Graco 3A0238P Ac Hydraulic Power Pack Module Users Manual Module, Instructions Parts, English

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Instructions-Parts

AC Hydraulic
Power Pack Module

3A0238P
EN

AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated
applicators used with Graco HFR™ and VRM™ Metering Systems.
For professional use only.
2500 psi (17 MPa, 172 bar) Maximum Hydraulic Working Pressure

Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information.

24D829 AC Hydraulic Power Pack Module Shown

r_24d829_3A0238_1f

Related Manuals

Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AC Hydraulic Power Pack Modules . . . . . . . . . . . 2
Applicator Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Individual Applicators . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 10
AC Power Pack Module . . . . . . . . . . . . . . . . . . . 10
Hydraulic Power Pack Stand . . . . . . . . . . . . . . . 11
Main Power Disconnect . . . . . . . . . . . . . . . . . . . 12
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connect Hydraulic Hoses . . . . . . . . . . . . . . . . . 15
Connect Material Hoses to System . . . . . . . . . . 18
Connect Communication Cables . . . . . . . . . . . . 19
Connect Proximity Cables . . . . . . . . . . . . . . . . . 19
Connect Electrical Cord . . . . . . . . . . . . . . . . . . 20
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove Hydraulic Power Pack Shroud . . . . . . . 27
Install Hydraulic Power Pack Shroud . . . . . . . . . 27
Remove Hydraulic Power Pack . . . . . . . . . . . . . 27
Install Hydraulic Power Pack . . . . . . . . . . . . . . . 29
Replace Tank Gasket . . . . . . . . . . . . . . . . . . . . . 29
Remove Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove Hydraulic Gear Pump . . . . . . . . . . . . . 32
Install Hydraulic Gear Pump . . . . . . . . . . . . . . . 33
Install FCM Upgrade Token . . . . . . . . . . . . . . . . 34
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
AC Hydraulic Power Pack Module . . . . . . . . . . . 36
Mix Module Stand . . . . . . . . . . . . . . . . . . . . . . . 38
Heat Exchanger Assembly . . . . . . . . . . . . . . . . 40
230V and 400V MixHead Panel . . . . . . . . . . . . . 42
MixHead Hydraulic Power Pack . . . . . . . . . . . . . 44
Pneumatic Boom Arm . . . . . . . . . . . . . . . . . . . . 50
Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Hose and Cable Kits . . . . . . . . . . . . . . . . . . . . . . . 54
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 55
Electrical Schematics . . . . . . . . . . . . . . . . . . . . 58
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
AC Power Pack Module . . . . . . . . . . . . . . . . . . . 66
AC Power Pack Stand . . . . . . . . . . . . . . . . . . . . 68
Pneumatic Boom . . . . . . . . . . . . . . . . . . . . . . . . 69
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 72

Related Manuals
Manual

2

Description

Manual

Description

312753

L-Head, Operation-Maintenance

313873

VRM, Operation

312752

S-Head, Operation-Maintenance

313874

VRM, Repair-Parts

313536

GX-16, Operation

3A0395

309582

Circulation and Return Tube Kits,
Instructions-Parts

Stainless Steel Tank Stands, Instructions-Parts

3A0862

Hose Extension Kits, Instructions-Parts

313997

HFR, Operation

313998

HFR, Repair-Parts

3A0238P

Models

Models
AC Hydraulic Power Pack Modules
The table below lists kit numbers for 230V and 400 VAC hydraulic power pack modules. The modules can come with
a hydraulic power pack, boom, and hose kits for S-Head and L-Head applicators. For applicator kits, see Applicator
Kits and Individual Applicators on page 4 (sold separately).
Includes:

Kit No.

Voltage

S-Head
Hose Kits

L-Head
Hose Kits
✔

Not included
Hydraulic
Power
Pack
✔

L-Head
Applicators
Only
✔

S-Head
Applicators
Only

24D829

230V

Boom
✔

24D830

230V

✔

24D834✖

400V

✔

24D835✖

400V

✔

24D831

230V

24D832

230V

24D836✖

400V

24D837✖

400V

24F297★

230V

✔

✔

24F298★✖

400V

✔

✔

24J912★

230V

✔

✔

24J913★✖

400V

✔

✔

✔

✔
✔

✔

✔

✔
✔

✔
✔

✔

✔

✔
✔

✔
✔

✔

✔

✔
✔

✔

✔

★ Purchase required hoses separately. See Hose and Cable Kits on page 54 for hose kits.
✖ See 400 V Power Requirements.

400 V Power Requirements
•

400 V systems are intended for International voltage
requirements. Not for voltage requirements in North
America.

•

If a 400 volt configuration is operated in North America, a special transformer rated for 400 V (“Y” configuration (4 wire)) may be required.

•

North America mostly employs a 3 wire or Delta
configuration. The two configurations are not interchangeable.

3A0238P

3

Models

Applicator Kits
The table below lists S-Head and L-Head applicators kits. All applicator kits come with an injection nozzle and needle
valve calibration kit.

Applicator
L-Head

S-Head

Kit No.

Model

Maximum Working
Pressure
psi (MPa, bar)

24A084
24A085
24A086
24A090
24A092
24A093

20.20.6/10
20.20.10/14
20.20.13/20
30100-500-4
30100-625-2
30110-625-4

3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)

Individual Applicators
L-Head
The table below lists individual model numbers and chamber inside diameters. See L-Head manual for more information.

Model

Impingement
Chamber ID
(mm)

Exiting Chamber
ID (mm)

Maximum
Working
Pressure
psi (MPa, bar)

20.20.5/8
20.20.6/10
20.20.10/14
20.20.13/20
20.20.16/25

5
6
10
13
16

8
10
14
20
25

3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)

CE Approved
✔

S-Head

GX-16

The table below lists individual model numbers and
stroke lengths. See S-Head manual for more information.

The table below lists individual model numbers. See
GX-16 manual for more information.

4

Model

Stroke
(in.)

Maximum Working
Pressure
psi (MPa, bar)

30110-500-2
30100-500-4
30100-625-2
30110-625-4

2.25
4
2.25
4

3000 (21, 206)
3000 (21, 206)
3000 (21, 206)
3000 (21, 206)

Applicator
GX-16

Model
24E876
24E877
24E878
24J187
24K233
24K234

3A0238P

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.

DANGER
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Contact with high voltage equipment and improper grounding,
setup, or usage of the system can cause death or serious injury.
•
•
•

Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
This equipment must be grounded. Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

WARNING
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
•
•
•

Read MSDSs to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
•
•

3A0238P

Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

5

Warnings

WARNING
WARNING
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.
•
•
•
•
•
•
•

Engage trigger lock when not dispensing.
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.

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.

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:
•
•
•
•
•
•
•
•
•

6

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.

3A0238P

Warnings

WARNING
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
•
•

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.
Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.

EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
•

•
•
•
•
•
•
•
•

Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
Do not alter or modify equipment.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.

MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•
•

Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.Pressurized equipment can start
without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
•

3A0238P

Do not touch hot fluid or equipment.

7

Warnings

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.

Material Self-ignition

Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
•

•

•
•

Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.

•
•

Keep Components A and B
Separate

Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.

8

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 ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid™ (TSL™), Part
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
Never use solvent on one side if it has been contaminated from the other side.
Always lubricate threaded parts with ISO pump oil
or grease when reassembling.

Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.

3A0238P

Warnings

Changing Materials
•

When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

•

Always clean the fluid inlet strainers after flushing.

•

Check with your material manufacturer for chemical
compatibility.

•

Most materials use ISO on the A side, but some use
ISO on the B side.

•

Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.

3A0238P

9

Component Identification

Component Identification
AC Power Pack Module
24D829 AC Power Pack Module shown with circulation lines

B
C

E

D

A

r_24d829_3A0238_1f

FIG. 1: Typical Installation
Key:
A
B
C
D
E

10

AC Hydraulic Power Pack
Hose Kit (includes A, B, and hydraulic hoses)
Boom (not included with all power pack kits)
Applicator (not included)
GMS™ Fluid Manifold (not included)

3A0238P

Component Identification

Hydraulic Power Pack Stand
AG
AH

AB

AN

AD

AV
AW

AF

AM

AC
AJ
AA
AX
AL
AK
AE, AS
AU

AP
AT
r_24C065_3a0238_1d

r_24C065_3a0238_11e

FIG. 2
Key:
AA 10 Gallon Hydraulic Oil Reservoir (see Technical Data on
page 70 for specifications)
AB Electric Motor
AC Dipstick
AD Hydraulic Housing
AE Heat Exchanger
AF Filter
AG Shroud
AH Mixhead Accumulator - 1200 psi (24.1 MPa, 241 bar) precharge
AJ Cleanout Directional Valve
AK Accumulator Directional Valve
AL Dispense Directional Valve
AM Applicator Adapter Housing
AN Diverter Block

3A0238P

AP
AR
AS
AT
AU
AV
AW
AX

Main Power Disconnect
Electronics Panel (inside stand)
Heat Exchanger Cover
Cycle Stop Button
Stand
Hydraulic Pressure Gauge
Return Accumulator - 150 psi (1.0 MPa, 10 bar) precharge
Check Valve

11

Component Identification

Main Power Disconnect

Circuit Breakers

Below are the on and off positions for the main power
disconnect (AP) located on the AC Power Pack module.
NOTE: The power must be turned “On” at the GMS
unit first.
On position

r_121148_3a0238_1a

Circuit breakers are located inside the power pack frame
stand.

Off Position

CB113

r_121148_3a0238_2a

CB125

FIG. 3: Main Power Disconnect

r_24d427_3a0238_1c

FIG. 4: Circuit Breakers

12

Model
230V

Ref. No.
CB125

Size
30 A

400V

CB113
CB125

5A
20 A

CB113

5A

Component
Directional Valve and
heat exchanger fan
Motor
Directional valve and
heat exchanger fan
Motor

3A0238P

Component Identification

Fluid Control Module (FCM)
BA
BC

BE

TI12337A

BB

TI12336A

BF

BD

FIG. 5
Key:
BA
BB
BC
BD
BE
BF

Fluid Control Module
Base
Module Connection Screws
Access Cover
Module Status LEDs
CAN Connectors

3A0238P

FCM Cable Connections
FCM
Connections

Cable

1

123673

2

123673

3

121686

4

121686

5

24E052

6

122497

CAN connector 1

123762

CAN connector 2

123856

13

Component Identification

Diagnostic Information
7

Module Status LED Signal
Green on
Yellow
Red solid
Red flashing fast
Red flashing slow

Diagnosis
System is powered up
Internal communication in progress
FCM hardware failure
Uploading software
Token error

Solution
Replace FCM
Remove token and upload software
token again.

Adjust Selector Switch
The fluid control module uses a 16-position selector
switch. Set selector switch (S) to specific selection
according to the settings listed in the following table.
Setting 1 is the only valid position.
Selector Switch Settings

14

Setting

Zone

0

0

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

A

A

B

B

C

C

D

D

E

E

F

F

3A0238P

Setup

Setup
Connect Hydraulic Hoses
Avoid breathing of vapors and contact with Isocyante
as some people have severe allergic reactions. See
Isocyanate Conditions on page 8.
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components.
1. Anchor the stand to the floor (mounting hardware
not included). See Dimensions on starting on page
66 for mounting dimensions. Suggested anchors:
McMaster-Carr (part no. 92403A400).
NOTE: The AC power pack (A) needs to be mounted
no more than 6 ft (1.8m) away from the front of the
GMS unit.
2. If the AC power pack has a boom (C), anchor the
boom to the floor (mounting hardware not included).
See Dimensions on starting on page 66 for mounting dimensions. Suggested anchors: McMaster-Carr
(part no. 92403A400).
NOTE:
• If your AC Power Pack Module has a boom (C),
the AC Power Pack (A) needs to be installed
within 12 in. (304.8 mm) of the boom and the
boom needs to be installed within 3 ft (1 m) of
the GMS unit.
• Ensure that the hose connections for applicator
(D) face the mast. See FIG. 1 on page 10.
3. If the AC power pack has a boom (C), mount the
applicator (D) to the boom (C). Complete Installation instructions in the applicator manual.

Hydraulic lines could rupture and cause injury. Use
hydraulic hoses with a pressure rating higher than
what the system is set to.
Twisted hydraulic hoses can cause the hoses to
fatigue sooner and rupture. Ensure that the hydraulic
hoses do not twist between the AC power pack and
the applicator.
NOTICE
Damage can occur to the directional valve if the
hydraulic hose diameter is larger than 3/8 in. (9.5
mm).
To prevent damage to the applicator or directional
valves, do not allow any dirt or foreign matter to
enter the lines, when connecting the hose kit (B) to
the applicator (D) and hydraulic power pack (A).

Connect Hydraulic Hoses to Power Pack
1. Connect L-Head hydraulic hoses:
a. Connect the hydraulic hose fittings (A1, A2, B1,
and B2) on the AC power pack to the ends of
hydraulic hose (401) on the mast side of the
boom (C) as listed in the table below. See FIG.
1, page 10 and FIG. 6, page 16.
2. Connect S-Head and GX-16 hydraulic hoses:
a. Connect the hydraulic hose fittings (A2 and B2)
on the AC power pack to the ends of hydraulic
hose (402) on the mast side of the boom (C) as
listed in the table below. See FIG. 1, page 10
and FIG. 6, page 16.
b.

3A0238P

Use caps (6) to plug A1 and B1 fittings.

15

Setup

Connect Hydraulic Hoses to Applicator
Hydraulic
Hose Fitting

Hydraulic
Hoses

Hydraulic Hose
Color Markings

A1✖
Cleanout close
Green/Green
A2
Material close
Green
B1✖
Cleanout open Green/White/Green
B2
Material open
Green/White
✖ Not used for S-Head and GX-16 applicators.

If the AC power pack (A) has a boom (C), these connections will be hanging off the end of the boom.
L-Head
See FIG. 8.
1. Connect the A1 hose, with green/green markings, to
the cleanout close port (CC) on the applicator.
2. Connect the A2 hose, with the green markings, to
the material close port (MC) on the applicator.

B2

B1

3. Connect the B1 hose, with the green/white/green
markings, to the cleanout open port (CO) on the
applicator.
4. Connect the B2 hose, with the green/white markings, to the material open (MO) port on applicator.

A1

5. Hand tighten each fitting.

A2

6. Bleed air from the hydraulic fluid lines. See the
applicator manual for instructions.

FIG. 6: L-Head Applicator Hydraulic Housing

7. Tighten each fitting 1-1/2 flats past hand tight.

B2
CC
CO
A2
ti17743a

FIG. 7: S-Head Applicator Hydraulic Housing
3. Hand tighten each fitting.
4. Tighten each fitting 1-1/2 flats past hand tight.
MC

MO

FIG. 8: Hydraulic connections on L-Head

16

3A0238P

Setup

S-Head and GX-16
See FIG. 9 and FIG. 10.
1. Connect the B2 hose, with green/white markings, to
the hydraulic open (HO) port fitting.
2. Connect the A2 hose, with green markings, to the
hydraulic close (HC) port fitting.
3. Hand tighten each fitting.
4. Bleed air from the hydraulic fluid lines. See the
applicator manual for instructions.
5. Tighten each fitting 1-1/2 flats past hand tight.
TOP

HC

RIGHT

HO

FIG. 9: Hydraulic connections on S-Head

HC
HO

ti17747a

FIG. 10: Hydraulic connections on GX-16

3A0238P

17

Setup

Connect Material Hoses to
System
For System With Circulation
NOTICE
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
1. Connect the A (red) and B (blue) supply hoses, from
hose kit (3), to the GMS material manifold. See FIG.
11.
2. Connect the other end of the supply hoses to the
applicator. See the applicator manual for fluid inlet
identification.

fluid inlet
fitting

r_257968_3a0238_1c

FIG. 12: Tank Stand Connections
5. Tighten each fitting.

For System Without Circulation

A

NOTICE
GMS material
manifold

B

3

Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
1. Connect the A (red) and B (blue) supply hoses, from
hose kit (3), to the GMS material manifold. See FIG.
11.
2. Connect the other end of the supply hoses to the
applicator. See the applicator manual for fluid inlet
identification.

421

422

3. Hand tighten each fitting.
4. Tighten each fittings 1-1/2 flats past hand tight.

FIG. 11
NOTE: The circulation hoses contain a 10 ft (3 m)
extension hose to reach the tank stands.
3. Connect the other end of the A (red) circulation
hose (421) to the fluid inlet fitting on the A (red) tank
stand. See FIG. 11 and FIG. 12.
4. Connect the other end of the B (blue) circulation
hose (422) to the fluid inlet fitting on the B (blue)
tank stand.

18

3A0238P

Setup

Connect Communication Cables
83

5. Connect the termination connector (425) to the connector (121), labeled 5A. Feed the connector (425)
and cables (121, 84) into the base cube and secure.

S-Head (Includes GX-16)

121

1. Connect control cable (84) to the motor control module splitter labeled “2A” found on the HFR unit.
Refer to the HFR manual for detailed locations

84
122

2. Connect the S-head proximity sensor to the electrical connector found within the material hose bundle.

123

3. Connect the other end of the cord to the electrical
connector found near the fluid manifold on the HFR.
FIG. 13
1. Feed end of communication cable (83) through bulkhead of the HFR base unit.

4. Feed the cables (121, 122, 123) into the base cube
and secure.

2. Connect communication cable (83) to any open
CAN connector of a GCA cube.

TI12337A

FIG. 14

Connect Proximity Cables
L-Head
1. Connect the applicator end of the proximity sensor
cable (418) to the dispense proximity sensor on the
L-Head.
2. Connect the applicator end of the proximity sensor
cable (419) to the cleanout proximity sensor on the
L-Head.
3. Connect the other end of the proximity sensor cable
(418) to the dispense proximity sensor cable (122),
labeled A1, on the AC power pack. See FIG. 13.
4. Connect the other end of the proximity sensor cable
(419) to the cleanout proximity sensor pigtail (123),
labeled 2C, on the AC power pack. See FIG. 13.
3A0238P

19

Setup

Connect Electrical Cord
Electrical Requirements. See Table 1.

NOTE: Power cord is not supplied. See Table 2.
Table 2: Power Cord Requirements
Model
Cord Requirements AWG (mm2)
230V
10 (5.3), 3 wire
400V
10 (5.3), 4 wire
✖ See 400 V Power Requirements, page 3.

Installing this equipment requires access to parts
which may cause electric shock or other serious
injury if work is not performed properly. Have a qualified electrician connect power and ground to main
power switch terminals, see FIG. 15. Be sure your
installation complies with all National, State, and
Local safety and fire codes.
Table 1: Electrical Requirements
(kW/Full Load Amps)
Voltage
Full Load
System
Model
(phase) Peak Amps*
Watts
230V
230V (3)
17
4000
400V✖
400V (3)
18
3200

Electrical Cord Wires by Model
230V, 3 phase: L1, L2, L3
400V, 3 phase ✖ : L1, L2, L3, N
✖ See 400 V Power Requirements, page 3.
Use 5/32 or 4 mm hex allen wrench to connect three
power leads to L1, L2, and L3.

* Full load amps with all devices operating at maximum
capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
✖ See 400 V Power Requirements, page 3.
L1 L2 L3

FIG. 15: 230V, 3 phase shown

N L1 L2 L3

FIG. 16: 400V, 3 phase shown

20

3A0238P

Startup

Startup

3. Press in the lower solenoid of the accumulator
charging directional valve.

The hydraulic power pack operates at a high pressure and high voltage. Be careful during operation
and always wear the appropriate protective gear.
1. Ensure all hydraulic connections are tight.
2. Turn on main power to power pack.
3. Turn power switch to the ON position.
4. Set system settings in ADM. See system operation
manual for instructions.

FIG. 17
4. Ensure that the pressure gauge is zero psi.

Operation

5. To relieve pressure in material hoses, perform Pressure Relief Procedure in HFR manual 313997.

Pressure Relief Procedure

Shutdown
1. Shutdown HFR.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

2. Turn main power switch to the OFF position.
3. Turn off and lock out main power.

Always relieve hydraulic pressure of AC power pack:
•
•

Before performing system maintenance
Long term (over night) shutdown

1. Shutdown the power pack. See Shutdown.
2. Open the needle valve to show the pressure on the
gauge.
NOTE: Ensure that the motor is not running.

3A0238P

21

Maintenance

Maintenance
Check the Accumulator Pre-Charge
Graco Charging Harness (part no. 124217) can be purchased to aid in quick charging of the accumulator.

Schedule

1. Turn off main power and lockout.

Procedure

Frequency

Check Accumulator Pre-Charge
Check Tightness of all Clamps and
Fittings
Check Hoses for Wear
Check Hydraulic Fluid and Filter

Weekly
Weekly
Monthly
6 months

NOTICE
Recommended Hydraulic Oil
Use Graco-approved Hydraulic Oil, Part No. 169236
(5 gal) or 207428 (1 gal)) or a premium, ISO grade
46 petroleum-based hydraulic oil containing rust
and oxidation inhibitors and anti-wear agents.
Before using any other type of oil in this motor, contact your Graco distributor. Unauthorized use of
lesser grade oil or substitutes may void the warranty.

2. Bleed the accumulator charging valve hydraulic
pressure to zero. See Pressure Relief Procedure,
page 21.
3. Connect the charging harness to the accumulator.
4. Check the reading on the nitrogen harness pressure
gauge. If the pressure is below 1200 psi, then
Pre-Charge the Accumulator to 1200 psi.
5. Repeat the procedure for the return accumulator
(AW, FIG. 2) with the precharge set to 150 psi
(1.0 MPa, 10 bar).

Pre-Charge the Accumulator
NOTICE
During this procedure the nitrogen bottle, the accumulator, and the charging harness will all be under
significant pressure. Use dry nitrogen gas only.
1. Check the Accumulator Pre-Charge.

Hydraulic Oil Working Temperature
The maximum hydraulic oil operating temperature is
180 °F (82 °C). The motor seals will wear faster and
leakage may occur if the pump is operated at higher
oil temperatures.
If the hydraulic oil temperature approaches 180 °F
(82 °C), check the hydraulic fluid supply cooling system, filters, etc. and clean or repair as needed.

2. Connect the other end of the harness to the nitrogen
bottle. Slowly open the nitrogen bottle valve while
observing the pressure gauge.
3. When the1200 psi is reached, close the nitrogen
valve.
4. Open the bleed valve on the charging harness to
relieve residual pressure in the charging harness.

Keep the hydraulic system clean
To reduce the risk of damaging the hydraulic driver,
verify that the hydraulic power supply fluid lines and
reservoir are clean and free from contaminants.
Carefully follow the manufacturer’s recommendations on reservoir and filter cleaning, flushing, and
periodic changes of hydraulic fluid.

5. Remove the charging harness and replace the bottle guard.
6. Repeat the procedure for the return accumulator
(AW, FIG. 2) with the precharge set to 150 psi
(1.0 MPa, 10 bar).

Always plug the hydraulic inlets, outlets and lines
when disconnecting them to avoid introducing dirt
and other contaminants into the system.

22

3A0238P

Maintenance

Check Hydraulic Fluid
NOTE: Standard temperature switch cuts out at a
housing temperature of 160°F (71°C) and approximately 180°F (82°C) hydraulic fluid temperature.

6. To add clean hydraulic fluid see Check Hydraulic
Fluid Level.

Check Hydraulic Fluid Level
87

1. Remove the breather filler cap (246).
2. If the fluid level is between the high and low tick
marks, the fluid level is correct.
3. If the fluid level falls below the low fluid level tick
mark, add fluid until the level is between the high
and low level tick marks.

FIG. 19: Drain Cap

Replace Hydraulic Filter
NOTICE

246

Be careful not to allow any debris into the hydraulic
tank when replacing the filter. If any debris falls into
the hydraulic tank, the debris must be removed or
machine damage will result.
high fluid level
low fluid level

FIG. 18: High and Low Fluid Level Marks
Check Condition of Hydraulic Fluid
1. Remove the breather filler cap (246).
2. Remove some of the hydraulic fluid.
3. Replace the fluid if the fluid becomes cloudy.

1. Shutdown the system. See Shutdown on page 21.
2. Relieve Pressure. See Pressure Relief Procedure
on page 21.
3. Use compressed air to remove any loose debris
around the hydraulic filter (245).
4. Apply a light coat of hydraulic fluid to the sealing
surface of the new hydraulic filter (245).
5. Replace the old filter with the new filter (245).
6. Start system.
7. Check for any leaks.

Replace Hydraulic Fluid
Use only recommended hydraulic fluids. See FIG. 19.
NOTE: Be prepared to collect 10 gallons (38 liters) of
fluid when emptying the tank.
1. Shutdown the system. See Shutdown on page 21.

245

2. Relieve Pressure. See Pressure Relief Procedure
on page 21.
3. Place a container below drain port.
4. Remove drain cap (87) from the side of the hydraulic
reservoir and drain the reservoir.

FIG. 20: Hydraulic Fluid Filter

5. Install drain cap (87).

3A0238P

23

Troubleshooting

Troubleshooting

Problem

Cause

Solution

Pressure gauge drops to zero while
in operation.

Accumulator precharge is too high.

Ensure accumulator precharge is
no more than 1200 psi.

No hydraulic pressure.

Motor is not turning.

Ensure main power is ON.
Ensure all electrical connections to
the motor are secure.
Check motor circuit breaker to see if
it has been tripped. Ensure all
cables are connected to FCM connectors.
Replace motor. See page 30.
Ensure all cables are connected to
FCM connectors. See FCM Cable
Connections, page 13.

Motor is spinning clockwise.

Switch two phases of incoming
power.

Leaking fluid from fittings.

Tighten leaking fittings.

Accumulator directional valve is not
charging.

Ensure accumulator charging directional valve is shifting. Verify LED
lights turn ON and OFF.
Check circuit breaker to see if it has
been tripped.
Replace directional valve. See page
27.
Replace accumulator.
Ensure all cables are connected to
FCM connectors. See FCM Cable
Connections, page 13.

Leaking hydraulic fluid around the
hydraulic filter.

24

Low hydraulic fluid level in oil reservoir.

Check hydraulic fluid level. Refill as
necessary.

Damaged or clogged filter.

Replace hydraulic filter. See page
27.

3A0238P

Troubleshooting

Problem
Hydraulic fluid over heating.

Material is not dispensing from
applicator.

Cause

Solution

Fan in base cube is not spinning.

Check electrical connections to fan.
Replace fan.

Heat exchanger in base cube is
clogged or leaking.

Replace.

Low hydraulic fluid level in oil reservoir.

Check hydraulic fluid level. Refill as
necessary.

Cycle rate too fast.

Increase time between shots.

Damaged gear pump.

Replace gear pump. See page 32.

Damaged coupler between motor
and gear pump.

Visually inspect coupler and spider
coupling between motor and gear
pump. Replace if necessary.

Material hoses are not connected.

Check material hoses for damage
or leaking fittings.
Ensure material hoses are connected properly. See Setup on
page 15.

Hydraulic fluid leaking around any
directional valves.

Damaged or worn o-ring.

Replace o-ring. Clean o-ring surfaces and grooves prior to replacement.

Hydraulic fluid leaking around
diverter block.

Damaged or worn o-ring.

Replace o-ring. Clean o-ring surfaces and grooves prior to replacement.

Applicator not cycling.
(continued on the next page)

No hydraulic pressure.

See page 24 for possible causes
and solutions.

Leaking fluid from fittings.

Tighten leaking fittings.

Hydraulic hoses are not connected.

Ensure hydraulic hoses are connected properly. See Setup on
page 15.

Pump shaft seal failure.

Replace gear pump. See Remove
Hydraulic Gear Pump, page 32.

Excessive air or foamy hydraulic oil.

3A0238P

25

Troubleshooting

Problem

Cause

Solution

Applicator not cycling. (continued)

Accumulator directional valve is not
charging.

Ensure accumulator charging directional valve is shifting. Verify LED
lights turn ON and OFF.
Check circuit breaker to see if it has
been tripped.
Replace directional valve. See page
27.
Replace accumulator.
Ensure all cables are connected to
FCM connectors. See FCM Cable
Connections, page 13.

Cleanout directional valve is not
cycling. (L-Head only)

Ensure main power is ON.
Ensure all electrical connections to
the directional valve are secure.
Check to see if the cleanout directional valve is shifting. Verify LED
lights turn ON and OFF.
Check circuit breaker to see if it has
tripped.
Replace directional valve. See page
27.
Ensure all cables are connected to
FCM connectors. See FCM Cable
Connections, page 13.

Material directional valve is not
cycling.

Ensure main power is ON.
Ensure all electrical connections to
the directional valve are secure.
Check to see if the material directional valve is shifting. Verify LED
lights turn ON and OFF.
Check circuit breaker to see if it has
tripped.
Replace directional valve. See page
27.
Ensure all cables are connected to
FCM connectors. See FCM Cable
Connections, page 13.

26

3A0238P

Repair

Repair
3. Disconnect all hydraulic lines from A1, A2, B1, and
B2 fittings at the applicator housing.

Remove Hydraulic Power Pack
Shroud
1. Remove four screws from base of shroud.

B2
B1

2. Lift shroud off of hydraulic power pack.

Install Hydraulic Power Pack
Shroud

A1
A2
FIG. 21: L-Head Applicator Hydraulic Housing

NOTICE
Do not over-torque any item that threads into the
hydraulic tank (237). This will strip the threads and
require tank replacement.
1. Place shroud on top of hydraulic power pack.
2. Install four screws securing shroud to hydraulic tank.

Remove Hydraulic Power Pack

B2

A2

NOTICE
If any debris falls into the hydraulic tank, the debris
must be removed or machine damage will result.
1. Perform Shutdown procedure, see page 21.
2. Perform Remove Hydraulic Power Pack Shroud
procedure.

3A0238P

ti17743a

FIG. 22: S-Head Applicator Hydraulic Housing
4. Disconnect all electrical cables connected to the
motor, directional valves, temperature switch, and
pressure transducer.

27

Repair

5. Disconnect heat exchanger inlet hose (76) and fitting from elbow fitting (249) on hydraulic housing
(206). Disconnect heat exchanger outlet hose (77)
and fitting from elbow fitting (248).

8. Remove the four bolts (57) and washers (56) securing the tank to the stand.

55

206
249

56, 57

56, 57

76
248

77

FIG. 23:Heat Exchanger Inlet and Outlet Hoses
6. Remove the two bolts from (258) from the fluid
housing (206) and replace each with a 5/16-18
thread eye bolt. Install a third 5/16-18 eye-bolt as
indicated.
206

FIG. 25

To prevent serious injury from the hydraulic power
pack falling, ensure that the hydraulic power pack is
secured to the hydraulic lift before removing from the
stand.
9. Lift the hydraulic power pack (55) and place on a
sturdy location capable of supporting up to 300 lbs
(136 kg).

258

258

Install third eye-bolt here
FIG. 24
7. Run a rope through the three eye-bolts and between
the motor and the accumulator. Secure to a hydraulic lift.

28

3A0238P

Repair

Install Hydraulic Power Pack
NOTICE
If any debris falls into the hydraulic tank, the debris
must be removed or machine damage will result.
NOTICE
Do not over-torque any item that threads into the
hydraulic tank. This will strip the threads and require
tank replacement.
1. Run a rope through the three eye-bolts and between
the motor and the accumulator. Secure to a hydraulic lift. See FIG. 24 on page 28.
2. Lift the Hydraulic Power Pack and place onto the
base enclosure. See FIG. 25.
3. Align the holes with the tank then install finger-tight
the four bolts (57) and washers (56) securing the
tank to the stand. Torque to 10 ft-lb (13.5 N•m).
4. Remove rope and lift.
5. Remove eye-bolts. Install original bolts (258) into
fluid housing (206). See FIG. 24 on page 28.

Replace Tank Gasket
1. Remove Hydraulic Power Pack. See page 27.
2. Remove hex head cap screws (239) and washers
(238) securing hydraulic housing (206) to tank
(237). Carefully remove motor (201) and hydraulic
housing assembly from tank.
3. Remove tank gasket (236). If tank (237) is damaged, replace tank.
4. Install thrust washers (038) onto hex head cap
screws (039). Apply pipe sealant 070408 to threads
of screws. Align tank gasket (036), hydraulic housing, and tank (020) then install screws. Torque to
15 ft-lb (20.3 N•m).
5. Perform Install Hydraulic Power Pack procedure,
see page 29.
NOTICE
Do not over-torque any item that threads into the
hydraulic tank (237). This will strip the threads and
require tank replacement.

6. Connect all electrical cables to the motor, three
directional valves, temperature switch, and pressure
transducer.

239
238

7. Connect all hydraulic lines to applicator housing.
See FIG. 21 on page 27.
8. Connect heat exchanger inlet hose (76) and fitting
to elbow fitting (249) on hydraulic housing (206).
Connect heat exchanger outlet hose (77) and fitting
to elbow fitting (248). See FIG. 23 on page 28.

206

236

237

FIG. 26

3A0238P

29

Repair

Remove Motor
1. Shutdown the system. See Shutdown on page 21.
2. Remove Hydraulic Power Pack. See page 27.

201

3. Disconnect the tube assembly (15Y684) from the
accumulator (242).
213
238, 239

205

202
203

264

242

201

206
212

204

206
FIG. 28
240

258

247

7. Remove four hex head cap screws (244), accumulator (242), and mounting plate (240) from the motor
(201).
NOTE: Do not lose the spider coupler (213).
8. Remove four socket head cap screws (205) and
motor (201) from the motor adapter plate (003)
9. Loosen the set screw from the motor coupler (202)
and remove the motor coupler.

257
237

FIG. 27
4. Remove two hex head cap screws (258) connecting
the support bracket (257) to the hydraulic housing
(206).
5. Carefully remove motor assembly from tank.
6. Remove the four socket head cap screws (204) connecting the motor adapter plate (203) to the hydraulic housing (206).

30

3A0238P

Repair

Install Motor
See FIG. 27 and FIG. 28.
1. Install motor coupler (202) onto motor (201). Apply
thread sealant to threads of screw. Torque motor
coupler set screw to 15 ft-lb (20.3 N•m).
NOTE: The coupler (202) must be 1.67-1.68 in. from
the face of the motor.

201

202

1.68

+.00
-.01

2. Apply thread sealant to threads of four socket head
cap screws (205). Use four screws (205) to attach
the motor adapter plate (203) to motor (201). Torque
to 90 ft-lb (122 N•m).
3. Use four hex head cap screws (244) to attach the
accumulator (242) and mounting plate (240) to
motor (201). Apply thread sealant to threads of
screw. Torque to 35 ft-lb (47 N•m).
4. Install spider coupler (213) into motor coupler (202).
5. Apply thread sealant to threads of four socket head
cap screws (204). Use four screws (204) to attach
the hydraulic housing (206) to the motor adapter
plate (203). Torque to 35 ft-lb (47 N•m).
NOTE: Be sure to align teeth of the pump coupler
(212) with the teeth of the motor coupler (202).
6. Connect the tube assembly (247) to the applicator
housing (206) and the accumulator (242). Torque to
1-1/2 flats past hand tight.
7. Install washers (238) onto hex head cap screws
(239). Align tank gasket (236), hydraulic housing
(206), and tank (237). Install screws (239). Torque
to 15 ft-lb (20.3 N•m).
8. Use two hex head cap screws (258) to connect the
support bracket (257).
9. Install Hydraulic Power Pack. See page 29.

3A0238P

31

Repair

Remove Hydraulic Gear Pump

212

1. Shutdown the system. See Shutdown on page 21.
211
2. Remove Hydraulic Power Pack. See page 27.

219

3. Disconnect the tube assembly (247) from the accumulator (242).

215
217

214
FIG. 30

238, 239
264

242

201

7. Remove the two hex head cap screws (214) and
carefully remove the gear pump (211) from the
hydraulic housing (206).
NOTE: Do not lose the pump coupler (212).
8. Remove the inlet fitting (219) and outlet fitting (215).

206

240

9. Loosen set screw and remove pump coupler (202).

258

247

257
237

FIG. 29
4. Remove two hex head cap screws (258) connecting
the support bracket (257) to the hydraulic housing
(206).
5. Carefully remove motor assembly from tank (237).
6. Disconnect the tube assembly (217) from the gear
pump (211) and hydraulic housing (206).

32

3A0238P

Repair

Install Hydraulic Gear Pump
See FIG. 29 and FIG. 30.
1. Install pump coupler (212) on the gear pump. Apply
thread sealant to threads of screw. Torque motor
couple set screw to 15 ft-lb. (20.3 N•m).
NOTE: The pump coupler (212) must be 0.06 in. –
0.07 in. from the face of the gear pump.
.07

+.00
-.01

212

211
2. Install inlet and outlet fittings (219, 215). Torque to
40 ft-lb (54 N•m).
3. Apply thread sealant to threads of two hex head cap
screws (258). Use two screws to attach the gear
pump (211) to the hydraulic housing (206). Torque
to 35 ft-lb (47 N•m).
4. Connect the tube assembly (217) to the hydraulic
housing (206) and outlet fitting (219). Torque to
1-1/2 flats past hand tight.
5. Install washers (238) onto hex head cap screws
(239) and apply thread sealant to threads of screws.
Align tank gasket (236), hydraulic housing (206),
and tank (237). Install screws (239). Torque to 15
ft-lb (20.3 N•m).
6. Install Hydraulic Power Pack. See page 29.
NOTE: When replacing the hydraulic gear pump, it is
recommended that the check valve (271) be replaced.

3A0238P

33

Repair

Install FCM Upgrade Token

Connect Cables

Note: FCM connection to system is temporarily disabled
during the installation of upgrade or key tokens.

Ensure all cables are connected to FCM connectors.
See FCM Cable Connections, page 13.

To install software upgrades:
1. Use correct software token stated in the table. See
Graco Control Architecture™ Module Programming
manual for instructions.
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module (System Settings, USB Logs,
Recipes, Maintenance Counters) may be reset to
factory default settings. Download all settings and
user preferences to a USB before the upgrade, for
ease of restoring them following the upgrade.
See manuals for locations of specific GCA components.
The software version history for each system can be
viewed in the technical support section at
www.graco.com.
Token

Application

16H821 HFR:
- Advanced Display Module
- Motor Control Module
- High Power Temperature Control Module
- Fluid Control Module (AC Power Pack)
- Discrete Gateway Module
- Communication Gateway Module

ti12334a1

FIG. 31: Remove Access Cover

34

3A0238P

Repair

3A0238P

35

Parts

Parts
AC Hydraulic Power Pack Module
Fluid
Lines
(3)

Description

Hydraulic Lines
A1
Cleanout close
A2
Material close
B1
Cleanout open
B2
Material open
Material Lines
AR
A side material return
AS
A side material supply
BR
B side material return
BS
B side material supply

Color
Identification
Green/Green
Green
Green/White/Green
Green/White
Red
Red
Blue
Blue

A1

A2

B1

B2

AR AS

BS BR

See Hose Kits on page 52 for fluid line connections.
24D829 AC Hydraulic Power Pack Module Shown
3

2e

2

AS

2a

1
BS
AR
10

BR
2b
1 Torque all screws on hydraulic and material hose
clamps to 6 ft-lbs (8 N•m).

2 Torque to 113 ft-lbs (153 N•m).

36

9

2c, 2d

r_24d829_3A0238_1f

2

3A0238P

Parts

Power Pack Kit and Quantity
24D829 24D830 24D831 24D832 24F297 24J912 24D834 24D835 24D836 24D837 24F298 24J913
Ref Part
1

2

2a

2b 257952

2c 109570
2d 100424
2e

3†

6

123140

9▲ 15M511
10 196548
▲

Description
MODULE,
mixhead
stand,
230v; see
page 38
MODULE,
mixhead
stand,
400v; see
page 38
ARM,
boom, floor
mounted;
includes
2a-2e
PLATE,
mounting,
floor, mast
BASE,
arm, floor
mount
WASHER
SCREW,
cap, hex hd
ARM,
pneumatic
boom; see
page 50
KIT, L-head
hose, ms
KIT,
S-head
hose, ms
KIT, L-head
hose,
no clamps
KIT,
S-head
hose,
no clamps
FITTING,
cap,
1/2 JIC, cs;
not shown
LABEL,
warning
LABEL,
caution

230 V Modules

1

1

1

400V Modules

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1
1

1

1

1

1

2

1

2

4

2

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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

3A0238P

1

† All hose kits (3) include hydraulic and material lines.
See Hose Kits on 52.

37

Parts

Mix Module Stand
61

54 2
76
6
54
2

69

86
3
87
3

75 5
77 6

2 54

54 2

74

1 55

62

59

56, 57
67
66
67
67

7

70

72

58
58

65

54 2
52
51
1
59

Fill power pack (55) tank with hydraulic oil. Check after initial startup to
ensure proper fluid level.

2 Apply anaerobic sealant to threads and torque to 17 ft-lbs (23 N•m).
3 Apply anaerobic pipe sealant to adapter fitting (86) threads and thread

63

in to power pack (55). Do not apply anaerobic pipe sealant to cap fitting
(87) threads.

71

7

4 Apply anaerobic sealant to threads and torque to 10 ft-lbs (13.5 N•m).
5 Apply anaerobic sealant to threads and torque to 6.5 ft-lbs (8.8 N•m).

64

70

6 Apply lubricant to threads and torque to 21 ft-lbs (28.4 N•m).
7 Tie wires here.

38

3A0238P

Parts

230V Mix Module Stand
400V Mix Module Stand
Ref.
No. Part
51
52 24D021
54 111800
55
56

U90205

57

110385

58
59

121160

60
61
62

115942
121171

63
64
65
66
67
68
69

123452
100166

69a
69b
69c
70
71

123589
123398
123590
24B855

117284
103646
100020
116610

72
73
74
75

102795
24C153
113796

76
77
78
79
80
81

24C621
15Y935
123855
122497
123303
123673

82
83
84
85

123856
121201
24C760
123764

3A0238P

86
Description
Qty
ENCLOSURE, frame
1
BRACKET, anchor, cube
4
SCREW, cap, hex hd; 5/16-18 x
16
0.625
1
MODULE, hydraulic power, mixhead; see page 44
WASHER, flat, 3/8, 0.41x1.25x.13, 4
ms
SCREW, machine; hex hd; 5/16-18 4
x 3 in.
GRIP, cord, 0.71-1.02
1
PANEL, mixhead, 230v
1
PANEL, mixhead, 400v
1
NUT, hex, flange head
3
GRIP, cord, 0.35-.63, 3/4
1
SWITCH, assy, disconnect, 230v 1
SWITCH, assy, disconnect, 400v 1
HOLDER, anchor, wire tie, nylon
7
NUT, full hex
7
PANEL, mixhead, assembly
1
BUSHING, wire protector, snap-in 3
PLUG, hole, 1-1/2 in. dia
5
PLUG, hole, 2 in. dia
2
COVER, assembly; includes
1
69a-69c
COVER, hydraulic module
1
GRILL, fan guard
1
RIVET, blind
4
WASHER, lock
7
SCREW, mach, phillips, pan hd,
7
#10-32 x 1/2
COVER, enclosure, heat
1
exchanger, assy; see page 40
SCREW, cap sch; #8-32 x 1.625
2
COVER, heat exchanger
1
SCREW, flanged, hex hd; 1/4-20 x 4
3/4
HOSE, heat exchanger, inlet
1
TUBE, heat exchanger, outlet
1
HARNESS, 5 pin, adapter
1
CABLE, cord set, reverse key
1
HARNESS, m12
2
HARNESS, ext, m12xm12, 5px5p, 2
mxf
HARNESS, can cable, delete +24v 1
CABLE, can, female-female, 6.0m 1
HARNESS, power, ac motor, 10ga 1
HARNESS, m8, 4p, straight x pigtail 1

87
90
92

122970 FITTING, adapter, JIC(08) x
SAE(08), m
123140 FITTING, cap, 1/2 jic, cs
24D495 CORD, fan, heat exchanger, mixhead
LABEL, identification, electronics

1
1
1
1

39

Parts

Heat Exchanger Assembly
801
806 4 5

804

802
808 3 5
805

807

805 1 2

7

Ref
801

Part
257967

802
803
804
805
806
807
808

15X621
122300
122301
122842
15U075
110755
100022

40

803
1

Torque to 65 ft-lb.

5

Apply anaerobic sealant to threads.

2

Apply lubricant to o-rings before
assembling.

6

Orient fan with airflow arrow pointing
toward cover.

3

Torque to 8 ft-lb.

7

Align fan plug as shown.

4

Torque to 2.5 ft-lb.

Description
COVER, enclosure, heat
exchanger
GASKET, fan, mounting
EXCHANGER, heat, m-4
FAN, 220v
FITTING, elbow, SAE x JIC
SCREW, cap, bh, 8-32 x 0.375
WASHER, plain
SCREW, cap, hex hd; 1/4-20 x
3/4

Qty
1
1
1
1
2
8
4
4

3A0238P

Parts

3A0238P

41

Parts

230V and 400V MixHead Panel
230V MixHead Panel Shown
See Electrical Schematics starting on page 58 for wire connections.
113

106

107

101
106
112
105

106
108

106
108

116

115

r_24c357_3a0238_3c

106, 108
117
114

121

122

103
101
GND
120

111
109

110

119
GND
102
r_24c357_3a0238_5b

42

r_24c357_3a0238_6b

r_24c357_3a0238_7b

3A0238P

Parts

230V and 400V MixHead Panels
Ref.
No. Part
101
102 289697
103 102598
104
105

289696
24D207

106
107

103833

108
109
110
111
112
113
114
115★

123452
100021
100015
100028
116876
123718
121807
24D265

116★ 123762
117★ 24E052
118★ 24E211
119

114993

120
121
122

102063
24F075
24D003

Description
Qty
PANEL, electric, heat
1
MODULE, cube, gca, base
1
SCREW, cap, socket head; #10-32
4
x 1/2
MODULE, gca, cube, fcm
1
POWER SUPPLY, 24vdc, 4A,
1
100w, 230vac in,
SCREW, machine
11
MODULE, breaker, mixhead, 230v
1
MODULE, breaker, mixhead, 400v
1
HOLDER, anchor, wire tie, nylon
3
SCREW, cap hex hd; 1/4-20 x 1
1
NUT, hex mscr
3
WASHER, lock
3
WASHER, flat
2
FILTER, emi, 6a, spade con
1
CONNECTOR, splitter
1
HARNESS, cable, can, 24vdc sup1
ply
CABLE, can, 90x90, fxf, 0.5m
1
HARNESS, mixhead, e-stop, mtr
1
strt
HARNESS, mixhead, e-stop, mtr
1
str
SCREW, pan washer hd; M4 x 0.7
1
x 8 mm
WASHER, lock, ext
1
HARNESS, proximity, S-head
1
HARNESS, proximity, L-head, pig1
tail

★ See Electrical Schematics starting on page 58 for
wire connections.

3A0238P

43

Parts

MixHead Hydraulic Power Pack
See Electrical Schematics starting on page 58.
244 5 13
241

See page 46 for assembly notes.
See Hose and Cable Kits starting on page 54.

247

240

242

201
256

244 5 13
241

266

243

203
205 4
202 1

13
5

13

See page 43.
238

239 5

13

254 8

13

253

206
2
14

221

236

255

12 222

8 13 254

252

257

246 11
245

258

253

223 12
213
243 2 14
12 218

249 15
212 1

2 14 219

44

13

243 2 14
214 3 13

2 14 216

See page 43.

5

217 12

204 3 13
237

3A0238P

Parts

L-Head Configuration
227 12

2 14 216

226 9 14
273
224

272

268

252

235 6

269

270,
271

15 230

232 16

2 14 228
7
3

274, 7
275

13 234

13

13 225

226 9 14
229 2 14
16 231

233 16
230 15

S-Head Configuration
Refer to figure above for additional
component callouts.

20 263

209
7 210

231
2 14 228

3A0238P

45

Parts

210 7
208 12

1

1

.07

212

202

201
207
1.68

+.00
-.01

211

+.00
-.01

251 10 13

19

250
263 20
209

1 Assemble coupler (202, 212) to specified dimension prior to
mounting motor and pump to housing.

13 Apply sealant to threads prior to assembly.

2 Torque to 40 ft-lbs (54 N•m).

14 Apply a light coating of lubricant to seals prior to assembly.

3 Torque to 35 ft-lbs (47 N•m).

15 Tighten tubing nuts hand tight and then with a wrench. Torque
1-1/2 flats.

4 Torque to 70 ft-lbs (95 N•m).
5 Torque to 15 ft-lbs (20 N•m).
6 Torque to 185 in.-lbs (20 N•m).
7 Torque to 62 in.-lbs (7 N•m).
8 Torque to 65 in.-lbs (7.3 N•m).
9 Torque to 10 ft-lbs (13 N•m).

16 Directional valves are supplied with o-rings.
17 Route all signal cables through cable ties on the filter side of the
power pack.

18 Route all power wires through cable ties on the filler side of the
power pack.

19 Apply lubricant to contact side of thermal switch harness (250)
prior to assembly.

10 Torque to 40 in.-lbs (4.6 N•m).
11 Torque 1/4 turn past hand tight.
12 Apply PTFE tape on installation end only prior to assembly.

46

20 Install roll pin (263) into diverter block (207) for orientation to
hydraulic housing (206).

21 Cables and leads removed for clarity.

3A0238P

Parts

MixHead Hydraulic Power Module
Ref
201
202
203
204
205
206
207
208
209
210
211
212
213
214
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231

Part
122953
16A954
15Y675
123338
C19852
15W772
16A599
100139
556555
104092
122966
16A955
16A956
123942
115597
15Y696
101353
122606
100627
127953
100721
101754
15Y629
C19834
122962
17B775
122964
122970
122967
16K154
24D636
232 24D634
233 125736
234 123366
235✖ 257432
236 15X622
237 257162
238 101971
239 111302
240 15Y680
241 123293
242 122952
243 121312
244 110963
245 15J937
246 116915
247 15Y684
248 121486
249 123528

3A0238P

Description
MOTOR, mixhead
COUPLER, motor
PLATE, motor adapter
SCREW, shc
SCREW, cap, socket head
HOUSING, hydraulic, module
BLOCK, diverter
PLUG, pipe
O-RING
SCREW, cap, sch
PUMP, gear, hydraulic
COUPLER, pump
COUPLER, spider
FASTENER, screw, cap, hex hd
FITTING, nipple
TUBE, pump to manifold
FITTING, nipple, pipe
FITTING, elbow, male, female
NIPPLE, short
VALVE, relief, anti-shock
PLUG, pipe
PLUG, pipe
HOUSING, adapter, mixhead
SCREW, cap, socket hd
PLUG, sae 03
GAUGE, pressure, 0-5000 psi
PLUG, sae 08
FITTING, adapter, jic(08)xsae(08)
FITTING, elbow, swivel, 90, jic(08)
BLOCK, blank
VALVE, cleanout, wiring, assembly
VALVE, acc loading, wiring, assembly
VALVE, directional, 1 sol, 24vdc
SCREW, shc
HARNESS, wire, transducer
GASKET, housing, to, tank
RESERVOIR, assembly, 8 gallon
WASHER, thrust
SCREW, cap, hex hd
PLATE, accumulator mounting
BRACKET, accumulator mounting
ACCUMULATOR, mixhead
FITTING, elbow, sae x jic
SCREW, cap, flange head
FILTER, oil, 18-23 psi bypass
CAP, breather filler
TUBE, manifold to accumulator
FITTING, elbow, male, 1/2jicx1/2npt
FITTING, elbow, swivel, 45, jic08, fm, 6k

Qty
L-Head S-Head
1
1
1
1
1
1
4
4
4
4
1
1
1
1
2
2
4
8
4
8
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
1
0
2
4
2
5
3
1
1
1
1
1
1
8
4
1
1
1
1
1
1
4
4
4
4
1
1
2
2
1
1
3
3
4
4
1
1
1
1
1
1
1
1
1
1
47

Parts

250
251
252
253
254
255▲
256▲
257
258
263
266
267✖
268
269
270
271
272
273
274
275

123367
102410
103413
123601
103833
189285
121208
257976
113802
123786
112395
125102
127952
127955
127963
127954
123253
156971
116575
100020

HARNESS, m8 x thermal switch, 4-pin
SCREW, cap soc hd
PACKING, o-ring
CLAMP, wire, harness, nylon, 3/4"
SCREW, mach, crbh
LABEL, caution
LABEL, hot surface
SUPPORT, tank to motor, ac power pack
SCREW, hex hd, flanged
FASTENER, pin, roll
SCREW, cap
HARNESS, din18, 3p, elbow
ACCUMULATOR, hydraulic
FITTING, adapter
MANIFOLD
VALVE, check, 100 psi
VALVE, needle, 1/4 NPT
FITTING, nipple, short
SCREW, cap
WASHER, lock

1
2
2
7
7
1
1
1
2
1
4
1
1
1
1
1
1
1
4
4

1
2
2
7
7
1
1
1
2
2
4
1
1
1
1
1
1
1
4
4

▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
✖ Not shown.

48

3A0238P

Parts

3A0238P

49

Parts

Pneumatic Boom Arm
313
313
312
311
318
317

317

319

3 320, 321

308

3 322

325 1
326

315

324

To c
y

314

lind

er
3 323
316

328

338
322

333
2 310
305

336

309
335 2
329

332

305
2 307
301

3
327

2 334

1 331
337

To manifold

330

306
303

50

1

Torque to 35 ft-lbs (47.5 N•m).

2

Hand tighten only. Do not torque.

3

Apply PTFE tape on installation end only prior to assembly.

307
2

305
2 304

302

305

r_257553_3a0238_2a

3A0238P

Parts

Pneumatic Boom Arm
3

Ref.
No.
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339

Part
Description
Qty
1
24D349 BASE, boom assembly
1
BEARING, thrust, 45 x 65 x 14
1
15Y044 BEARING, support
1
113470 BOLT, hex
10
109570 WASHER, plain
5
100018 WASHER, lock, spring
5
100338 NUT, jam
1
POST, boom assembly
1
122634 COLLAR, 2.875 clamp 1pc
4
100096 SCREW, cap, hex hd; 1/2-13 x 2
1
ARM, boom assembly
1
15Y045 PIN, pivot, arm, boom
2
122633 COLLAR, 1.125 clamp 1pc
1
122653 CYLINDER, air, with nut
1
122640 BEARING, bronze,1/2 x 3/4 x 1/2
1
122652 ROD, clevis, w/pin
2
122646 BEARING, flange,1/2 x 3/4, bronze
2
122635 COLLAR, 1/2 clamp 1pc
1
122637 PIN, clevis,1/2 x 3-1/2,sst
1
15Y065 BUSHING, 1/2 x 1/4 npt, mf, ss, 6k,
316
1
15Y064 FITTING, plug, 1/4 npt, modified
2
116654 FITTING, tube, swivel, male elbow
1
122648 MUFFLER, 1/2 npt
1
122638 BOLT, EYE, 0.38-16 x 4-1/4
1
100133 WASHER, lock
6
100731 WASHER
3
100054 FITTING, lubtn, st
1
122650 VALVE, solenoid, 4way 3pos w/lvr
1
517449 MUFFLER, sintered, 1/4/ npt
1
121643 FITTING, elbow,1/4 x 1/4 npt,
swivel, ext
2
100721 PLUG, pipe
1
103893 ELBOW, street
1
122651 VALVE, bleed nmf 20 10 sk
3
15B588 SCREW, socket hd cap; 1/4-20 x
1.5
3
100015 NUT, hex mscr
3
100016 WASHER, lock
12
54106 TUBE, plyeth 0.375 OD
7
54118 TUBE, polyethylene
2
U70068 LABEL, stripe, 2in.,yellow/black

3A0238P

51

Parts

Hose Kits
L-Head Hose Kit Shown
413 1 3
413 1 3

416
417

409 2

414 1 3

408
407
406

403

5

402

2 412
401

416

404

406
405

410

411

4
421
423 7

15 401

401 13

14 401

401 12

403 9

11 402

424 6
422

10 402

403 8
r_24d628_3a0238_1h

1 Wrap bundle of hose with electrical tape every 2 ft.
2 Torque to 6 ft-lbs (8 N•m).
3 Wrap electrical tape on each end of scuff guard (413, 414, and
420)

10 Connect to A side supply fitting on applicator.
11 Connect to A side return fitting on applicator.
12 Connect material open hose to B2 connection marked on
mixhead housing adapter (224).

4 Connect to B (blue) side on system manifold.
5 Connect to A (red) side on system manifold.
6 Connect to B (blue) side tank stand.
7 Connect to A (red) side tank stand.
8 Connect to B side supply fitting on applicator.
9 Connect to B side return fitting on applicator.

52

13 Connect material close hose to A2 connection marked on
mixhead housing adapter (224).

14 Connect clean-out open hose to B1 connection marked on
mixhead housing adapter (224).

15 Connect clean-out close hose to A1 connection marked on
mixhead housing adapter (224).
16. Torque all screws on hydraulic and material hose clamps to 6
ft-lbs (8 N•m).

3A0238P

Parts

Hose Kits

Ref
401✿

Part
24A524

402

262193

403

262194

404
405
406
407
408
409
410
411
412
413‡
414‡
416
417
418✖✿

123896
123897
122643
122644
122645
107218
123100
123070
104594

122642
122641
24D002
123660

419✖✿

24D004

420‡
421

262191

422

262192

423

123106

424

123107

425✖

124527

426✖

124528

Description
HOSE, assy, hydraulic, 3/8, 20 ft (6
m); JIC 8; 4000 psi
HOSE, A, 25 ft. (7.6 m), 1/2 in.,
moisture-lock
HOSE, B, 25 ft. (7.6 m), 1/2 in.,
moisture-lock
FITTING, swivel, JIC 8(f) x JIC 8(f)
FITTING, swivel, JIC10(f)x JIC10(f)
NUT, rail
CLAMP, hose, 3/8 in.
PLATE, cover
SCREW, cap, sch; 1/4-20 x 2.75
CLAMP, hose, boom, 7/8 in.
COVER, plate
SCREW, cap; 1/4-20 x 3.25
JACKET, scuff, 7 ft. (2.1 m)
JACKET, scuff, 15 ft. (4.5 m)
SNAP, spring, 140#, 3/8, 1/4, zinc
CHAIN, 3/16 OD
HARNESS, proximity, material dispense, L-Head, ext
HARNESS, proximity, material dispense, S-Head, ext
HARNESS, proximity, clean-out,
L-head, 20 ft. (6 m)
JACKET, scuff 25 ft. (7.6m)
HOSE, A, 10 ft. (4.6 m), 1/2 in.,
moisture-lock
HOSE, B, 10 ft (4.6 m), 1/2 in., moisture-lock
FITTING, elbow, (08) JIC x 1/2 npt;
sst
FITTING, elbow, (10) JIC x 1/2 npt;
sst
HARNESS, male, cap, jumper
HARNESS, resistor; m12(m) x
m12(f); 7.8 in. (198.12 mm)

Quantity
Boom Hose Kits
No Boom Hose Kits
L-Head
S-Head
L-Head
S-Head
4
2
4
2
2

2

2

2

2

2

2

2

2
2
40
20
20
20
20
10
20
2
2
2
1
1

2
2
20
40
20
20
20
10
20
2
2
2
1

2
2

2
2

1
1

1

1
1

1

1

1
1

1
1

1

1

1

1

1

1

1

1

1

1

1

1

1

1
1

1

✖ Not shown.
‡ Order 24E954 for replacement scuff guard. Contains
200 ft (60.9 m) of braided polyester mesh.
✿ See Hose and Cable Kits on page 54 for additional
sizes.
See manual 3A0862 for material and hydraulic hose
extensions.

3A0238P

53

Hose and Cable Kits

Hose and Cable Kits
Required for power pack modules 24F297 and 24F298.
Length
ft (m)

Compatible Applicators and Part Number
S-Head

L-Head

Qty.

Heated or Unheated A and B Material Hoses
Maximum operating pressure: 3500 psi (24 MPa, 241 bar)
10 ft (4.6 m)
See manual 3A0237 for See manual 3A0237 for
25 (7.6)
part numbers.
part numbers.
50 (15.2)
Hydraulic and Material Hose Extension Kits; see manual 3A0862
25 (7.6)
24F237
24F235
50 (15.2)
24F238
24F236

4

1
1

Hydraulic Hose Assemblies
Maximum operating pressure: 4000 psi (28 MPa, 275 bar)
20 (6)
24A524
24A524 (4)
25 (7.6)
24F257
24F257 (4)
50 (15.2)
24F258
24F258 (4)
Proximity Sensor Cable (426)
7.8 in. (198.12 mm)
124528

2 (4)
2 (4)
2 (4)
1

Termination Connector Cap (425)
NA

124527

1

Material Proximity Cable Harness
20 (6)
123660
25 (7.6)
123658
50 (15.2)
123659

24D002
24F239
24F240

1
1
1

L-Head Cleanout Proximity Cable Harness
20 (6)
25 (7.6)
50 (15.2)

24D004
24F241
24F242

1
1
1

54

3A0238P

Optional Equipment

Optional Equipment
Fluid Level Sensor 24E347

Hydraulic Pressure Gauge Kit 24C872

6°
206
515 1
503 3

502 2

514

511 1

1 513
501 1
222 2

1 516

r_257840_3a0238_24e347

512
r_257840_3a0238_24c872

1 Torque to 16 in.-lbs (1.8 N•m.
2 Connect cable (502) to (503).
3 Route and cable tie (503) with existing signal-wire bundle
and connect free end of (503) to port #3 of FCM.

1 Apply sealant to threads prior to assembly.
2 Remove plug (222) from (206).
3 Verify alignment for pump and cover clearance. Adjust
(512) angle as required.

Ref.
No.
501
502
503

Part
Description
Qty
2
C19950 SCREW, cap, sch; #4-40
1
123549 SENSOR, assy, level, cap, proximity
1
121686 CABLE, m8 x m8, 4p, f x m, st x rt,
2m

3A0238P

Ref.
No.
511
512
513
514
515
516

Part
156971
108417
177021
113093
804582
C19337

Description
FITTING, nipple, short
ELBOW, female
NIPPLE, pipe, hex
CONNECTOR, pipe
GAUGE, pressure, 0-500 psi
FITTING, nipple

Qty
1
1
1
2
1
1

55

Optional Equipment

Hydraulic RTD Sensor Kit 24E348
524 4

3

523 5
522
521 1

r_257840_3a0238_24E348

1 Apply sealant to threads prior to assembly.
2 Remove plug (223) from (206).
3 Connect signal end of (523) to (524).
4 Route and cable tie (524) with existing signal-wire bundle
and connect free end of (524) to port #4 of FCM.

5 Apply a minimal amount of thermal grease to contact end
of (523).

Ref.
No.
521
522
523
524

56

Part
15T071
15T072
124262
121686

Description
Qty
1
HOUSING, temp, rtd
1
GRIP, cord, straight through
1
SENSOR, rtd, 1 kohm, 6 ft
1
CABLE, m8 x m8, 4p, f x m, st x rt,
2m

3A0238P

Optional Equipment

3A0238P

57

HARNESS
24D359

1
2

ACCUM

24D634

CLEAN-OUT

24D636

HARNESS
24D359

1
2

1
2
3
4
5

1
2
3
4
5

1
2
3
4
5

HARNESS
24D265

1
2
3
4
5

LABEL SPL 1

LABEL SPL 2

1
2
3
4
5

1
2
3
4
5
LABEL CAN 1

1
2
3
4
5

DISPENSE
RELAY

BRN

BLK

2
RED

3

6
-

BLU

A B C

D

D

D

A B C

A B C

D

A B C

1711

+
1
1710

5
+

GRD

58
4

1
2
3

1
2
3

LABEL A1

DISPENSE

125736

Optional Equipment

Electrical Schematics

230V Power Pack

3A0238P

A1

A2

SEE PAGE 2/5

125740

DISPENSE
RELAY

CR309

3130

3120

HARNESS
16K749

24D636

4

3

2

1

5

4

3

2

1

5

4

3

2

1
2
3
4
4

1
2
3
4
5

M12 5 PIN
MALE

123855

PX247

123549
HYL-OIL
LO-LVL
(OPTION)

LABEL 1

SIGNAL

SIGNAL

COMMON

SIGNAL

1
2
3
4
5

1
2
3
4
5
LABEL 1

1
2
3
4
5

1
2
3
4

S-HEAD = PLUG INTO MCM #1, PORT 2B ON HFR UNIT

LABEL 3

1
2
3
4
LABEL 3

1
2
3
4

1

3

3

4

LABEL CAN 2

CONNECT WITH 123762
CABLE FROM
121807 SPLITTER

118

2

5

CAN COM 1

1
2
3
4

M8 4 PIN
FEMALE

1

01

23

2

1
2
3
4
5

M12 5 PIN
FEMALE

1

1

1
2
3
4

2

2

3

3

4

4

5

5

CAN COM 2

4

LABEL 2

1
2
3
4
5

5
4
3
2
1

LABEL 2

1
2
3
4
5

LABEL 4

1
2
3
4

1
2
3
4

5
4
3
2
1

SIGNAL

SIGNAL

COMMON

SIGNAL

SIGNAL

LABEL 4

5
4
3
2
1

15R347

RTD290

OIL TEMP

M12 5 PIN
FEMALE

HARNESS
121201

SIGNAL

EXC

M8 4 PIN
M8 4 PIN MALE
MALE

HARNESS
121686

1
2
3
4
5

HARNESS
123856
M12 5 PIN M12 5 PIN
MALE
FEMALE

LABEL 4

1
2
3
4

HARNESS
123303
HARNESS
123673
M12 5 PIN M12 5 PIN
FEMALE
MALE

LABEL 2

M12 5 PIN
MALE

M8 4 PIN
M8 4 PIN FEMALE
FEMALE

#1 FLUID CONTROL
MODULE FRONT VIEW

1
2
3
4
5

M12 5 PIN M12 5 PIN
MALE
FEMALE

HARNESS
123673

HARNESS
24C292

HARNESS
121686
M8 4 PIN
M8 4 PIN
M8 4 PIN
MALE
MALE
FEMALE

LABEL 1

M12 5 PIN
MALE
M12 5 PIN
FEMALE
SIGNAL

HARNESS
123303

L-HEAD = PLUG INTO FCM #1, PORT 1B ABOVE

LABEL 2A

1
2
3
4

M12 4 PIN M12 5 PIN
MALE
FEMALE

OTS234
123367

OIL TEMP
HI

LABEL 1C

SOL210
CLEAN OUT
RETRACT

SOL204
CLEAN OUT
EXTEND

LABEL 1B

TYPICAL

4

3

2

1

5

4

3

2

1

5

4

3

2

1

LABEL 2C

SOL211
ACCUM
CLOSE

SOL205
ACCUM
OPEN

LABEL 2A

HARNESS
M24022

HARNESS
24D004

3

C

C

2

PX249

1

B A

B A

CLEAN-OUT OPEN
PROX
(L HEAD ONLY)

LABEL 2C

123764

24D634

B A
C

1

LABEL 1A

B A

45

C

3A0238P
GND

67

200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249

Optional Equipment

230V Power Pack - 2

59

250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
317
318
319
300

60

USE WITH
L-HEAD
ONLY

LABEL 5A

1
2
3
4
5

M12 5 PIN
MALE

1561

LABEL 5A

1
2
3
4
5

X0

A2

123362

MTR_STRT

A1

123362

C_STOP

2860

2790

2651

2651

CYCLE-STOP

2650

2650

M12 5 PIN
FEMALE

HARNESS
24F075

HARNESS
24E052

LABEL 5

1
2
3
4
5
6
7
8
5

6

1
2
3
4
5

1
2
3
4
5
7

M12 5 PIN
FEMALE

1
2
3
4
5

LABEL 6

1
2
3
4
5

1
2
3
4
5

LABEL 6

SHLD

+SIG

DC COM

-SIG

M12 5 PIN
MALE
+5VDC

HARNESS
122497

M12 5 PIN
FEMALE

LABEL 6

M12 5 PIN M12 5 PIN
FEMALE
MALE

#1 FLUID CONTROL
MODULE BACK VIEW

1
2
3
4
5
6
7
8

M12 8 PIN
FEMALE

HARNESS
24C292

TYPICAL

GND

DC COM

DC COM

1561

HARNESS
24E211
DC COM

HARNESS
124527

1560

1561

1562

IF L-HEAD
ATTACH
DEVICE
SHOWN
AT LEFT

+24V DC

DC COM

164

PRESS XDUCER
PX270

Optional Equipment

230V Power Pack - 3

3A0238P

Optional Equipment

230V Power Pack - 4

A

B

P

T

B

A

B

P

T

A

B

M

3A0238P

61

HARNESS
24D359

1
2

ACCUM

24D634

CLEAN-OUT

24D636

1
2

HARNESS
24D359

1
2
3
4
5

1
2
3
4
5

LABEL SPL 2

1
2
3
4
5

1
2
3
4
5

HARNESS
24D265

1
2
3
4
5

LABEL SPL 1

1
2
3
4
5
LABEL CAN 1

1
2
3
4
5

DISPENSE
RELAY

BRN

BLK

2
3

6
-

RED

BLU

A B C

A B C

A B C

A B C

1710

+
1
1711

5
+

D

D

D

D

GRD

62
4

1
2
3

1
2
3

LABEL A1

DISPENSE

125736

Optional Equipment

400V Power Pack

3A0238P

24D636

LABEL 1C

LABEL 1A

LABEL 3

LABEL 1

1
2
3
4

1
2
3
4
5

LABEL 3

LABEL 1

1
2
3
4
5

1
2
3
4
LABEL 3

LABEL 1

1
2
3
4
5

1
2
3
4

2

3

4

3

1

LABEL CAN 2

CONNECT WITH 123762
CABLE FROM
121807 SPLITTER

1

1
2
3
4

1
2
3
4
5

5

2

2

1

1

4

2

3

3

1
2
3
4

1
2
3
4
5

4

4

5

5

LABEL 4

1
2
3
4

5
4
3
2
1

LABEL 2

1
2
3
4
5

LABEL 4

1
2
3
4

LABEL 2

5
4
3
2
1

1
2
3
4
5

1
2
3
4

LABEL 4

LABEL 2

1
2
3
4
5

5
4
3
2
1

4

3

2

1

5

4

3

2

1

5

4

3

2

LABEL 2C

24D634

B A
C

1

B A

3A0238P
C

LABEL 1B

LABEL 2A

LABEL 2C

1

2

B A

C

3

B A

C

Optional Equipment

400V Power Pack -2

63

64

USE WITH
L-HEAD

LABEL 5A

1
2
3
4
5

DISPENSE
RELAY

ATTACH
L-HEAD
DEVICE
SHOWN
AT LEFT

LABEL 2A

LABEL 5A

1
2
3
4

1
2
3
4
5

LABEL 5

1
2
3
4
5
6
7
8

1
2
3
4
5

1
2
3
4
5
6
7
8

7

5

6

1
2
3
4
5

1
2
3
4
5

LABEL 6

LABEL 6

1
2
3
4
5
1
2
3
4
5

LABEL 6

Optional Equipment

400V Power Pack -3

3A0238P

Optional Equipment

400V Power Pack -4
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375

3A0238P

LOCATED ON THE MIX HEAD
HYDRAULIC POWER PACK
CLOSED

A

B

P

T

GUN TRIGGER
DIRECTIONAL VALVE

PRESSURE
TRANSDUCER

ACCUMULATOR
60 CU. IN.
1200 PSI PRECHARGE

PRESSURE
GAUGE

ACCUMULATOR
10 CU. IN.
100 PSI PRECHARGE
ESTCODE

A
A
P
SANDWICH
CHECK VALVE
100 PSI CRACK

B

T

B

ACCUMULATOR
DIRECTIONAL VALVE

OIL OVERTEMP
SWITCH

ANTI-SHOCK
PRESSURE
RELIEF
VALVE

M

5 HP
230/400/3/50-60
1750 RPM
PUMP

HEAT
EXCHANGER

FILTER
OIL LEVEL
SENSOR

65

Dimensions

Dimensions
AC Power Pack Module
Front View

Top View

7.7 ft (2.3 m)

Side View

26 in.
(660.4 mm)

8.4 ft
(2.5 m)

See page 67 for mounting dimensions.

66

3A0238P

Dimensions

Mounting Dimensions

24 in. (609.6 mm)

AC Power Pack Stand
page 68

13 in.
(330 mm)

5 in.
(127 mm)
22 in.
(558.8 mm)

Pneumatic
Boom
page 69

14 in.
(355.6 mm)

3A0238P

67

Dimensions

AC Power Pack Stand
Front View

Side View

4.7 ft
(1.4 m)

r_24c065_3a0238_9d

26 in.
(660.4 mm)

r_24c065_3a0238_8d

19.48 in. (494.79 mm)

Top View

13 in.
(330 mm)

18 in.
(457.2 mm)

r_24c065_3a0238_10d

24 in. (609.6 mm)

68

3A0238P

Dimensions

Pneumatic Boom

Front View
Side View

8.4 ft
(2.5 m)

r_24d628_3a0238_2h
r_24d628_3a0238_3h

7.7 ft (2.3 m)

16 in.
(406.4 mm)

Mounting Dimensions
24 in.
(609.6 mm)

14 in.
(355.6 mm)

22 in. (558.8 mm)

3A0238P

69

Technical Data

Technical Data
Maximum hydraulic fluid working pressure . . . . . . . . . .

2500 psi (17 MPa, 172 bar)

Minimum hydraulic hose working pressure . . . . . . . . . .

3000 psi (21 MPa, 207 bar)

Maximum hydraulic fluid temperature . . . . . . . . . . . . . .

180°F (82°C)

Maximum ambient temperature. . . . . . . . . . . . . . . . . . .

120°F (49°C)

Hydraulic reservoir capacity . . . . . . . . . . . . . . . . . . . . .

10 gallons (38 liters)

Recommended hydraulic fluid . . . . . . . . . . . . . . . . . . . .

ISO VG Number 46 or ASTM Grade 215

Accumulator hydraulic fluid capacity . . . . . . . . . . . . . . .

1 gallon (3.8 liters)

Accumulator precharge . . . . . . . . . . . . . . . . . . . . . . . . .

1200 psi (nitrogen)

Accumulator precharge (small) . . . . . . . . . . . . . . . . . . .

150 psi (1.0 MPa, 10 bar)

Accumulator capacity (small). . . . . . . . . . . . . . . . . . . . .

10 in^3 (164 cc)

Maximum Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

415 lbs (188 kg)

Minimum cycle time . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 seconds (shot time + time between shots)

Voltage (Phase)
230V Mix Module Stand . . . . . . . . . . . . . . . . . . . . . . . .

230 (3)

400V Mix Module Stand . . . . . . . . . . . . . . . . . . . . . . . .

400 (3)

Power Pack Maximum Amperage
230V System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 A

400V System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 A

70

3A0238P

Technical Data

3A0238P

71

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.
Toll Free: 1-800-746-1334 or Fax: 330-966-3006

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.
2ULJLQDOLQVWUXFWLRQV7KLVPDQXDOFRQWDLQV(QJOLVK00$

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



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : Yes
Page Mode                       : UseOutlines
XMP Toolkit                     : 3.1-701
Copyright                       : 2010, Rev P November 2014
Marked                          : True
Job Ref                         : A141M, Z092775
Web Statement                   : 3A0238P -  AC Hydraulic Power Pack Module, Instructions-Parts, English
Keywords                        : 3A0238, 3A0238P, 3A0238EN, 3A0238EN-P, MM 3A0238, AC Hydraulic Power Pack Module, Graco HFR Metering System, HFR, VRM, HVR, Graco Metering System
Producer                        : Acrobat Distiller 10.0.0 (Windows)
Format                          : application/pdf
Title                           : 3A0238P - AC Hydraulic Power Pack Module, Instructions-Parts, English
Creator                         : Heath McCartney
Description                     : AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated applicators used with Graco HFR™ and VRM™ Metering Systems
Create Date                     : 2009:12:15 10:08:57Z
Creator Tool                    : FrameMaker 11.0
Modify Date                     : 2014:12:03 12:52:53-06:00
Metadata Date                   : 2014:12:03 12:52:53-06:00
Document ID                     : uuid:fe299d24-0abe-4f63-9105-c9146785b0d9
Instance ID                     : uuid:b4af13ef-9a8a-4d3b-a70d-59ead67acefa
Page Count                      : 72
Language                        : en
Subject                         : AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated applicators used with Graco HFR™ and VRM™ Metering Systems
Author                          : Heath McCartney

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