 2 2 2 1336 073019 LUBRICANT, thermal 1 1 1 1 1 1

24J109, HEATER, fix, pr, 2

viscon, 2 hose

313998S 63

Page 64

Parts

Quantity

Ref Part Description

24G617, HEATER, fix, pr,

1hose, 1fts, viscon

24J105, HEATER, fix, pr, 1

viscon, 1 std

24J106, HEATER, fix, pr, 1

vis, 1 std, 2 hose

24J107, HEATER, fix, pr,

2viscon

24J108, HEATER, fix, pr, 2

viscon, 1 hose

1337 070268 LUBRICANT, thread 1 1 1 1 1 1 1338 123325 FITTING, compression, 1/8npt, ss 1 1 1 1339 070408 SEALANT, pipe, sst 1 1 1 1 1 1 1340 070274 TAPE, tfe, sealant 1 1 1 1 1 1 1341 24J537 BRACKET, heater, viscon, hfr, painted 1 1 1 2 2 2 1342 24J787 HEATER, sst 1 1 1 2 2 2 1343 124813 FITTING, elbw, 90, jic08x1/4npt 1 1 1 2 2 2 1344 124814 FITTING, rducr, 1/2nptx1/4npt 1 1 1 2 2 2 1345 262120 SENSOR, fluid temp rtd 1 1 1 2 2 2 1346 124586 COUPLING, hex, 1/2npt 1 1 1 2 2 2 1347 124885 FITTING, elbow, 90, jic(08)x1/2npt 1 1 1 2 2 2 1348 124956 FITTING, elbow, 45 deg, 3/4 conduit 1 1 1 2 2 2 1349 124955 CONDUIT, 3/4, gray seal tite 1 1 1 2 2 2 1350 124909 WASHER, reducer, 1in-3/4in 2 2 2 4 4 4 1351 123798 CABLE, m8, 4-pin, mf, 1m, molded 1 1 1 2 2 2 1353 124957 FITTING, elbow, 90 deg, conduit 1 1 1 2 2 2 1354 24J142 HARNESS, wire, hptcm, heater, fixed 1 1 1 2 2 2 1355 114225 TRIM, edge protection 0.330 0.670 0.670 1356 105676 SCREW, mach, pnh 1 1 1 2 2 2

24J109, HEATER, fix, pr, 2

viscon, 2 hose

64 313998S

Page 65

Heater Sub-Assemblies

Heat Power Panel Module

Parts

1007

1004, 1006

1005, 1006

1004, 10061004, 1006

Tie wires at this point.

Torque connector screws to 16 in-lb

(1.8 N•m).

1005, 1006

1001

24C332_313998_3f

1010

1009

1011

1008

24C332_313998_8f

1002

1015

1016

24C332_313998_7f

FIG. 22: Heat Power Panel Modules

1014

1012

1003

24C332_313998_1f

313998S 65

Page 66

Parts

1004, 1006

1007

1004, 1006

1005, 1006

1004, 1006

Tie wires at this point.

Torque connector screws to 16 in-lb (1.8 N•m).

1011

1004, 1006

1005, 1006

24C332_313998_6f

100910101008

24C332_313998_4f

1002

1015

1016

24C332_313998_7f

FIG. 23: Heat Power Panel Modules

1003

24C332_313998_4f

1014

1012

66 313998S

Page 67

Quantity

Parts

Ref Part Description

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

MODULE, panel,

pwr, heat, hose, pr, lv

MODULE, panel,

pwr, heat, hose, lv

MODULE, panel,

pwr, heat, pri, lv

1001 PANEL, electric, heat 1 1 1 1 1 1 1 1

1002 255774 MODULE, high power temp, gca 2 1 1 2 1 1

1003 MODULE, assy, pwr, heat, hose, pri, hv 1

MODULE, assy, pwr, heat, hose, hv 1

MODULE, assy, pwr, heat, pri, hv 1

MODULE, assy, pwr, no heat, hv 1

MODULE, assy, pwr, heat, hose, pri, lv 1

MODULE, assy, pwr, heat, hose, lv 1

MODULE, assy, pwr, heat, pri, lv 1

MODULE, assy, pwr, no heat, lv 1

1004 123452 HOLDER, anchor, wire tie, nylon 5 5 4 4 5 5 4 4

1005 116876 WASHER, flat 4 3 3 2 4 3 3 2

1006 103833 SCREW, mach, crbh (matrix) 9 8 7 6 9 8 7 6

1007 125306 CABLE, can, female / female 0.5m 1 1

1008 100021 SCREW, cap hex hd (matrix) 1 1 1 1 1 1 1 1

1009 100028 WASHER, lock 2 2 2 2 2 2 2 2

1010 100015 NUT, hex mscr 2 2 2 2 2 2 2 2

1011 24C311 HARNESS, wire, pdb, ground 1 1 1 1 1 1 1 1

1012 24C318 HARNESS, wire, pdb, terminal 1 1 1 1 1 1 1 1

1014 24C304 HARNESS, wire, pdb, inline heater 2 1 1 2 1 1

MODULE, panel,

pwr, no heat, lv

1015 15R535 BRACKET, mounting, GCA high power 4 2 2 4 2 2

1016 117831 SCREW, mach., pan hd (matrix) 8 4 4 8 4 4

313998S 67

Page 68

Parts

Heater - Aluminum with Carbon Steel Fittings, 24C426 Heater - Aluminum with Stainless Steel Fittings, 24P165

24P165 Shown

1111

1110

9 6 2

1106

1104

1106a

1112

1113

1109

4 3

1101

r_24p165

1105

1103

2 4

1107

1102

1108

Torque to 120 ft-lb (163 N•m)

Torque to 23 ft-lb (31 N•m)

Torque to 40 ft-lb (54 N•m)

Apply lubricant to o-rings before assembling into heater.

Tighten NPT thread at least on turn after RTD has been tightened.

Apply thermal paste when assembling thermal switch.

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

68 313998S

1105

r_24c106_313998_2

Page 69

Assembly

Ref

1101 15J090

1102 124132

1103 15H305

1104 121309

1105 15H304

1106 15H306

24C426

Part

Assembly 24P165

15J090

124132

126561

126562

126563

126564◆

Parts

Description Qty

HEATER, machined, 1 zone, 3500 psi 1

O-RING 4

FITTING, plug hollow hex 1-3/16 sae 4

FITTING, adapter, sae-orb x jic 2

FITTING, plug 9/16 sae 3

ADAPTER, thermocouple, 9/16 x 1/8 1

1106a 120336

1107 15B135

1108 16A112

1109 295607

1110

1111

1112

1113

1115

1116 ---

1117 ---

--- Not available for individual sale.

◆ Item 1106 include fluoroelastomer o-ring.

◆

16T320

16A112

561460

123325

124262

123408

100518

---

O-RING, packing

MIXER, immersion heater 4

HEATER, immersion (1500W 230V) 4

PLUG, outlet 1

FITTING, compression, 1/8npt, ss

SENSOR, rtd, 1kohm, 90deg, 4pin, tip

HARNESS, m8 x thermal switch, 3-pin

SCREW, mach, mnhd

LUBRICANT, thermal

TAPE, tfe, sealant 1

LUBRICANT, thread 1

313998S 69

Page 70

Parts

Heater 24J787

1422 1427 1428

1416

1421 1426

1408

1409

1435

1409

1407

1406

1404

1405

1434

1409

1404

1417 1418 1419 1420

1410 1411

1408

1429 1430 1431

1412

1403

1402

1410 1423

1412

1433

1401

ti17875a

70 313998S

Page 71

Ref Part Description Qty

1401† --- BLOCK, heater, machined 1 1402 15A990 GASKET, heater 1 1403 15A811 COVER, heater controls, bottom 1 1404 15A991 GASKET, heater 2 1405 15A809 ENCLOSURE, controls, heater 1 1406 15A810 COVER, heater controls, top 1 1407 15B625 LABEL, plate, warning 1 1408 111962 SCREW, cap, button hd 10 1409 100055 SCREW, drive, #6 10 1410 107542 WASHER, lock, spring 10 1411 117367 SCREW, shcs, m8x18 6 1412† 117344 FITTING, tube, compression 2 1413▲ 172953 LABEL, designation 1 1414 111307 WASHER, lock, external 1 1415 116343 SCREW, ground 1 1416 15B828 HOUSING, light, heater, viscon hp 1 1417 106216 NUT, lock 1 1418 15B827 LENS, light, glass 1 1419 103338 PACKING, o-ring 1 1420 117483 SCREW, jam, socket 1 1421 111802 SCREW, cap, hex hd 1 1422 112731 NUT, hex, flanged 1 1423 109114 SCREW, cap, sch 4 1424 100166 NUT, full hex 4 1425 102360 WASHER, flat 4 1426 15U075 SCREW, cap, bh, 8-32 x .37 2 1427 555388 NUT, # 8-32 hex 2 1428 100079 WASHER, lock, spring 2 1429 108674 THERMOSTAT 1 1430 105676 SCREW, mach, pnh 2 1431 073019 LUBRICANT, thermal 1 1432 235524 WIRE, assy 1 1433▲ 177922 TAG, warning 1 1434▲ 16K138 LABEL, brand, viscon hp, nvh 1 1435▲ 15B623 LABEL, plate, des, viscon hp 1 1442▲ 15B777 LABEL, warning, viscon hp 1 1443▲ 15B819 LABEL, warning, viscon hp 1

Parts

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

--- Not for individual sale

† Items available for purchase in kit 24K290

313998S 71

Page 72

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.

1204

1203

1201

1202

Torque to 23 in-lb (2.6 N•m).

Part is reference number 15 in hydraulic power pack assembly. See Hydraulic DC Power Pack

Module on page 54.

Ref Part Description Qty

1201 15H204 KNOB, pressure adjustment 1 1202 15H512 LABEL, control, H25 1 1203 15Y370 ADAPTER, pressure relief 1 1204 116624 SCREW, set, socket head 1

72 313998S

Page 73

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.

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.

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.

313998S 73

Page 74

Logic Drawings

230V, 1 Phase, No Heat

LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

L11L1

1L1

230V/

1PH/

50-60HZ

L21L2

1L2

DISC-1

GND

1L1

1L21L2

1L1

1L2

CB1A

63A

CB5

1080

1100

1340

1360

1340

POWER FILTER

L1/P

L2/N

LINE

GND

150 151

HARNESS 24C515

BLK

WHT

GND

1080

1100

PG105

GND

331

MCM B VOLUME

HARNESS 24C318

1390 BR

1400 BL

LOAD

POWER SUPPLY

121808 123466

1340

1360

PG133

755

CAN SPLITTER

MISC B VOLUME

152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199

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

74 313998S

Page 75

230V, 1 Phase, with Heat

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

151

1L1

L11L1

1L1

230V/

1PH/

50-60HZ

L21L2

1L2

151

1L2

DISC-1

GND

1L1

1L2

1L1

1L2

1L11L1

1L2

1L11L1

1L2

1L11L1

1L2

CB1A

63A

CB2

40A

CB3 15A

CB4

40A

CB5

1080

1100

1160

1180

1220

1240

1280

1300

1340

1360

1340

POWER FILTER

L1/P

L2/N

LINE

GND

Logic Drawings

GND

CAN SPLITTER

331

511

580

755

GND

MCM B VOLUME

PRIMARY HT B VOLUME

TANK

B VOLUME

HOSE HT B VOLUME

MISC B VOLUME

HARNESS 24C515

BLK

WHT

HARNESS 24C304

HARNESS 24C517

HARNESS 24C303

HARNESS 24C318

1390 BR

1400 BL

LOAD

POWER SUPPLY

121808 123466

PG105

GND

1080

1100

PG116

1160

1180

PG121

1220

1240

PG127

1280

1300

PG133

1340

1360

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

313998S 75

Page 76

Logic Drawings

150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199

148

1L1

1L2

148

1L2

1L1

1L2

1L11L1

1L2

1L11L1

1L2

1L1

1L2

CB9

40A

CB8 15A

CB7

40A

CB6

1660

1680

1720

1740

1780

1800

1840

1860

HARNESS 24C304

HARNESS 24C517

HARNESS 24C303

HARNESS 24C318

1660

1680

1720

1740

1780

1800

1840

1860

PG166

PG172

PG178

PG184

649

718

824

GND

PRIMARY HT

A VOLUME

TANK A VOLUME

HOSE HT

A VOLUME

MISC

A VOLUME

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

76 313998S

Page 77

230V, 3 Phase, No Heat

LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

L11L1

1L1

230V/

3PH/

50-60HZ

L21L2

L31L3

DISC-1

GND

1L1

1L21L2

1L31L3

1L1

1L21L2

CB1 30A

CB5 5A

1080

1100

1120

1340

1360

1340

POWER FILTER

L1/P

L2/N

LINE

GND

Logic Drawings

GND

CAN SPLITTER

MCM

331

B VOLUME

MISC

755

B VOLUME

HARNESS 24C516

BLK

RED

WHT

HARNESS 24C318

1390 BR

1400 BL

LOAD

POWER

SUPPLY

121808 123466

PG105

GND

1080

1100

1120

PG133

1340

1360

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

313998S 77

Page 78

Logic Drawings

230V, 3 Phase, with Heat

LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

151

L11L1

1L1

230V/

3PH/

50-60HZ

L21L2

151

1L2

151

1L3

L31L3

DISC-1

GND

1L11L1

1L21L2

1L31L3

CB1 30A

1L31L3

1L11L1

CB2 40A

1L21L2

1L31L3

CB3 15A

1L11L1

1L21L2

CB4 40A

1L31L3

1L11L1

CB5 5A

1080

1100

1120

1160

1180

1220

1240

1280

1300

1340

1360

1340

POWER FILTER

L1/P

L2/N

LINE

GND

HARNESS 24C516

BLK

RED

WHT

HARNESS 24C304

HARNESS 24C517

HARNESS 24C303

HARNESS 24C318

1390 BR

1400 BL

LOAD

POWER SUPPLY

121808 123466

GND

1080

1100

1120

1160

1180

1220

1240

1280

1300

1340

1360

PG105

GND

PG116

PG121

PG127

PG133

CAN SPLITTER

331

511

580

755

GND

MCM B VOLUME

PRIMARY HT B VOLUME

TANK

B VOLUME

HOSE HT B VOLUME

MISC B VOLUME

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

78 313998S

Page 79

150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199

148

1L1

1L3

1L2

148

1L31L3

1L21L2

1L1

1L31L3

1L2

1L3 1840

1L3

1L2

1L1

1L3

1L2

30A

CB9

40A

CB8 15A

CB7

40A

CB6

1660

1680

1720

1740

1780

1800

1860

HARNESS 24C304

HARNESS 24C517

HARNESS 24C303

HARNESS

HARNESS 24C318

24C318

1660

1680

1720

1740

1780

1800

1840

1860

PG166

PG172

PG178

PG184

Logic Drawings

PRIMARY HT

649

A VOLUME

TANK A VOLUME

GND

HOSE HT

718

A VOLUME

MISC

824

A VOLUME

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

313998S 79

Page 80

Logic Drawings

400V, 3 Phase, No Heat

LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

400V/

3PH/

50-60HZ

L11L1

L21L2

1L1

1L1 1L1

L31L3

N1N

GND

DISC-1

1L1

1N1N

CB1A

63A

CB5

1340

1360

1081

1101

1360

POWER FILTER

L1/P

L2/N

LINE

1340

GND

LOAD

1080

1100

POWER FILTER

L1/P

L2/N

LINE

GND

HARNESS 24C515

BLK

WHT

HARNESS 24C318

1390 BR

1400 BL

LOAD

POWER SUPPLY

121808 123466

GND

1080

1100

1340

1360

PG105

GND

PG133

331

755

CAN SPLITTER

MCM B VOLUME

MISC B VOLUME

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

80 313998S

Page 81

400V, 3 Phase, with Heat

LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149

400V/

3PH/

50-60HZ

L11L1

L21L2

1L1

1L1 1160

1L1 1220

151

1L2

N1N

L31L3

1L2 1280

1L2 1340

151

1L3

GND

DISC-1

1L1

1N1N

CB1A

63A

1L1

1N1N 1180

CB2

40A

1L1

1N1N 1240

CB3

15A

1L2

1N1N 1300

CB4

40A

1L2

1N1N 1360

CB5

1081

1101

1360

POWER FILTER

L1/P

L2/N

LINE

1340

GND

Logic Drawings

HARNESS 24C515

1080

1100

LOAD

POWER FILTER

L1/P

L2/N

LINE

1390 BR

1400 BL

LOAD

GND

HARNESS 24C304

HARNESS 24C517

HARNESS 24C303

HARNESS 24C318

BLK

WHT

POWER SUPPLY

121808 123466

GND

1080

1100

1160

1180

1220

1240

1280

1300

1340

1360

PG105

GND

PG116

PG121

PG127

PG133

331

511

GND

580

755

CAN SPLITTER

MCM B VOLUME

PRIMARY HT B VOLUME

TANK B VOLUME

HOSE HT B VOLUME

MISC B VOLUME

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

313998S 81

Page 82

Logic Drawings

150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199

1L3

1L2

148

1L3

1L2 1780

1N 1860

1L3

1N1N 1680

CB9

40A

1L3

1N1N 1740

CB8 15A

1L2

1N1N 1800

CB7

40A

1L2

CB6

1660

1720

1840

HARNESS

24C304

HARNESS

24C517

HARNESS

24C303

HARNESS

24C318

1660

1680

1720

1740

1780

1800

1840

1860

PG166

PG172

PG178

PG184

649

718

824

GND

PRIMARY HT A VOLUME

TANK A VOLUME

HOSE HT A VOLUME

MISC A VOLUME

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

82 313998S

Page 83

A (Red) Heat

Logic Drawings

614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

PRIMARY HT LOW VOLUME

HARNESS

24C265

167

BRN

PG166

6400

1660

1680

A1+

A2-

CR642

CON863

6420

BLU

HARNESS

24C267

6490

6500

A - RED

HPTCM PRIMARY LOW VOLUME

M12 5 PIN

MALE

CAN COMM PORT

2 3 4 5

M12 5 PIN

MALE

CAN COMM PORT

2 3 4 5

HARNESS

16A522

M8 3 PIN

MALE

+24VDC

SIGNAL

PG646 PG647

GND

M8 3 PIN

FEMALE

1 4 3

FEMALE

M8 4 PIN

1 2

3 4

M8 3 PIN

FEMALE

4 3

M8 4 PIN

MALE

EXC

1 2

SIGNAL

3 4

M8 3 PIN

MALE

EXC

1 4

SIGNAL

6480

6520

HARNESS

VR 24C313 FR 24C312

PRIMARY TEMP

PRIMARY HEATER

DB-1

SEE CONFIGURATION

6480

6520

RTD618

PRIMARY TEMP

OTS628

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

313998S 83

Page 84

Logic Drawings

683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740 741 742 743 744 745 746 747 748 749 750 751

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

HOSE HT LOW VOLUME

179

BRN

PG178

HARNESS

24C274

7090

1780

1800

A1+

CR711

CON-869

A - RED

HPTCM HOSE LOW VOLUME

FEMALE

M8 4 PIN

1 2

3 4

M8 4 PIN

MALE

1 2 3 4

EXC

SIGNAL

M8 3 PIN

FEMALE

4 3

CAN COMM PORT

M12 5 PIN

MALE

M12 5 PIN

MALE

1 2 3 4 5

HARNESS 16A522

M8 3 PIN

MALE

7110

BLU

7170

+24VDC

SIGNAL

PG715

CB718

GND

A2-

7310

7290

7350

7330

PG728

M8 3 PIN

FEMALE

1 4 3

4 3

PG716

7172

7210

HARNESS

VR 24C315 FR 24C314

7290

7310

7330

7350

PRIMARY

SECONDARY

TRANS1 24C418

HOSE TEMP

RTD688

HOSE HEATER SEE CONFIGURATION

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

84 313998S

Page 85

B (Blue) Heat

Logic Drawings

476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544

LOCATED IN THE MAIN SUPPORT ENCLOSURE

PRIMARY HT HI VOLUME

HARNESS

117

24C265

BRN

PG116

5020

1160

1180

A1+

A2-

CR504

CON794

5040

BLU

HARNESS

24C267

5110

5120

B - BLUE

HPTCM PRIMARY HI VOLUME

FEMALE

M8 4 PIN

1 2

3 4

M8 3 PIN

FEMALE

4 3

M8 4 PIN

MALE

1 2 3 4

M8 3 PIN

MALE

1 4 3

EXC

SIGNAL

EXC

SIGNAL

PG508

5100

5140

CAN COMM PORT

HARNESS

16A522

M8 3 PIN

SIGNAL

GND

MALE

PG509

GND

+24VDC

M12 5 PIN

MALE

1 2 3 4 5

M12 5 PIN

MALE

1 2 3 4 5

M8 3 PIN

FEMALE

1 4 3

HARNESS

VR 24C313 FR 24C312

PRIMARY HEATER

DB-1

SEE CONFIGURATION

5100

5140

PRIMARY TEMP

RTD480

PRIMARY TEMP

OTS490

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

313998S 85

Page 86

Logic Drawings

545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613

LOCATED IN THE MAIN SUPPORT ENCLOSURE

HOSE HT HI VOLUME

HARNESS

129

24C263

BRN

PG127

HARNESS

24C274

5710

1280

1300

A1+

CR573

CON800

B - BLUE

HPTCM HOSE HI VOLUME

FEMALE

M8 4 PIN

1 2

3 4

M8 4 PIN

MALE

1 2 3 4

EXC

SIGNAL

M8 3 PIN

FEMALE

4 3

CAN COMM PORT

M12 5 PIN

MALE

M12 5 PIN

MALE

1 2 3 4 5

HARNESS 16A522

M8 3 PIN

MALE

SIGNAL

PG578

GND

5730

BLU

+24VDC

5790

CB579

A2-

5930

5910

5970

5950

PG590

M8 3 PIN

FEMALE

1 4 3

4 3

PG577

5792

5830

5910

5930

5950

5970

PRIMARY

SECONDARY

TRANS1 24C418

HARNESS

VR 24C315 FR 24C314

HOSE TEMP

RTD550

HOSE HEATER SEE CONFIGURATION

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

86 313998S

Page 87

DC Hydraulic Power Pack

Logic Drawings

890 891 892 893 894 895 896 897 898 899 900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940 941 942 943 944 945 946 947 948 949 950 951 952 953 954 955 956 957 958

LOCATED ON THE MAIN HYDRAULIC POWER PACK

HV SOL234 LV SOL372

'A' RED

ISO LUBE

PUMP

+5 VDC GND

HYDRAULIC CYLINDER

PUMP POSITION

SIGNAL

FIXED RATIO

MACHINE FRONT

FACING PUMPS

GND

+5 VDC

VARIABLE RATIO VERTICAL PUMP

SIGNAL

OIL LEVEL

SENSOR

OPTIONAL

HV PX262

LV PX400

HV SOL241 LV SOL378

123313

HV LPT280 LV LPT416

RTD OPTIONAL

PRESSURE

GAUGE

OPTIONAL

'B' BLUE

OIL TEMP

PRESSURE

RELIEF

VALV E

HV RTD290 LV RTD428

OIL OVERTEMP SWITCH

MCM FAN HV M772 LV M841

HYD. FAN HV M762 LV M831

HV M310 LV M450

PUMP

HV OTS264 LV OTS402

COOLER

FILTER 15J437

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

313998S 87

Page 88

Logic Drawings

Motor Control Module (MCM)

For MCM wiring of Circ Spray Models, see the HFR for Circ Spray Operation manual.

200

LOCATED ON THE HYDRAULIC

201

POWER PACK - FIXED RATIO

202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268

M12 5 PIN

POS 1 = 2000psi

(DEFAULT)

POS 3 = 3000psi

CAN COMM PORT

MALE

M12 5 PIN

MALE

1 2 3 4 5

CAN COMM PORT

2 3 4 5

M8 4 PIN

FEMALE

1 2 3 4

START

PB235

SOL240

DISPENSE

GUN

START

FS247

HARNESS

123303

SIGNAL

+24VDC

COMMON

SIGNAL

M12 5 PIN

MALE

M12 5 PIN

FEMALE

1 2 3 4 5

HYD-OIL LO-LVL

PX262

121061

1 1

SWITCH POSITION

SHOWN FOR

REF ONLY

B-CODE

M12 5 PIN

FEMALE

1 2 3 4 5

M12 5 PIN

FEMALE

1 2 3 4 5

M12 5 PIN

FEMALE

1 2 3 4 5

M12 5 PIN

MALE

1 2 3 4 5

M12 5 PIN

MALE

1 2 3 4 5

HARNESS

123303

M12 5 PIN

MALE

1 2 3 4 5

+5VDC

-SIG

DC COM

+SIG

SHLD

+5VDC

-SIG

DC COM

+SIG

SHLD

SIGNAL

COMMON

SIGNAL

DISPENSE SIGNAL

TO HYDRAULIC

DISP. HEAD FCM

SIGNAL

DC COM

PRESS XDUCER FIXED RATIO ONLY RED 'A' VOLUME

PRESS XDUCER BLUE 'B' VOLUME

VALVE ASSY

123313

SOL234

PUMP LEFT

SOL241

PUMP RIGHT

OIL TEMP

OTS264 123367

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

88 313998S

Page 89

269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337

OIL TEMP

RTD290

OPTION

SIGNAL

EXC

M8 4 PIN

MALE

Logic Drawings

LPT280

258669

M8 4 PIN

FEMALE

1 2

3 4

M8 4 PIN

FEMALE

1 2 3 4

M8 4 PIN

FEMALE

1 2 3 4

15 PIN DSUB

FEMALE

M8 4 PIN

15 PIN DSUB

1112

4 1

13 10

75 8

MALE

EXC

SHLD

COMMON

SIGNAL

MALE

EXC

1 2

SIGNAL

3 4

MALE

1112

4 1

13 10

75 8

BLK

RED

BLU

GND

1120

HARNESS

24C516

109

HARNESS

24C515

109

PG105

3 PHASE

PG105

1 PHASE

GND

1080

1580

L2 L3

1100

L2 L3

1600

PUMP POSITION

MOTOR TEMP

RTD292

M310

ENCODER

MOTOR

GND

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

313998S 89

Page 90

Logic Drawings

Miscellaneous Power

752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820

MISC B - BLUE HI VOLUME

135

1360

1340

PG133

1360

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

FOR FIXED OR VARIABLE

RATIO

TERMINAL STRIP MOUNTED ON BACKPANEL

HARNESS 24C518

11 14

CR504

11 14

CR573

M762

1 2

7940

8000

1 2

CON794

CON800

MOTOR FAN HYD HEAT EXCH'R

M772

MOTOR FAN MCM

230VAC POWER TO THE FAN

MOTOR

230VAC POWER TO THE FAN

MOTOR

HYD

VALV E ASSY

USED ONLY WITH PRIMARY HEAT OPTION

USED ONLY WITH HOSE HEAT OPTION

SOL234 SOL241

230VAC POWER TO THE HYDRAULIC POWER VALVE

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

90 313998S

Page 91

Logic Drawings

821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876 877 878 879 880 881 882 883 884 885 886 887 888 889

MISC A - RED LOW VOLUME

185

1860

1840

PG184

1860

LOCATED IN THE MAIN SUPPORT ENCLOSURE FOR VARIABLE RATIO ONLY

TERMINAL STRIP MOUNTED

ON BACKPANEL

HARNESS 24C518

11 14

CR642

11 14

CR711

M831

1 2

8630

8690

1 2

CON863

CON869

MOTOR FAN HYD HEAT EXCH'R

M841

MOTOR FAN MCM

230VAC POWER TO THE FAN MOTOR

HYD

VALV E ASSY

USED ONLY WITH PRIMARY HEAT

OPTION

USED ONLY WITH HOSE HEAT

OPTION

SOL372 SOL378

230VAC POWER TO THE HYDRAULIC POWER VALVE

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

313998S 91

Page 92

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 ....50psi(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 ............1/4npsm(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; see 400 V Power Requirements, page 4

Amperage Requirement........... SeeModels on page 4

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

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

Hydraulic reservoir capacity........8gal. (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 313998S

Page 93

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.................... 5kA

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 ............................... 24Vdc,Class 2, Graco-provided power supply

Enclosure ..................................... Type1

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.

313998S 93

Page 94

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 author ized 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 retur ned 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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

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

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 313998

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised November 2014

Graco 313998S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

Product Configurator

Whip Hose Bundles

Individual B (Blue) Heated Whip Hose

Individual A (Red) Heated Whip Hose

B (Blue) Individual

A (Red) Individual

Hose Bundling Accessories

Applicator

B (Blue) Applicator Orifice

Iso A (Red) Applicator Orifice

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

Dispense Valve Interface Kit

Flow Meters

Pump Feed Kits

B (Blue) and A (Red) Feed Tanks

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

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

A (Red) and B (Blue) Components

Moisture Sensitivity of Isocyanates

Foam Resins with 245 fa Blowing Agents

Changing Materials

Shutdown

Pressure Relief Procedure

Flushing

Repair

Pumpline

Hydraulic Power Pack Repair

Parts

Base Machine

Base Machine Sub-Assemblies

Power Pack Module Sub-Assemblies

Heater Options

Heater Sub-Assemblies

Kits

DC Power Pack Pressure Adjustment Kit, 24C067

DC Power Pack Hydraulic Pressure Adjustment Setup

Logic Drawings

230V, 1 Phase, No Heat

230V, 1 Phase, with Heat

230V, 3 Phase, No Heat

230V, 3 Phase, with Heat

400V, 3 Phase, No Heat

400V, 3 Phase, with Heat

A (Red) Heat

B (Blue) Heat

DC Hydraulic Power Pack

Motor Control Module (MCM)

Miscellaneous Power

Technical Data

Motor Control Module Technical Data

Graco Standard Warranty

Graco Information