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Repair - Parts VRM™ 313874E EN Hydraulic, Plural-component, Variable-Ratio Proportioner. For pouring and dispensing sealants and adhesives. For professional use only. Not approved for use in European explosive atmosphere locations. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information, including maximum working pressure and approvals. ti17663a Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Important Two-Component Material Information . 8 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8 Keep Components A (Red) and B (Blue) Separate 8 Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9 A (Red) and B (Blue) Components . . . . . . . . . . . . . 9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Linear Position Sensor Replacement . . . . . . . . 10 Hydraulic Driver Removal . . . . . . . . . . . . . . . . . 11 Dura-Flo Lower Removal . . . . . . . . . . . . . . . . . 12 Hydraulic Power Pack Repair . . . . . . . . . . . . . . 14 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Systems, 24F391, 24F872, 24F873 . . . . . . . . . 22 Machine Base, 24C168 . . . . . . . . . . . . . . . . . . . 23 Power Pack Module . . . . . . . . . . . . . . . . . . . . . 27 Power Pack Module Sub-Assemblies . . . . . . . . 28 Vertical Driver Pumps . . . . . . . . . . . . . . . . . . . . 32 Hydraulic Vertical Actuator . . . . . . . . . . . . . . . . 34 Electrical Panels . . . . . . . . . . . . . . . . . . . . . . . . 35 Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fluid Control Panel . . . . . . . . . . . . . . . . . . . . . . 37 Applicator Assembly . . . . . . . . . . . . . . . . . . . . . 38 Mixer Manifold, 24F668 . . . . . . . . . . . . . . . . . . . 40 Mixer Assembly, 24H027 . . . . . . . . . . . . . . . . . 42 Floor Mounted Support . . . . . . . . . . . . . . . . . . . 43 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Logic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 230V 3 Phase Power Distribution Box . . . . . . . 45 400V 3 Phase Power Distribution Box . . . . . . . 46 B (Blue) Hydraulic Power Pack . . . . . . . . . . . . 47 A (Red) Hydraulic Power Pack . . . . . . . . . . . . . 48 Main Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 49 B (Blue) Hydraulic Power Pack and Dispense Head Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . 50 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 52 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 52 2 313874E Related Manuals Related Manuals Manuals are available at www.graco.com. Component manuals in U.S. English: System Manuals 313873 VRM Setup - Operation Power Distribution Box Manual 3A0239 Power Distribution Boxes Instructions-Parts Pumpline Manuals 3A0022 U-Cup Dura-Flo™ Lowers 3A0021 Vertical Hydraulic Driver Repair-Parts Feed System Manuals 3A1159 VRM Feed Systems Valve Manuals 310550 1/2 in. NPT Fluid Port Ball Seat Applicator 310551 3/4 in. NPT Fluid Port Ball Seat Applicator 3A1792 DV Series Dispense Valves 313874E 3 Models Models System 24F872 60 A 230 (3) 24F391 55 A 400 (3) 55 A 400 (3) 24F873 * approved Full Load Peak Amps Voltage Per Phase* (phase) ✔ Approximate Output per Hydraulic Maximum Fluid Max Flow Cycle (A+B)** Pressure Working Pressure ‡ System Rate◆** Ratio** psi (MPa, bar) Watts† lb/min (kg/min) gal. (liter) 24,000 66 (30) 1.0 (3.8) 1.63 2000 (14, 138) 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. ◆ Flow rate is independent of frequency 50/60 Hz. ‡ If a motor control module is replaced, see Adjust Motor Control Module Selector Switch on page 16 to set the machine to the proper maximum fluid working pressure. 4 313874E Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • • • Read MSDSs to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to: • • Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. + • • • • • • 313874E 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. 5 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. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • • • • • • • • • • • 6 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. 313874E Warnings 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. 313874E 7 Important Two-Component Material Information 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 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: • • • • Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. • • 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 pump wet cups 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. 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. 8 313874E A (Red) and B (Blue) Components 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. 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. 313874E 9 Repair Repair Linear Position Sensor Replacement 713 718 711 704 9 2 722, 723 710 4 708 3 707 716 4 9 701 712 4 702 715 5 706 1 714 6 3 708 705 ti17670a 1 Torque to 100 ft-lb (135 N•m). 6 Torque to 10-12 in-lb (1.1-1.4 N•m). 2 Torque to 350 in-lb (39.5 N•m). 7 Apply thread sealant to threads. 3 Apply a light coating of lubricant to seals and surfaces specified. 8 Torque to 30-36 ft-lb (41-49 N•m). 4 9 Torque to 50-60 ft-lb (68-81 N•m). 5 Apply adhesive to surfaces specified. Orient ref 701 with date code on casting opposite of 0.25 diameter hole as shown. Ref 704 to be on opposite side of 0.25 diameter hole as shown. FIG. 1 NOTE: See FIG. 1 for part references. 1. Perform Shutdown procedure. See operation manual for procedure. 2. Remove pumpline shield. 5. Use a 1-1/4 in. wrench to loosen the linear position sensor. Remove the linear position sensor. 6. Carefully insert the new linear position sensor through the hole in the plate (713) and into the vertical hydraulic driver. Use a 1-1/4 in. wrench to gently tighten. 3. Insert a large allen wrench through the center of the lift ring (717) then twist to loosen. Remove lift ring. 4. Disconnect linear position sensor cable. Route the cable through the hole in the plate (713) directly above the linear position sensor (718). 10 313874E Repair Hydraulic Driver Removal NOTE: This procedure details how to remove the hydraulic driver. Hydraulic driver rebuild information is in the hydraulic driver manual. 622 620 619 618 604 3 621 623 _1c ti17669a 604 3 601 2 605 4 606 1 603 3 2 607 Isometric View 608 1 1 Torque 50-60 ft-lb (68-81 N•m). 3 Apply thread lubricant. 2 Torque 145-155 ft-lb (196-210 N•m). 4 Apply thread sealant. 602 613 FIG. 2 NOTE: See FIG. 1 and FIG. 2 for part references. 7. Remove the drip fittings connected to the base of the vertical hydraulic actuator. 1. Perform Shutdown and Pressure Relief Procedure procedures. See operation manual for procedures. 8. Remove four screws (705) connecting hydraulic driver to vertical actuator housing (704). 2. Remove the pump shield. 9. Remove three screws (706) that connect the bottom plate (702) to the rest of the hydraulic driver. 3. Remove three screws (716). Remove top plate (713). 10. Remove the hydraulic driver (701). 4. Remove three tie rods (712). Remove plate (711) with linear position sensor (718). 5. Remove three tie rods (710). 11. See hydraulic driver manual for rebuild information. NOTE: Install hydraulic driver in reverse order. See notes in the applicable parts illustrations for torque and other specifications. 6. Loosen the coupling nut (603) to disconnect the actuator and pump rods. 313874E 11 Repair Dura-Flo Lower Removal NOTE: This procedure details how to remove the Dura-Flo Lower. Rebuild information is in the Dura-Flo Lower manual. 622 620 619 618 604 3 621 623 _1c ti17669a 604 3 601 2 605 4 606 1 603 3 2 607 Isometric View 608 1 1 Torque 50-60 ft-lb (68-81 N•m). 3 Apply thread lubricant. 2 Torque 145-155 ft-lb (196-210 N•m). 4 Apply thread sealant. 602 613 FIG. 3 See FIG. 3 for part references. 1. Perform Shutdown and Pressure Relief Procedure procedures. See operation manual for procedures. NOTE: Install Dura-Flow Lower in reverse order. See notes in the applicable parts illustrations for torque and other specifications. 2. Loosen the coupling nut (603) to disconnect the hydraulic vertical actuator and pump rods. 3. Use a large adjustable wrench to remove the large inlet feed fittings at the base of the Dura-Flo Lowers. 4. Remove three screws (608). 5. Remove Dura-Flo Lower. 6. See Dura-Flo Lower manual for rebuild information. 12 313874E Repair 313874E 13 Repair Hydraulic Power Pack Repair 435 8 434 26 11 403 6 415 2 6 7 12 421, 422 5 14 445 11 431 11 11 432 433 11 15 430 429 428 446 11 418 417 2 416 10 12 419 404 3 11 406 5 444 414 10 421, 427 4 405 2 40912 437 11 410 2 12 2 41212 426 411 401 413 10 408 3 11 8 423 9 11 12 425 9 424 438 402 10 13 407 406 1 +.01 .30 -.00 420 436 Assemble coupler to specified dimensions prior to mounting assembly to housing. 2 Torque to 40 ft-lb (54 N•m). 3 Torque to 35 ft-lb (47 N•m). 4 Torque to 20 ft-lb (27 N•m). 5 Torque to 15 ft-lb (20 N•m). 6 Torque to 10 ft-lb (14 N•m). 7 Torque to 58 in-lb (6.5 N•m). 431 24 +.00 .45 -.02 402 1 448, 449 1 _1j 8 Torque to 34 in-lb (3.8 N•m). 9 Torque 1/4 turn past hand-tight. 15 Prior to installing Ref. 428 into Ref. 426, install Ref. 429 into Ref. 428 and adjust head 1/8 in. from surface. 10 Apply PTFE tape on installation end only. 24 Align fan plug as shown. 11 Apply sealant to threads. 26 Apply thermal lubricant to contact side. 12 Apply light coating of lubricant to seals. 13 Fill reservoir with hydraulic fluid. 14 Orient with airflow arrow pointing toward mounting bracket. FIG. 4: Hydraulic DC Power Pack 14 313874E Repair Remove Hydraulic Power Pack Shroud Replace Fan 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. See FIG. 4 on page 14. 1. Perform Shutdown procedure. See operation manual for procedure. 2. Remove Hydraulic Power Pack Shroud, see procedure on this page. 3. Remove four screws (432) connecting fan to mounting plate. 2. Install four screws securing shroud to hydraulic tank. 4. Remove fan and install new fan. Replace Hydraulic Filter Filter is located at right rear of hydraulic power pack. See FIG. 4 on page 14. NOTICE If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result. 5. Install four screws (432) connecting fan to Motor and Motor Control Module. 6. Install Hydraulic Power Pack Shroud, see procedure on this page. Remove Motor Control Module 1. Perform Shutdown procedure. See operation manual for procedure. 2. Use compressed air to remove any loose debris around the hydraulic filter. See FIG. 4 on page 14. 3. Remove new filter from wrapping. 1. Perform Shutdown procedure. See operation manual for procedure. 4. Apply a light coat of hydraulic fluid to the o-ring on the face of the hydraulic filter. 2. Remove Hydraulic Power Pack Shroud, see procedure on this page. 5. Being careful not to allow any debris into the hydraulic tank remove old filter from tank then quickly install new filter. 3. Remove four screws (432) connecting fan to Motor and Motor Control Module. Remove fan and mounting plate. 4. Note the location of each Motor Control Module cable then remove all electrical cables on the left and right sides of the Motor Control Module. 5. Remove six screws (429) 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. 313874E 15 Repair Adjust Motor Control Module Selector Switch 4. Install access cover (D). NOTICE D 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. 5. The system must be configured to have a maximum working pressure of 2000 psi (13.8 MPa, 138 bar). Set the selector switch according to the following table. MCM Switch Position B (Blue) 1 A (Red) 2 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. S 257396_3b9905_04b FIG. 5 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 15. See FIG. 4 on page 14. 1. Perform Adjust Motor Control Module Selector Switch procedure on page 16. NOTICE • • Do not install components rated to less than the maximum working pressure. 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 FIG. 5. 3. Set the selector switch (S). 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 (429) securing Motor Control Module in place. 5. Install electrical cables on left and right sides of the Motor Control Module. 6. Install four screws (432) connecting fan to Motor and Motor Control Module. Install fan and mounting plate. 7. Install Hydraulic Power Pack Shroud, see procedure on page 15. 16 313874E Repair 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. 6. Remove the two bolts (446) from the fluid housing (403) 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. 6. See FIG. 4 on page 14 for full hydraulic power pack view. 403 446 446 NOTICE If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result. _1j1 Install third eye-bolt here 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. FIG. 6 See FIG. 4 on page 14. 7. Run a rope through the three eye-bolts and between the motor and the Motor Control Module. Secure to a hydraulic lift. 1. Perform Shutdown procedure. See operation manual for procedure. 2. Perform Remove Hydraulic Power Pack Shroud, see procedure on page 15. 3. Perform Remove Motor Control Module procedure, see page 15. 8. Remove the four bolts (304) and washers (303) securing the tank to the electrical enclosure. See Power Pack Module on page 27. 9. Lift the hydraulic power pack and place on a sturdy location capable of supporting up to 300 lb (136 kg). 4. Remove four screws (705) to disconnect hydraulic vertical actuator from hydraulic power pack. See FIG. 1 on page 10. 5. Disconnect heat exchanger inlet hose and fitting from elbow fitting (417). Disconnect heat exchanger outlet hose and fitting from elbow fitting (425). 313874E 17 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. 4 on page 14. 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 (304) and washers (303) securing the tank to the electrical enclosure. Torque to 10 ft-lb (14 N•m). Replace Tank Gasket, Tank See FIG. 4 on page 14. 1. Perform Remove Hydraulic Power Pack procedure, see page 17. 2. Remove hex head cap screws (422) securing hydraulic housing (403) to tank (420). Carefully remove motor (401) 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 (421) onto hex head cap screws (422). Apply pipe sealant to threads of screws. Align tank gasket (419), hydraulic housing, and tank (420) then install screws. Torque to 15 ft-lb (20 N•m). 5. Perform Install Hydraulic Power Pack procedure, see page 18. Remove Motor 4. Remove rope and lift. 5. Remove eye-bolts. Install original bolts (446) into fluid housing (403). See FIG. 6. 6. Perform Install Motor Control Module procedure, see page 16. 7. Connect heat exchanger inlet hose and fitting to elbow fitting (417). Connect heat exchanger outlet hose and fitting to elbow fitting located on rear right face of tank. See Power Pack Module on page 27. 8. Install four screws (705) to connect hydraulic vertical actuator to hydraulic power pack. See FIG. 1 on page 10. 18 See FIG. 4 on page 14. 1. Perform Remove Hydraulic Power Pack procedure, see page 17. 2. Remove four hex head cap screws (422) securing hydraulic housing (403) and motor (401) to tank (420). Carefully remove motor and hydraulic housing assembly from tank. 3. Remove four hex head cap screws (427) connecting mounting bracket (426) to motor. 313874E Repair 4. Remove four socket head cap screws (404) securing motor to hydraulic housing. Carefully remove motor from hydraulic housing. Remove Hydraulic Gear Pump 5. Loosen set screw for motor coupler (402) then remove motor coupler. See FIG. 4 on page 14. Install Motor 1. Perform Remove Hydraulic Power Pack procedure, see page 17. See FIG. 4 on page 14. 1. Use four hex head cap screws (427) and thrust washers (421) to install Motor Control Module mounting bracket (426) onto motor (401). 2. Install motor coupler (402) onto motor (401). 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 (407) into motor coupler. 4. Use four socket head cap screws (404) to attach hydraulic housing (403) 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). 2. Remove hex head cap screws (422) securing hydraulic housing (403) to tank. Carefully remove motor (401) and hydraulic housing assembly. 3. Remove tube (411). 4. Remove elbow fittings (410, 412) from gear pump (405). 5. Remove two hex head cap screws (408) securing gear pump to hydraulic housing. 6. Remove spider coupler (407). 7. Loosen set screw for gear coupler (406) then remove gear coupler from gear pump. Install Hydraulic 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 (421) onto hex head cap screws (422). Apply pipe sealant to threads of screws. Align tank gasket (419), hydraulic housing, and tank (420) then install screws. Torque to 15 ft-lb (20 N•m). 6. Perform Install Hydraulic Power Pack procedure, see page 18. See FIG. 4 on page 14. 1. Install gear coupler (406) onto gear pump (405). 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 (407) into gear coupler. 3. Use two hex head cap screws (408) 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 (410, 412). Install elbow fittings into gear pump. See FIG. 4 on page 14. for fitting alignment. Torque both fittings to 40 ft-lb (54 N•m). 313874E 19 Repair 5. Apply a light coating of lubricant to seals of tube (411). Install tube (411) onto elbow fitting (410) and straight fitting (409). 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 (421) onto hex head cap screws (422). Apply pipe sealant to threads of screws. Align tank gasket (419), hydraulic housing, and tank (420) then install screws. Torque to 15 ft-lb (20 N•m). 7. Perform Install Hydraulic Power Pack procedure, see page 18. 20 313874E Repair 313874E 21 Parts Parts Systems, 24F391, 24F872, 24F873 104 103 109 108 102 105 107 101 ti17663a Ref Part 101 24C168 102 ------103 104 105 106 107 108 109 ----------24F726 24F951 Description BASE, var ratio, bare MODULE, power distribution box, 400v, 3-phase, base, non-CE MODULE, power distribution box, 230v, 3-phase MODULE, power distribution box, 400v, 3-phase PUMP, vertical driver, 580SS PUMP, vertical driver, 430SS MODULE, electric, panels MODULE, flow meter APPLICATOR, mast mount HOSE, 3/4 ID, 180 in. long, female/male HOSE, 1/4 ID, 180 in. long, female/male 106 24F872, SYSTEM, 230v 1 Quantity 24F391, SYSTEM, 400v 1 1 24F873, SYSTEM, 400v CE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 --- Not for sale. 22 313874E Parts Machine Base, 24C168 271 235 270 240 229 238 204 237 272 236 225 234 239 4 264, 248 220 263 211 210, 262 8 3 212, 213, 248 214, 262 269, 262 265 Shown for reference only 2 248, 217 250 11 14 202 248, 232 233 244 268 216 266 267 215 214, 262 2 Torque to 150 in-lb (16.9 N•m). 3 Torque to 300 in-lb (33.9 N•m). 4 5 Connect ref 252 to port 10 on each motor control module. 7 Apply thread sealant to pipe threads. Torque to 62 in-lb (7.0 N•m). 8 Apply thin coating of lubricant to seals. 10 Connection point for footswitch, ref 260. ti17668a 11 Route ref 250 through wireway and connect to B (Blue) high volume MCM port 2B. 14 Route power cable of ref 263 through wire loops and secure with wire ties on heat panel. Route communication cables through wire loops. FIG. 7: Machine Base, 1 of 2 313874E 23 Parts 231 255 ti17765a 253 252 5 241 223 225 203 228 255 2 204 204 2 224 222 218 227 226 219 253 247 220 259, 254 10 201 251 261 258 ti17767a 230 FIG. 8: Machine Base, 2 of 2 24 313874E Parts Ref Part 201 --202 --203 110996 204 111800 210 103413 211 --212 111803 213 100731 214 121309 215 --216 100333 217 110837 218 24E451 219 15V551 220 121003 222 255235 223 24E647 224 --225 120060 226 110755 227 100016 228 121253 229 24B855 230 --231 --232 122970 233 123140 234 --235 --236 --237 123347 238 123942 239 --240▲ 15F674 241 24E896 243 16C779 244▲ 15M511 245 246 247 248 250 --------124344 251 252 253 254 255 256 16E779 124476 255468 ----24F516 313874E Description FRAME, pump, dual, vertical MODULE, power pack, enclosure NUT, hex, flange head SCREW, cap, hex head PACKING, o-ring PLATE, hydraulic adapter SCREW, cap, hex head WASHER FITTING, adapter, SAE-ORB x JIC COVER, wireway SCREW, cap, hex head SCREW, flange, hex MODULE, GCA, ADM SHIELD, membrane, ADM CABLE, can, female / female 3.0 m BRACKET, mounting, assembly BRACKET, adm mounting RIVET, aluminum CLIP, speed, tubular WASHER, plain WASHER, lock KNOB, display adjustment COVER, assembly COVER, pump, front COVER, enclosure, slotted FITTING, adapter, JIC(08) x SAE(08) FITTING, cap, 1/2 JIC COVER, front, driver COVER, back, driver PLATE, name, valve cover CLIP, tree, removable FASTENER, screw, cap, hex head STRIP, polyurethane foam LABEL, safety, motor CABLE, M8, 4-pin, male/female, 2 m LABEL, identification, electronics LABEL, warning, English, Spanish, French FLUID, hydraulic SEALANT, pipe PLUG, hole, 1.5 in. dia SEALANT, anaerobic CABLE, GCA, M12-5pin, male/female, 1.0 m LABEL, VRM, metering system CABLE, M8, 4-pin, male/male, 3 m KIT, accessory, light tower BUSHING, wire protector, 0.875 dia BUSHING, wire protector, snap-in FLUID, IGS™ Qty 1 2 4 14 4 2 8 8 6 2 4 8 1 0.1 1 1 1 2 10 1 1 1 2 1 2 2 2 2 2 2 12 4 6 2 2 1 1 Ref 258 259 261 262 263 264 Part 16G195 121581 124128 --123313 123366 265 266 267 268 269 270 271 272 273† 16H782 16H783 16H785 16H784 121312 16G251 16G252 15U075 --- Description LABEL HARNESS, I/O, M12 x M12 BUSHING, wire protector, snap-in LUBRICANT, grease VALVE, directional, hydraulic SCREW, socket head cap, 10-24 x 1.125 TUBE, hydraulic TUBE, hydraulic TUBE, hydraulic TUBE, hydraulic FITTING, elbow, SAE x JIC HOUSING, filter FILTER, air SCREW, cap, 8-32 x 0.37 SOFTWARE Qty 1 1 4 1 2 8 1 1 1 1 2 2 2 8 1 --- Not for sale. † To install or update software, purchase software upgrade token 16G365. ▲ Replacement Danger and Warning labels, tags and cards are available at no cost. 18 1 2 1 1 1 1 1 1 4 1 25 Parts 26 313874E Parts Power Pack Module 309 307 1 304 2 308 303 306 305 310 _1d Ref 301 302 303 304 305 306 307 308 309 Part ----U90205 802277 --111800 15Y935 24C621 123528 310 311 312▲ 313▲ 24C518 --189930 15H108 1 Torque to 10 ft-lb (14 N•m). 2 Apply sealant to threads. _2d 301 Description Qty 1 ENCLOSURE, frame 1 MODULE, hydraulic power 4 WASHER, flat, 3/8, 0.41 x 1.25 x 0.13 4 SCREW, machine 1 COVER, enclosure, heat exchanger 2 SCREW, cap, button head 1 TUBE, heat exchanger, outlet 1 HOSE, heat exchanger, inlet 1 FITTING, elbow, swivel, 45, JIC08, female/male 2 CORD, fan, heat exchanger, MCM 1 SEALANT, anaerobic 1 LABEL, caution, electric shock (not shown) 1 LABEL, pinch point (not shown) --- Not for sale. ▲ Replacement Danger and Warning labels, tags and cards are available at no cost. 313874E 27 Parts Power Pack Module Sub-Assemblies Hydraulic DC Power Pack Module 435 8 434 26 11 403 6 415 2 6 7 12 421, 422 5 14 445 11 431 11 11 432 433 11 15 430 429 428 446 11 418 417 2 416 10 12 419 404 3 11 406 5 444 414 10 421, 427 4 405 2 40912 437 11 410 2 12 2 41212 426 411 408 3 423 9 11 12 425 9 424 402 10 13 407 _1j 406 1 +.01 .30 -.00 420 436 1 Assemble coupler to specified dimensions prior to mounting assembly to housing. 2 Torque to 40 ft-lb (54 N•m). 3 Torque to 35 ft-lb (47 N•m). 5 Torque to 15 ft-lb (20 N•m). 6 Torque to 10 ft-lb (14 N•m). 7 Torque to 58 in-lb (6.5 N•m). +.00 .45 -.02 8 Torque to 34 in-lb (3.8 N•m). 9 Torque 1/4 turn past hand-tight. 15 Prior to installing Ref. 428 into Ref. 426, install Ref. 429 into Ref.428 and adjust head 1/8 in. from surface. Apply PTFE tape on installation end only. 24 Align fan plug as shown. 11 Apply sealant to threads. 26 Apply thermal lubricant to contact side. 12 Apply light coating of lubricant to seals. 13 Fill reservoir with hydraulic fluid. 14 Orient with airflow arrow pointing toward mounting bracket. 10 Torque to 20 ft-lb (27 N•m). 431 24 402 1 448, 449 4 11 8 401 413 10 438 FIG. 9: Hydraulic DC Power Pack 28 313874E Parts Ref Part 401 --402 16A951 403 --404 123338 405 --406 16A952 407 16A953 408 123942 409 15T939 410 122520 411 --412 122606 413 115597 414 101353 415 122527 416 100721 417 121312 418 101754 419 --420 --421 101971 422 111302 423 15J937 424 116915 425 121486 426 15Y912 427 100057 428 257396 429 101550 430 --431 122301 432 112310 433 100644 434 123367 435 102410 436 --437 123303 438 295709 439 --440 --441 --443▲189285 444▲121208 445▲15H108 446 109468 447 --448 123601 449 103833 Description MOTOR, power connector, assembly COUPLER, motor HOUSING, machined, hydraulic SCREW, socket head cap, 3/8-16 x 2.75 PUMP, gear, hydraulic, H39 COUPLER, pump COUPLER, spider SCREW, cap, hex head FITTING, straight, JIC8 x SAE8 FITTING, elbow, male, SAE x JIC TUBE, pump to tube outlet FITTING, elbow, male, female NIPPLE FITTING, nipple, pipe VALVE, relief PLUG, pipe FITTING, elbow, SAE x JIC PLUG, pipe GASKET, housing, to, tank RESERVOIR, assembly, 8 gallon WASHER, thrust SCREW, cap, hex head FILTER, oil, 18-23 psi bypass CAP, breather filler FITTING, elbow, male, 1/2 JIC x 1/2 NPT BRACKET, MCM mounting SCREW, cap hex head MODULE, motor control SCREW, cap PLATE, mounting, fan FAN, 220V SCREW, cap SCREW, cap HARNESS, M8 x thermal switch, 4-pin SCREW, socket head cap FLUID, hydraulic (gallon) HARNESS, M12 SCREW, socket head LUBRICANT, grease SEALANT, pipe SEALANT, pipe LABEL, caution LABEL, hot surface LABEL, pinch point SCREW, cap, hex head LUBRICANT, thermal CLAMP, wire, harness, nylon, 3/4 SCREW, mach Qty 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 --- Not for sale. ▲ Replacement Danger and Warning labels, tags and cards are available at no cost. 313874E 29 Parts Heat Exchanger Assembly 501 504 506 4 5 502 508 3 5 505 507 _1f 505 1 2 _2f 7 Ref Part 501 --502 503 504 505 506 --122300 122301 122842 15U075 507 508 510 511 110755 100022 ----- 503 1 Torque to 65 ft-lb (88 N•m). 5 Apply sealant to threads. 2 Apply lubricant to o-rings before assembling. 6 Orient fan with airflow arrow pointing toward cover. 3 Torque to 8 ft-lb (11 N•m). 7 Align fan plug as shown. 4 Torque to 2.5 ft-lb (3.4 N•m). Description COVER, enclosure, heat exchanger GASKET, fan, mounting EXCHANGER, heat, M-4 FAN, 220V FITTING, elbow, SAE x JIC SCREW, cap, button head, 8-32 x 0.37 WASHER, plain SCREW, cap, hex head LUBRICANT, thread SEALANT, anaerobic Qty 1 1 1 1 2 8 4 4 1 1 --- Not for sale. 30 313874E Parts 313874E 31 Parts Vertical Driver Pumps 604 3 622 620 619 618 _1c 621 623 ti17669a 604 3 601 606 1 2 605 4 603 3 2 607 608 1 602 613 Isometric View 624 626 1 Torque 50-60 ft-lb (68-81 N•m). 2 Torque 145-155 ft-lb (196-210 N•m). 3 Apply thread lubricant. 4 Apply thread sealant. 625 627 628 629 32 313874E Parts Ref 601 602 602 603 604 605 606 607 608 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 Part --L430S2 L580S2 184096 184130 15Y798 --108098 106166 124146 ------184278 236272 112279 189221 103927 --15F931 237063 108673 123724 103778 113187 --- Description ACTUATOR, vertical, hydraulic LOWER, u-cup, 430cc, enclosed LOWER, u-cup, 580cc, enclosed NUT, coupling COLLAR, coupling ADAPTER, female thread ROD, tie WASHER, lock, spring NUT, machine, hex FITTING, elbow, 90, 2 npt, male/female LUBRICANT, thread SEALANT, anaerobic SEALANT, pipe TOOL, wrench, packing nut HOLDER, bottle BOTTLE CAP CLAMP, hose TUBE, nylon RING, lift VALVE, relief TEE, street FITTING, nipple, hex, 1/2 NPT x 3/8 NPT PLUG, pipe CONNECTOR, female, tube TUBE, polyethylene, 1/2” OD Quantity PUMP, vertical driver, PUMP, vertical driver, 430SS 580SS 1 1 1 1 1 1 2 2 1 1 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 45 45 1 1 1 1 1 1 1 1 1 1 1 1 1 1 --- Not for sale. 313874E 33 Parts Hydraulic Vertical Actuator 713 718 711 704 9 2 722, 723 710 4 708 3 707 716 4 9 701 712 4 702 715 5 706 1 714 6 3 708 705 ti17670a 1 Torque to 100 ft-lb (135 N•m). 6 Torque to 10-12 in-lb (1.1-1.4 N•m). 2 Torque to 350 in-lb (39.5 N•m). 7 Apply thread sealant to threads. 3 Apply a light coating of lubricant to seals and surfaces specified. 8 Torque to 30-36 ft-lb (41-49 N•m). 4 9 Torque to 50-60 ft-lb (68-81 N•m). 5 Apply adhesive to surfaces specified. Orient ref 701 with date code on casting opposite of 0.25 diameter hole as shown. Ref 704 to be on opposite side of 0.25 diameter hole as shown. Ref Part Description 701 257909 DRIVER, hydraulic, vertical, 4.75 in. stroke 702 --PLATE, base 704 16E938 HOUSING, vertical, actuator 705 15J889 SCREW, hex 706 113820 SCREW, cap, hex head 707 103413 PACKING, o-ring 708 100731 WASHER 710 15Y715 ROD, tie, 10 in. long 711 15Y756 PLATE, mounting 712 15Y726 ROD, tie, 3 in. long 713 15Y745 PLATE, top, 7.25 diameter 714 16D023 HOUSING, magnet 34 Qty 1 1 1 4 3 2 4 3 1 3 1 1 Ref 715 716 718 719 720 722 723 Part 15G747 122988 258669 ----100307 --- Description MAGNET, linear sensor SCREW, cap, socket, flat SENSOR LUBRICANT, grease ADHESIVE, retaining NUT, hex SEALANT, anaerobic Qty 1 3 1 1 1 4 1 --- Not for sale. 313874E Parts Electrical Panels Base shown for reference only ti17663a 905 ti17671a 902 903 904 901 Ref Part 901 --- Description Qty MODULE, panel, power, no heat, high 1 volume 902 --MODULE, panel, power, no heat, low 1 volume 903 115942 NUT, hex, flange head 6 904 --PLUG, hole, 1.5 in. diameter 2 905 --BUSHING, wire protector, snap-in 2 906 24E900 CABLE, 5-pin, male/female (not 3 shown) --- Not for sale. 313874E 35 Parts Power Panel 1 1004 1006 1 Tie wires at this point. 1005 1006 _2a 1011 Grounding Detail 1010 1001 1003 1009 1011 1010 1012 1009 _3a _1a Ref 1001 1003 Part ----- 1004 1005 1006 1008 1009 1010 1011 1012 123452 116876 103833 100021 100028 100015 --24D547 Description PANEL, electric, heat MODULE, assy, power, no heat, high volume HOLDER, anchor, wire tie, nylon WASHER, flat SCREW, machine SCREW, cap hex head WASHER, lock NUT, hex HARNESS, wire, ground, 8AWG HARNESS, wire, male, 2-pin, 16/2 Qty 1 1 4 2 6 1 2 2 1 1 --- Not for sale. 36 313874E Parts Fluid Control Panel _4a 1102 1105 1106 1107 _3a 1109 1110 1105 1110 1109 1108 _2a 1101 1103 _1a 1104 Ref 1101 1102 1103 1104 1105 Part --289697 102598 289696 --- 1106 1107 1108 1109 1110 1111 1112 102063 114993 100021 100015 100028 123452 103833 Description Qty PANEL, electric, heat 1 MODULE, cube, GCA, base 1 SCREW, cap, socket head 4 MODULE, GCA, cube, FCM 1 HARNESS, wire, ground, terminal, 1 4 in. WASHER, lock 1 SCREW, machine, pan wash head 1 SCREW, cap hex head 1 NUT, hex 2 WASHER, lock 2 HOLDER, anchor, wire tie (not shown) 4 SCREW, machine (not shown) 4 --- Not for sale. 313874E 37 Parts Applicator Assembly 1201 1 1204 1205 1216 1207 1202 1211, 1208, 1212 1206 1210, 1211 1203 1209 ti17673a ti17672a 1 Torque to 28 ft-lb (38 N•m). 2 Tie wires here. 3 Use electrical tape (1215) to secure scuff jacket. NOTE: Items 1213 and 1214 are used for connecting grounding wire(1208) to the machine base. Ref Part Description 1201 24F668 MANIFOLD, mix, low viscosity, mast mount, 1/2 1202 122955 HARNESS, M12 x mini din 1203 123660 CABLE, eurofast, male/female, 6.0 m 1204 --TUBE, polyethylene 0.375 OD 1205 U70058 FITTING, union, “y”, 3/8 tube 1206 --SUPPORT, mast, floor mounted 1207 123395 HARNESS, power valve, tank 1208 --HARNESS, ground, 10AW, 1/4, #10, 24 ft long 38 Qty 1 2 3 12.1 2 1 1 1 Ref 1209 1210 1211 1212 1213 1214 1215 1216 Part --123452 103833 100718 100028 100015 --16G194 Description GUARD, spiral, 1/2 in. HOLDER, anchor, wire tie, nylon SCREW, machine WASHER WASHER, lock (not shown) NUT, hex (not shown) TAPE, electrical, vinyl LABEL, Graco G Qty 18 2 3 2 2 2 1 1 --- Not for sale. 313874E Parts 313874E 39 Parts Mixer Manifold, 24F668 1313 2 1304 1 1309 1306 1 1 1310 1329, 1330 1 1331 1 1305 1 1333 1311 1320 2 1 1312 1307 1319 3 1 1308 1322 2 1318 1 1334 1321 2 1323 2 1 1303 1317 4 1 1302 1324 1314 1325 1326 1316 1301 1315 ti17674a 1 Apply pipe sealant to threads. 2 Apply PTFE tape to threads. FIG. 10: Mixer Manifold, Image 1 of 2 40 313874E Parts Ref Part Description Qty 1301 24H027 MANIFOLD, mix, low viscosity, 1/2 1 1302 15U426 BUSHING, reducing, 2 3/4 nptf-1/2nptm 1303 122763 FITTING, elbow, straight, 3/4 npt, 90 4 1304 V1M350 VALVE, ball, 3/4 in. 2 1305 123514 FITTING, tee, run, 3/4, male/ female/ 2 female 1306 124433 FITTING, swivel, 3/4 npt x 12 JIC, 1 male/female 1307 123980 FITTING, swivel, 3/4 x 1/2, male/ 2 female 1308 121387 FITTING, nipple, 1/2 npt x 3.0 long 2 1309 918537 APPLICATOR, ball seat, 1/2 port, 1 60:1 1310 166443 NIPPLE, hex 2 1311 U70023 VALVE, needle, 3/4 npt, female 2 1312 15M861 FITTING, reducer, pipe, 3/4 x 1/4 2 1313 121018 FITTING, elbow, male, swivel, 4 1/4 npt 1314 256444 PLATE, mount, mixer 1 1315 100016 WASHER, lock 4 1316 111687 SCREW, cap, hex head 4 1317 --MANIFOLD, 3-station, air 1 1318 104472 SCREW, cap 2 1319 120900 VALVE, solenoid, 3-way 3 1320 113319 FITTING, air 6 1321 101754 PLUG, pipe 3 1322 123550 FITTING, 3/8 tube x 3/8 npt, female/ 1 male 1323 111881 MUFFLER 2 1324 100017 SCREW, cap, hex head 4 1325 100018 WASHER, lock, spring 4 1326 100338 NUT, jam 4 1327 --SEALANT, pipe 1 1328 --TAPE, tfe, sealant 1 1329 16F997 BUSHING, 3/4 x 1/4 npt, male/ 1 female 1330 16F998 FITTING, plug, 1/4 npt 1 1331 262205 FITTING, swivel, npt x JIC 1 1333 24G466 APPLICATOR, ball seat, 1/2 port, 1 UHMW 1334 112268 SWIVEL, union 2 --- Not for sale. 313874E 41 Parts Mixer Assembly, 24H027 Gauge Port 1401 1 1406 Gauge Port Service Port 1 1405 Service Port 1 1406 2 1409 4 1408 1404 1403 2 1407 ti8383a1 1414 5 3 1402 1 1413 1420 1 5 1416 1418 5 5 1415 Ref 1401 1402 1403† 1404† 1405 1406 1407† 1408† 1409† 1410 1411 1412 1413 42 1 Apply pipe sealant to threads. 2 Apply lubricant to o-ring surfaces before assembly 3 Torque to 33-37 ft-lb (45-50 N•m). 4 Apply thread sealant. Part 192976 192979 114353 108818 101748 101970 112973 240452 102982 ------192977 Description MANIFOLD, high pressure VALVE, check SPRING, compression BALL PLUG, pipe PLUG, pipe PACKING, o-ring SEAT PACKING, o-ring SEALANT, pipe LUBRICANT, grease SEALANT, anaerobic PIPE, center, mixer manifold 1419 5 1417 5 ti17675a Qty 1 2 2 2 2 4 2 2 2 1 1 1 1 1414 1415 1416 1417 1418 1419 1420 124912 16G560 16G373 123042 110980 114271 296178 SLEEVE, mixer jacket 1 MIXER, 3/4 x 23 5 FITTING, adapter, mixer, 1 npt 1 HOSE, vacuum, 1 in. ID 42 CLAMP, hose 1 STRAP, retaining 2 FITTING, union, swivel, 3/4 mpt x 1 1/2 fpt † Recommended spare parts. Keep two of each on hand at all times. --- Not for sale. 313874E Parts Floor Mounted Support 1501 1502 1503 1504 1 24E850_1b 1 Ref 1501 1502 1503 1504 Part ----109570 100424 Torque to 113 ft-lb (153 N•m). Description PLATE, mating, floor, mast BASE, arm, floor mount WASHER, plain SCREW, cap, hex head Qty 1 1 4 4 --- Not for sale. 313874E 43 Parts Hoses 1602 1601 24F726 shown Ref Part 1601 24F710 24F950 1602 124435 124726 44 Description HOSE, coupled, 180 in. long, 3/4 iD, 1-1/16 JIC HOSE, coupled, 180 in. long, 1/4 ID, 1/2-20 JIC FITTING, union, 12JIC, male x male FITTING, union, JIC05, male x male Quantity 24F726, HOSE, 24F951, HOSE, 3/4 ID, 180 in. long, 1/4 ID, 180 in. long, female/male female/male 1 1 1 1 313874E 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 L2 1L2 L1 1L1 1L2 1L3 1L1 1L2 1L3 151 151 151 1L1 1L2 L3 1L3 1L1 GND 230V/ 3PH/ 50-60HZ DISC-1 313874E 1L2 1L1 1L3 1L2 1L1 CB5 5A CB1 30A 1 1360 1340 1120 1100 1080 1360 1360 1340 1340 LOAD GND L2/N L1/P POWER FILTER LINE THIS PAGE IS FOR ASSEMBLY: 24C683 AND 257764 LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION 1400 BL 1390 BR HARNESS 24C318 HARNESS 24C516 1120 WHT 121808 POWER SUPPLY 1100 1360 1340 1080 RED GND BLK 755 1 331 1 CAN SPLITTER 123466 PG133 L3 L2 L1 GND PG105 MISC B VOLUME MCM B VOLUME 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 1L1 1L1 CAP 1L2 1L2 148 1L1 148 1L3 CAP 1L3 1L3 148 1L1 1L3 1L1 1L3 1L2 CB6 5A CB10 30A 1860 1840 1620 1600 1580 HARNESS 24C318 HARNESS 24C516 WHT RED BLK 1860 1840 1620 1600 1580 PG184 L3 L2 L1 GND PG156 824 2 469 2 MISC A VOLUME MCM A VOLUME Logic Drawings Logic Drawings 230V 3 Phase Power Distribution Box FIG. 11: Logic Drawings, Page 1 45 GND 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 1N 1N 1N 151 L3 1L2 L1 1L1 1L1 N 1N 151 L2 1L2 1L1 GND 400V/ 3PH/ 50-60HZ DISC-1 46 1N 1L1 1N 1L1 CB5 5A CB1A 63A 1 1360 1340 1100 1080 1360 1360 1340 1340 LOAD GND L2/N L1/P POWER FILTER LINE THIS PAGE IS FOR ASSEMBLY: 24F142 LOCATED IN THE MAIN PDB ENCLOSURE CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION 1400 BL 1390 BR HARNESS 24C318 HARNESS 24C515 121808 POWER SUPPLY 1100 1360 1340 1080 WHT GND BLK 755 1 331 1 CAN SPLITTER 123466 PG133 L3 L2 L1 GND PG105 MISC B VOLUME MCM B VOLUME 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 1L2 1L2 1N 1N 1N 148 1L2 148 1N 1L2 1N 1L2 CB6 5A CB10A 63A 1860 1840 1600 1580 HARNESS 24C318 HARNESS 24C515 WHT BLK 1860 1840 1600 1580 PG184 L3 L2 L1 GND PG156 2 824 2 469 MISC A VOLUME MCM A VOLUME Logic Drawings 400V 3 Phase Power Distribution Box FIG. 12: Logic Drawings, Page 2 313874E GND 2B 1 2C 1 67 0X 365 PX262 121061 HYD-OIL LO-LVL 1 2 3 4 1 2 7 SHLD +SIG 1 SEE OPTIONAL MATL LEVEL SENSOR 4 3 2 1 5 4 3 2 1 5 1 2 SIGNAL SIGNAL COMMON +24VDC SIGNAL 1 2 3 4 5 M12 5 PIN MALE OPTION MATL LO-LVL 2C 1 2 3 4 5 SIGNAL -24VDC +24VDC 4 3 2 1 1 2 3 4 5 7 1 2 3 4 5 1 M12 5 PIN MALE SIGNAL SIGNAL COMMON SIGNAL SIGNAL 4 3 2 1 5 4 3 2 1 5 4 M12 5 PIN FEMALE 1 -SIG +5VDC DC COM HARNESS 123303 8 1 2 3 4 5 1 2 3 4 5 1 4 M12 5 PIN FEMALE 10 B-CODE 8 M12 5 PIN MALE M12 5 PIN FEMALE 9 1 2 3 4 5 M12 5 PIN MALE 3 HARNESS 123303 1 2 3 4 M8 4 PIN FEMALE 1 B-CODE 9 1 2 3 4 5 M12 5 PIN FEMALE 2 1 10 1 2 3 4 M8 4 PIN MALE 1 2 3 4 5 M12 5 PIN MALE 67 3 CABLE 124476 CAN COMM PORT CAN COMM PORT 1 2 3 4 5 M12 5 PIN MALE 45 2 1 M8 4 PIN MALE POS 1 = 2000psi (DEFAULT) OPTION FS247 START DISPENSE GUN SOL240 PB235 START MCM ANALOG LOW VOLUME 2A 1 45 B - BLUE OTS264 123367 OIL TEMP HI DC COM SIGNAL DISPENSE SIGNAL TO HYDRAULIC DISP. HEAD FCM SOL241 PUMP RIGHT SOL234 PUMP LEFT VALVE ASSY 123313 PRESS XDUCER BLUE 'B' VOLUME 1 7C 1 7B 1 7A 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 OPTION RTD290 OIL TEMP SIGNAL EXC 1 3 1 2 3 4 M8 4 PIN MALE PG105 1 PHASE PG105 3 PHASE 1 2 3 4 M8 4 PIN FEMALE GND GND GND GND MCM HI VOLUME L3 L3 L2 L2 12 11 5 1 2 3 4 15 PIN DSUB 1 2 3 4 1 109 HARNESS 24C515 109 15PIN DSUB 5 1 2 3 4 M8 4 PIN MALE 6 1 2 3 4 M8 4 PIN MALE HARNESS 24C516 12 13 M8 4 PIN FEMALE L1 L1 3 6 M8 4 PIN FEMALE 1080 1580 1 LOCATED ON THE HYDRAULIC POWER PACK VARIABLE RATIO = BLUE 1100 1600 9 L1 L2 13 1 1 BLU RED BLK 1 SIGNAL EXC 1 SIGNAL COMMON SHLD EXC 11 L3 GND 8 1120 2 3 4 5 6 7 9 15 14 13 12 11 10 1 2 3 4 5 6 7 01 15 14 13 12 11 10 01 GND 23 313874E 23 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 MOTOR ENCODER M310 RTD292 MOTOR TEMP LPT280 258669 PUMP POSITION Logic Drawings B (Blue) Hydraulic Power Pack 8 FIG. 13: Logic Drawings, Page 3 47 23 SIGNAL 2 SIGNAL SIGNAL COMMON +24VDC 2 2 1 2 3 4 5 M12 5 PIN MALE HARNESS 123303 10 1 2 3 4 M8 4 PIN MALE CAN COMM PORT CAN COMM PORT 2 OPTION MATL LO-LVL 2C 1 2 3 4 5 M12 5 PIN FEMALE 1 2 3 4 M8 4 PIN FEMALE 1 2 3 4 5 M12 5 PIN MALE 1 2 3 4 5 45 7 B-CODE 8 B-CODE 9 SIGNAL -24VDC +24VDC 2 10 1 67 4 3 2 1 1 2 3 4 5 1 2 3 4 5 7 2 M12 5 PIN MALE M12 5 PIN FEMALE 2 SHLD +SIG DC COM -SIG +5VDC SIGNAL SIGNAL COMMON SIGNAL SIGNAL HARNESS 123303 2 1 2 3 4 5 1 2 3 4 5 8 M12 5 PIN MALE 9 1 2 3 4 5 M12 5 PIN MALE M12 5 PIN FEMALE 1 2 3 4 5 M12 5 PIN FEMALE 1 4 3 2 1 5 4 3 2 1 5 4 3 2 OTS402 123367 OIL TEMP HI HARNESS 123395 SOL386 RATIO CHECK SOL378 PUMP RIGHT SOL372 PUMP LEFT VALVE ASSY 123313 PRESS XDUCER RED 'A' VOLUME 2 7C 2 7B 2 7A OPTION RTD428 OIL TEMP SIGNAL EXC 2 3 1 2 3 4 M8 4 PIN MALE PG156 1 PHASE PG156 3 PHASE 1 2 3 4 M8 4 PIN FEMALE GND GND GND GND M12 5 PIN MALE 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 L3 L3 L2 L2 12 11 5 1 2 3 4 15 PIN DSUB 1 2 3 4 2 159 HARNESS 24C515 159 15 PIN DSUB 5 1 2 3 4 M8 4 PIN MALE 6 1 2 3 4 M8 4 PIN MALE HARNESS 24C516 12 13 M8 4 PIN FEMALE L1 L1 3 6 M8 4 PIN FEMALE 1580 1580 A - RED 1600 1600 1 2 3 4 5 6 7 9 15 14 13 12 11 10 MCM LOW VOLUME 1620 1 2 3 4 5 6 7 9 SIGNAL 2 13 GND L1 L2 L3 BLU RED BLK 2 2 SIGNAL EXC 2 COMMON SHLD EXC 11 15 14 13 12 11 10 01 8 GND 48 23 338 LOCATED ON THE HYDRAULIC 339 POWER PACK VARIABLE RATIO 340 RED 'A' 341 342 67 343 POS 2 = 2000psi 344 (DEFAULT) 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 M8 4 PIN 361 CABLE MALE 124476 362 363 1 364 2 MCM ANALOG 365 227 HI VOLUME 3 366 4 367 368 369 2A 370 1 371 2 372 2 373 374 3 375 376 4 377 378 5 379 SOL379 380 #2 DISPENSE VALVE 381 382 2B 1 383 2 384 2 385 386 3 387 388 4 389 390 5 391 392 393 394 2C OPTION 1 395 396 2 2 397 398 HYD-OIL 3 399 LO-LVL 400 4 401 402 PX400 403 121061 404 SEE OPTIONAL MATL 405 LEVEL SENSOR 406 MOTOR ENCODER M450 RTD429 MOTOR TEMP LPT416 258669 PUMP POSITION Logic Drawings A (Red) Hydraulic Power Pack 8 01 FIG. 14: Logic Drawings, Page 4 313874E 45 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 135 1360 313874E 1 1340 1340 1340 1340 1340 1360 1360 1360 1360 1360 PG133 14 14 CR573 11 CR504 11 HARNESS 24C518 1 2 HARNESS 24C518 1 2 8000 7940 M772 A2 BR BL MOTOR FAN MCM A2 CON800 A1 M762 MOTOR FAN HYD HEAT EXCH'R CON794 A1 1 2 1 2 SOL234 SOL241 USED ONLY WITH HOSE HEAT OPTION USED ONLY WITH PRIMARY HEAT OPTION HYD VALVE ASSY 230VAC POWER TO THE FAN MOTOR 230VAC POWER TO THE FAN MOTOR TERMINAL STRIP MOUNTED ON BACKPANEL LOCATED IN THE MAIN SUPPORT ENCLOSURE 230VAC POWER TO THE HYDRAULIC POWER VALVE 821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876 877 878 879 880 881 882 883 884 885 886 887 888 889 185 2 1840 1840 1840 1840 1840 1860 1860 1860 1860 1860 PG184 MISC A - RED LOW VOLUME 1860 MISC B - BLUE HI VOLUME 14 14 CR711 11 CR642 11 HARNESS 24C518 1 2 HARNESS 24C518 1 2 8690 8630 M841 A2 BR BL MOTOR FAN MCM A2 CON869 A1 M831 MOTOR FAN HYD HEAT EXCH'R CON863 A1 1 2 1 2 SOL372 SOL378 USED ONLY WITH HOSE HEAT OPTION USED ONLY WITH PRIMARY HEAT OPTION HYD VALVE ASSY 230VAC POWER TO THE FAN MOTOR 230VAC POWER TO THE FAN MOTOR TERMINAL STRIP MOUNTED ON BACKPANEL LOCATED IN THE MAIN SUPPORT ENCLOSURE 230VAC POWER TO THE HYDRAULIC POWER VALVE Logic Drawings Main Enclosure FIG. 15: Schematics, Page 5 49 1840 1340 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 50 'A' RED ISO LUBE PUMP HV SOL234 LV SOL372 B A +5 VDC A A P VARIABLE RATIO VERTICAL PUMP +5 VDC GND FIXED RATIO MACHINE FRONT FACING PUMPS SIGNAL PUMP POSITION HYDRAULIC CYLINDER B T LOCATED ON THE MAIN HYDRAULIC POWER PACK SIGNAL GND B HV LPT280 LV LPT416 123313 HV SOL241 LV SOL378 HV PX262 LV PX400 OIL LEVEL SENSOR OPTIONAL 'B' BLUE PRESSURE RELIEF VALVE PRESSURE GAUGE OPTIONAL OIL TEMP RTD OPTIONAL HV RTD290 LV RTD428 M MCM FAN HV M772 LV M841 PUMP HV M310 LV M450 HYD. FAN HV M762 LV M831 OIL OVERTEMP SWITCH FILTER 15J437 COOLER HV OTS264 LV OTS402 959 960 961 962 963 964 965 966 967 968 969 970 971 972 973 974 975 976 977 978 979 980 981 982 983 984 985 986 987 988 989 990 991 992 993 994 995 996 997 998 999 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 123478 P 3 1 5 3 1 5 3 1 5 120900 102 101 2 4 120900 SOL-386 RED MCM PORT 7B 103 104 103 CLOSE 104 2 4 SOL-240 BLUE MCM PORT 2A CLOSE 105 106 105 120900 106 2 4 SOL-379 RED MCM PORT 2A EXH LOCATED ON DISPENSE HEAD DISPENSE HEAD PNEUMATICS CLOSE 101 CLOSE 101 102 OPEN OPEN OPEN OPEN CLOSED BLUE RATIO CHECK VALVE RED RATIO CHECK VALVE BLUE DISPENSE VALVE RED DISPENSE VALVE CLOSED CLOSED CLOSED Logic Drawings B (Blue) Hydraulic Power Pack and Dispense Head Pneumatics FIG. 16: Schematics, Page 6 313874E Technical Data Technical Data Air Inlet Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-100 psi (0.59-0.69 MPa, 5.9-6.9 bar) Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, UHMW Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . 8 gal. (30 liters) each Recommended Hydraulic Fluid . . . . . . . . . . . . . . . . . . . Citgo A/W Hydraulic Oil, ISO Grade 46 Weight (varies by machine layout) . . . . . . . . . . . . . . . . . 1390 lb (630 kg) Dimensions The dimensions of the machine vary by machine layout. The distance from the machine base to the dispense stand can be varied significantly because of the hoses. Ref A (Height) B (Width) C (Depth) in. (mm) 79 (2007) 63 (1600) 115 (2921) B A ti17663a C 313874E 51 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. 2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 313874 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised November 2014