PHE 2081 CONTROL FLOW LIQUID ANTI- ICE SYSTEM

Transcription

1 June, 00

2 PHE 08 CONTROL FLOW LIQUID ANTI- ICE SYSTEM

3 WELCOME TO PRAIRIE HYDRAULIC EQUIPMENT LTD. Established in 978 and conveniently located in Calgary s Foothills Industrial Park; we provide a full range of services to the hydraulic industry including repair, installation, maintenance, and fabrication. Our shop, fully equipped for machining, honing, lathe work, and a full range of testing equipment includes the following: MACHINE SHOP Lathes Milling Machine 50 Ton Press Torque Wrench can develop 00,000 foot pounds, capable of removing large piston nuts Fabrication Shop equipped with stick and mig welders HONING Capable of honing cylinders from to diameter and up to 40 feet long CYLINDERS Cylinders are disassembled and all dimensions are measured (e.g.: Cylinder ID, Piston OD, Rod OD, and Gland ID). Rods are rolled to check for straightness and all cylinders are tested after reassembly. HYDRAULIC PUMPS, MOTORS, VALVES, ETC. Equipped with a 75 horse power test bench and a lapping machine All pumps and motors are bench tested before being shipped SNOW PLOWS AND SANDERS We offer complete sales and service on a full range of VIKING plows and sanders. As well as, the PHE Accu Cast Hydraulic Systems, PHE Blade Saver Power Float System, and the PHE Control Flow Liquid Systems for winter sanding trucks. These systems are designed and built in Calgary, for Western Canadian weather conditions. PARTS DEPARTMENT Carries a variety of parts, seals, fittings, and hoses Can make 4 wire hose up to ¼ diameter Dealer for PERMCO pumps and motors, DELTA Q Axial piston pumps, WHELEN Emergency Lighting SALES DEPARTMENT Fully experienced to assist in design and fabrication SUPERIOR CUSTOMER SERVICE 4 hour Emergency Callout Service, 7 days a week Limited 0 day warranty on repairs Experienced staff with a broad base of hydraulic system experience FOR ALL OF YOUR HYDRAULIC EQUIPMENT NEEDS Please call us at Tel Direct line Fax Or prairie@prairiehydraulic.com

4 SECTION WARRANTY PRAIRIE HYDRAULIC EQUIPMENT LTD. LIMITED WARRANTY Prairie Hydraulic Equipment Ltd. warrants electronic products of its own manufacture to be free from defects in material and workmanship for a period of two years from the date of shipment or delivery. All other parts of our own manufacture are warranted for a period of one year. This warranty does not cover damage or failure resulting from neglect, misuse, accident, lack of maintenance, improper installation, redesign of assemblies or any other cause beyond the control of Prairie Hydraulic Equipment Ltd. Warning: In the past it has been found that from time to time people have drilled holes in our control consoles for the purpose of mounting radio microphones and other such items. As a result of this we have had drill cuttings and in some cases the actual mounting screws interfering with electronic components. Actions such as the above will most certainly void the warranty. The obligation of Prairie Hydraulic Equipment Ltd. under this warranty is expressly limited to replacement or repair of parts shown to be defective by our inspection. All other damage and claims, statutory or otherwise, are expressly waived by the purchaser. Prairie Hydraulic Equipment Ltd. is not responsible for consequential damages or contingent liabilities arising out of failure of any product or component part. The defective part must be returned freight prepaid to the manufacturer within 0 days after discovery of the defect. Permission to return a part for inspection must be granted in writing by a Prairie Hydraulic Equipment Ltd. representative. A Prairie Hydraulic Equipment Ltd. warranty claim number must accompany any returned part. Prairie Hydraulic Equipment Ltd. will furnish without charge, f.o.b. our shop, a replacement for any part of Prairie Hydraulic Equipment Ltd. manufacture found to be defective within the warranty period. Prairie Hydraulic Equipment Ltd. will make final determination as to whether repair or replacement will be made. If a replacement part is supplied, it will be of equal or superior quality, but may be of more current design. Components supplied by Prairie Hydraulic Equipment Ltd. that are of other manufacture shall be subject to the warranty of the manufacturer. Labour for replacement of faulty parts, that are necessarily replaced in a shop other than at Prairie Hydraulic Equipment Ltd. and with our approval will be paid at a rate not exceeding 75% of the normal retail labour rate charged by that shop. Prairie Hydraulic Equipment Ltd. will determine the maximum amount of time that will be paid for this replacement using industry standards as a guideline. Repair work carried out by Prairie Hydraulic Equipment Ltd. will be warranted for a period not to exceed 0 days, provided such repairs are carried out in a manner recommended by Prairie Hydraulic Equipment Ltd. and NOT as a "temporary repair" or "patch job".

5 SECTION WARRANTY P.H.E. Claim number Date of Claim Date Purchased ALL INFORMATION REQUESTED BELOW MUST BE SUPPLIED OR YOUR CLAIM WILL BE DENIED. PRODUCT SERIAL# MODEL # DEALER WHERE PRODUCT WAS PURCHASED (IF OTHER THAN P.H.E.) PHONE # PROBLEM REPAIR ACTION REQUIRED PARTS REQUIRED LABOUR REQUIRED HRS RETAIL LABOUR RATE $ HR FOR P.H.E. USE ONLY P.H.E. APPROVAL DATE PARTS REQUIRED LABOUR $ PER HR. (75% OF RETAIL LABOUR RATE) PARTS MAIL OR FAX TO: PRAIRIE HYDRAULIC EQUIPMENT LTD STREET. SE CALGARY ALBERTA TC 4A6 TELEPHONE TOLL FREE FAX

6 SECTION INTRODUCTION INSTALLATION INSTRUCTIONS PHE 080 CONTROL-FLOW ANTI-ICE SYSTEM Congratulations on your purchase of the PHE 080 anti-ice system. To begin installation you should first unpack all shipping cartons to familiarize yourself with the various components and to ensure that you have all of the required parts. If you have purchased a skid mounted tank and spray-bar assembly, you should now slide it into place and make sure it is securely locked into position. The spray bar is normally shipped by mounting it upside down in the skid. This can now be removed, turned over and replaced in the proper orientation. Route the electrical cable from the skid to the rear of the cab in such a manner that it is protected from damage. Surplus cable can be coiled neatly and tied to the front of the skid. You will have to supply a pedestal or post in the cab with a flat plate on the top that is oriented at the right angle and direction for the console to sit on. Locate and route the supplied cables from the console to the rear of the cab and to the volt battery + pos. and neg. terminals as per the tags on the pigtails at the ends of the cables. A hole will have to be drilled in the rear of the cab to accommodate the panel mount CPC connector on the main cable. The temperature sensor should be routed to the drivers side mirror bracket. The speed signal can generally be picked up at the transmission sensor, when it is hooked up properly you should have a speed reading on the PHE 080 console that is reliable through the full speed range. If you have problems obtaining a good speedometer signal, contact Prairie Hydraulic Equipment Ltd. For help. If you are using our Hypro centrifugal pump for your liquid pump you will have to route hoses (min. ½ ) from your 5 GPM Hydraulic circuit to the pump motor at the back of the skid. You will probably want quick couplers in these lines. If you are installing the PHE 080 on a flusher truck unit there will be a lot of work required to connect the valves and flow meter to the existing plumbing you may want to consider having this done by Prairie Hydraulic Equipment Ltd. in our shop. Partially fill the liquid tank with water for testing. Open the ball valves on the suction and re-circulation lines Start the truck engine and turn on the PTO if necessary and ensure that the pump is circulating water properly. Carefully read and follow the instructions under flow calibration in the programming manual. This completes the installation of the PHE 080 Control-flow Anti-ice system. If you have any problems please contact Prairie Hydraulic Equipment Ltd. (40) , Toll free (800) or Fax (40)

7 SECTION INTRODUCTION DEFLECTOR PRODUCT TANK AGITATION VENTURIES MANUAL BUTTERFLY VALVE RIGHT SPRAY BAR MANUAL BUTTERFLY VALVE OPTIONAL FILL SUCTION FLUSHER.TCW FLUSHER TRUCK ANTI-ICE ELECTRONIC FLOW METER ELECTRONIC PROPORTIONAL BUTTERFLY VALVE ELECTRONIC ON-OFF BALL VALVE SCREEN ELECTRONIC ON-OFF BALL VALVE MANUAL BUTTERFLY VALVE MANUAL BALL VALVE MANUAL BUTTERFLY VALVE CENTRIFUGAL PUMP MAIN MANIFOLD ELECTRONIC ON-OFF BALL VALVE MAIN SUCTION LEFT SPRAY BAR CENTER SPRAY BAR

8 SPEEDO PRESSURE FLOW METER CONVEYOR SPINNER BUTTERFLY DIRECTION BUTTERFLY MOTOR LEFT CENTER RIGHT SPARE WIRING DIAGRAMS 9 PIN CPC CONNECTOR REVISED //00 DISPLAY MASTER SWITCH LED LOW LIQUID LAMP VOLT 4 5 VOLT PAUSE SWITCH I/R GND V POS DISPLAY FUSE PROGRAM SWITCH V POS GROUND PROGRAM SWITCH LANE CONTROL SWITCHES PROG LANE LAMPS C LEFT CENTER RIGHT 4 5 ROTARY SWITCH RIGHT () R R R R R R R R TEMP. 4 PRESSURE SPD PHE CONTROL-FLOW 000V WIRING DIAGRAM NOTE: ALL LED RESISTORS ARE 60 OHMS C 8 4 ROTARY SWITCH LEFT () 6 PIN CPC CONNECTOR Temp probe Battery Ground Speedo Signal V Ign.

9 R R Y Y Y Y Y Y WIRING DIAGRAMS 08 Rear Box Wiring CONSOLE PLUG (9 PIN AMP) A B C D E F G H K L M N 4 REAR OF TRUCK CAB A B C D E F G H K L M N R R 87A 87A pressure flow spare right center left B-motor B-direction Flow Meter G S +5 V 5 V P. sw. + Ground Stud A B C D E F G H K L M N P R S PSI GROUND SIGNAL +5 VOLTS MOT. MOT. GROUND SIGNAL +V GROUND SIGNAL +V GROUND SIGNAL +V PRESSURE SWITCH FLOW METER FLOW CONTROL VALVE R.H. LANE CONTROL CENTER LANE CONTROL L.H. LANE CONTROL - I J I J I J

10 WIRING DIAGRAMS FLOW CONTROL MOTOR FLOW CONTROL DIRECTION LEFT CENTER RIGHT SPARE FLOW PRESSURE RETURN UNUSED R R Y Y Y Y Y Y pressure flow spare right center left B-motor B-direction Flow Meter GS+5 V 5 V FLOW CONTROL MOTOR FLOW CONTROL DIRECTION LEFT CENTER RIGHT SPARE V POS. V POS. V POS. V POS. V POS. V POS. PRESSURE SWITCH

11 WIRING DIAGRAMS 7 PIN BALL VALVES FLOW CONTROL VALVE VOLT + FLOW METER 080 LAYOUT.TCW REAR BOX BACK OF CAB 4 PIN CONSOLE 6 PIN 9 PIN V TEMP SPEED 4 PIN PANEL MOUNT 4 PIN CABLE MOUNT PHE 08 HARNESS LAYOUT PHE 4

12 WIRING DIAGRAMS ELECTRICAL TROUBLESHOOTING On page One of this section you will find a wiring diagram of the console that includes a layout of the PHE 000V board. In the lower left corner of this board you will find a row of 8 red LED s labeled as follows: Conveyor, Spinner, Butterfly direction, Butterfly motor (these control the flow control motor), Left, Center, Right and spare. Just below these you will find yellow LED s labeled Speedo, Pressure and Flow meter. At the top left of the board you will find green LED s labeled volt and 5 volt. Page of this section depicts the rear board, which is found in the gray box at the rear of the unit near the lane control valves. This board has red and 6 yellow LED s labeled Pressure, Flow, Spare, Right, Center, Left, B-motor and B-direction. Below and to the right of these are more green ones labeled V and 5V. All of the above lights are provided for the purpose of troubleshooting. If for instance nothing is working and you open the console to gain access to the main board and find that the green volt lamp is not on it would tell you that there is no power to the board. If the volt one is on but the 5 volt one is not it would indicate that there is power to the board but the 5 volt control circuit is not working. If the left lane switch is on but the left lane valve does not open you can check the left lane lamp on the main board, if it is on then the switch and main board are doing there job and sending the signal to the rear. If the rear board lamp is on then it is doing its job and sending a signal to the valve so you will have to check the valve and its wiring. If on the other hand the rear board lamp is not on you might want to check the wiring between the front and rear units. The flow lamps on both boards are sensing the pulses from the flow meter therefore if there is flow and they are not on or pulsing it may indicate a problem with the flow meter or its wiring. The lamps marked B-motor are the power to the flow control Valve and the lamps marked B-direction are for reversing the direction of the flow control valve. On some of the older valves the relays for this directional control are incorporated in the valve. These valves had wires in the harness and when the volt pos. and the volt neg. wires are energized the valve will close. When the pos. and neg. wires are energized as above and the directional wire is also fed volts the valve will open. The newer versions have only wires and the direction is changed by reversing the polarity through a pair of relays which are energized by grounding the directional circuit at pin 86 on both relays in the rear box. This relay circuit is fully described on the rear box wiring schematic on page of this section. The following charts describe the various conditions of the valves and the corresponding light and circuit conditions. 5

13 WIRING DIAGRAMS Lane control valves Condition Light Power to Motor Direction Circuit Opening On Yes Grounded Closing Off Yes Not Grounded Full Open On Yes Grounded Full Closed Off Yes Not Grounded Flow control valve Condition Motor Light Direction Light Opening Pulsing On Closing Pulsing Off Stationary Off Off The pulsing of the motor light in the above chart is an actual indication of what the valve motor is doing. In order to properly and smoothly control the valve position the motor is pulsed at a rate of once every.5 seconds for a duration of 0. second to second depending on the distance the valve must traverse. In other words, if you were to change the rate from 00 litres per lane KM to 500 litres per lane KM this would require a large valve position change and so the motor would be pulsed for second every.5 seconds or almost continually. As the valve approaches the required position the pulse duration would gradually decrease to a low of 0. second for every.5 seconds. By doing this we prevent the valve from overrunning and hunting. By using the information from these LED lamps and a little common sense almost any problem can be traced to its origin. Keep in mind that the electronics on these boards are all solid state and are probably the last thing that is going to fail. The most common failures are things like broken wires or poor grounds and burned out motors and switches. If at any time you have a problem that you can not diagnose yourself please pick up your phone and call Prairie Hydraulic Equipment Ltd. at Phone or Fax or prairie@prairiehydraulic.com 6

14 SECTION 4 COMPUTER PHE 000V ANTI-ICE PROGRAMMING MANUAL NOTE: The PHE 08 System must be calibrated before it will run properly. PROGRAM SETUP To enter the operator programming mode, set the programming key to the program position, and power the unit on. Program settings are done with the up/down switch. Left rotary switch to position 0 = clock setup. Right switch to position 0 = minutes. Right switch to position = hours. Right switch to position = day of week (Sunday=). Right switch to position = date of month. Right switch to position 4 = month. Right switch to position 5 = year. Left rotary switch to position = manual operation. This will allow manual operation of the system for test purposes. Lane switches operate lane valves. Toggle switch Up opens flow control valve / Toggle switch Down closes flow control valve. Left rotary switch to position = application rate setup. Right switch position = rate select. note: the first eight positions are adjustable from 0 to 500 l/km. The last two positions are adjustable from 000 to 5000 l/km. Left rotary switch to position = cutoff speed, i.e. the speed at which the ball valves shut off and turn back on as the truck stops and starts. NOTE: you must switch to a new position to save the setting. i.e. give the left switch a click either direction. NOTE: To load factory parameters, remove the panel switch connector (9) from the console circuit board, and place a jumper across pins 4 and 5. Place the programming switch in the program position, and power on. Watch LCD display.

15 SECTION 4 COMPUTER TRUCK SETUP Flow calibration: Note: ensure that the left lane switch is in the off position and the unit is powered off. Get the calibration number from the tag on the Flow Meter, (typical values are 680 for the 00 Gal. Flow meter and 68 for the 00 Gal. Flow meter). With the programming key in the program position, hold the up/down switch in the up position and power the unit on. Release the up/down switch. Use the up/down switch to adjust the calibration number to the above value. If after testing with a container of known capacity, your output is low or high by a given percentage, you can increase or decrease the above number by that percentage to tweak the system and test again. When calibration is complete. Turn the left lane switch on, this will save your calibration number, turn the left lane switch back off and you are done. Speed calibration: Note: ensure that the left lane switch is in the off position and the unit is powered off. With the programming key in the program position, hold the up/down switch in the down position and power the unit on. Drive the truck at 50 kph and place the left lane switch in the on position. Calibration is complete. To save program turn power off, turn program switch off, programming is complete. If you have any problems with the above programming instructions or any other Questions, please do not hesitate to call Prairie Hydraulic Equipment Ltd. (40) , or (800) Fax (40) prairie@prairiehydraulic.com

16 SECTION 5 FLOW METER Procedure To Re-Calibrate Flow Meter ) Remove Flow Motor from sprayer and flush with clean water to remove any chemicals. ) Remove flange bofts or clamp from the Flow Meter. ) Remove the turbine hub and turbine from inside Flow Meter. 4) Clean turbine and turbine hub of metal filings and any other foreign material, such as wettable powders. Confirm that the turbine blades are not worn. Hold turbine and turbine hub in your hand and spin turbine. It should spin freely with very little drag. 5) If transducer (XDCR) assembly is replaced or if turbine stud is adjusted or replaced, verify the turbine fit before reassembling. Hold turbine hub with turbine on transducer. Spin turbine by blowing on it. Tighten turbine stub until turbine stalls. Loosen turbine stud / turn. The turbine should spin freely. 6) Re-assemble Flow Meter. 7) Use a low pressure (5 psi) [4.5 kpa] jet of air thru Flow Meter in one direction and then again in opposite direction to verify that the turbine spins freely. It there is drag, loosen hex stud on the bottom of turbine hub /6 turn until the turbine spins freely. 8) It turbine spins freely, and if cables have checked out O.K., but Flow Meter is still not totaling properly, replace Flow Meter transducer. ]

17 SECTION 5 FLOW METER RFM 00 Poly Flow Meter Replacements Parts Item Description Raven Part # Outlet Housing Assembly Outlet Housing Hub Housing, Inlet O-Ring, Viton End Bearing/PC Assembly End Bearing/PC Assembly Kit x ½ Flat Hd. SS Screw PC Assembly O-Ring, Viton End bearing Assembly Retaining Clamp O- Ring, Viton RFM 00 Turbine x ½ Pan Hd. SS Screw Turbine Hub/Bearing Assembly Turbine Stud Assembly Thread Sealer (Not Shown) Mounting Bracket, RFM 00 (Not Shown) Hose Clam (Not Shown) Cable Kit (Not Shown)

18 OPTIONAL FLOW CONTROL VALVE Wiring Motor QX Stack SECTION Valves 6 KZCO FLOW ORDERING CONTROL INFORMATION VALVE Part Number Format STACK VALVES OPTIONS (Up to ) QTY Type Wiring Motor (Blank) -Poly Grey(Std.) N Nylon (Black) - QX (/4 FP) 4 - QX4 ( FP) 5 - QX5 ( ¼ FP) 6 - QX6 ( ½ FP) FC Wiring Code 0 - No FC Valve on Stack K - 50K N - 4 Shut-Off Valve Type Female NPT Outlets - -way valve 5 - -way BL ACeR 6 - -way BL V-ball Regulating valve Options available only for QX4 QHP Quick Connect Fitting A - -way valve D - -way BL ACeR V - -way BL V-ball Regulating valve Number of Shut Off s 0 to 9 X = 0 FC Motor CT 0 - No FC Q - 7 sec O - sec U - 8 sec X - 5 sec Hairpin outlet fittings must be ordered separately! Each fitting includes () O-rings. Order fitting for each outlet. Poly Propylene Fittings Nylon Fittings QHP-050 / HB QHP-050L / HB 90 QHP-075 /4" HB QHP-075L /4" HB 90 QHP-075F /4" HB FNPT QHP-00 " HB QHP-00L " HB 90 QHP-00M " HB MNPT Catalog QHN-050 / HB QHN-050L / HB 90 QHN-075 /4" HB QHN-075L /4" HB 90 QHN-075F /4" HB FNPT QHN-00 " HB QHN-00L " HB 90 QHN-00M " HB MNPT Available Motor CT Cycle VDC QX/QX4 M -.8 sec N -.5 sec O - sec P -.5 sec Q - 7 sec QX5/QX6 U - 8 sec W - sec X - 5 sec Y -.5 sec Z -.5 sec Other Options A - QHP Valve End Cap (QX, QX4) B - Blank Lid (No Dome) on Motor Case C - NC Normally CLOSED D - Dual NPT Inlet manifold End Caps E - V Clamp manifold inlet NPT F - NPT Valve End Cap G - Reversed manifold End Caps O - NO Normally OPEN R - Replacement Assembly S - Sub Assembly (not fully assembled) L - Less Mounting Brackets V - 80 º Operation X - Blank End Caps Both ends Wiring Type Codes (see Engineering section for details) A - 60A -wire w/ place male plug, ( Power, signal) - VDC B - 60B -wire w/4 place male plug, ( Power, signal) - VDC E wire Eliminator, -Power, (+) signal Port, (+) signal Port F wire, Power, signal, VDC G - 66D 4-wire, Power, (4v signal)(v signal) VDC, 4VAC/DC I wire,( Power, -relay control) VDC K - 50K -wire motor control DPDT /4 VDC N K w/ -wire Potentiometer Position Feedback sales@kzco.com inc. QX Stack Valves 59

19 QX5 & QX6 Stack Valves ¼ FP and ½ FP Stack Valves Poly Propylene and Nylon Construction SS Ball, Stem & Hardware 50 psi 70F ON OFF Relay Control Wiring.5 sec cycle time QX5 and QX6 stack valves have NPT and Clamp SECTION 6 KZCO FLOW CONTROL VALVE 600-iY QX Stack Valves 500 Series - QX5 Stack Valves are /4" FP Valves 600 Series - QX6 Stack Valves are /" FP Valves Dimension Example Part # Description A B C D E F G 500 / 600-iZ Single -way poly ON/OFF valve with manifold N500 / N600-iZ Single -way nylon ON/OFF valve with manifold / 600-iZ Double stack poly -way valves w/manifold & mounting brackets N500 / N600-iZ Double stack nylon -way valves w/manifold & mounting brackets / 600-iZ Triple stack poly -way valves w/manifold & mounting brackets N500 / N600-iZ Triple stack nylon -way valves w/manifold & mounting brackets / 600-4iZ Four stack poly -way valves w/manifold & mounting brackets N500 / N600-4iZ Four stack nylon -way valves w/manifold & mounting brackets / 600-5iZ Five stack poly -way valves w/manifold & mounting brackets N500 / N600-5iZ Five stack nylon -way valves w/manifold & mounting brackets SEE PAGE 59 IN THIS SECTION FOR OTHER CONFIGURATIONS sales@kzco.com inc Catalog

20 Parts: QX5 & QX6 & SECTION 6 KZCO FLOW CONTROL VALVE QX Stack Valves ** Parts Included in Repair Kit QX5-RKT sales@kzco.com Catalog inc. 6

21 Series 900 Hydraulically-Driven Centrifugal Pumps SECTION 7 HYPRO PUMP Installation, Operation, Repair and Parts Manual Description Hypro centrifugal pumps are designed for agricultural and industrial spraying and transfer of a variety of fluids: water, insecticides, herbicides, wettable powders, emulsifies, liquid fertilizers, etc. Polypropylene centrifugal pumps can also be used to pump acid fertilizer, calcium chloride and other highly corrosive liquids such as sulfuric and phosphoric acids. Hypro Series 900 hydraulic motordriven centrifugal pumps provide smooth performance. They can be conveniently mounted on the tractor or sprayer, becoming part of the vehicle s hydraulic system and freeing the PTO for other uses. The Hypro close coupled design reduces the mounting space required, eliminating long shafts and couplers between the pump and motor. Max. Flow Rate: gpm Max. Pressure: psi Ports:... "NPT Inlet -/ NPT Outlet Hydraulic Ports.../ NPT Inlet ½ NPT Tank

22 WARNING: DO NOT PUMP FLAMMABLE OR EXPLOSIVE FLUIDS SUCH AS GASOLINE, FUEL OIL, KEROSENE, ETC. DO NOT USE IN EXPLOSIVE ATMOSPHERES. THE PUMP SHOULD BE USED ONLY WITH LIQUIDS COMPATIBLE WITH THE PUMP COMPONENT MATERIALS. FAILURE TO TOLLOW THIS WARNING CAN RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE AND WILL VOID THE PRODUCT WARRANTY.. Do not pump at pressures higher than the maximum recommended for your system... Maximum liquid temperatures are 400 F for Series 900 centrifugal pumps.. Disconnect power before servicing. 4. Release all pressure within the system before servicing any component. General Safety Information SECTION 7 HYPRO PUMP 5. Drain all liquids from the system before servicing any component. Flush with water. 6. Secure the discharge lines before starting the pump. An unsecured line may whip, causing personal injury and/or property damage. 7. Check hose for weak or worn conditions before each use. Make certain that all connections are tightly secured. 8. Periodically inspect the pump and the system components. Perform routine maintenance as required. (see repair instructions) 9. Use only pipe, hose and fittings rated for the maximum psi rating of the pump. 0. Do not use these pumps for pumping water or other liquids for human or animal consumption. Hazardous Substance Alert Always drain and flush pump before servicing or disassembling for any reason (see instructions). Always drain and flush pumps prior to returning unit for repair. Before returning pump for service/repair, drain out all liquids and flush unit with neutralizing liquid. Then, drain the pump. Attach tag or include written notice certifying that this has been done. All L4 Models-Open Center Systems Models include Tank Port Adapter with built in Check Valve Assembly and Pressure Port Adapter. HMC & HM4C Models Only-closed Center and Small Open Center Systems Models include Tank Port Adapter with built in Check Valve Assembly and Pressure Port Adapter with three different size-metering orifices and HM4c models. Remove orifice for use with closedcenter systems. Also remove for small open center systems with a maximum flow of 8 gpm for HMC Model; 0 gpm for HM4C Model. If necessary, the pressure port adapter may be used without a metering orifice installed and any closed center system, provided the pressure differential across the hydraulic motor does not exceed 800 psi (.4Mpa). Installation Instructions continuous load. Refer to the pump Selection Guide to confirm you have the proper pump for your hydraulic system. (Turn the shaft using a deep socket wrench on the impeller nut.) If it cannot be turned, open the pump casing to look for obstructions. Clean out any corrosion built up where the casing fits over the eye of the impeller. Plumbing Hook-up Preliminary to Mounting Consult the owner s manual to determine the type and capacity of hydraulic system. Make sure the hydraulic system is recommended to operate with a To Boom Nozzles or Spray Gun

23 SECTION 7 HYPRO PUMP The Suction Line To get the full capacity from the pump, the suction line should be the same sized as the pump suction port. A smaller size line can be HMAC used to lower pump output, but the suction line MUST be at least one size larger than the discharge line. (Example: If the discharge line is ¾, use suction line) The line must be free of air leaks. Use good quality hose that cannot be collapsed by suction. Relief valves are not normally recommended to regulate spray pressure with centrifugal pumps. Strainer Installation While line strainers are recommended on the suction side for roller pumps, piston pumps and other positive displacement pumps, the recommended placement of a strainer for a centrifugal pump is on the discharge line. The will eliminate any possible restriction that the strainer could create if it were installed in the suction side. The best location in the discharge line is immediately after the pump. The alternate location is immediately after the pump. The alternate location is in the suction side if the strainer s capacity is adequate for the pump s required flow. Priming the Pump IMPORTANT: PUMP MUST NOT BE RUN DRY Before starting the pump, the suction line and pump must be filled with liquid and all discharge lines must be open. On self-priming models, only the pump chamber needs to be filled with liquid. The pump must not be run unless it is completely filled with liquid because there is a danger of damaging the mechanical seal, which depends on the liquid for its lubrication. Non self-priming models should be mounted below the level of the liquid. The suction line should slope down to the pump and be free of dips and bends. If this cannot be done, a foot valve should be installed in the end of the suction line so that the line can be completely filled with liquid before starting the pump. For best priming results, the top vent plug should be removed from the pump casing, and a vent line (/4 tubing is sufficient) should be installed running back to the top of the tank. This line prevents air lock and allows the pump to prime itself by bleeding off trapped air. The small stream of liquid that returns to the tank during operation is negligible. The discharge from this line should be positioned in the tank above the high liquid level. Self-priming models can be primed by removing the top vent plug and filling the priming chamber. The priming chamber will fill to the level of the inlet port. After use, the priming chamber should be flushed and drained to avoid chemical corrosion and damage from freezing. Drain by removing the lower drain plug. General Pump Selection Guide (Refer to Hypro 70 for more specific recommendations) Model Number Closed Center Load Sensing Flow Compensating Open Center 90-HMC 9-5 gpm 90-HMC ** 4-7 gpm 90-HMC Not recommended Not Recommended 7-4 gpm 90-HM4C All All 5-8 gpm 90-HM5C All All -8 gpm ** Alternate HM4C Controlling the Pump Flow The best way to control the flow is be incorporating two control valves in a pipe tee immediately after the strainer in the discharge line. This permits controlling agitation flow independently of the nozzle flow. In any centrifugal pump, it is the large volume of liquid, which puts load on the drive. Use only the flow needed to develop the pressure required at the boom and to maintain adequate agitation. Hydraulic motor-driven centrifugal pumps are easily adjusted to the exact flow required, as explained in the operating instructions of this manual. Hooking Up the Hydraulic Motor to the Tractor Hydraulic System Hypro Series 900HMC hydraulic motor-driven pumps can be mounted on either the tractor or sprayer. When hooking up, make sure that no dirt or liquid gets into the hydraulic motor. IMPORTANT: KEEP ALL HYDRAULIC CONNECTIONS CLEAN. Be sure to connect the hydraulic motor into the system correctly by putting the pressure line to the Pressure Port Adapter and return line to the Tank Port Adapter. The port adapters on the hydraulic motor are sized to accommodate ½ NPT fittings. For maximum performance the hydraulic lines should also be at least ½ in size. For lines longer than 8 or for the HMC models, hydraulic line size should be at least ¾ in order to reduce heat generation. The tank (OUT) port adapter with a built-in check valve assembly will guard against reverse operation allowing you to reverse oil flow to

24 SECTION 7 HYPRO PUMP operate other equipment. This adapter MUST NOT BE REMOVED. On HMC and HM4C model pumps, the pressure (IN) port adapter is two-piece assembly consisting of an open (unrestricted) adapter with a one metering orifice inserted at the factory. Two additional orifices are packed loose with the pumps (see the operations section). When using the HMC or HM4C unit on any flow compensating (load sensing) closed center system, or any small open center system with a maximum flow of 8 gpm for HMC or 0 gpm for HM4C, the metering orifice should be removed from the pressure port adapter. When using these units on flow compensated systems, connect to the motor priority circuit if your tractor has one. Standard spool valves, which are found on all tractor hydraulic systems, can cause potentially damaging high peak pressure in the hydraulic system when closed, because of abrupt shut-off of oil flow in both the supply and return lines. When shutting off the pump, move the selector to the FLOAT position to allow the centrifugal ump to come to a stop gradually. Open Center Systems All Models Adjusting Centrifugal Pump Output. Open the bypass adjustment screw ½ turns from fully closed. Turn the bypass screw in, to achieve the flow for the desired gpm and psi. NOTE: HMC and HMC motors have a bypass screw set at -½ tuns from fully closed at the factory. HMC and HIV4C have the bypass screw fully closed from the factory.. Start tractor. Leave the directional valve in the neutral position allows hydraulic oil to circulate for approximately 0 to 5 minutes or until adequately warmed.. Prime the centrifugal pumps with all valves open (See the installation instructions and system configuration diagram). 4. Close the agitation line valve and keep the control valve and the boom shut-off valve open. Note, the spray pressure. 5. Now open the agitation line valve until you have desired circulation in the tank. Recheck the spray pressure. If it is too low, close down the agitation line vale until the desired spray pressure is reached. If the spray pressure is too high, throttle the centrifugal pump by closing down the control valve. Closed Center (Pressure Compensated) HIVC and HM4C models only On a pressure compensated system the amount of oil that is allowed to flow through the hydraulic motor is regulated by a metering orifice in the pressure port adapter. Three different sizes of orifices are supplied with HMC and Hm4C model pumps to allow flexibility in the flow required for individual sprayer needs. The smallest of the orifices is installed in the port adapter at the factory. The smaller the orifice the less hydraulic oil goes through the motor, so the pump will run slower and the flow of Operation liquid pumped and spray pressure will also be less. As the hydraulic oil flow is increased (by installing a larger orifice), the amount of liquid being pumped and the spray pressure is also increased. Installing and Removing Metering Orifice. Shut off the hydraulic system.. Disconnect the line to the pressure port of the hydraulic motor.. Remove the adapter from the motor using a /6 wrench. 4. Make sure the o-ring is on the metering orifice before installing into port adapter. The orifice is removed or installed in the port adapter by tapping either in or out of the adapter. A. To remove tap the orifice out from the small end of the adapter. B. To install tap the orifice in from the large end of the adapter. The orifice is seated when a snap sound is heard. Adjusting Centrifugal Pump Output. Open the bypass adjusting screw in the hydraulic motor, three turns.. Start the tractor and allow the hydraulic oil to circulate approximately 0 to 5 minutes or until adequately warmed.. Close and lock down the bypass adjusting screw in hydraulic motor. 4. Prime the centrifugal pump with all valves open (See installation instructions and system configuration diagram). 5. Close the agitation line valve and the control valve; the boom shut off valve. 4

25 SECTION 7 HYPRO PUMP 6. With the pump running, open the control valve until pressure gauge indicates the desired spraying pressure. 7. Open the agitation line valve until sufficient agitation is observed. Then, if spray pressure drops, readjust control valve to restore to the desire pressure. 8. If a sufficient boom pressure cannot be attained the # size orifice, and repeat steps. 9. If sufficient boom pressure cannot be attained the # size orifice, install the # size orifice and repeat steps If a sufficient boom pressure still cannot be attained with the # orifices remove the orifice and repeat steps 5-7. Closed Center (Load Sensing) All Models Many tractors are being introduced with load sensing systems (also referred to as flow and pressure compensated systems which simplify system setup and eliminate many of the problems associated with using the wrong size pump motors on given hydraulic system. Usually, any of Hypro s 900HMC models may be used on this type of system, provided the hydraulic system produces sufficient oil flow for the hydraulic motor being used. (Refer to the pump selection guide.) This system maintains a constant flow of hydraulic oil for a given pressure drop. The flow is adjustable with a flow control valve installed in the hydraulic system (Such as the Tortoise/Hare control on John Deere tractors). Because this system has adjustable flow, there is no need to bypass the flow control with orifices as in a closed center pressure compensated system. Flush Pump after Use One of the most common causes for faulty pump performance is gumming or corrosion inside the pump. Flush the pump and entire system with a solution that will chemically neutralize the liquid pumped. Mix according to the manufacturer s directions. This will dissolve most residues remaining in the pump, leaving the inside of the pump clean for the next use. To Prevent Corrosion After cleaning the pump as directed above, flush it with permanent type automobile antifreeze (Prstone, Zerex, etc.) containing a rust inhibitor. Use a 50% solution that is half antifreeze and half water, or fill the pump with FLUID FILM and then drain it. A protective coating of FLUID FILM and then drain it. A protective coating of fluid FILM will remain on the inner pump surfaces. Save the excess FLUID FILM for the next application. Plug the ports to keep out air during storage. For short periods of idleness, noncorrosive liquids may be left in the pump, BUT AIR MUST KEPT OUT. Plug the ports or the seal port or the seal port connections. Adjusting Centrifugal Pump Output. Make sure the orifice from the pressure port adapter of the hydraulic motor has been removed (HMC and HM4C models only).. Close and lock down the bypass adjusting screw in the hydraulic motor.. Set the tractor hydraulic flow control valve for minimum hydraulic oil flow to remote outlet (Tortoise position). 4. Set the tractor and allow the hydraulic oil to circulate for approximately 0 to 5 minutes or until adequately warmed. 5. Prime the centrifugal pump with all valves open. (See the installation instructions and system configuration diagram). 6. Close the agitation line valve and open the control valve and the boom shut-off valve. 7. Slowly adjust the tractor hydraulic flow control valve until the desired boom pressure is attainted. 8. Open the agitation line valve until sufficient agitation is observed. Then, if spray pressure drops, readjust the tractor hydraulic flow control valve to restore to the desired pressure. 5

26 Repair Instructions SECTION 7 HYPRO PUMP Hypro Repair Tools: Tool Box # ¼ Allen Wrench # Support Bars () # *Port Brush # /6 Allen Wrench # *Brush Holder # Large Retaining Ring Pliers # *Small Retaining Ring Pliers # NOTE: In the case of severe pump seal leak, check the shaft ball bearing in the hydraulic motor for possible contamination. Shop Tools Needed Bench Vice *Arbor Press *Air or Hand Drill Small Knife Metal Pipe "dia. x 4 "high (Bearing Seating Tool) PVC Pipe ¾ dia. x 4 6 high (Seal Seating Tool) Crescent Wrench of Two Flat Screwdrivers (approx. 0 long) 9/6, 5/8 and 7/8 sockets Hammer or Rubber Mallet Small Screwdriver (recommended) Large File (optional) and 9/6 Box End Wrench of Lubricating Spray (WD-40 or LPS) Small amount of hydraulic oil cleaning solvent tank (recommended) Pump Housing Disassembly NOTE: Instructions on the page in italics describe procedures for the Series 900P Polypropylene Centrifugal Pumps, when different than the cast iron pumps.. Using a 9/6 box end wrench, remove the fourhexhead bolts holding the pump casing to the mounting flange. (If necessary, tap pump casing discharge port with rubber mallet or hammer to separate.)[using a / wrench, remove the six bolts from the front. For the two bottom bolts holding the base, you will need to hold the two nuts with another / wrench. Also remove the 5 /6 screw from the rear near the outlet port]. To remove the impeller nut, insert a large screwdriver or file (at least 0 long) into impeller vanes to prevent impeller from turning when loosening nut. Use a 5/8 socket wrench to remove the impeller nut by turning it counterclockwise. (Fig. 5) [Use 7/8 deep socket wrench to remove plastic seal nut, then 9/6 deep socket to remove metal jam nut and washer.]. Once nut [and washed] is removed, place a screwdriver on each side (as in Fig. 6) behind the impeller and pry away from the mounting flange. Remove woodruff key from the shaft. Remove o-ring from the mounting flange. Pump Seal Removal. Lightly lubricate the shaft for easier removal of the seal. Using two screwdrivers positioned opposite each other, pry the rotary portion of the seal from the shaft. (Fig. 7) Fig. 6. Using a ½ box end wrench, remove the four bolts holding the motor to the mounting flange. Remove motor. [Remove the plastic back cover flange. Knock the seal out from back with a hammer and screwdriver. Use a ¼ Allen wrench and ½ box end wrench to remove the mounting flange from the hydraulic motor.]. Using a screwdriver and hammer, tap out the stationary portion of the mechanical seal from the motor side of the mounting flange. (If the motor is not removed, the seal can be pried out with a small screwdriver. CAUTION: The seal will be damaged by removal in this manner. A new seal MUST be used when pump is reassembled.) 6

27 SECTION 7 HYPRO PUMP Clean-Up Of Pump Housing. Using a circular bottle-type wire brush with air or hand drill, clean the discharge port, suction port and the sealing areas of the o-ring on the pump casing and mounting flange. Using the port brush, clean the seal cavity in the mounting flange. [The last step should not be performed on the 900P]. After wire brush cleaning, it is recommended that the pump casing and mounting flange be further cleaned in a solvent tank to remove rust and corrosion particles. Seal Replacement/Pump Housing Reassembly. Lubricate the seal cavity in the mounting flange with, 40, LPS or equivalent. Do not lubricate the shaft.. Install the stationary portion of the mechanical seal by sliding over the shaft with the mechanical seal by sliding over the shaft with the ceramic side out. IMPORTANT: Make sure both the seal cavity and seal are clean and lubricated.. To seat the seal in the seal cavity, use a piece of ¾ PVC pipe 4 to 6 in length. Lubricate sealing surface on seal after it is seated. Do not lubricate the shaft. 4. To install the rotary portion of the mechanical seal, place it over the shaft with the carbon side facing in, and press until it bottoms out against the stationary portion. (Fig. 8) Fig. 7 Fig Install rubber gasket over shaft against rotary portion of seal. 6. Insert woodruff key into shaft key slot. Place impeller on shaft. Put impeller nut on shaft end, using a large screwdriver or file in the impeller vanes for support, tighten impeller nut securely. 7. Install the o-ring on the mounting flange. Replace the o-ring if worn or damaged. 8. Place the pump casing on the mounting flange, insert and tighten the bolts. Disassembly and Repair of the Hydraulic Motor IMPORTANT: The work area as possible to prevent contamination of parts. Fig. 9 Fig. 0. Place hydraulic motor in vice (Fig. 9). Remove tank port adapter and pressure port adapter with large crescent wrench or /6 box end wrench.. Using a 9/6 box end wrench, loosen the nut on the bypass adjusting screw. 4. Using a small screwdriver, remove the bypass adjusting screw from the motor. (This will remove the screw, nut, washer and thread-seal gasket.) 5. Using a ¼ Allen wrench, remove the socket head bolts from the motor end plate. 6. If motor end plate will not lift off easily, use a small screwdriver to carefully pry apart the boss portion of the end plate and gerotor housing until free (Fig. 0). If gerotor housing will not lift off easily, carefully pry apart the boss area between the gerotor housing and the motor body. (It may be necessary to alternate sides when prying apart motor sections.) 7. Remove both parts of the gerotor, on HMC models, remove the woodruff key from the shaft. 8. ON HMC, HIVC and HM4C models, remove the roll pin from the shaft. 9. Remove the o-ring from the motor end plate and body with a flat instrument such as a knife blade. 0. Inspect motor end plate, body and gerotor housing for wear and/or gouging. If gouging has occurred in both the motor end plate and body, the motor is not repairable. If gouging has occurred in the motor end plate, body or gerotor housing, the part that is worn must be replaced.. While motor is completely disassembled, clean all parts in a solvent bath. 7

28 SECTION 7 HYPRO PUMP To Remove the Shaft Assembly From the Motor Body. Remove the slinger from the motor shaft.. Using the large retaining ring pliers, remove the retaining ring next to the ball bearing in the motor body. NOTE: If bearing is binding against the retaining ring so that it cannot easily be removed, place the motor body (threaded portion of the shaft up) and place on arbor press. Using a piece of unthreaded metal pipe ( dia x 4 high), slide over the shaft and gently press down with the arbor press just enough to relieve the pressure on the retaining ring.. Place body in position on arbor press. Threaded portion of the shaft should be inside the fixture. Press out shaft assembly with arbor press. Hydraulic Motor Shaft Disassembly and Repair. Remove large snap ring from shaft with a screwdriver. Remove thrust bearing assembly from shaft (includes the thrust bearing and two thrust bearing races) and the seal spacer.. Remove the small snap ring next to the shaft ball bearing.. To remove the bearing from the shaft, place the shafts (threaded end up) in the arbor press fixture. Place the two support bars provided in the repair kit opposite each other and between the seal on the shaft and the arbor press fixture. Using an arbor press, press the shaft through the bearing, seal spacer and seal. 4. Over the large end of the shaft, install the seal spacer, thrust bearing race, thrust bearing, second thrust bearing race and the large retaining ring. To Install Shaft Bearing. Over the threaded end of the shaft, install the spacer ring and the ball bearing. Fig. Fig. 4. Insert the shaft (threaded end down) into the arbor press fixture. Place the two support bars opposite each other and between the bearing and the fixture. Place on an arbor press and carefully press the shaft down allowing just enough room for snap ring next to the bearing to be installed. IMPORTANT: Make sure the spacer ring between the seal and bearings free floating (not binding). NOTE: Should the main needle bearings in the hydraulic motor need replacement, check other internal parts for damage and wear. To Install the Shaft Assembly in the Motor Body. Replace motor body in a vise with large end of shaft facing up.. Install the o-ring in the body.. Install the woodruff key or roll pin on the shaft. Place the inner gear of the gerotor on to the shaft making sure gerotor slot lines up with the key in the shaft. NOTE: The woodruff key can slide up behind the inner gear of the gerotor when the gear is installed. Make sure the key is visible in the slot after the gear is in place. 4. Install the outer portion of the gerotor, making sure the gerotor is centered within the o-ring grove on the body. 5. Install the gerotor housing, making sure the pins in the gerotor housing line with their respective holes in the body. 6. Lightly lubricate the area between the inner and the outer gerotor motor and the outer gerotor and gerotor housing with hydraulic oil or mineral oil. 7. For units with a motor end plate plug, remove retaining ring with small retaining ring pliers. Tap plug out from the inside of the end plate. Remove the o-ring, inspect and replace if necessary. 8. Install o-ring on the motor end plate. 9. Place end plate on gerotor housing, making sure holes in end plate line up with pins in the gerotor housing. 0. Install four socket head bolts in motor end plate and using a ¼ Allen wrench, tighten bolts in a criscross pattern to approximately 5 ft lbs of torque.. Install the thread seal gasket on the bypass adjusting screw. Put the gasket on from the slotted end and turn until four threads on the screw is showing. Install the washer and the nut. Install bypass-adjusting screw in the motor end plate. A. For closed center hydraulic systems, turn the bypass adjusting screw in until it bottoms out in the end plate. Tighten nut down with 9/6 box end wrench. B. For open center hydraulic system, turn the bypass adjusting screw in until it bottoms out in the end plate; then tun back ½ 8