Graco 3A0238P Ac Hydraulic Power Pack Module Users Manual Module, Instructions Parts, English
2015-04-02
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Instructions-Parts
AC Hydraulic
Power Pack Module
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
See page 3 for model information.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
24D829 AC Hydraulic Power Pack Module Shown
r_24d829_3A0238_1f
3A0238P
EN
Related Manuals
2 3A0238P
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 Description
312753 L-Head, Operation-Maintenance
312752 S-Head, Operation-Maintenance
313536 GX-16, Operation
309582 Circulation and Return Tube Kits,
Instructions-Parts
313997 HFR, Operation
313998 HFR, Repair-Parts
313873 VRM, Operation
313874 VRM, Repair-Parts
3A0395 Stainless Steel Tank Stands, Instruc-
tions-Parts
3A0862 Hose Extension Kits, Instructions-Parts
Manual Description
Models
3A0238P 3
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).
★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 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.
Kit No. Voltage
Includes: Not included
Boom
S-Head
Hose Kits
L-Head
Hose Kits
Hydraulic
Power
Pack
L-Head
Applicators
Only
S-Head
Applicators
Only
24D829 230V ✔✔✔✔
24D830 230V ✔✔ ✔ ✔
24D834✖400V ✔✔✔✔
24D835✖400V ✔✔ ✔ ✔
24D831 230V ✔✔ ✔
24D832 230V ✔✔ ✔
24D836✖400V ✔✔ ✔
24D837✖400V ✔✔ ✔
24F297★230V ✔✔
24F298★✖ 400V ✔✔
24J912★230V ✔✔
24J913★✖ 400V ✔✔
Models
4 3A0238P
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.
Individual Applicators
L-Head
The table below lists individual model numbers and chamber inside diameters. See L-Head manual for more informa-
tion.
S-Head
The table below lists individual model numbers and
stroke lengths. See S-Head manual for more informa-
tion.
GX-16
The table below lists individual model numbers. See
GX-16 manual for more information.
Applicator Kit No. Model
Maximum Working
Pressure
psi (MPa, bar)
L-Head
24A084 20.20.6/10 3000 (21, 206)
24A085 20.20.10/14 3000 (21, 206)
24A086 20.20.13/20 3000 (21, 206)
S-Head
24A090 30100-500-4 3000 (21, 206)
24A092 30100-625-2 3000 (21, 206)
24A093 30110-625-4 3000 (21, 206)
Model
Impingement
Chamber ID
(mm)
Exiting Chamber
ID (mm)
Maximum
Working
Pressure
psi (MPa, bar) CE Approved
20.20.5/8 5 8 3000 (21, 206) ✔
20.20.6/10 6 10 3000 (21, 206)
20.20.10/14 10 14 3000 (21, 206)
20.20.13/20 13 20 3000 (21, 206)
20.20.16/25 16 25 3000 (21, 206)
Model
Stroke
(in.)
Maximum Working
Pressure
psi (MPa, bar)
30110-500-2 2.25 3000 (21, 206)
30100-500-4 4 3000 (21, 206)
30100-625-2 2.25 3000 (21, 206)
30110-625-4 4 3000 (21, 206)
Applicator Model
GX-16 24E876
24E877
24E878
24J187
24K233
24K234
Warnings
3A0238P 5
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 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 regula-
tions.
WARNINGWARNINGWARNING
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 swal-
lowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
Warnings
6 3A0238P
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 treat-
ment.
• 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 ser-
vicing 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:
• 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.
WARNINGWARNINGWARNING
WARNING
Warnings
3A0238P 7
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 prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or flu-
ids 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 com-
ponent. 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 manufac-
turer’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 Proce-
dure 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.
WARNINGWARNINGWARNING
WARNING
Warnings
8 3A0238P
Isocyanate Conditions
Material Self-ignition
Keep Components A and B
Separate
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 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 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.
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 (isocyanate) and component B (resin)
parts.
Warnings
3A0238P 9
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 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.
Component Identification
10 3A0238P
Component Identification
AC Power Pack Module
Key:
A AC Hydraulic Power Pack
B Hose Kit (includes A, B, and hydraulic hoses)
C Boom (not included with all power pack kits)
D Applicator (not included)
E GMS™Fluid Manifold (not included)
FIG. 1: Typical Installation
24D829 AC Power Pack Module shown with circulation lines
C
B
D
A
E
r_24d829_3A0238_1f
Component Identification
3A0238P 11
Hydraulic Power Pack Stand
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) pre-
charge
AJ Cleanout Directional Valve
AK Accumulator Directional Valve
AL Dispense Directional Valve
AM Applicator Adapter Housing
AN Diverter Block
AP Main Power Disconnect
AR Electronics Panel (inside stand)
AS Heat Exchanger Cover
AT Cycle Stop Button
AU Stand
AV Hydraulic Pressure Gauge
AW Return Accumulator - 150 psi (1.0 MPa, 10 bar) precharge
AX Check Valve
FIG.2
r_24C065_3a0238_1d
AF
AA
AH
AB
AD
AE, AS
AJ
AK
AL
AM
AN
AU
AG
r_24C065_3a0238_11e
AP
AT
AC
AV
AW
AX
Component Identification
12 3A0238P
Main Power Disconnect
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.
Circuit Breakers
Circuit breakers are located inside the power pack frame
stand.
FIG. 3: Main Power Disconnect
Off Position
On position
r_121148_3a0238_1a r_121148_3a0238_2a
FIG. 4: Circuit Breakers
Model Ref. No. Size Component
230V CB125 30 A Directional Valve and
heat exchanger fan
CB113 5 A Motor
400V CB125 20 A Directional valve and
heat exchanger fan
CB113 5 A Motor
r_24d427_3a0238_1c
CB125CB113
Component Identification
3A0238P 13
Fluid Control Module (FCM)
Key:
BA Fluid Control Module
BB Base
BC Module Connection Screws
BD Access Cover
BE Module Status LEDs
BF CAN Connectors
FCM Cable Connections
FIG.5
TI12337A TI12336A
BA
BE
BB
BC
BD
BF
FCM
Connections Cable
1 123673
2 123673
3 121686
4 121686
5 24E052
6 122497
CAN connector 1 123762
CAN connector 2 123856
Component Identification
14 3A0238P
Diagnostic Information
7
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
Module Status LED Signal Diagnosis Solution
Green on System is powered up -
Yellow Internal communication in progress -
Red solid FCM hardware failure Replace FCM
Red flashing fast Uploading software -
Red flashing slow Token error Remove token and upload software
token again.
Setting Zone
00
11
22
33
44
55
66
77
88
99
AA
BB
CC
DD
EE
FF
Setup
3A0238P 15
Setup
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 mount-
ing 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.1onpage10.
3. If the AC power pack has a boom (C), mount the
applicator (D) to the boom (C). Complete Installa-
tion instructions in the applicator manual.
Connect Hydraulic Hoses
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. Use caps (6) to plug A1 and B1 fittings.
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.
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).
Setup
16 3A0238P
✖Not used for S-Head and GX-16 applicators.
3. Hand tighten each fitting.
4. Tighten each fitting 1-1/2 flats past hand tight.
Connect Hydraulic Hoses to Applicator
If the AC power pack (A) has a boom (C), these connec-
tions 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.
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 mark-
ings, to the material open (MO) port on applicator.
5. Hand tighten each fitting.
6. Bleed air from the hydraulic fluid lines. See the
applicator manual for instructions.
7. Tighten each fitting 1-1/2 flats past hand tight.
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
FIG. 6: L-Head Applicator Hydraulic Housing
FIG. 7: S-Head Applicator Hydraulic Housing
B2
A2
A1
B1
B2
A2
ti17743a
FIG. 8: Hydraulic connections on L-Head
CC
CO
MO
MC
Setup
3A0238P 17
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.
FIG. 9: Hydraulic connections on S-Head
FIG. 10: Hydraulic connections on GX-16
HO
HC
TOP RIGHT
HO
HC
ti17747a
Setup
18 3A0238P
Connect Material Hoses to
System
For System With Circulation
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.
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.
5. Tighten each fitting.
For System Without Circulation
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.
3. Hand tighten each fitting.
4. Tighten each fittings 1-1/2 flats past hand tight.
NOTICE
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
FIG.11
3
421
GMS material
manifold
422
A
B
FIG. 12: Tank Stand Connections
NOTICE
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
fluid inlet
fitting r_257968_3a0238_1c
Setup
3A0238P 19
Connect Communication Cables
1. Feed end of communication cable (83) through bulk-
head of the HFR base unit.
2. Connect communication cable (83) to any open
CAN connector of a GCA cube.
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.
5. Connect the termination connector (425) to the con-
nector (121), labeled 5A. Feed the connector (425)
and cables (121, 84) into the base cube and secure.
S-Head (Includes GX-16)
1. Connect control cable (84) to the motor control mod-
ule splitter labeled “2A” found on the HFR unit.
Refer to the HFR manual for detailed locations
2. Connect the S-head proximity sensor to the electri-
cal connector found within the material hose bundle.
3. Connect the other end of the cord to the electrical
connector found near the fluid manifold on the HFR.
4. Feed the cables (121, 122, 123) into the base cube
and secure.
FIG.13
FIG.14
83
121
122
123
84
TI12337A
Setup
20 3A0238P
Connect Electrical Cord
Electrical Requirements. See Table 1.
* 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.
NOTE: Power cord is not supplied. See Table 2.
✖See 400 V Power Requirements, page 3.
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.
Installing this equipment requires access to parts
which may cause electric shock or other serious
injury if work is not performed properly. Have a quali-
fied 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)
Model
Voltage
(phase)
Full Load
Peak Amps*
System
Watts
230V 230V (3) 17 4000
400V✖400V (3) 18 3200
Table 2: Power Cord Requirements
Model Cord Requirements AWG (mm2)
230V 10 (5.3), 3 wire
400V 10 (5.3), 4 wire
FIG. 15: 230V, 3 phase shown
FIG. 16: 400V, 3 phase shown
L1 L2 L3
L1 L2 L3
N
Startup
3A0238P 21
Startup
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.
Operation
Pressure Relief Procedure
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.
3. Press in the lower solenoid of the accumulator
charging directional valve.
4. Ensure that the pressure gauge is zero psi.
5. To relieve pressure in material hoses, perform Pres-
sure Relief Procedure in HFR manual 313997.
Shutdown
1. Shutdown HFR.
2. Turn main power switch to the OFF position.
3. Turn off and lock out main power.
The hydraulic power pack operates at a high pres-
sure and high voltage. Be careful during operation
and always wear the appropriate protective gear.
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splash-
ing or moving parts.
FIG.17
Maintenance
22 3A0238P
Maintenance
Schedule
Check the Accumulator Pre-Charge
Graco Charging Harness (part no. 124217) can be pur-
chased to aid in quick charging of the accumulator.
1. Turn off main power and lockout.
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
1. Check the Accumulator Pre-Charge.
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.
5. Remove the charging harness and replace the bot-
tle guard.
6. Repeat the procedure for the return accumulator
(AW, FIG. 2) with the precharge set to 150 psi
(1.0 MPa, 10 bar).
Procedure Frequency
Check Accumulator Pre-Charge Weekly
Check Tightness of all Clamps and
Fittings
Weekly
Check Hoses for Wear Monthly
Check Hydraulic Fluid and Filter 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, con-
tact your Graco distributor. Unauthorized use of
lesser grade oil or substitutes may void the war-
ranty.
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 sys-
tem, filters, etc. and clean or repair as needed.
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 recommenda-
tions on reservoir and filter cleaning, flushing, and
periodic changes of hydraulic fluid.
Always plug the hydraulic inlets, outlets and lines
when disconnecting them to avoid introducing dirt
and other contaminants into the system.
NOTICE
During this procedure the nitrogen bottle, the accu-
mulator, and the charging harness will all be under
significant pressure. Use dry nitrogen gas only.
Maintenance
3A0238P 23
Check Hydraulic Fluid
NOTE: Standard temperature switch cuts out at a
housing temperature of 160°F (71°C) and approxi-
mately 180°F (82°C) hydraulic fluid temperature.
Check Hydraulic Fluid Level
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.
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.
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.
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.
5. Install drain cap (87).
6. To add clean hydraulic fluid see Check Hydraulic
Fluid Level.
Replace Hydraulic Filter
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.
FIG. 18: High and Low Fluid Level Marks
246
high fluid level
low fluid level
FIG. 19: Drain Cap
NOTICE
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.
FIG. 20: Hydraulic Fluid Filter
87
245
Troubleshooting
24 3A0238P
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 con-
nectors.
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 direc-
tional 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.
Low hydraulic fluid level in oil reser-
voir.
Check hydraulic fluid level. Refill as
necessary.
Leaking hydraulic fluid around the
hydraulic filter.
Damaged or clogged filter. Replace hydraulic filter. See page
27.
Troubleshooting
3A0238P 25
Hydraulic fluid over heating. 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 reser-
voir.
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 is not dispensing from
applicator.
Material hoses are not connected. Check material hoses for damage
or leaking fittings.
Ensure material hoses are con-
nected properly. See Setup on
page 15.
Hydraulic fluid leaking around any
directional valves.
Damaged or worn o-ring. Replace o-ring. Clean o-ring sur-
faces and grooves prior to replace-
ment.
Hydraulic fluid leaking around
diverter block.
Damaged or worn o-ring. Replace o-ring. Clean o-ring sur-
faces and grooves prior to replace-
ment.
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 con-
nected properly. See Setup on
page 15.
Excessive air or foamy hydraulic oil. Pump shaft seal failure. Replace gear pump. See Remove
Hydraulic Gear Pump, page 32.
Problem Cause Solution
Troubleshooting
26 3A0238P
Applicator not cycling. (continued) Accumulator directional valve is not
charging.
Ensure accumulator charging direc-
tional 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 direc-
tional 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 direc-
tional 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.
Problem Cause Solution
Repair
3A0238P 27
Repair
Remove Hydraulic Power Pack
Shroud
1. Remove four screws from base of shroud.
2. Lift shroud off of hydraulic power pack.
Install Hydraulic Power Pack
Shroud
1. Place shroud on top of hydraulic power pack.
2. Install four screws securing shroud to hydraulic tank.
Remove Hydraulic Power Pack
1. Perform Shutdown procedure, see page 21.
2. Perform Remove Hydraulic Power Pack Shroud
procedure.
3. Disconnect all hydraulic lines from A1, A2, B1, and
B2 fittings at the applicator housing.
4. Disconnect all electrical cables connected to the
motor, directional valves, temperature switch, and
pressure transducer.
NOTICE
Do not over-torque any item that threads into the
hydraulic tank (237). 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.
FIG. 21: L-Head Applicator Hydraulic Housing
FIG. 22: S-Head Applicator Hydraulic Housing
B2
A2
A1
B1
B2
A2
ti17743a
Repair
28 3A0238P
5. Disconnect heat exchanger inlet hose (76) and fit-
ting from elbow fitting (249) on hydraulic housing
(206). Disconnect heat exchanger outlet hose (77)
and fitting from elbow fitting (248).
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.
7. Run a rope through the three eye-bolts and between
the motor and the accumulator. Secure to a hydrau-
lic lift.
8. Remove the four bolts (57) and washers (56) secur-
ing the tank to the stand.
9. Lift the hydraulic power pack (55) and place on a
sturdy location capable of supporting up to 300 lbs
(136 kg).
FIG. 23:Heat Exchanger Inlet and Outlet Hoses
FIG.24
76
206
249
248
77
206 258
258
Install third eye-bolt here
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.
56, 57
56, 57
55
Repair
3A0238P 29
Install Hydraulic Power Pack
1. Run a rope through the three eye-bolts and between
the motor and the accumulator. Secure to a hydrau-
lic 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.
6. Connect all electrical cables to the motor, three
directional valves, temperature switch, and pressure
transducer.
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.
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 dam-
aged, 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 hous-
ing, 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
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 (237). This will strip the threads and
require tank replacement.
FIG.26
239
238
206
236
237
Repair
30 3A0238P
Remove Motor
1. Shutdown the system. See Shutdown on page 21.
2. Remove Hydraulic Power Pack. See page 27.
3. Disconnect the tube assembly (15Y684) from the
accumulator (242).
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) con-
necting the motor adapter plate (203) to the hydrau-
lic housing (206).
7. Remove four hex head cap screws (244), accumula-
tor (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.
FIG.27
242
238, 239
201
264
240
247
258
257
206
237
FIG.28
201
205 203
202
213
204
206
212
Repair
3A0238P 31
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.
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.
1.68
+.00
-.01
202201
Repair
32 3A0238P
Remove Hydraulic Gear Pump
1. Shutdown the system. See Shutdown on page 21.
2. Remove Hydraulic Power Pack. See page 27.
3. Disconnect the tube assembly (247) from the accu-
mulator (242).
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).
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).
9. Loosen set screw and remove pump coupler (202).
FIG.29
242
238, 239
201
264
240
247
258
257
206
237
FIG.30
217
211
214
219 215
212
Repair
3A0238P 33
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.
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.
.07 +.00
-.01
212
211
Repair
34 3A0238P
Install FCM Upgrade Token
Note: FCM connection to system is temporarily disabled
during the installation of upgrade or key tokens.
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 soft-
ware 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 compo-
nents.
The software version history for each system can be
viewed in the technical support section at
www.graco.com.
Connect Cables
Ensure all cables are connected to FCM connectors.
See FCM Cable Connections, page 13.
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
FIG. 31: Remove Access Cover
ti12334a1
Repair
3A0238P 35
Parts
36 3A0238P
Parts
AC Hydraulic Power Pack Module
Torque all screws on hydraulic and material hose
clamps to 6 ft-lbs (8 N•m).
Torque to 113 ft-lbs (153 N•m).
1
2
1
2a
2b
A2
B2
A1
B1
BRBSASAR
See Hose Kits on page 52 for fluid line connections.
Fluid
Lines
(3) Description
Color
Identification
Hydraulic Lines
A1 Cleanout close Green/Green
A2 Material close Green
B1 Cleanout open Green/White/Green
B2 Material open Green/White
Material Lines
AR A side material return Red
AS A side material supply Red
BR B side material return Blue
BS B side material supply Blue
BS
AS
BR
AR
2c, 2d
2e
2
2
r_24d829_3A0238_1f
10
9
3
24D829 AC Hydraulic Power Pack Module Shown
Parts
3A0238P 37
▲Replacement Danger and Warning labels, tags, and
cards are available at no cost.
†All hose kits (3) include hydraulic and material lines.
See Hose Kits on 52.
Power Pack Kit and Quantity
24D829 24D830 24D831 24D832 24F297 24J912 24D834 24D835 24D836 24D837 24F298 24J913
Ref Part Description 230 V Modules 400V Modules
1 MODULE,
mixhead
stand,
230v; see
page 38
1 1 1 1 1 1
MODULE,
mixhead
stand,
400v; see
page 38
1 1 1 1 1 1
2 ARM,
boom, floor
mounted;
includes
2a-2e
1 1 1 1
2a PLATE,
mounting,
floor, mast
1 1 1 1
2b 257952 BASE,
arm, floor
mount
1 1 1 1
2c 109570 WASHER 1 1 1 1
2d 100424 SCREW,
cap, hex hd 1 1 1 1
2e ARM,
pneumatic
boom; see
page 50
1 1 1 1
3† KIT, L-head
hose, ms 1 1
KIT,
S-head
hose, ms
1 1
KIT, L-head
hose,
no clamps
1 1
KIT,
S-head
hose,
no clamps
1 1
6 123140 FITTING,
cap,
1/2 JIC, cs;
not shown
2 2 4 2 2 4
9▲15M511 LABEL,
warning 111111111111
10
▲
196548 LABEL,
caution 111111111111
Parts
38 3A0238P
Mix Module Stand
51
65
67
58
67
52
54
58
69
72
74
75
54
77
59
62
54
59
70
67
66
86
87
55
56, 57
54
54
Fill power pack (55) tank with hydraulic oil. Check after initial startup to
ensure proper fluid level.
Apply anaerobic sealant to threads and torque to 17 ft-lbs (23 N•m).
Apply anaerobic pipe sealant to adapter fitting (86) threads and thread
in to power pack (55). Do not apply anaerobic pipe sealant to cap fitting
(87) threads.
Apply anaerobic sealant to threads and torque to 10 ft-lbs (13.5 N•m).
Apply anaerobic sealant to threads and torque to 6.5 ft-lbs (8.8 N•m).
Apply lubricant to threads and torque to 21 ft-lbs (28.4 N•m).
Tie wires here.
1
2
3
4
5
6
7
71
63
70
64
76
61
1
33
6
2
2
2
6
5
2
2
7
7
Parts
3A0238P 39
230V Mix Module Stand
400V Mix Module Stand
Ref.
No. Part Description Qty
51 ENCLOSURE, frame 1
52 24D021 BRACKET, anchor, cube 4
54 111800 SCREW, cap, hex hd; 5/16-18 x
0.625
16
55 MODULE, hydraulic power, mix-
head; see page 44
1
56 U90205 WASHER, flat, 3/8, 0.41x1.25x.13,
ms
4
57 110385 SCREW, machine; hex hd; 5/16-18
x 3 in.
4
58 121160 GRIP, cord, 0.71-1.02 1
59 PANEL, mixhead, 230v 1
PANEL, mixhead, 400v 1
60 115942 NUT, hex, flange head 3
61 121171 GRIP, cord, 0.35-.63, 3/4 1
62 SWITCH, assy, disconnect, 230v 1
SWITCH, assy, disconnect, 400v 1
63 123452 HOLDER, anchor, wire tie, nylon 7
64 100166 NUT, full hex 7
65 PANEL, mixhead, assembly 1
66 123589 BUSHING, wire protector, snap-in 3
67 123398 PLUG, hole, 1-1/2 in. dia 5
68 123590 PLUG, hole, 2 in. dia 2
69 24B855 COVER, assembly; includes
69a-69c
1
69a COVER, hydraulic module 1
69b 117284 GRILL, fan guard 1
69c 103646 RIVET, blind 4
70 100020 WASHER, lock 7
71 116610 SCREW, mach, phillips, pan hd,
#10-32 x 1/2
7
72 COVER, enclosure, heat
exchanger, assy; see page 40
1
73 102795 SCREW, cap sch; #8-32 x 1.625 2
74 24C153 COVER, heat exchanger 1
75 113796 SCREW, flanged, hex hd; 1/4-20 x
3/4
4
76 24C621 HOSE, heat exchanger, inlet 1
77 15Y935 TUBE, heat exchanger, outlet 1
78 123855 HARNESS, 5 pin, adapter 1
79 122497 CABLE, cord set, reverse key 1
80 123303 HARNESS, m12 2
81 123673 HARNESS, ext, m12xm12, 5px5p,
mxf
2
82 123856 HARNESS, can cable, delete +24v 1
83 121201 CABLE, can, female-female, 6.0m 1
84 24C760 HARNESS, power, ac motor, 10ga 1
85 123764 HARNESS, m8, 4p, straight x pigtail 1
86 122970 FITTING, adapter, JIC(08) x
SAE(08), m
1
87 123140 FITTING, cap, 1/2 jic, cs 1
90 24D495 CORD, fan, heat exchanger, mix-
head
1
92 LABEL, identification, electronics 1
Parts
40 3A0238P
Heat Exchanger Assembly
801 804
806
802
807
805
Torque to 65 ft-lb.
Apply lubricant to o-rings before
assembling.
Torque to 8 ft-lb.
Torque to 2.5 ft-lb.
Apply anaerobic 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
Ref Part Description Qty
801 257967 COVER, enclosure, heat
exchanger
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 0.375 8
807 110755 WASHER, plain 4
808 100022 SCREW, cap, hex hd; 1/4-20 x
3/4
4
Parts
3A0238P 41
Parts
3A0238P 43
230V and 400V MixHead Panels
★See Electrical Schematics starting on page 58 for
wire connections.
Ref.
No. Part Description Qty
101 PANEL, electric, heat 1
102 289697 MODULE, cube, gca, base 1
103 102598 SCREW, cap, socket head; #10-32
x 1/2
4
104 289696 MODULE, gca, cube, fcm 1
105 24D207 POWER SUPPLY, 24vdc, 4A,
100w, 230vac in,
1
106 103833 SCREW, machine 11
107 MODULE, breaker, mixhead, 230v 1
MODULE, breaker, mixhead, 400v 1
108 123452 HOLDER, anchor, wire tie, nylon 3
109 100021 SCREW, cap hex hd; 1/4-20 x 1 1
110 100015 NUT, hex mscr 3
111 100028 WASHER, lock 3
112 116876 WASHER, flat 2
113 123718 FILTER, emi, 6a, spade con 1
114 121807 CONNECTOR, splitter 1
115★24D265 HARNESS, cable, can, 24vdc sup-
ply
1
116★123762 CABLE, can, 90x90, fxf, 0.5m 1
117★24E052 HARNESS, mixhead, e-stop, mtr
strt
1
118★24E211 HARNESS, mixhead, e-stop, mtr
str
1
119 114993 SCREW, pan washer hd; M4 x 0.7
x8mm
1
120 102063 WASHER, lock, ext 1
121 24F075 HARNESS, proximity, S-head 1
122 24D003 HARNESS, proximity, L-head, pig-
tail
1
Parts
44 3A0238P
MixHead Hydraulic Power Pack
See Electrical Schematics starting on page 58.
See page 46 for assembly notes.
See Hose and Cable Kits starting on page 54.
256
266
255
201
240
203
205
202
247
243
244
244
242
253
254
236
246
245
237
See page 43.
241
241
254
253
258
257
217 204
214
243
221
219
218
252
222
223
249
243
239
238
See page 43.
212
213
206
513
813
513
113
5
13
5
13
8
11
214
15
12
214
214
216
214
13
4
313
313
12
2
14
12
113
5
12
Parts
3A0238P 45
9
227
252
228
216
235
274,
232
233
231
234
225
226
226
229
230
214
214
12
14
6
16
16
16
713
914
214
15
313
224
230
15
7
13
231
210
7
209
263
228
214
L-Head Configuration
S-Head Configuration
Refer to figure above for additional
c
omponent callouts.
20
272
273
269
268
275
270,
271
Parts
46 3A0238P
1.68
+.00
-.01
.07 +.00
-.01
208
251
250
210
207
263
209
7
12
20
19
10 13
11
202
212
211
201
Assemble coupler (202, 212) to specified dimension prior to
mounting motor and pump to housing.
Torque to 40 ft-lbs (54 N•m).
Torque to 35 ft-lbs (47 N•m).
Torque to 70 ft-lbs (95 N•m).
Torque to 15 ft-lbs (20 N•m).
Torque to 185 in.-lbs (20 N•m).
Torque to 62 in.-lbs (7 N•m).
Torque to 65 in.-lbs (7.3 N•m).
Torque to 10 ft-lbs (13 N•m).
Torque to 40 in.-lbs (4.6 N•m).
Torque 1/4 turn past hand tight.
Apply PTFE tape on installation end only prior to assembly.
Apply sealant to threads prior to assembly.
Apply a light coating of lubricant to seals prior to assembly.
Tighten tubing nuts hand tight and then with a wrench. Torque
1-1/2 flats.
Directional valves are supplied with o-rings.
Route all signal cables through cable ties on the filter side of the
power pack.
Route all power wires through cable ties on the filler side of the
power pack.
Apply lubricant to contact side of thermal switch harness (250)
prior to assembly.
Install roll pin (263) into diverter block (207) for orientation to
hydraulic housing (206).
Cables and leads removed for clarity.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Parts
3A0238P 47
MixHead Hydraulic Power Module
Qty
Ref Part Description L-Head S-Head
201 122953 MOTOR, mixhead 11
202 16A954 COUPLER, motor 11
203 15Y675 PLATE, motor adapter 11
204 123338 SCREW, shc 44
205 C19852 SCREW, cap, socket head 44
206 15W772 HOUSING, hydraulic, module 11
207 16A599 BLOCK, diverter 11
208 100139 PLUG, pipe 22
209 556555 O-RING 48
210 104092 SCREW, cap, sch 48
211 122966 PUMP, gear, hydraulic 11
212 16A955 COUPLER, pump 11
213 16A956 COUPLER, spider 11
214 123942 FASTENER, screw, cap, hex hd 22
216 115597 FITTING, nipple 21
217 15Y696 TUBE, pump to manifold 11
218 101353 FITTING, nipple, pipe 11
219 122606 FITTING, elbow, male, female 11
220 100627 NIPPLE, short 11
221 127953 VALVE, relief, anti-shock 11
222 100721 PLUG, pipe 11
223 101754 PLUG, pipe 11
224 15Y629 HOUSING, adapter, mixhead 11
225 C19834 SCREW, cap, socket hd 44
226 122962 PLUG, sae 03 44
227 17B775 GAUGE, pressure, 0-5000 psi 11
228 122964 PLUG, sae 08 02
229 122970 FITTING, adapter, jic(08)xsae(08) 42
230 122967 FITTING, elbow, swivel, 90, jic(08) 53
231 16K154 BLOCK, blank 1
24D636 VALVE, cleanout, wiring, assembly 1
232 24D634 VALVE, acc loading, wiring, assembly 11
233 125736 VALVE, directional, 1 sol, 24vdc 11
234 123366 SCREW, shc 84
235✖257432 HARNESS, wire, transducer 11
236 15X622 GASKET, housing, to, tank 11
237 257162 RESERVOIR, assembly, 8 gallon 11
238 101971 WASHER, thrust 44
239 111302 SCREW, cap, hex hd 44
240 15Y680 PLATE, accumulator mounting 11
241 123293 BRACKET, accumulator mounting 22
242 122952 ACCUMULATOR, mixhead 11
243 121312 FITTING, elbow, sae x jic 33
244 110963 SCREW, cap, flange head 44
245 15J937 FILTER, oil, 18-23 psi bypass 11
246 116915 CAP, breather filler 11
247 15Y684 TUBE, manifold to accumulator 11
248 121486 FITTING, elbow, male, 1/2jicx1/2npt 11
249 123528 FITTING, elbow, swivel, 45, jic08, fm, 6k 11
Parts
48 3A0238P
▲Replacement Danger and Warning labels, tags, and
cards are available at no cost.
✖Not shown.
250 123367 HARNESS, m8 x thermal switch, 4-pin 11
251 102410 SCREW, cap soc hd 22
252 103413 PACKING, o-ring 22
253 123601 CLAMP, wire, harness, nylon, 3/4" 77
254 103833 SCREW, mach, crbh 77
255▲189285 LABEL, caution 11
256▲121208 LABEL, hot surface 11
257 257976 SUPPORT, tank to motor, ac power pack 11
258 113802 SCREW, hex hd, flanged 22
263 123786 FASTENER, pin, roll 12
266 112395 SCREW, cap 44
267✖125102 HARNESS, din18, 3p, elbow 11
268 127952 ACCUMULATOR, hydraulic 11
269 127955 FITTING, adapter 11
270 127963 MANIFOLD 11
271 127954 VALVE, check, 100 psi 11
272 123253 VALVE, needle, 1/4 NPT 11
273 156971 FITTING, nipple, short 11
274 116575 SCREW, cap 44
275 100020 WASHER, lock 44
Parts
3A0238P 49
Parts
50 3A0238P
Pneumatic Boom Arm
301
308
316
323
322
320, 321
314
309
310
305
304
305
303
326
324
319
318
317
317
311
312
313
313
315
2
Torque to 35 ft-lbs (47.5 N•m).
Hand tighten only. Do not torque.
Apply PTFE tape on installation end only prior to assembly.
1
2
3
305
306
307
327
3
2
2
307
305
2
3
3
3
1
325
336
335
334
2
2
332
333
322
338
337
330
331
328
329
1
To cylinder
To manifold
302 r_257553_3a0238_2a
Parts
3A0238P 51
Pneumatic Boom Arm
3
Ref.
No. Part Description Qty
301 24D349 BASE, boom assembly 1
302 BEARING, thrust, 45 x 65 x 14 1
303 15Y044 BEARING, support 1
304 113470 BOLT, hex 1
305 109570 WASHER, plain 10
306 100018 WASHER, lock, spring 5
307 100338 NUT, jam 5
308 POST, boom assembly 1
309 122634 COLLAR, 2.875 clamp 1pc 1
310 100096 SCREW, cap, hex hd; 1/2-13 x 2 4
311 ARM, boom assembly 1
312 15Y045 PIN, pivot, arm, boom 1
313 122633 COLLAR, 1.125 clamp 1pc 2
314 122653 CYLINDER, air, with nut 1
315 122640 BEARING, bronze,1/2 x 3/4 x 1/2 1
316 122652 ROD, clevis, w/pin 1
317 122646 BEARING, flange,1/2 x 3/4, bronze 2
318 122635 COLLAR, 1/2 clamp 1pc 2
319 122637 PIN, clevis,1/2 x 3-1/2,sst 1
320 15Y065 BUSHING, 1/2 x 1/4 npt, mf, ss, 6k,
316
1
321 15Y064 FITTING, plug, 1/4 npt, modified 1
322 116654 FITTING, tube, swivel, male elbow 2
323 122648 MUFFLER, 1/2 npt 1
324 122638 BOLT, EYE, 0.38-16 x 4-1/4 1
325 100133 WASHER, lock 1
326 100731 WASHER 6
327 100054 FITTING, lubtn, st 3
328 122650 VALVE, solenoid, 4way 3pos w/lvr 1
329 517449 MUFFLER, sintered, 1/4/ npt 1
330 121643 FITTING, elbow,1/4 x 1/4 npt,
swivel, ext
1
331 100721 PLUG, pipe 2
332 103893 ELBOW, street 1
333 122651 VALVE, bleed nmf 20 10 sk 1
334 15B588 SCREW, socket hd cap; 1/4-20 x
1.5
3
335 100015 NUT, hex mscr 3
336 100016 WASHER, lock 3
337 54106 TUBE, plyeth 0.375 OD 12
338 54118 TUBE, polyethylene 7
339 U70068 LABEL, stripe, 2in.,yellow/black 2
Parts
52 3A0238P
Hose Kits
417
416
416
413
Wrap bundle of hose with electrical tape every 2 ft.
Torque to 6 ft-lbs (8 N•m).
Wrap electrical tape on each end of scuff guard (413, 414, and
420)
Connect to B (blue) side on system manifold.
Connect to A (red) side on system manifold.
Connect to B (blue) side tank stand.
Connect to A (red) side tank stand.
Connect to B side supply fitting on applicator.
Connect to B side return fitting on applicator.
Connect to A side supply fitting on applicator.
Connect to A side return fitting on applicator.
Connect material open hose to B2 connection marked on
mixhead housing adapter (224).
Connect material close hose to A2 connection marked on
mixhead housing adapter (224).
Connect clean-out open hose to B1 connection marked on
mixhead housing adapter (224).
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).
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
414
401
403
402
405
404
413 1
1 3
3
3
L-Head Hose Kit Shown
424
423
422
421
4
5
6
7
r_24d628_3a0238_1h
401
401
401
401
403
403402
402
13
1214
15
8
9
10
11
409
408
2
406
406
412
2
410 411
407
Parts
3A0238P 53
Hose Kits
✖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.
Ref Part Description
Quantity
Boom Hose Kits No Boom Hose Kits
L-Head S-Head L-Head S-Head
401✿24A524 HOSE, assy, hydraulic, 3/8, 20 ft (6
m); JIC 8; 4000 psi
4 2 4 2
402 262193 HOSE, A, 25 ft. (7.6 m), 1/2 in.,
moisture-lock
2 2 2 2
403 262194 HOSE, B, 25 ft. (7.6 m), 1/2 in.,
moisture-lock
2 2 2 2
404 123896 FITTING, swivel, JIC 8(f) x JIC 8(f) 2 2 2 2
405 123897 FITTING, swivel, JIC10(f)x JIC10(f) 2 2 2 2
406 122643 NUT, rail 40 20
407 122644 CLAMP, hose, 3/8 in. 20 40
408 122645 PLATE, cover 20 20
409 107218 SCREW, cap, sch; 1/4-20 x 2.75 20 20
410 123100 CLAMP, hose, boom, 7/8 in. 20 20
411 123070 COVER, plate 10 10
412 104594 SCREW, cap; 1/4-20 x 3.25 20 20
413‡ JACKET, scuff, 7 ft. (2.1 m) 2 2
414‡ JACKET, scuff, 15 ft. (4.5 m) 2 2
416 122642 SNAP, spring, 140#, 3/8, 1/4, zinc 2 2
417 122641 CHAIN, 3/16 OD 1 1
418✖✿ 24D002 HARNESS, proximity, material dis-
pense, L-Head, ext
1 1
123660 HARNESS, proximity, material dis-
pense, S-Head, ext
1 1
419✖✿ 24D004 HARNESS, proximity, clean-out,
L-head, 20 ft. (6 m)
1 1
420‡ JACKET, scuff 25 ft. (7.6m) 1 1
421 262191 HOSE, A, 10 ft. (4.6 m), 1/2 in.,
moisture-lock
1 1 1 1
422 262192 HOSE, B, 10 ft (4.6 m), 1/2 in., mois-
ture-lock
1 1 1 1
423 123106 FITTING, elbow, (08) JIC x 1/2 npt;
sst
1 1 1 1
424 123107 FITTING, elbow, (10) JIC x 1/2 npt;
sst
1 1 1 1
425✖124527 HARNESS, male, cap, jumper 1 1
426✖124528 HARNESS, resistor; m12(m) x
m12(f); 7.8 in. (198.12 mm)
1 1
Hose and Cable Kits
54 3A0238P
Hose and Cable Kits
Required for power pack modules 24F297 and 24F298.
Length
ft (m)
Compatible Applicators and Part Number
Qty.S-Head L-Head
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
part numbers.
See manual 3A0237 for
part numbers. 4
25 (7.6)
50 (15.2)
Hydraulic and Material Hose Extension Kits; see manual 3A0862
25 (7.6) 24F237 24F235 1
50 (15.2) 24F238 24F236 1
Hydraulic Hose Assemblies
Maximum operating pressure: 4000 psi (28 MPa, 275 bar)
20 (6) 24A524 24A524 (4) 2 (4)
25 (7.6) 24F257 24F257 (4) 2 (4)
50 (15.2) 24F258 24F258 (4) 2 (4)
Proximity Sensor Cable (426)
7.8 in. (198.12 mm) 124528 1
Termination Connector Cap (425)
NA 124527 1
Material Proximity Cable Harness
20 (6) 123660 24D002 1
25 (7.6) 123658 24F239 1
50 (15.2) 123659 24F240 1
L-Head Cleanout Proximity Cable Harness
20 (6) 24D004 1
25 (7.6) 24F241 1
50 (15.2) 24F242 1
Optional Equipment
3A0238P 55
Optional Equipment
Fluid Level Sensor 24E347 Hydraulic Pressure Gauge Kit 24C872
Ref.
No. Part Description Qty
501 C19950 SCREW, cap, sch; #4-40 2
502 123549 SENSOR, assy, level, cap, proxim-
ity
1
503 121686 CABLE, m8 x m8, 4p,fxm,stxrt,
2m
1
503
1
501
502 2
3
Torque to 16 in.-lbs (1.8 N•m.
Connect cable (502) to (503).
Route and cable tie (503) with existing signal-wire bundle
and connect free end of (503) to port #3 of FCM.
1
2
3
r_257840_3a0238_24e347
Ref.
No. Part Description Qty
511 156971 FITTING, nipple, short 1
512 108417 ELBOW, female 1
513 177021 NIPPLE, pipe, hex 1
514 113093 CONNECTOR, pipe 2
515 804582 GAUGE, pressure, 0-500 psi 1
516 C19337 FITTING, nipple 1
515
6°
Apply sealant to threads prior to assembly.
Remove plug (222) from (206).
Verify alignment for pump and cover clearance. Adjust
(512) angle as required.
1
2
3
514
511
512
516
513 1
1
1
206
222 2
1
r_257840_3a0238_24c872
Optional Equipment
56 3A0238P
Hydraulic RTD Sensor Kit 24E348
Ref.
No. Part Description Qty
521 15T071 HOUSING, temp, rtd 1
522 15T072 GRIP, cord, straight through 1
523 124262 SENSOR, rtd, 1 kohm, 6 ft 1
524 121686 CABLE, m8 x m8, 4p,fxm,stxrt,
2m
1
Apply sealant to threads prior to assembly.
Remove plug (223) from (206).
Connect signal end of (523) to (524).
Route and cable tie (524) with existing signal-wire bundle
and connect free end of (524) to port #4 of FCM.
Apply a minimal amount of thermal grease to contact end
of (523).
1
2
3
4
5
524 4
3
521 1
522
523 5
r_257840_3a0238_24E348
Optional Equipment
3A0238P 57
Optional Equipment
58 3A0238P
Electrical Schematics
230V Power Pack
DISPENSE
321
-+
654
-+
CBA D
CBA D
CBA D
CBA D
BLUBRN
BLK RED
GRD
125736
1710
1711
DISPENSE
RELAY
LABEL A1
3
2
1
3
2
1
CLEAN-OUT
ACCUM
2
1
2
1
24D636
24D634
2
3
4
1
5
LABEL SPL 2
4
3
2
1
5
4
3
2
1
5
LABEL SPL 1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
LABEL CAN 1
HARNESS
24D265
HARNESS
24D359
HARNESS
24D359
Optional Equipment
3A0238P 59
230V Power Pack - 2
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
6
2
4
0
7
5
3
1
1
SIGNAL
SIGNAL
COMMON
SIGNAL
SIGNAL
HARNESS
123303
2
3
4
5
1
2
3
4
5
1
2
3
4
SOL205
SOL211
ACCUM
OPEN
ACCUM
CLOSE
1
2
3
4
5
SOL210
1
2
3
4
5
1
2
3
4
M12 5 PIN
MALE
HARNESS
123303
SIGNAL
SIGNAL
COMMON
SIGNAL
SIGNAL
SOL204
#1 FLUID CONTROL
MODULE FRONT VIEW
M8 4 PIN
FEMALE
CLEAN OUT
EXTEND
CLEAN OUT
RETRACT
M12 5 PIN
MALE
M8 4 PIN
FEMALE
CAN COM 1 CAN COM 2
M8 4 PIN
FEMALE
M8 4 PIN
MALE
HARNESS
121686
M12 5 PIN
FEMALE
M12 5 PIN
MALE
HARNESS
123673
M12 5 PIN
MALE
M12 5 PIN
FEMALE
HARNESS
123673
GND
HARNESS
24C292
LABEL 1
LABEL 1
LABEL 4
LABEL 1A
LABEL 1B
LABEL 2A
LABEL 2C
LABEL 1 LABEL 2
LABEL 2
LABEL 2
LABEL 3
LABEL 3
OTS234
OIL TEMP
HI
123367
LABEL 1C
123764
HARNESS
24D004
CLEAN-OUT OPEN
PROX
(L HEAD ONLY)
HARNESS
M24022
123549
HYL-OIL
LO-LVL
(OPTION)
PX247
M8 4 PIN
MALE
RTD290
M8 4 PIN
MALE OIL TEMP
EXC
SIGNAL
15R347
M8 4 PIN
FEMALE M8 4 PIN
MALE
HARNESS
121686
LABEL 4
LABEL 4
LABEL 2C
M12 5 PIN
FEMALE
M12 5 PIN
FEMALE
HARNESS
121201
M12 5 PIN
MALE
HARNESS
123856
LABEL CAN 2
CONNECT WITH 123762
CABLE FROM
121807 SPLITTER
A1 A2
125740
DISPENSE
RELAY
3120
CR309
M12 4 PIN
MALE
LABEL 2A
HARNESS
16K749
3130
TYPICAL
M12 5 PIN
FEMALE
M12 5 PIN
MALE
123855
L-HEAD = PLUG INTO FCM #1, PORT 1B ABOVE
S-HEAD = PLUG INTO MCM #1, PORT 2B ON HFR UNIT
SEE PAGE 2/5
4
3
2
1
55
4
3
2
1
12
34
4
3
2
1
4
3
2
1
M12 5 PIN
FEMALE
5
M12 5 PIN
FEMALE
5
4
3
2
1
4
3
2
1
4321543215
4
3
2
1
4
3
2
1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
CBA
CBA
CBA
PX249
CBA
312
4
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
43215
4
3
2
1
4
3
2
1
4
4
3
2
1
5
24D636 24D634
118
Optional Equipment
60 3A0238P
230V Power Pack - 3
290
299
297
295
292
260
288
286
284
282
280
278
276
274
272
270
268
264
266
262
258
256
254
252
250
291
298
294
296
293
261
289
287
285
283
281
279
277
275
273
271
269
265
267
263
259
257
255
253
251
300
301
310
308
306
303
302
309
305
307
304
311
312
319
317
317
314
313
318
316
318
315
300
USE WITH
L-HEAD
ONLY
IF L-HEAD
ATTACH
DEVICE
SHOWN
AT LEFT
#1 FLUID CONTROL
MODULE BACK VIEW
M12 8 PIN
FEMALE
M12 5 PIN
MALE
PRESS XDUCER
PX270
+5VDC
-SIG
DC COM
+SIG
SHLD
M12 5 PIN
FEMALE
M12 5 PIN
MALE
HARNESS
122497
GND
HARNESS
24C292
LABEL 6
LABEL 6
LABEL 6
HARNESS
24E052
CYCLE-STOP
X0
C_STOP
2790
2860
LABEL 5
DC COM
A1 A2
MTR_STRT
123362
123362
2650
1561
1561
HARNESS
24E211
DC COM
DC COM
DC COM 1561
+24V DC 1560
M12 5 PIN
MALE
LABEL 5ALABEL 5A
HARNESS
124527
2651
1562
2650
2651
HARNESS
24F075
TYPICAL
5 6
4
3
2
1
M12 5 PIN
FEMALE
55
4
3
2
1
7
M12 5 PIN
FEMALE
5
4
3
2
1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
8
7
6
5
4
3
2
1
8
7
6
M12 5 PIN
FEMALE
5
4
3
2
1
5
4
3
2
1
164
Optional Equipment
3A0238P 61
230V Power Pack - 4
M
B
AB
PT
AB
PT
BA
Optional Equipment
62 3A0238P
400V Power Pack
DISPENSE
321
-+
654
-+
CBA D
CBA D
CBA D
CBA D
BLUBRN
BLK RED
GRD
125736
1710
1711
DISPENSE
RELAY
LABEL A1
3
2
1
3
2
1
CLEAN-OUT
ACCUM
2
1
2
1
24D636
24D634
2
3
4
1
5
LABEL SPL 2
4
3
2
1
5
4
3
2
1
5
LABEL SPL 1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
LABEL CAN 1
HARNESS
24D265
HARNESS
24D359
HARNESS
24D359
Optional Equipment
3A0238P 63
400V Power Pack -2
1
4
3
2
1
5
2
3
4
5
1
2
3
4
5
1
2
3
4
5
4
3
2
1
1 2
3 4
4
3
2
1
4
3
2
1
55
4
3
2
1
4
3
2
1
43215 43215
4
3
2
1
4
3
2
1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
LABEL 1
LABEL 1
LABEL 4
LABEL 1A
LABEL 1B
LABEL 2A
LABEL 2C
LABEL 1 LABEL 2
LABEL 2
LABEL 2
LABEL 3
LABEL 3
LABEL 1C
CBA
CBA
CBA
CBA
312
4
3
2
1
LABEL 3
4
3
2
1
4
3
2
1
4
3
2
1
LABEL 4
LABEL 4
24D636 24D634
LABEL 2C
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
43215
LABEL CAN 2
CONNECT WITH 123762
CABLE FROM
121807 SPLITTER
Optional Equipment
64 3A0238P
400V Power Pack -3
5 6
4
3
2
1
55
4
3
2
1
7
5
4
3
2
1
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
8
7
6
LABEL 6
LABEL 6
LABEL 6
5
4
3
2
1
8
7
6
LABEL 5
5
4
3
2
1
5
4
3
2
1
USE WITH
L-HEAD
LABEL 5ALABEL 5A
AT TAC H
L-HEAD
DEVICE
SHOWN
AT LEFT
DISPENSE
RELAY
4
3
2
1
LABEL 2A
Optional Equipment
3A0238P 65
400V Power Pack -4
342
351
349
347
344
311
340
338
336
334
332
330
328
326
324
322
319
315
317
313
309
307
305
303
301
343
350
346
348
345
312
341
339
337
335
333
331
329
327
325
323
321
316
318
314
310
308
306
304
302
361
368
366
363
358
356
354
352
362
369
365
367
364
360
357
355
353
320
359
371
373
372
375
374
370
300
AB
PT
AB
AB
PT
LOCATED ON THE MIX HEAD
HYDRAULIC POWER PACK
FILTER
GUN TRIGGER
DIRECTIONAL VALVE
ANTI-SHOCK
PRESSURE
RELIEF
VALVE
PUMP
OIL OVERTEMP
SWITCH
OIL LEVEL
SENSOR
CLOSED
PRESSURE
TRANSDUCER
5 HP
230/400/3/50-60
1750 RPM
HEAT
EXCHANGER
SANDWICH
CHECK VALVE
100 PSI CRACK
ACCUMULATOR
DIRECTIONAL VALVE
PRESSURE
GAUGE ACCUMULATOR
10 CU. IN.
100 PSI PRECHARGE
ACCUMULATOR
60 CU. IN.
1200 PSI PRECHARGE
M
ESTCODE
Dimensions
68 3A0238P
AC Power Pack Stand
Front View Side View
Top View
13 in.
(330 mm)
24 in. (609.6 mm)
19.48 in. (494.79 mm)
4.7 ft
(1.4 m)
26 in.
(660.4 mm)
18 in.
(457.2 mm)
r_24c065_3a0238_9d
r_24c065_3a0238_8d
r_24c065_3a0238_10d
Dimensions
3A0238P 69
Pneumatic Boom
Front View
Side View
Mounting Dimensions
24 in.
(609.6 mm)
16 in.
(406.4 mm)
r_24d628_3a0238_2h
r_24d628_3a0238_3h
22 in. (558.8 mm)
14 in.
(355.6 mm)
7.7 ft (2.3 m)
8.4 ft
(2.5 m)
Technical Data
70 3A0238P
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 ..................... 10gallons (38 liters)
Recommended hydraulic fluid .................... ISOVGNumber 46 or ASTM Grade 215
Accumulator hydraulic fluid capacity ............... 1gallon (3.8 liters)
Accumulator precharge ......................... 1200 psi (nitrogen)
Accumulator precharge (small) ................... 150 psi (1.0 MPa, 10 bar)
Accumulator capacity (small)..................... 10in^3 (164 cc)
Maximum Weight .............................. 415lbs(188 kg)
Minimum cycle time............................ 7seconds (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 ................................. 17A
400V System ................................. 18A
Technical Data
3A0238P 71
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.
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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.
Toll Free: 1-800-746-1334 or Fax: 330-966-3006
