Graco 313998S Hfr Users Manual HFR, Repair Parts, English

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313998S

EN

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.

See page 4 for model information and maximum

working pressure.

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

ti19598a

2 313998S

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Important Two-Component Material Information 19

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

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

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

19

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DC Power Pack Pressure Adjustment Kit, 24C067

72

DC Power Pack Hydraulic Pressure Adjustment

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Related Manuals

313998S 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

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 EP™Gun

313536 GX-16, Operation

312185 MD2 Valve, Instructions-Parts

312752 S-Head Operation-Parts

312753 L-Head Operation-Parts

309550 Fusion®AP Gun

309856 Fusion MP Gun

312666 Fusion CS Gun

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

Models

4 313998S

Models

See Product Configurator on page 5 for detailed prod-

uct configuration information.

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and

mix chamber sizes may be less.

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

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

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

★approved.

‡The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If

hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of

the hoses. If 2000 psi hoses were purchased and installed by Graco, the working pressure for the machine is

already setup for the lower 2000 psi (13.8 MPa, 138 bar) working pressure by Graco. If the machine was pur-

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

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

change in working pressure is made by changing a rotary switch setting in the Motor Control Module. The mini-

mum 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 Amer-

ica, a special transformer rated for 400 V (“Y” con-

figuration (4 wire)) may be required.

• North America mostly employs a 3 wire or Delta

configuration. The two configurations are not inter-

changeable.

System

Full Load

Peak Amps

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**

Maximum

Fluid Working

Pressure ‡

psi (MPa, bar)

HFR,

Non-Heated

55 A 230V (1) 12,650

-- 50 (22.7) 0.084 1.9:1 3000

(20.7, 207)

29 A 230V (3) 11,340

55A★✖ 400V (3) 12,650

HFR,

Heated

116 A 230V (1) 26,680

6,000 50 (22.7) 0.084 1.9:1 3000

(20.7, 207)

73 A 230V (3) 28,600

75A★✖ 400V (3) 28,600

Product Configurator

313998S 5

Product Configurator

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

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

HFR-A------

Ref.: 1 2 3 4 5 6

Configurator Revision

Base

Voltage

B (Blue) Pump

A (Red) Pump

Primary/Hose Heat

High Volume/Low Volume

Hose Bundle Assembly

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

High Volume/Low Volume

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

Product Configurator

6 313998S

† Pump size listed is the combined volume dispensed

in one extending stroke and one retracting stroke.

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

Ref. 6 Part

B (Blue) Applicator Hose or High Volume/

Low Volume Hose Bundle Assembly

NN -- No Hose

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

Product Configurator

313998S 7

Whip Hose Bundles

Individual B (Blue) Heated Whip

Hose

Individual A (Red) Heated Whip

Hose

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

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

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

Product Configurator

8 313998S

Hoses

B (Blue) Individual

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

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

Product Configurator

313998S 9

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

Product Configurator

10 313998S

Hose Bundling Accessories

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 exam-

ple: A (red) pump size = 20 cc, B (blue) pump size = 100

cc, 20 cc + 100 cc = 120 cc. Since the pump sizes com-

bined = 120 cc, an applicator may be selected which

does not have a signal communicating to the HFR.

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

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

Product Configurator

313998S 11

B (Blue) Applicator Orifice

S-Head and L-Head

GX-16

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

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

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

Product Configurator

12 313998S

EP™Gun

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 For Use With Applicator:

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

0.51 mm Poly

Orifice

24C751 EP 250 Poly Side Orifice, Std

0.79 mm Poly

Orifice

24C752 EP 250 Poly Side Orifice, Std

1.19 mm Poly

Orifice

24C753 EP 250 Poly Side Orifice, Std

1.52 mm Poly

Orifice

24C754 EP 250 Poly Side Orifice, Std

1.70mm Poly

Orifice

24C755 EP 250 Poly Side Orifice, Std

2.18 mm Poly

Orifice

24C756 EP 250 Poly Side Orifice, Std

0.41 mm Poly

Orifice

24C805 EP 250 Poly Side Orifice

0.61 mm Poly

Orifice

24C806 EP 250 Poly Side Orifice

0.71 mm Poly

Orifice

24C807 EP 250 Poly Side Orifice

0.89 mm Poly

Orifice

24C808 EP 250 Poly Side Orifice

0.99 mm Poly

Orifice

24C809 EP 250 Poly Side Orifice

1.07 mm Poly

Orifice

24C810 EP 250 Poly Side Orifice

1.32 mm Poly

Orifice

24C811 EP 250 Poly Side Orifice

1.40 mm Poly

Orifice

24C812 EP 250 Poly Side Orifice

1.60 mm Poly

Orifice

24C813 EP 250 Poly Side Orifice

1.85 mm Poly

Orifice

24C815 EP 250 Poly Side Orifice

Orifice Kit 24E251 EP 375, 6 Blue, 6 Red

0.51 mm Poly

Orifice

24C761 EP 375 Poly Side Orifice, Std

0.79 mm Poly

Orifice

24C762 EP 375 Poly Side Orifice, Std

1.19 mm Poly

Orifice

24C763 EP 375 Poly Side Orifice, Std

1.52 mm Poly

Orifice

24C764 EP 375 Poly Side Orifice, Std

1.70 mm Poly

Orifice

24C765 EP 375 Poly Side Orifice, Std

2.18 mm Poly

Orifice

24C766 EP 375 Poly Side Orifice, Std

0.41 mm Poly

Orifice

24C794 EP 375 Poly Side Orifice

0.61 mm Poly

Orifice

24C795 EP 375 Poly Side Orifice

0.71 mm Poly

Orifice

24C796 EP 375 Poly Side Orifice

0.89 mm Poly

Orifice

24C797 EP 375 Poly Side Orifice

0.99 mm Poly

Orifice

24C798 EP 375 Poly Side Orifice

1.07 mm Poly

Orifice

24C799 EP 375 Poly Side Orifice

1.32 mm Poly

Orifice

24C800 EP 375 Poly Side Orifice

1.40 mm Poly

Orifice

24C801 EP 375 Poly Side Orifice

1.60 mm Poly

Orifice

24C802 EP 375 Poly Side Orifice

1.85 mm Poly

Orifice

24C804 EP 375 Poly Side Orifice

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

Product Configurator

313998S 13

EP Gun

AC Power Pack with

S-Head/L-Head Hoses, Optional

Boom

Dispense Valve Interface Kit

Description Part For Use With Applicator:

0.51 mm Iso Ori-

fice

24D223 EP 250 Iso Side Orifice, Std

0.79 mm Iso Ori-

fice

24D224 EP 250 Iso Side Orifice, Std

1.19 mm Iso Ori-

fice

24D225 EP 250 Iso Side Orifice, Std

1.52 mm Iso Ori-

fice

24D226 EP 250 Iso Side Orifice, Std

1.70mm Iso Ori-

fice

24D227 EP 250 Iso Side Orifice, Std

2.18 mm Iso Ori-

fice

24D228 EP 250 Iso Side Orifice, Std

0.41 mm Iso Ori-

fice

24D229 EP 250 Iso Side Orifice

0.61 mm Iso Ori-

fice

24D230 EP 250 Iso Side Orifice

0.71 mm Iso Ori-

fice

24D231 EP 250 Iso Side Orifice

0.89 mm Iso Ori-

fice

24D232 EP 250 Iso Side Orifice

0.99 mm Iso Ori-

fice

24D233 EP 250 Iso Side Orifice

1.07 mm Iso Ori-

fice

24D234 EP 250 Iso Side Orifice

1.32 mm Iso Ori-

fice

24D235 EP 250 Iso Side Orifice

1.40 mm Iso Ori-

fice

24D236 EP 250 Iso Side Orifice

1.60 mm Iso Ori-

fice

24D237 EP 250 Iso Side Orifice

1.85 mm Iso Ori-

fice

24D238 EP 250 Iso Side Orifice

0.51 mm Iso Ori-

fice

24D239 EP 375 Iso Side Orifice, Std

0.79 mm Iso Ori-

fice

24D240 EP 375 Iso Side Orifice, Std

1.19 mm Iso Ori-

fice

24D241 EP 375 Iso Side Orifice, Std

1.52 mm Iso Ori-

fice

24D242 EP 375 Iso Side Orifice, Std

1.70 mm Iso Ori-

fice

24D243 EP 375 Iso Side Orifice, Std

2.18 mm Iso Ori-

fice

24D244 EP 375 Iso Side Orifice, Std

0.41 mm Iso Ori-

fice

24D245 EP 375 Iso Side Orifice

0.61 mm Iso Ori-

fice

24D246 EP 375 Iso Side Orifice

0.71 mm Iso Ori-

fice

24D247 EP 375 Iso Side Orifice

0.89 mm Iso Ori-

fice

24D248 EP 375 Iso Side Orifice

0.99 mm Iso Ori-

fice

24D249 EP 375 Iso Side Orifice

1.07 mm Iso Ori-

fice

24D250 EP 375 Iso Side Orifice

1.32 mm Iso Ori-

fice

24D251 EP 375 Iso Side Orifice

1.40 mm Iso Ori-

fice

24D252 EP 375 Iso Side Orifice

1.60 mm Iso Ori-

fice

24D253 EP 375 Iso Side Orifice

1.85 mm Iso Ori-

fice

24D254 EP 375 Iso Side Orifice

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

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

Product Configurator

14 313998S

Flow Meters

Flow Meter Electronics (Necessary)

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

Flow Meter Calibration Kit (per applicator)

Pump Feed Kits

Part Description

24J318 Flow Meter Electronics Kit

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)

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

Part Description

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

Pump Kit

246369 H515 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246375 H716 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

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

Pump Kit

257769 High-Flo®(Air/Fluid) Carbon Steel Complete

Supply Pump Kit

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

Pump Kit

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 Husky™515 Pump, Drum with Riser Tube

246367 Husky 716 Pump, Drum with Riser Tube

24D329 Husky 1050 Pump, Drum with Riser Tube

233052 Husky 515 Diaphragm Pump, Drum with Riser

Tube

233057 Husky 716 Diaphragm Pump, Drum with Riser

Tube

24D097 Husky 1050 SS Pump, Drum with Riser Tube

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

Riser Tubes

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

with Riser Tubes

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

with Riser Tubes

246481 Husky 515 Pump with Carbon Steel Fluid Plumb-

ing

246482 Husky 716 Pump with Carbon Steel Fluid Plumb-

ing

24D332 Husky 1050 Pump with Carbon Steel Fluid

Plumbing

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

ing

24D100 Husky 515 Pump with Stainless Steel Fluid

Plumbing

24D101 Husky 716 Pump with Stainless Steel Fluid

Plumbing

24D102 Husky 1050 Pump with Stainless Steel Fluid

Plumbing

24D103 2:1 Supply Pump with Stainless Steel Fluid

Plumbing

24D104 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24D105 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

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

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

24E398 One Monarch 5:1 Pump, 5G

24E399 One Monarch 5:1 Pump, 55G

246419 Carbon Steel Riser Tube Assembly

246477 Carbon Steel Return Tube

246483 Air Supply for Feed Pump and Gun

Product Configurator

313998S 15

B (Blue) and A (Red) Feed Tanks

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

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 Con-

trol 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

Product Configurator

16 313998S

Additional Accessories

Miscellaneous

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 conjunc-

tion 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

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

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 EP and Fusion®Gun Ratio Check

24F235 25 ft hose extensions for L-Head applicator;

material, hydraulic, and signal cables

24F236 50 ft hose extensions for L-Head applicator;

material, hydraulic, and signal cables

24F237 25 ft hose extensions for S-Head applicator;

material, hydraulic, and signal cable

24F238 50 ft hose extensions for S-Head applicator;

material, hydraulic, and signal cable

24K206 Nip Sensor Kit

24H019 Air Inlet Filter for Hydraulic Power Pack

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

Part Description

24F843 Single DGM Cube with Board

24F844 Two DGM Cubes with Board

24G830 Single DGM Cube

Warnings

313998S 17

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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 reg-

ulations.

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, inhala-

tion 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.

Warnings

18 313998S

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 manu-

facturer’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.

WARNING

Important Two-Component Material Information

313998S 19

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Keep Components A (Red) and

B (Blue) Separate

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 equip-

ment, 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.

WARNING

Spraying or dispensing materials containing isocya-

nates 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 ventila-

tion 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 per-

sonal protective equipment, including chemically

impermeable gloves, boots, aprons, and goggles, is

also required for everyone in the work area.

Some materials may become self-igniting if applied

too thickly. Read material manufacturer’s warnings

and material MSDS.

Cross-contamination can result in cured material in

fluid lines which could cause serious injury or dam-

age equipment. To prevent cross-contamination of

the equipment’s wetted parts, never interchange

component A (Red) and component B (Blue) parts.

A (Red) and B (Blue) Components

20 313998S

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 crystal-

lization 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 contam-

inated 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 mul-

tiple 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 follow-

ing 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.

Shutdown

313998S 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 trig-

ger until the pump stops moving.

2. Press the power key on the ADM

3. Turn main power switch (MP) to OFF position.

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

(FV).

5. Perform Pressure Relief Procedure on page 22.

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

manual.

ti9883a1

FV

Pressure Relief Procedure

22 313998S

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.

3. For models with an EP Gun installed, engage gun

safety lock.

4. Relieve pressure in EP Gun or dispense valve. See

related manual.

ti9879a1

SA

SB

Flushing

313998S 23

Flushing

• Flush out old fluid with new fluid, or flush out old

fluid with a compatible solvent before introducing

new fluid.

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common

solvents. Use only moisture-free solvents. See

Technical Data on page 92 for wetted components.

See solvent manufacturers information for material

compatibility.

• To flush feed hoses, pumps, and heaters separately

from heated hoses, set PRESSURE RELIEF/DIS-

PENSE valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION . Flush through bleed

lines (N).

• 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 mois-

ture-free plasticizer or oil. Do not use water. See

Important Two-Component Material Information

on page 19.

Flush equipment only in a well-ventilated area. Do not

dispense flammable fluids. Do not turn on heaters

while flushing with flammable solvents.

SA

SB

ti9880a1

N

N

Repair

24 313998S

Repair

Pumpline

See Z-Series Chemical Pumps manual, HFR Hydraulic

Driver manuals for more detailed pumpline repair infor-

mation.

Remove Chemical Pumps

This procedure removes the chemical pumps so that

replacement parts can be installed. See Z-Series Chem-

ical 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.

Pump Outlet

Pump Inlet

Fluid Manifold Inlet

24C352_313998_4g1

Repair

313998S 25

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.

7. Remove two shoulder bolts from LVDT collar then

remove collar from B side pump shaft. See FIG.2.

8. Remove coupler from the A and B side pump shafts.

See FIG.2.

9. Unscrew LVDT sensor assembly and spool assem-

bly from pump outlet housing. Wipe off spool

assembly. See FIG.2.

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

FIG.2.

FIG. 1: Lube Cylinder

FIG.2

Lube Cylinder Inlet Fitting (behind cylinder)

Lube Cylinder Outlet Fitting

Punch Slot (same on opposite side)

24C352_313998_2g1

Nuts

LVDT Collar

LVDT Sensor Assembly

(behind pump)

Coupler

LVDT Spool Assembly

Pump Outlet Housing

24C352_313998_2g1

Repair

26 313998S

Install Chemical Pumps

Reconnect or install a different size chemical pump to

achieve desired ratio.

1. Install ISO lube cylinder on A side pump. Apply light

coating of lubricant on o-rings on outside of small

cylinder.

2. Install nuts on tie rods after the pumps have been

installed. Torque to 50-60 ft-lb (68-81 N•m).

3. Install coupler on A and B side pump shafts.

4. Install LVDT Assembly.

a. Apply a very light coat of hydraulic oil on LVDT

sensor tube and install through pump outlet

housing. Install spool assembly.

b. Install LVDT collar on coupler and pump shaft.

Ensure that the split on the LVDT collar does not

ride in the spool assembly.

c. Apply thread sealant to shoulder bolts then

install in LVDT collar. Torque to 40-50 in-lb

(4.5-5.6 N•m).

5. After the IsoGuard Select cylinder has been

installed on the A side pump, apply pipe sealant on

cylinder outlet fitting.

6. Perform Prime IsoGuard Select®Cylinder proce-

dure, see page 26.

7. Reconnect inlet and outlet fluid lines.

Prime IsoGuard Select®Cylinder

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 out-

let 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.

FIG. 3: IsoGuard Select System

24C352_313998_8g1

Repair

313998S 27

Remove HFR Hydraulic Driver

This procedure removes the HFR Hydraulic Driver so

replacement parts can be installed. See HFR Hydraulic

Driver manual for replacement parts installation proce-

dure.

1. Perform Remove Chemical Pumps procedure, see

page 24.

2. Disconnect the fluid manifold inlet lines. Do not dis-

connect the fluid line connections at the heater.

3. Remove pump support brackets. Each bracket is

secured with three screws at the base frame and

two screws at the manifold bracket.

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

This procedure installs the hydraulic driver after replace-

ment 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 bot-

tom-right corners.

3. Install pump support brackets, torque to 300 in-lb

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

to hydraulic driver.

4. Connect fluid manifold inlet lines.

5. Perform Install Chemical Pumps procedure, see

page 26.

FIG.4

155 104

156

124

125

155

188

156

112

111

180

24C352_313998_5g1

Fluid Manifold Inlet

24C352_313998_4e1

Repair

28 313998S

Remove PowerHouse Pumpline

The Hydraulic Power Pack must be removed to perform

some Hydraulic Power Pack repair procedures. In order

to remove the Hydraulic Power Pack, the PowerHouse

pumpline must be removed. See Hydraulic Power

Pack Repair starting on page 32 for more information.

1. Perform Shutdown procedure, see page 21.

2. Flush the system, see page 23.

3. Disconnect the chemical pump inlet, pump outlet,

and fluid manifold inlet lines. Do not disconnect the

fluid line connections at the heater.

4. Remove lube cylinder inlet and outlet fittings. Let

cylinder drain.

5. See FIG. 6. Remove four screws (107) securing

pumpline to hydraulic power pack. This will also

loosen manifold plate (104) from hydraulic driver.

Pump Outlet

Pump Inlet

Fluid Manifold Inlet

24C352_313998_4e1

FIG. 5: Lube Cylinder, Viewed from Rear Left of

Machine

FIG.6

Lube Cylinder Inlet Fitting

Lube Cylinder Outlet Fitting

Punch Slot (same on opposite side)

24C352_313998_8e1

155 104

156

124

125

155

188

156

112

111

180

24C352_313998_5g1

Repair

313998S 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.

FIG.7

24C352_313998_4e1

Repair

30 313998S

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 install-

ing the PowerHouse pumpline at the end of the Hydrau-

lic 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 proce-

dure, see page 26.

5. Connect the chemical pump inlet, pump outlet, and

fluid manifold inlet lines.

Pump Outlet

Pump Inlet

Fluid Manifold Inlet

24C352_313998_4e1

Repair

313998S 31

Repair

32 313998S

Hydraulic Power Pack Repair

FIG. 8: Hydraulic DC Power Pack

720

725

723

711

710

708

724

713

712

709

714

705

706

719

717

718

746

734

735

715

716

704

729

702

721,

707

701

726 738

737

728

721, 722

744

730733732731745

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).

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.

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.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

24

26

9

11

2

12

3

11 5

10

12

2

12

2

12

311

10

811 26

10

2

12

10

2

12 411

727

511

9

13

6

11

7

11

14 15

11

6

11

8

.45 +.00

-.02

702 1

.30 +.01

-.00

1

702 24

731

257442_3A0998_1j

11

5

11

Repair

313998S 33

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

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.

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 pro-

cedure on this page.

3. Remove four screws (732) connecting fan to mount-

ing plate.

4. Remove fan and install new fan.

5. Install four screws (732) connecting fan to Motor

and Motor Control Module.

6. Install Hydraulic Power Pack Shroud, see proce-

dure on this page.

Remove Motor Control Module

See FIG. 8 on page 32.

1. Perform Shutdown procedure, see page 21.

2. Remove Hydraulic Power Pack Shroud, see pro-

cedure on this page.

3. Remove four screws (732) connecting fan to Motor

and Motor Control Module. Remove fan and mount-

ing plate.

4. Note the location of each Motor Control Module

cable then remove all electrical cables on the left

and right sides of the Motor Control Module.

5. Remove six screws (729) securing Motor Control

Module in place.

6. Slowly and carefully slide the Motor Control Module

up until the cable on the bottom of the Motor Control

Module can be accessed and removed. Disconnect

the cable.

7. Slide the Motor Control Module up and remove.

NOTICE

Do not over-torque any item that threads into the

hydraulic tank. This will strip the threads and

require tank replacement.

NOTICE

If any debris falls into the hydraulic tank, the debris

must be removed or machine damage will result.

Repair

34 313998S

Adjust Motor Control Module Selector

Switch

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.

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 selec-

tor 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 cor-

rect 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.

To set the Motor Control Module selector switch:

1. Turn machine power off.

2. Remove the access cover (D). See FIG.9.

3. Set the selector switch (S).

4. Install access cover (D).

NOTICE

If the Motor Control Module is replaced, the selec-

tor switch must be set prior to initial startup of the

Motor Control Module or damage may occur.

• 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.

FIG.9

S

257396_3b9905_04b

D

Repair

313998S 35

Install Motor Control Module

This procedure starts assuming that the old Motor Con-

trol 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.

2. Slide the Motor Control Module into the slot.

3. Attach the cable on the bottom of the Motor Control

Module.

4. Install the six screws (729) securing Motor Control

Module in place.

5. Install electrical cables on left and right sides of the

Motor Control Module.

6. Install four screws (732) connecting fan to Motor

and Motor Control Module. Install fan and mounting

plate.

7. Install Hydraulic Power Pack Shroud, see proce-

dure on page 33.

Remove Hydraulic Power Pack

This procedure removes the hydraulic power pack from

the machine as a single unit to enable further disassem-

bly. 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 proce-

dure, see page 33.

4. Perform Remove PowerHouse Pumpline proce-

dure, see page 28.

5. Disconnect heat exchanger inlet hose and fitting

from elbow fitting (617). Disconnect heat exchanger

outlet hose and fitting from elbow fitting (025).

6. Remove the two bolts (746) from the fluid

housing (703) and replace each with a strong

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

5/16-18 eye-bolt as indicated. See FIG. 10. See FIG.

8 on page 32 for full hydraulic power pack view.

7. Run a rope through the three eye-bolts and between

the motor and the Motor Control Module. Secure to

a hydraulic lift.

8. Remove the four bolts (604) and washers (603)

securing the tank to the electrical enclosure. See

Power Pack Module on page 52.

9. Lift the hydraulic power pack and place on a sturdy

location capable of supporting up to 300 lbs.

NOTICE

Motor Control Module selector switch position must

be set prior to startup of Motor Control Module or

damage may occur.

The hydraulic power pack weighs up to 300 lb. To

avoid serious injury due the hydraulic power pack fall-

ing, 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.

FIG.10

703 746

746

Install third eye-bolt here

257442_313998_1j1

Repair

36 313998S

Install Hydraulic Power Pack

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.

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.

Replace Tank Gasket, Tank

See FIG. 8 on page 32.

1. Perform Remove Hydraulic Power Pack proce-

dure, see page 35.

2. Remove hex head cap screws (722) securing

hydraulic housing (703) to tank (720). Carefully

remove motor (701) and hydraulic housing assem-

bly from tank.

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

tank.

4. Install thrust washers (721) onto hex head cap

screws (022). Apply pipe sealant to threads of

screws. Align tank gasket (719), hydraulic housing,

and tank (720) then install screws. Torque to

15 ft-lb (20 N•m).

5. Perform Install Hydraulic Power Pack procedure,

see page 36.

Remove Motor

See FIG. 8 on page 32.

1. Perform Remove Hydraulic Power Pack proce-

dure, see page 35.

2. Remove four hex head cap screws (722) securing

hydraulic housing (703) and motor (701) to

tank (020). Carefully remove motor and hydraulic

housing assembly from tank.

3. Remove four hex head cap screws (727) connecting

mounting bracket (726) to motor.

4. Remove four socket head cap screws (704) secur-

ing motor to hydraulic housing. Carefully remove

motor from hydraulic housing.

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.

NOTICE

Do not over-torque any item that threads into the

hydraulic tank. This will strip the threads and

require tank replacement.

Repair

313998S 37

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). Cou-

pler 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 cou-

pler. Apply pipe sealant to threads of screws. Torque

to 35 ft lb (47 N•m).

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.

Remove Hydraulic Gear Pump

See FIG. 8 on page 32.

1. Perform Remove Hydraulic Power Pack proce-

dure, see page 35.

2. Remove hex head cap screws (722) securing

hydraulic housing (703) to tank. Carefully remove

motor (701) and hydraulic housing assembly.

3. Remove tube (711).

4. Remove elbow fittings (710, 712) from gear

pump (705).

5. Remove two hex head cap screws (708) securing

gear pump to hydraulic housing.

6. Remove spider coupler (707).

7. Loosen set screw for gear coupler (706) then

remove gear coupler from gear pump.

Install Hydraulic Gear Pump

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).

NOTICE

Do not over-torque any item that threads into the

hydraulic tank. This will strip the threads and

require tank replacement.

Repair

38 313998S

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.

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.

NOTICE

Do not over-torque any item that threads into the

hydraulic tank. This will strip the threads and

require tank replacement.

Parts

313998S 39

Parts

Base Machine

FIG. 11: Base Machine, Image 1 of 6

127

193

123

147

112

110

175

ti19598a

Parts

40 313998S

FIG. 12: Base Machine, Image 2 of 6

155 104

156

124

125

155

156

112

105, 150 151, 165

See Power Distribution

Box manual

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).

1

2

3

4

1

188

111 171

2

3

ti19600a

180

110

ti19601a

187

189

110 4

Parts

313998S 41

FIG. 13: Base Machine, Image 3 of 6

161 102 101 176

110

108

132

129

130

128

110

121

115

114

Torque to 40-50 ft-lb (54-68 N•m).

IsoGuard Select fluid, 24F516.

Torque to 17 ft-lb (23 N•m).

1

2

3

1

ti19603a

157

154

158

2

3

Parts

42 313998S

FIG. 14: Base Machine, Image 4 of 6

118, 119, 120

116, 117

168

110

160

146

132

110

163

Apply sealant to pipe threads.

Do not apply sealant to threads.

Torque to 40-50 ft-lb (54-68 N•m).

1

2

3

2

162 1

3

152, 153

109

ti19604a

168

Parts

313998S 43

FIG. 15: Base Machine, Image 5 of 6

126

122

142

132

166

153

183

†

†

143

141 131

106

131

139

136

134

135

144, 145

144, 145

183

153

166

132

122

126

5

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.

1

2

3

4

5

6

7

140

2

6

6

4

4

143 2

135 6

7

31

7

1

4

4

†

†

167

156

133

24C352_313998_9e

†

†

Parts

44 313998S

FIG. 16: Base Machine, Image 6 of 6

24C352_313998_11

194

196

195

Parts

313998S 45

Ref Part Description

Quantity

BASE,

fixed ratio,

non-stainless

BASE,

fixed ratio,

stainless

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

Parts

46 313998S

† See Z-Series Chemical Pumps manual for parts

information.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

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 15H108▲LABEL, pinch point 1 1

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

123108 FITTING, elbow, 3/4 sae x 1/2 JIC, sst 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 LABEL, HFR metering system 1 1

176 15M511▲LABEL, warning, eng/span/fre 1 1

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

Ref Part Description

Quantity

BASE,

fixed ratio,

non-stainless

BASE,

fixed ratio,

stainless

Parts

313998S 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 infor-

mation.

Parts

48 313998S

Non-Stainless Steel Fluid Manifold 255629,

Stainless Steel Fluid Manifold 289999

Aluminum Manifold with Stainless Steel Fittings, 24P166

308

302

302b

314

315

304

301

312

313 317

314

303

302a

318

306

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.

**Apply PTFE or thread sealant to tapered threads.

1

2

3

4

5

2

1

3

3

2

3

307

255629_313998_1a

4

4

5

Parts

313998S 49

▲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.

Ref

Part

Description

Qt

y

Assembly

255629

Assembly

289999

Assembly

24P166

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

2

317▲189285 189285 189285 LABEL, caution 1

318† 150829 150829 150829 SPRING, compression 2

Parts

50 313998S

Non-SST Fluid Inlet Assemblies, 255159

Aluminum Fluid Inlet Assemblies with Stainless Steel Fittings, 24P167

--- Not available for individual sale.

ti9841a1

405 406

414

410

409

408

407

404

403

402

401,

412

413

401

A Side Shown

** Apply sealant to all non-swivel fittings.

411

Ref

Part

Description Qty

Assembly

255159

Assembly

24P167

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

Parts

313998S 51

SST Fluid Inlet Assemblies

506

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

508

504

503

502

501

505,

507

509

501, 512

B (Blue) Side Assembly shown,

A (Red) Assembly also included

24D285_313998_1a

Ref Part Description Qty

501 112268 SWIVEL, union 3

502 512485 VALVE, ball, sst 2

503 123111 FITTING, nipple, hex, 3/4npt,

3k, ss

4

504 501118 FITTING, tee 4

505 102124 THERMOMETER, dial 2

506 120300 GAUGE, press, fluid,

(waterborne)

2

507 500352 BUSHING, hex hd, sst 2

508 516308 FITTING, bushing, reducer,

sst

2

509 15D757 HOUSING, thermometer,

Viscon®hp

2

510 SEALANT, pipe, sst 1

511 TAPE, tfe, sealant 1

512 123980 FITTING, straight, swivel, 1/2

x 3/4, FM, sst

1

Parts

52 313998S

Power Pack Module

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

608

609

606

605

601

603

604

607

610

Torque to 10 ft-lb (14 N•m).

Apply sealant to threads.

1

2

2

1

24C273_313998_1d 24C273_313998_2d

Ref Part Description Qty

601 ENCLOSURE, frame, painted 1

602 MODULE, hydraulic power 1

603 U90205 WASHER, flat, 3/8, 0.41 x 1.25 x 0.13, ms 4

604 802277 SCREW, machine (matrix) 4

605 COVER, enclosure, heat exch, assy 1

606 111800 SCREW, cap, btn hd (matrix) 2

607 15Y935 TUBE, heat exchanger, outlet 1

608 24C621 HOSE, heat exchanger, inlet 1

609 123528 FITTING, elb, swvl, 45, jic08, fm, 6k 1

610 24C518 CORD, fan, heat exch, mcm 2

611 SEALANT, anaerobic 1

612 189930▲LABEL, caution, electric shock (not shown) 1

613 15H108▲LABEL, pinch point (not shown) 1

Parts

313998S 53

Parts

54 313998S

Power Pack Module Sub-Assemblies

Hydraulic DC Power Pack Module

FIG. 17: Hydraulic DC Power Pack

720

725

723

711

710

708

724

713

712

709

714

705

706

719

717

718

746

734

735

715

716

704

729

702

721,

707

701

726 738

737

728

721, 722

744

730733732731745

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).

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.

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.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

24

26

9

11

2

12

3

11 5

10

12

2

12

2

12

311

10

811 26

10

2

12

10

2

12 411

727

511

9

13

6

11

7

11

14 15

11

6

11

8

.45 +.00

-.02

702 1

.30 +.01

-.00

1

706 24

731

_313998_1j

748, 749

736

703

11

5

11

Parts

313998S 55

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref Part Description Qty

701 24C719 MOTOR, power connector, assembly 1

702 16A951 COUPLER, motor 1

703 15W772 HOUSING, machined.hydraulic, module 1

704 123338 SCREW, shc, 3/8-16 x 2.75, s(matrix) 4

705 122295 PUMP, gear, hydraulic, h39 1

706 16A952 COUPLER, pump 1

707 16A953 COUPLER, spider 1

708 123942 SCREW, cap, hex hd (matrix) 2

709 15T939 FITTING, straight, jic8 x sae8 1

710 122520 FITTING, elbow, male, sae x jic 1

711 15W798 TUBE, pump to tube outlet 1

712 122606 FITTING, elbow, male, female 1

713 115597 NIPPLE 1

714 101353 FITTING, nipple, pipe 1

715 122527 VALVE, relief, t-10a cavity, 0-25g 1

716 100721 PLUG, pipe 1

717 121312 FITTING, elbow, sae x jic 1

718 101754 PLUG, pipe 1

719 15X622 GASKET, housing, to, tank 1

720 RESERVOIR, assembly, 8 gallon 1

721 101971 WASHER, thrust 4

722 111302 SCREW, cap, hex hd (matrix) 4

723 15J937 FILTER, oil, 18-23 psi bypass 1

724 116915 CAP, breather filler 1

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

726 15Y912 BRACKET, mcm mounting 1

727 100057 SCREW, cap hex hd (matrix) 4

728 257396 MODULE, motor control 1

729 101550 SCREW, cap, sch (matrix) 7

730 PLATE, mounting, fan 1

731 122301 FAN, 220v 1

732 112310 SCREW, cap, sch (matrix) 8

733 100644 SCREW, cap, sch (matrix) 2

734 123367 HARNESS, m8 x thermal switch, 4-pin 1

735 102410 SCREW, cap soc hd (matrix) 1

736 FLUID, hydraulic (gallon) 8

737 123303 HARNESS, m12 2

738 295709 SCREW, soc.hd (matrix) 4

739 LUBRICANT, grease 1

740 SEALANT, pipe, sst 1

741 SEALANT, pipe, sst 1

743 189285▲LABEL, caution 1

744 121208▲LABEL, hot surface 1

745 15H108▲LABEL, pinch point 1

746 109468 SCREW, cap, hex head 2

747 LUBRICANT, thermal 1

748 123601 CLAMP, wire, harness, nylon, 3/4 5

749 103833 SCREW, mach, crbh 5

Parts

56 313998S

Heat Exchanger Assembly

801 804

806

802

807

805

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).

Apply sealant to threads.

Orient fan with airflow arrow pointing

toward cover.

Align fan plug as shown.

1

2

3

4

5

6

7

7

805

4 5

3 5

808

803

1 2

257931_313998_1f

257931_313998_2f

Ref Part Description Qty

801 257967 COVER, enclosure, heat exch,

painted

1

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)

8

807 110755 WASHER, plain 4

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

810 LUBRICANT, thread 1

811 SEALANT, anaerobic 1

Parts

313998S 57

Heater Options

FIG. 18: Heater Options, Image 1 of 4

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.

1

2

3

4

5

6

7

8

9

10

12

922 910 908 913 914

908

925

903

901

906

908

905

929 930

916

918919 917

912

911

909

931

932

902

926

5

6

10 10

9

9

9

908 9

10

10

920

24C327_313998_1L

904

904

Parts

58 313998S

FIG. 19: Heater Options, Image 2 of 4

1

935

934

933

938

928

927

921

905

907

905

Non-Heated Models Only

915

1

212

3

4

Ref. 924, 258757 shown

8

8

7

24C327_313998_1L

24C327_313997_9f

24C327_313998_2L

Parts

313998S 59

Ref Part Description

Quantity

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

No 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

Parts

60 313998S

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

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

sensor

2 2 2 1

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

Ref Part Description

Quantity

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

No Heat

Parts

313998S 61

FIG. 20: Heater Options, Image 3 of 4

Torque to 17 ft-lb (23 N•m).

Apply lubricant to threads of tube fitting and

torque to 21 ft-lb (28 N•m).

9

10

10

1331

ti17873a

1303

1302

1301

1332 1342

1312

1311

1341

1314

1313

1342

1341

10

10

10

24J707 Shown

Parts

62 313998S

FIG. 21: Heater Options, Image 4 of 4

ti17874a

9

1308

1354

1334

1343

1345

1344

1348

1346 1347

1354 1349

1353

1347

1346

1344

1345

1343

1351

1350

Parts

313998S 63

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

24J109, HEATER, fix, pr, 2

viscon, 2 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, rtd, 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

Parts

64 313998S

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

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

24J109, HEATER, fix, pr, 2

viscon, 2 hose

Parts

313998S 65

Heater Sub-Assemblies

Heat Power Panel Module

FIG. 22: Heat Power Panel Modules

1004, 10061004, 1006

1007

1004,

1005,

1001

1005, 1006

1003

1014

1012

24C332_313998_8f

1010

1009

1011

1008

1006

1006

1002

1015

1016

Tie wires at this point.

Torque connector screws to 16 in-lb

(1.8 N•m).

1

2

1

1

1

2

24C332_313998_3f

24C332_313998_1f

24C332_313998_7f

Parts

66 313998S

FIG. 23: Heat Power Panel Modules

1005, 1006 1004, 1006

1007

1004,

1004,

1004, 1006

1011

1003

1014

1012

1006

1006

1002

1015

1016

100910101008

Tie wires at this point.

Torque connector screws to 16 in-lb

(1.8 N•m).

1

2

1

1

1

1005, 1006

2

24C332_313998_6f

24C332_313998_4f

24C332_313998_4f

24C332_313998_7f

Parts

313998S 67

Ref Part Description

Quantity

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

MODULE, panel,

pwr, no heat, 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

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

Parts

68 313998S

Heater - Aluminum with Carbon Steel Fittings, 24C426

Heater - Aluminum with Stainless Steel Fittings, 24P165

1106

1104

1103

1105

1105

1102

1107

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.

1

2

3

4

6

8

9

14

2 4

4

1

1101

r_24p165

1109

1110

1111

1112

1113

4

4

8

9 6 2

4 3

2 4

1106a

r_24c106_313998_2

24P165 Shown

Parts

313998S 69

--- Not available for individual sale.

◆Item 1106 include fluoroelastomer o-ring.

Ref

Part

Description Qty

Assembly

24C426

Assembly

24P165

1101 15J090 15J090 HEATER, machined, 1 zone, 3500 psi 1

1102 124132 124132 O-RING 4

1103 15H305 126561 FITTING, plug hollow hex 1-3/16 sae 4

1104 121309 126562 FITTING, adapter, sae-orb x jic 2

1105 15H304 126563 FITTING, plug 9/16 sae 3

1106 15H306 126564◆ADAPTER, thermocouple, 9/16 x 1/8 1

1106a 120336 ◆O-RING, packing 1

1107 15B135 16T320 MIXER, immersion heater 4

1108 16A112 16A112 HEATER, immersion (1500W 230V) 4

1109 295607 561460 PLUG, outlet 1

1110 123325 FITTING, compression, 1/8npt, ss 1

1111 124262 SENSOR, rtd, 1kohm, 90deg, 4pin, tip 1

1112 123408 HARNESS, m8 x thermal switch, 3-pin 1

1113 100518 SCREW, mach, mnhd 2

1115 --- LUBRICANT, thermal 1

1116 --- --- TAPE, tfe, sealant 1

1117 --- --- LUBRICANT, thread 1

Parts

70 313998S

Heater 24J787

ti17875a

1401

1433

1412

1410

1402

1403

1404

1409

1434

1405

1404

1406

1407

1408

1409

1435

1410

1408

1429

1412

1430

1431

1411

1423

1421

1426

1416

1422

1427

1428

1417

1418

1419

1420

1409

Parts

313998S 71

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

--- Not for individual sale

† Items available for purchase in kit 24K290

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

Kits

72 313998S

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.

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

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.

4

5

1204

1203

1201

1202

2

1

Kits

313998S 73

DC Power Pack Hydraulic

Pressure Adjustment Setup

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) clock-

wise until it stops.

5. Turn the pressure adjustment knob counter-clock-

wise two full turns.

6. Turn main power switch to ON position.

7. Setup the machine to spray in Operator mode. See

HFR operation manual 313997 if necessary.

8. While watching the ADM and listening to the motor,

begin spraying material.

NOTE: If the ADM displays an overpressure situation,

the relief pressure is set too high.

NOTE: If it sounds like the motor is spinning too fast

and/or it sounds like hydraulic fluid is being dumped

back to the tank, the relief pressure is set too low.

9. If the relief pressure is set too high: Clear the

over pressure warning on the ADM then turn the

pressure adjustment knob counterclockwise 1/4

turn. See HFR operation manual 313997 if neces-

sary.

If the relief pressure is set too low: Turn the pres-

sure adjustment knob clockwise 1/4 turn.

10. Repeat the previous two steps until the relief pres-

sure is correctly set.

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.

Logic Drawings

74 313998S

Logic Drawings

230V, 1 Phase, No Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

190

199

197

195

192

160

188

186

184

182

180

178

176

174

172

170

168

164

166

162

158

156

154

152

150

191

198

194

196

193

161

189

187

185

183

181

179

177

175

173

171

169

165

167

163

159

157

155

153

151

50-60HZ

1PH/

230V/

DISC-1

L21L2

L11L1

GND

1L1

MISC

B VOLUME

CB5

1L1

1L2

1L2

PG133

755

1L1

CB1A

1L1

1L21L2

HARNESS

24C515

HARNESS

24C318

63A

5A

1340

1360

1340

1360

MCM

B VOLUME

PG105

1080

1100

331

GND

L1

GND

L2

L3

1080

1100

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1

1

1

BLK

WHT

Logic Drawings

313998S 75

230V, 1 Phase, with Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

50-60HZ

1PH/

230V/

DISC-1

L21L2

L11L1

GND

1L1

CB1A

1L1

1L2

1L2

HARNESS

24C515

63A

151

1L2

TANK

B VOLUME

CB3

PG121

GND

PRIMARY HT

B VOLUME

CB2

PG116

511

HOSE HT

B VOLUME

CB4

PG127

580

MISC

B VOLUME

CB5

PG133

755

HARNESS

24C303

HARNESS

24C304

HARNESS

24C318

40A

15A

40A

5A

151

1L1

1L1

1L1

1L2

1L2

1L11L1

1L2

1L2

1L11L1

1L2

1L2

1L11L1

1L2

1L2

1220

1240

1220

1240

1160

1180

1160

1180

1280

1300

1280

1300

1340

1360

1340

1360

MCM

B VOLUME

PG105

1080

1100

331

GND

L1

GND

L2

L3

HARNESS

24C517

1080

1100

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1

1

1

1

1

1

BLK

WHT

Logic Drawings

76 313998S

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

190

199

197

195

192

160

188

186

184

182

180

178

176

174

172

170

168

164

166

162

158

156

154

152

150

191

198

194

196

193

161

189

187

185

183

181

179

177

175

173

171

169

165

167

163

159

157

155

153

151

148

1L2

TANK

A VOLUME

CB8

PG172

GND

PRIMARY HT

A VOLUME

CB9

PG166

649

HOSE HT

A VOLUME

CB7

PG178

718

HARNESS

24C303

HARNESS

24C304

40A

15A

40A

148

1L1

1L1

1L1

1L2

1L2

1L11L1

1L2

1L2

1L11L1

1L2

1L2

1720

1740

1720

1740

1660

1680

1660

1680

1780

1800

1780

1800

HARNESS

24C517

MISC

A VOLUME

CB6

PG184

824

HARNESS

24C318

5A

1L2

1L2

1840

1860

1840

1860

1L1

1L1

2

2

2

2

Logic Drawings

313998S 77

230V, 3 Phase, No Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

50-60HZ

3PH/

230V/

DISC-1

L31L3

L21L2

L11L1

GND

1L1

MISC

B VOLUME

CB5

1L1

1L21L2

PG133

755

1L1

CB1

1L1

1L21L2

HARNESS

24C516

HARNESS

24C318

30A

5A

1L31L3

1340

1360

1340

1360

MCM

B VOLUME

PG105

1080

1100

331

GND

L1

GND

L2

L3

1120

1080

1100

1120

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1

1

1

BLK

RED

WHT

Logic Drawings

78 313998S

230V, 3 Phase, with Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

50-60HZ

3PH/

230V/

DISC-1

L31L3

L21L2

L11L1

GND

151

1L3

151

1L2

TANK

B VOLUME

CB3

PG121

GND

PRIMARY HT

B VOLUME

CB2

PG116

511

HOSE HT

B VOLUME

CB4

PG127

580

MISC

B VOLUME

CB5

PG133

755

HARNESS

24C303

HARNESS

24C304

HARNESS

24C516

HARNESS

24C318

40A

15A

40A

5A

1L11L1

1L21L2

151

1L1

1L31L3

CB1

30A

1L31L3

1L11L1

1L31L3

1L21L2

1L11L1

1L21L2

1L31L3

1L11L1

1220

1240

1220

1240

1160

1180

1160

1180

1280

1300

1280

1300

1340

1360

1340

1360

MCM

B VOLUME

PG105

1080

1100

331

GND

L1

GND

L2

L3

1120

HARNESS

24C517

1080

1100

1120

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1

1

1

1

1

1

BLK

RED

WHT

Logic Drawings

313998S 79

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

190

199

197

195

192

160

188

186

184

182

180

178

176

174

172

170

168

164

166

162

158

156

154

152

150

191

198

194

196

193

161

189

187

185

183

181

179

177

175

173

171

169

165

167

163

159

157

155

153

151

148

1L3

148

1L2

TANK

A VOLUME

CB8

PG172

GND

PRIMARY HT

A VOLUME

CB9

PG166

649

HOSE HT

A VOLUME

CB7

PG178

718

HARNESS

24C303

HARNESS

24C304

HARNESS

24C318

40A

15A

40A

148

1L1

30A

1L3

1L1

1L1

1L2

1L2

1L31L3

1L1

1L1

1L21L2

1L31L3

1720

1740

1720

1740

1660

1680

1660

1680

1780

1800

1780

1800

HARNESS

24C517

MISC

A VOLUME

CB6

PG184

824

HARNESS

24C318

5A

1L2

1L2

1L3

1L3 1840

1860

1840

1860

2

2

2

2

Logic Drawings

80 313998S

400V, 3 Phase, No Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

50-60HZ

3PH/

400V/

DISC-1

L31L3

L21L2

L11L1

N1N

GND

MISC

B VOLUME

CB5

1N1N

PG133

755

1L1

CB1A

1L1

1N1N

HARNESS

24C515

HARNESS

24C318

63A

5A

1340

1360

1340

1360

MCM

B VOLUME

PG105

1080

1100

331

GND

L1

GND

L2

L3

1081

1101

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1080

1100

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1L1 1L1

1

1

1

BLK

WHT

Logic Drawings

313998S 81

400V, 3 Phase, with Heat

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

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

151

50-60HZ

3PH/

400V/

DISC-1

L31L3

L21L2

L11L1

N1N

GND

1N

151

1L3

151

1L2

1L1

TANK

B VOLUME

CB3

1L1 1220

1N1N 1240

PG121

GND

1220

1240

1L1

PRIMARY HT

B VOLUME

CB2

1L1 1160

1N1N 1180

PG116

1160

1180

511

1L2

HOSE HT

B VOLUME

CB4

1L2 1280

1N1N 1300

PG127

1280

1300

580

1L2

MISC

B VOLUME

CB5

1L2 1340

1N1N 1360

PG133

1340

1360

755

1L1

MCM

B VOLUME

CB1A

1L1

1N1N

PG105

1080

1100

331

GND

HARNESS

24C303

HARNESS

24C304

HARNESS

24C515

HARNESS

24C318

40A

63A

15A

40A

5A

L1

GND

L2

L3

HARNESS

24C517

1081

1101

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1080

1100

1360

1340

1340

1360

POWER

SUPPLY

121808 123466

CAN SPLITTER

GND

POWER

FILTER

L1/P

L2/N

LOAD

LINE

1390 BR

1400 BL

LOCATED IN THE MAIN PDB ENCLOSURE

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

1

1

1

1

1

1

BLK

WHT

Logic Drawings

82 313998S

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

190

199

197

195

192

160

188

186

184

182

180

178

176

174

172

170

168

164

166

162

158

156

154

152

150

191

198

194

196

193

161

189

187

185

183

181

179

177

175

173

171

169

165

167

163

159

157

155

153

151

148

1N

148

1L3

148

1L2

1L3

TANK

A VOLUME

CB8

1720

1N1N 1740

PG172

GND

1720

1740

1L3

PRIMARY HT

A VOLUME

CB9

1660

1N1N 1680

PG166

1660

1680

649

1L2

HOSE HT

A VOLUME

CB7

1L2 1780

1N1N 1800

PG178

1780

1800

718

HARNESS

24C303

HARNESS

24C304

40A

15A

40A

1L3

1L3

HARNESS

24C517

1L2

MISC

A VOLUME

CB6

1840

1N

1N 1860

PG184

1840

1860

824

HARNESS

24C318

5A

2

2

2

2

Logic Drawings

313998S 83

A (Red) Heat

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

M8 3 PIN

FEMALE

3

4

1

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

4

6

HPTCM PRIMARY LOW VOLUME

3

4

1

1

M8 3 PIN

FEMALE

4

3

2

1

2

M8 4 PIN

FEMALE

4

3

2

1

M8 4 PIN

MALE

RTD618

PRIMARY TEMP

EXC

SIGNAL

3

4

1

M8 3 PIN

MALE

EXC

SIGNAL

OTS628

PRIMARY TEMP

CR642

A1+ A2-

3

4

1

M8 3 PIN

MALE

HARNESS

16A522

+24VDC

SIGNAL

6420

GND 3

GND

5

PRIMARY HT

LOW VOLUME

PG166

167

34

CON863

12

HARNESS

24C267

6400

1660

1680

DB-1

6480

6520

PRIMARY HEATER

SEE CONFIGURATION

654

663

661

659

656

624

652

650

648

646

644

642

640

638

636

634

632

628

630

626

622

620

618

616

614

655

662

658

660

657

625

653

651

649

647

645

643

641

639

637

635

633

629

631

627

623

621

619

617

615

674

681

679

676

672

670

668

664

675

682

678

680

677

673

671

669

665

666

667

6490

6500

PG646 PG647

VR 24C313

FR 24C312

HARNESS

6480

6480

6480

6480

6520

6520

6520

6520

BLU

BRN

HARNESS

24C265

6

2

4

0

7

5

3

1

A - RED

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

1

2

4

53

2

2

2

2

2

Logic Drawings

84 313998S

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

725

735

733

731

727

695

723

721

719

717

715

713

711

709

707

705

703

699

701

697

693

691

689

687

685

726

734

729

732

728

696

724

722

720

718

716

714

712

710

708

706

704

700

702

698

694

692

690

688

686

744

751

749

746

742

740

738

736

745

748

750

747

743

741

739

737

M8 3 PIN

FEMALE

3

4

1

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

4

6

HPTCM HOSE LOW VOLUME

3

4

1

1

M8 3 PIN

FEMALE

4

3

2

1

2

M8 4 PIN

FEMALE

4

3

2

1

M8 4 PIN

MALE

RTD688

HOSE TEMP

EXC

SIGNAL

CR711

A1+ A2-

3

4

1

M8 3 PIN

MALE

HARNESS

16A522

+24VDC

SIGNAL

7110

GND 3

GND

5

HOSE HT

LOW VOLUME

PG178

179

34

CON-869

12

7090

1780

1800

7172

7210

HOSE HEATER

SEE CONFIGURATION

CB718

TRANS1

SECONDARY

PRIMARY

7290

7310

7330

7350

PG728

730

683

684

BLU

BRN

7170

7310

7290

7350

7330

HARNESS

24C274

PG715

24C418

VR 24C315

FR 24C314

HARNESS

PG716

6

2

4

0

7

5

3

1

A - RED

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

2

4

53

2

2

2

2

2

Logic Drawings

313998S 85

B (Blue) Heat

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

M8 3 PIN

FEMALE

3

4

1

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

4

6

HPTCM PRIMARY HI VOLUME

3

4

1

1

M8 3 PIN

FEMALE

4

3

2

1

2

M8 4 PIN

FEMALE

4

3

2

1

M8 4 PIN

MALE

RTD480

PRIMARY TEMP

EXC

SIGNAL

3

4

1

M8 3 PIN

MALE

EXC

SIGNAL

OTS490

PRIMARY TEMP

CR504

A1+ A2-

3

4

1

M8 3 PIN

MALE

HARNESS

16A522

+24VDC

SIGNAL

5040

GND 3

GND

5

PRIMARY HT

HI VOLUME

PG116

117

34

CON794

12

HARNESS

24C267

5020

1160

1180

DB-1

5100

5140

PRIMARY HEATER

SEE CONFIGURATION

516

525

523

521

518

486

514

512

510

508

506

504

502

500

498

496

494

490

492

488

484

482

480

478

476

517

524

520

522

519

487

515

513

511

509

507

505

503

501

499

497

495

491

493

489

485

483

481

479

477

534

541

539

536

532

530

528

526

535

542

538

540

537

533

531

529

527

543

544

BLU

BRN

5110

5120

PG509

HARNESS

24C265

5100

5100

5100

5100

5140

5140

5140

5140

PG508

VR 24C313

FR 24C312

HARNESS

6

2

4

0

7

5

3

1

B - BLUE

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

1

2

4

53

1

1

1

11

Logic Drawings

86 313998S

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

585

595

593

591

587

555

583

581

579

577

575

573

571

569

567

565

563

559

561

557

553

551

549

547

545

586

594

589

592

588

556

584

582

580

578

576

574

572

570

568

566

564

560

562

558

554

552

550

548

546

604

611

609

606

602

600

598

596

605

612

608

610

607

603

601

599

597

613

M8 3 PIN

FEMALE

3

4

1

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

4

6

HPTCM HOSE HI VOLUME

3

4

1

1

M8 3 PIN

FEMALE

4

3

2

1

2

M8 4 PIN

FEMALE

4

3

2

1

M8 4 PIN

MALE

RTD550

HOSE TEMP

EXC

SIGNAL

CR573

A1+ A2-

3

4

1

M8 3 PIN

MALE

HARNESS

16A522

+24VDC

SIGNAL

5730

GND 3

GND

5

HOSE HT

HI VOLUME

PG127

129

34

CON800

12

5710

1280

1300

5792

5830

HOSE HEATER

SEE CONFIGURATION

CB579

TRANS1

SECONDARY

PRIMARY

5910

5930

5950

5970

PG590

590

HARNESS

24C263

BLU

BRN

PG578

5790

5930

5910

5970

5950

HARNESS

24C274

24C418

PG577

VR 24C315

FR 24C314

HARNESS

6

2

4

0

7

5

3

1

B - BLUE

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

2

4

53

1

1

1

1

1

Logic Drawings

313998S 87

DC Hydraulic Power Pack

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

930

939

937

935

932

900

928

926

924

922

920

918

916

914

912

910

908

904

906

902

898

896

894

892

890

931

938

934

936

933

901

929

927

925

923

921

919

917

915

913

911

909

905

907

903

899

897

895

893

891

948

955

953

950

946

944

942

940

949

956

952

954

951

947

945

943

941

957

958

TP

BA

AB

PUMP POSITION

+5 VDC GND

SIGNAL

HV LPT280

LV LPT416

HV SOL241

LV SOL378

HV SOL234

LV SOL372

123313

+5 VDC

GND

SIGNAL

M

OIL OVERTEMP

SWITCH

OIL TEMP

RTD OPTIONAL HV OTS264

LV OTS402

FIXED RATIO

MACHINE FRONT

FACING PUMPS

VARIABLE RATIO

VERTICAL PUMP

'B' BLUE

'A' RED

ISO LUBE

PUMP

HV RTD290

LV RTD428

COOLER

FILTER

15J437

HV M310

LV M450

PRESSURE

GAUGE

OPTIONAL

PRESSURE

RELIEF

VALVE

PUMP

HYD. FAN

HV M762

LV M831

MCM FAN

HV M772

LV M841

HYDRAULIC CYLINDER

OIL LEVEL

SENSOR

OPTIONAL

HV PX262

LV PX400

LOCATED ON THE MAIN

HYDRAULIC POWER PACK

A

B

Logic Drawings

88 313998S

Motor Control Module (MCM)

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

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

1

240

249

247

245

242

210

238

236

234

232

230

228

226

224

222

220

218

214

216

212

208

206

204

202

200

241

248

244

246

243

211

239

237

235

233

231

229

227

225

223

221

219

215

217

213

209

207

205

203

201

0X

START

PB235

1

2

3

4

5

SOL240

1

2

3

4

5

START

FS247

1

2

3

4

HYD-OIL

LO-LVL

5

4

3

2

1

M12 5 PIN

MALE

M12 5 PIN

FEMALE

5

4

3

2

1

HARNESS

123303

DISPENSE

GUN

M8 4 PIN

FEMALE

4

3

2

1

258

265

263

260

256

254

252

250

259

266

262

264

261

257

255

253

251

267

268

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

M12 5 PIN

MALE

5

4

3

2

1

CAN COMM PORT

2

10

1

SWITCH POSITION

SHOWN FOR

REF ONLY

4

3

2

1

7

SIGNAL

SIGNAL

COMMON

SIGNAL

SIGNAL

M12 5 PIN

FEMALE

5

SIGNAL

+24VDC

COMMON

SIGNAL

SIGNAL

4

3

2

1

8

M12 5 PIN

FEMALE

5

4

3

2

1

9

M12 5 PIN

FEMALE

5

4

3

2

1

5

M12 5 PIN

MALE

HARNESS

123303

2

3

4

5

1

2

3

4

5

1

2

3

4

4

3

2

1

5

M12 5 PIN

MALE

PRESS XDUCER

BLUE 'B' VOLUME

4

3

2

1

5

M12 5 PIN

MALE

PRESS XDUCER

FIXED RATIO ONLY

RED 'A' VOLUME

B-CODE

B-CODE

SOL234

SOL241

OTS264

OIL TEMP

HI

PX262

121061

+5VDC

-SIG

DC COM

+SIG

SHLD

+5VDC

-SIG

DC COM

+SIG

SHLD

VALVE ASSY

123313

DISPENSE SIGNAL

TO HYDRAULIC

DISP. HEAD FCM

PUMP

LEFT

PUMP

RIGHT

123367

SIGNAL

DC COM

6

2

4

0

7

5

3

1

LOCATED ON THE HYDRAULIC

POWER PACK - FIXED RATIO

2A

2B

2C

7A

7B

7C

27

8

9

6

2

4

0

7

5

3

1

6

2

4

0

7

5

3

1

POS 3 = 3000psi

(DEFAULT)

POS 1 = 2000psi

1

1

1

1

1

1

1 1

1

1

3

3

ss

Logic Drawings

313998S 89

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

BLK

L2

L3

L1

GND

RTD290

4

3

2

1

M8 4 PIN

MALE

M8 4 PIN

FEMALE

4

3

2

1

OIL TEMP

EXC

SIGNAL

310

319

317

315

312

279

308

306

304

302

300

298

296

294

292

290

287

283

285

281

277

275

273

271

269

311

318

314

316

313

280

309

307

305

303

301

299

297

295

293

291

289

284

286

282

278

276

274

272

270

329

336

334

331

326

324

322

320

330

337

333

335

332

328

325

323

321

4

3

2

1

6

M8 4 PIN

FEMALE

L1

GND

L2 L3

GND

1080

1100

1120

12

109

4

3

2

1

M8 4 PIN

FEMALE

13

15

8

13 10

4 1

9

32

1112

6

14

75

11

15 PIN DSUB

FEMALE

4

3

2

1

M8 4 PIN

MALE

4

3

2

1

M8 4 PIN

MALE

15 PIN DSUB

MALE

GND

RED

BLU

3

5

RTD292

MOTOR TEMP

EXC

SIGNAL

PUMP POSITION

EXC

COMMON

SIGNAL

15

8

13 10

4 1

9

32

1112

6

14

75

LPT280

258669

ENCODER

HARNESS

24C516

288

327

MOTOR

PG105

OPTION

L1

GND

L2 L3

GND

1580

1600

HARNESS

24C515

PG105

M310

3 PHASE

1 PHASE

109

3

6

5

11

13

12

SHLD

1

1

1

1

1

1

Logic Drawings

90 313998S

Miscellaneous Power

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

CON794

A1 A2

CR504

11 14

MISC B - BLUE

HI VOLUME

PG133

135

792

801

799

797

794

762

790

788

786

784

782

780

778

776

774

772

770

766

768

764

760

758

756

754

752

793

800

796

798

795

763

791

789

787

785

783

781

779

777

775

773

771

767

769

765

761

759

757

755

753

810

817

815

812

808

806

804

802

811

818

814

816

813

809

807

805

803

819

820

1360

1340

2

1

2

1

MOTOR

FAN

HYD

HEAT

EXCH'R

1340

1360

2

1

2

1

MOTOR

FAN

MCM

HARNESS

24C518

1340

1360

SOL234

SOL241

HARNESS

24C518

1340

1360

HYD

VALVE

ASSY

1340

1360

CON800

A1 A2

CR573

11 14

1340

1360

M762

M772

7940

8000

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

FOR FIXED OR VARIABLE

RATIO

TERMINAL STRIP MOUNTED

ON BACKPANEL

USED ONLY WITH PRIMARY HEAT

OPTION

USED ONLY WITH HOSE HEAT

OPTION

230VAC POWER TO THE

HYDRAULIC POWER VALVE

230VAC POWER TO THE FAN

MOTOR

230VAC POWER TO THE FAN

MOTOR

1

BL

BR

Logic Drawings

313998S 91

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

861

871

869

867

863

831

859

857

855

853

851

849

847

845

843

841

839

835

837

833

829

827

825

823

821

862

870

865

868

864

832

860

858

856

854

852

850

848

846

844

842

840

836

838

834

830

828

826

824

822

880

887

885

882

878

876

874

872

881

888

884

886

883

879

877

875

873

889

866

CON863

A1 A2

CR642

11 14

MISC A - RED

LOW VOLUME

PG184

185

1860

1840

2

1

2

1

MOTOR

FAN

HYD

HEAT

EXCH'R

1840

1860

2

1

2

1

MOTOR

FAN

MCM

HARNESS

24C518

1840

1860

SOL372

SOL378

HARNESS

24C518

1840

1860

HYD

VALVE

ASSY

1840

1860

CON869

A1 A2

CR711

11 14

1840

1860

M831

M841

8630

8690

LOCATED IN THE MAIN

SUPPORT ENCLOSURE

FOR VARIABLE RATIO ONLY

TERMINAL STRIP MOUNTED

ON BACKPANEL

USED ONLY WITH PRIMARY HEAT

OPTION

USED ONLY WITH HOSE HEAT

OPTION

230VAC POWER TO THE

HYDRAULIC POWER VALVE

230VAC POWER TO THE FAN

MOTOR

230VAC POWER TO THE FAN

MOTOR

2

BL

BR

Technical Data

92 313998S

Technical Data

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

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

Motor Control Module Technical Data

313998S 93

Motor Control Module Technical Data

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.

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)

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.

Original instructions. This manual contains English. MM 313998

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

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

www.graco.com

Revised November 2014

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