Series. This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown.

Transcription

1 2525 GARDNER ROAD, BROADVIEW, IL Outside U.S G4 SERIES ELECTRIC POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - Rev. - A Date - 05/10 This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Electrical Brackets Wiring Diagrams - pg Pendants - pg. 3-4 Valve Sub-Assemblies - pg.8-9 Manifold Sub-Assemblies - pg Common Components used in all G4 Series pumps - pg. 3-4 Pump Sub-Assemblies and Sub-Components - pg. 5-7 Series G 1.5 hp 4 1,1 Kw Reservoirs - pg. 16

2 How to Identify Parts for Your Model. MODEL MATRIX Understanding our model number configurations: PUMP CLASS Sample Model #: G L M R Model Performance Series Power Consumption Valve Function Reservoir Size Description: 0 = Dump 2 = 1.5 Gal G = Gen II Pump 1 = 115 VAC 4 = 1.5 HP 1 = Dump 2 Way 3 = 2.5 Gal 2 = 2 Way Manual 5 = 5 Gal 2 = 230 VAC 3 = 3 Way Manual 6 = 10 Gal 4 = 4 Way Manual 7 = 20 Gal 5 = 2 Way Solenoid 6 = 3 Way Solenoid 7 = 4 Way Solenoid 8 = Port Block PUMP TYPE OPTION 1 Options OPTION 2 OPTION 3 C = Caster Wheel Kit D = Dig. Pressure Gauge F = Foot Switch (motor) G = Gauge (intergrated) H = Heat Exchanger L = Locking Style Manifold M = Motor Pendant O = Oil Filter P = Pressure Switch R = Roll Cage S = Foot Switch (valve) MODEL NUMBER & DATE CODE LOCATION DATE CODE COVER PLATE STAMPING LOCATION Series G 1.5 hp 4 1,1 Kw MODEL DECAL PLACEMENT 2

3 Common components used in pumps NOTE: This illustration is for reference only. The appearance of your unit may differ from the unit shown. 3

4 Common components used in pumps ITEM # DESCRIPTION 115 V. 230 V. QTY. 002 PUMP ASM. G4&G6 2 STAGE SEE PAGE RESERVOIR SEE PAGE RESERVOIR GASKET BREATHER VENT 3/8" NPT PIPE PLUG 1/2" FLUSH W/ COATING SAE #12 HEX PLUG WITH PORT HHCS 1/4-20 X.75 PLT SEALING WASHER RESERVOIR DECAL G LABEL SAFE USE ELEC BLANK DECAL 3 X MANIFOLD ASM SEE PAGE VALVE GASKET VALVE GASKET (4WAY LOCK) SHCS 3/8-16 X 2 1/4 (2WAY, 3WAY & 4WAY) SHCS 3/8-16 X 2 3/4 (LOCK 3WAY/4WAY) SHCS 3/8-16 X 1 1/4 (DUM P VALVE) VAL ADP W/ CHECK ASM HEX PIPE PLG 3/8" (DUM P, 2WAY & 3WAY) HEX PIPE PLG 3/8" W/ COAT (4 WAY) SHCS 3/8-16 X 1.75 (DUM P VALVE) VALVE ASM. SEE PAGE SHCS 3/8-16 X 3 1/2 (SOLENOID ONLY) LOCKWASHER 3/8 PLATED LOCKWASHER 3/8 PLATED (SOLENOID ONLY) ROLL PIN 1/8 X 3/8 LG (SOLENOID ONLY) RET VLV DECAL (3 WAY M ANUAL) RET VLV DECAL (4 WAY M ANUAL) RET VLV DECAL (3 WAY SOLENOID) RET VLV DECAL (4 WAY SOLENOID) MAGNET HANDLE 1.5 /2.5 GAL RESERVOIR STRAIN RELIEF 3/8 NPT(SOLENOID ONLY) DECAL OVERLAY CONTROL BOX ASM G4 PUMPS SEE PAGE MEMBRANE SWITCH (NON PENDANT PUMPS) FITTING,CORD L-TIGHT LOCKNUT 1/2 INCH SIMPLEX DECAL 5.71" x 1.15" (SOL /MOTOR PENDANT) RING TERMINAL 1/4" LOCKNUT 3/8 NPT (SOLENOID ONLY) PENDANT ASSEMBLY (SOLENOID & MOTOR) WIRE NUT TAN COIL WITH DIN CONN (SOLENOID ONLY) MOLD DIN CONN W/ CORD (SOLENOID ONLY) SIGHT GAUGE MEMBRANE SWITCH LABEL * * DECAL PENDANT INSTRUCTION * * SIMPLEX DECAL 1.25" x 0.25" * * HEX NUT 5/16-18 ZINC PLTD Y Y LOCKWASHER 5/ GASKET-MOTOR PUMP GASKET G COVER PLATE G PIN,DOWEL 3/16 1" LONG SHCS 3/8-16 X 3/4 LG MOTOR 1 1/2 HP DS DS FHCS 1/4-28 x 0.50 LONG MOTOR STANDOFF * G SERIES PENDANT DECAL KIT

5 Pump Sub Assembly (46632) PUMP SUB ASM. 5

6 Pump Sub Assembly (46632) PUMP SUB ASM. ITEM # DESCRIPTION PART # QTY. 001 PUMP BODY G BEARING ROLLER 5/8x13/16x5/8 WIDE THRUST BEARING THRUST WASHER ECCENTRIC SHAFT ASSEMBLY 7/8" SEE PAGE THRUST BEARING THRUST WASHER ECCENTRIC SHAFT ADAPTER G O-RING 1 7/8X2" URE RETAINING RING POW'R BUD DUMP PLUG O-RING 3/16X5/ BACKUP WASHER MALE TEE 1/8" PIPE TO 1/4" TUBE PIPE PLUG 1/4" FLUSH W/ COATING UNLOADING PISTON ASSEMBLY SEE PAGE MALE ELBOW 1/4" TUBE 1/4" PIPE BALL 1/8" G3 PISTON BLOCK TUBE OUTLET TUBE PISTON BLOCK BALL 5/16" UNLOADING SPRING ADJUSTING SCREW G O-RING 5/8X3/4 URETH PIPE PLUG FLUSH 1/16 W/ COATING PLATE-BOTTOM GEAR-SET 3/ S SHAFT-IDLER SCREEN TUBE-GUIDE SHCS 1/4-28 X 1 3/ PLATE-SCREEN MTG MALE ELBOW 1/8 PIPE SPRING ROLL PIN 1/8 X 3/4 LONG BALL STOP G GASKET 29/64 X 5/ SPRING CAP UNLOADING VALVE TUBE RETURN BEARING ROLLER 1 1/4x1 1/2x3/4 WIDE BEARING ROLLER 1/2x11/16x1/2 WIDE RING-RETAINING PIPE PLUG 1/8" FLUSH W/ COATING CART REL. VAL. ASSEMBLY SHAFT SEAL G PISTON BLOCK ASM G-SERIES 0.290" SEE PAGE SHCS 5/16-24 X

7 Sub Component Assemblies (45533) PISTON BLK ASM. ITEM # DESCRIPTION PART # QTY. 001 PISTON BLOCK G BALL 1/8" SPRING BALL STOP BALL RETAINER INTAKE SEAT GASKET 25/64X19/ PLUG PISTON BLOCK GASKET 29/64 X 5/ ADAPTER-.290 PISTON SPRING, PISTON PISTON-.290 DIA (46745) ECCEMTRIC SHAFT ASM. ITEM # DESCRIPTION PART # QTY. 001 ECCENTRIC SHAFT 7/8" ECCENTRIC RING G ROLL BEARI 1 1/8x1 3/8x3/4 WIDE RETAINING RING EXTERNAL 1 1/8" THRUST WASHER 1 1/8" ID COAT 68026C 2.00 (43766) UNLOADING PISTON ASM. ITEM # DESCRITPION PART # QTY. 01 UNLOAD PISTON O RING 1/4X3/8 * BACK-UP WASHER TEF DOWEL PIN 1/8X3/4 LG G 5 REBUILD KIT ( * = COMPONENTS) -- PART #

8 Valve Sub Assembly (69094) 2 WAY MANUAL (69101) 4 WAY MANUAL (69691) 3 WAY MANUAL PART# ITEM # DESCRIPTION 2 WAY VAL. QTY WAY VALVE BALL VALVE STEM O-RING BACKUP WASHER SCREW VALVE HANDLE ROLL PIN SEAT - EXT RELIEF CONE - EXT RELIEF SPRING - RELIEF VALVE ACORN NUT WASHER ADJUSTING SCREW ADAPTER ASSY SPRING NS PIPE PLUG /4 SOC PIPE PLUG HEX ST. PIPE PLUG SPRING CAP LOCKWASHER Y NS = NOT SHOWN RELEIF REPLACEMENT KIT ( ++ = COMPONENTS) -- PART # ITEM # DESCRIPTION 3 WAY VAL QTY. 4 WAY VAL QTY. 01 VALVE ROTOR O-RING * 2.00 * SUBPLATE- VALVE O-RING * 1.00 * THRUST WASHER THRUST BEARING O-RING * 1.00 * UPPER VALVE BLOCK DRIVE LOK PIN O-RING * 6.00 * WASHER * 4.00 * SHEAR SEAL SPRING WASHER DETENT SPRING BALL VALVE HANDLE SCREW SCREW NS SCREW O-RING * 1.00 * SHEAR SEAL LOCKWASHER Y Y PACKING KIT 3 & 4 WAY MANUAL VALVE ( * = COMPONENTS) -- PART #

9 Valve Sub Assemblies (46285) 4 WAY SOLENOID VALVE ITEM # DESCRIPTION PART # QTY. 001 BODY-VALVE SLIDER TANDEM CENTER BALL 3/16" SET SCREW 1/4-28 X 1/4 CUP O-RING 7/32X11/ BACK UP WASHER SHEAR SEAL SPRING O-RING 2 5/8 X 2 3/ BEARING ROLLER 5/16x1/2x5/16 WIDE PIN BEARING SET SCREW 5/16-18 X 1/4 CUP SHCS #10-32 X 1" LG PLATED VALVE TOP PLATE MACHINED BALL 1/4" O-RING 3/16X5/ O-RING SAE PORT # SPRING O-RING 5/16X7/16 URE * PUSHER-SOLENOID PACKING KIT 4 WAY SOLENOID VALVE (* = COMPONENTS) -- PART #54491 * * * * 9

10 Manifold Sub Assemblies (69570) 3 WAY STANDARD PART# PART# ITEM# DESCRIPTION 3 WAY MAN. ASM QTY. ITEM# DESCRIPTION 3 WAY MAN. ASM QTY. 01 RET. VALVE MANIFOLD NS PIPE PLUG NOZZLE-VALVE PIPE PLUG-FLUSH SEAT - EXT RELIEF * O-RING CONE - EXT RELIEF * WASHER SPRING - RELIEF VALVE * ACORN NUT ADJUSTING SCREW NS = NOT SHOWN RELEIF REPLACEMENT KIT (* = COMPONENTS) -- PART # (69100) 4 WAY STANDARD PART# PART# ITEM# DESCRIPTION 4 WAY MAN. ASM QTY. ITEM# DESCRIPTION 4 WAY MAN. ASM QTY. 01 VALVE MANIFOLD SPRING - RELIEF VALVE * ADJUSTING SCREW CONE - EXT RELIEF * ACORN NUT SEAT - EXT RELIEF * WASHER PIPE PLUG RELEIF REPLACEMENT KIT (* = COMPONENTS) -- PART #

11 Manifold Sub Assemblies (68581) 4 WAY LOCKING PART # PART # ITEM # DESCRIPTION 3 WAY LOCK QTY. ITEM # DESCRIPTION 4 WAY LOCK QTY. 01 VALVE BODY LOCK VAL SPRING - RELIEF VALVE BALL CONE - EXT RELIEF RELEASE GLAND SEAT - EXT RELIEF O-RING * BU-WASHER * RELEASE SCREW ASM BALL RETAINER O-RING * O-RING BALL SPOOL-LOCK VALVE O RING * SEAT RELIEF VALVE ADJ SCREW PIPE PLUG RELEIF REPLACEMENT KIT (++ = COMPONENTS) -- PART # PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492 (69621) 3 WAY LOCKING PART# PART# ITEM# DESCRIPTION 3 WAY LOCK QTY. ITEM# DESCRIPTION 4 WAY LOCK QTY. 01 VLV BODY LOCKING GASKET-PLUG SEAT - EXT RELIEF PLUG-SPOOL CONE - EXT RELIEF BALL SPRING - RELIEF VALVE GASKET WASHER SCREW PORT ADAPTER WASHER ACORN NUT RETAINING SLEEVE NOZZLE-VALVE O RING * PIPE PLUG 3/8" BACK-UP WASHER * PIPE PLUG 1/8" O-RING * 1.00 NS 1/16 PIPE PLUG HEX ST. PIPE PLUG COMPRESSION SPRING SPOOL LOCTITE PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492 RELEIF REPLACEMENT KIT (++ = COMPONENTS) -- PART #

12 ON J1 ON J1 G4 Series Electric Control Box Assemblies (46737) Control Box 115 V IN*LBS 150 IN*LBS SIMPLEX Part # Rev. A 220/240V 110/120V AC+ COM COM SW ADV COM RET GREEN YELLOW 16 25" 6 GREEN/YELLOW " 2 MOVE SELECTOR TO 110/120V IN*LBS 3 220/240V 110/120V 17 SIMPLEX Part # Rev. A AC+ COM COM SW ADV COM RET IN*LBS IN*LBS ITEM # DESCRIPTION PART # QTY. 001 CONTROL BOX MACH G4 PUMPS PLUG AND CORD ASSY CIRCUIT BOARD BASIC FITTING,CORD L-TIGHT LOCKNUT 1/2 INCH RING TERMINAL 1/4" SHCS #10-32X1/4" LG PLATED FUSE HOLDER 30 AMP FUSE 25 AMP SHCS #6-32 x 1/4 LONG SPADE TERMINAL HOOK UP WIRE 14 GA MACHINE SCREW W/ LOCK WASHER # HHCS 5/16-18 X HEX NUT 5/16-18 ZINC PLTD Y POWER CORD 14-3 IEC 69604R

13 ON J1 ON J1 G4 Series Electric Control Box Assemblies (46738) Control Box 230 V IN*LBS 150 IN*LBS SIMPLEX Part # Rev. A 220/240V 110/120V AC+ COM COM SW ADV COM RET GREEN YELLOW 16 25" 6 GREEN/YELLOW " MOVE SELECTOR TO 220/240V IN*LBS 16 72" 3 220/240V 110/120V 17 2 SIMPLEX Part # Rev. A AC+ COM COM SW ADV COM RET IN*LBS IN*LBS ITEM # DESCRIPTION PART # QTY. 001 CONTROL BOX MACH G4 PUMPS PLUG 20 AMPS-250V CIRCUIT BOARD BASIC FITTING,CORD L-TIGHT LOCKNUT 1/2 INCH RING TERMINAL 1/4" SHCS #10-32X1/4" LG PLATED FUSE HOLDER 30 AMP FUSE 12 AMP SHCS #6-32 x 1/4 LONG SPADE TERMINAL HOOK UP WIRE 14 GA MACHINE SCREW W/ LOCK WASHER # HHCS 5/16-18 X HEX NUT 5/16-18 ZINC PLTD Y POWER CORD 14-3 IEC 69604R

14 ON ON G4 Series Electric Wire Configurations MOTOR CONTROL WIRING DIAGRAM 115V. SET DIP SWITCHES AS SHOWN ON SWITCH TO BE IN 110/120V POSITION 2,4,8 1,3,5 E.M 110/120V 220/240V SIMPLEX Part # Rev. A J1 AC+ COM COM SW ADV COM RET GREEN YELLOW ORANGE GREEN 3.5 IN*LBS GREEN/YELLOW MOTOR CONTROL WIRING DIAGRAM 230V. SET DIP SWITCHES AS SHOWN ON SWITCH TO BE IN 220/240V POSITION 4,8 1 E.M 2,3,5 110/120V 220/240V SIMPLEX Part # Rev. A J1 AC+ COM COM SW ADV COM RET GREEN YELLOW ORANGE GREEN 3.5 IN*LBS GREEN/YELLOW 14

15 ON G4 Series Electric Wire Configurations SOLENOID CONTROL WIRING DIAGRAM 115V. SOLENOID CONTROL WIRING DIAGRAM 230V. SET DIP SWITCHES AS SHOWN 3.5 IN*LBS PENDANT ON SIMPLEX Part # Rev. A SWITCH TO BE IN 220/240V POSITION J1 220/240V 110/120V AC+ COM COM SW ADV COM RET GREEN YELLOW 4,8 1 E.M ADV 2,3,5 38 RET CORD 30" LONG CUT OFF GREEN/YELLOW WIRE AT END OF INSULATION ORANGE GREEN GREEN/YELLOW CUT OFF GREEN/YELLOW WIRE AT END OF INSULATION 15

16 Reservoirs (45996P) 1.5 GALLON RESERVIOR (46213P) 2.5 GALLON RESERVIOR (46046P) 5.0 GALLON RESERVIOR (46048P) 10 GALLON RESERVIOR (DS ) 20 GALLON RESERVIOR GALLON RESERVOIR NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY. THE APPEARANCE OF YOUR UNIT MAY DIFFER FROM UNIT SHOWN. 3 ITEM # DESCRIPTION 1.5 GALLON 2.5 GALLON 5.0 GALLON 10 GALLON 20 GALLON QTY. 03 RESERVOIR 45996P 46213P 46046P 46048P DS RESERVOIR GASKET BREATHER VENT 3/8" NPT PIPE PLUG SAE #12 HEX PLUG WITH PORT HHCS 1/4-20 x 3/4 LG PLATED SEALING WASHER G4 RESERVOIR DECAL SIGHT GAUGE COVER PLATE NS PIPE COUPLING 1/4 N/A N/A N/A NS NIPPLE N/A N/A N/A NS = NOT SHOWN NOTE: ALL RESERVOIRS ARE POWDER COATED BLACK 16