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SN : 17.

1027

PT. Porter Rekayasa Unggul


Manufacturer of Engineered Transport Equipment
Jl. Gatot Subroto Km. 8 Jatake
Tangerang - Indonesia 15136
Phone : (+62-21) 591 8951
Fax : (+62-21) 591 9037
www.porterrekayasa.com

SERVICE MANUAL
& PART CATALOG
LUBE SERVICE TRUCK
HYDRAULIC SYSTEM
on VOLVO FMX 440 HP 6x6
SERVICE
MANUAL
& PARTS CATALOG

Lube Service Truck


Hydraulic System
on VOLVO FMX 440 HP 6x6
CUSTOMER:
PT. MANDALA KARYA PRIMA

SN : 17.1027 www.porterrekayasa.com
PT. PORTER REKAYASA UNGGUL
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6
HEAD & WORKSHOP OFFICE : REPRESENTATIVE OFFICE :
Jl. Gatot Subroto KM. 8 Jatake Jl. Kol. Sarifudin Yoes No. 131
Tangerang, Banten - Indonesia 15136 Balikpapan - Kalimantan Timur
Phone : +62-21 - 591 8951 Phone : +62-21 - 591 8951
Fax : +62-21 - 591 9037 Fax : +62-21 - 591 9037
Website : www.porterrekayasa.com
Email : sales@porterrekayasa.com

CONTACT DETAILS
 MARKETING
 Mr. Firdaus Cell. Phone : +62 815 1952 8786

Email :
firdaus@porterrekayasa.com


sales@porterrekayasa.com

 Mr. Dony Wijaya Cell. Phone : +62 812 5242 3236

Email :
dony@porterrekayasa.com

 AFTER SALES & WARRANTY


 Mr. Joko L. Bantolo Cell. Phone : +62 812 836 4003

Email :
service@porterrekayasa.com

 SPARE PART & SERVICES


 Mr. Fajar Dwi Harsono Phone : +62 858 324 49460

+62-21 591 8951

Email : sparepart@porterrekayasa.com

Contact Details i
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

DISCLOSURE

Published by

PT. PORTER REKAYASA UNGGUL

Under Contract to

PT. MANDALA KARYA PRIMA

This manual contains proprietary information. Reproduction in whole or in part without the writ-
ten permission of PT. PORTER REKAYASA UNGGUL is expressly forbidden.

Any person and or the responsible legal body who copies or causes to have copies made will be
prosecuted to fullest extent of the law.

Copies this manual are controlled distribution to the offices listed below. Holders of the manual
are responsible for its safekeeping and in corporations of amendment as they are issued.

This book is designed for LUBE SERVICE TRUCK HYDRAULIC on VOLVO FMX 440 HP 6x6 completed
with the system attached which has following serial number :

Serial Number : 17.1027

Disclosure ii
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

INTRODUCTION

The purpose of this manual is to familiarize you


with the controls of your vehicle and to provide suf-
ficient information to enable you to perform minor
routine services necessary for continued efficient
operation. To protect your equipment, study this
manual before you start to operate the vehicle.

Every effort has been made to assure that your new


vehicle has been engineered and manufactured to
provide continued trouble-free service. Materials
selected to manufacture the many parts which
make up the vehicle exhaustive test and research
to make certain that acceptable, safe service life is
realized.

In additional, this manual is purposed to give you


good and unequivocal information for the use and
maintenance of your vehicle. We strongly advise to
store this manual in a save place in the vehicles cab-
in for later consultation.

Introduction iii
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

TABLE OF CONTENT
CONTACT DETAILS ��������������������������������������������������������������������������������������������������������������������������� i

DISCLOSURE ������������������������������������������������������������������������������������������������������������������������������������ ii

INTRODUCTION ����������������������������������������������������������������������������������������������������������������������������� iii

TABLE OF CONTENT ����������������������������������������������������������������������������������������������������������������������� iv

1. SPESIFICATION & GENERAL ARRANGEMENT DRAWING ���������������������������������������������������������� 1


1.1. Specification of Lube Service Truck ���������������������������������������������������������������������������������������������� 2
1.2. General Arrangement Drawing ������������������������������������������������������������������������������������������������������ 4

2. OPERATING INSTRUCTIONS ������������������������������������������������������������������������������������������������������ 5


2.1. Introductions ���������������������������������������������������������������������������������������������������������������������������������� 6
2.2. General Operating Procedures ������������������������������������������������������������������������������������������������������ 6
2.2.1. Pre-start Checks ������������������������������������������������������������������������������������������������������������������ 6
2.2.2. Compressor Operation ������������������������������������������������������������������������������������������������������ 6
2.2.3. Filling an Oil to Tank by Bottom Loading���������������������������������������������������������������������������� 8
2.2.4. Dispensing Oil, Coolant, and Grease ����������������������������������������������������������������������������������� 8
2.2.5. Waste Oil Operating Instuction��������������������������������������������������������������������������������������������� 9

3. MAINTENANCE SCHEDULE ������������������������������������������������������������������������������������������������������ 11


3.1. General ����������������������������������������������������������������������������������������������������������������������������������������� 12
3.2. Water Tanker System Maintenance Attention ��������������������������������������������������������������������������� 12
3.3. Maintenance Schedule Chart ����������������������������������������������������������������������������������������������������� 13

4. SCHEMATIC DIAGRAM ������������������������������������������������������������������������������������������������������������ 15


4.1. Schematic of Pneumatic System ������������������������������������������������������������������������������������������������� 16
4.2. Schematic of SAE 10 Oil Dispensing ������������������������������������������������������������������������������������������� 18
4.3. Schematic of SAE 30 Oil Dispensing ������������������������������������������������������������������������������������������� 19
4.4. Schematic of SAE 90 Oil Dispensing ������������������������������������������������������������������������������������������� 20
4.5. Schematic of 15W 40 Oil Dispensing ����������������������������������������������������������������������������������������� 21
4.6. Schematic of Coolant Dispensing ����������������������������������������������������������������������������������������������� 22
4.7. Schematic of Waste Oil Dispensing ������������������������������������������������������������������������������������������� 23
4.8. Schematic of Grease Dispensing System������������������������������������������������������������������������������������� 24
4.9. Schematic of Electric ������������������������������������������������������������������������������������������������������������������� 25

Table of Content iv
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5. PART LIST COMPONENTS �������������������������������������������������������������������������������������������������������� 28


5.1. Pneumatic System Part List ��������������������������������������������������������������������������������������������������������� 29
5.2. Hydraulic System Part List ����������������������������������������������������������������������������������������������������������� 31
5.3. Oil Dispensing System Part List ������������������������������������������������������������������������������������������������� 32
5.4. Coolant System Part List ������������������������������������������������������������������������������������������������������������� 34
5.5. Grease System Part List ������������������������������������������������������������������������������������������������������������� 35
5.6. Waste System Part List ��������������������������������������������������������������������������������������������������������������� 36
5.7. LIghting System Part List ������������������������������������������������������������������������������������������������������������� 37
5.8. Accessories Part List ������������������������������������������������������������������������������������������������������������������� 38

6. SUPPORTING PARTS MANUAL ������������������������������������������������������������������������������������������������ 39


6.1. INGERSOLL RAND ������������������������������������������������������������������������������������������������������������������������ . 40
6.2. GRACO ������������������������������������������������������������������������������������������������������������������������������������������ . 70
6.3. VICKERS �������������������������������������������������������������������������������������������������������������������������������������� . 174
6.4. MP FILTRI ��������������������������������������������������������������������������������������������������������������������������������������� 286
6.5. MACNAUGHT Flow Meter���������������������������������������������������������������������������������������������������������� . 289
6.6. RAASM 4-Way Evacuation Valve������������������������������������������������������������������������������������������������ . 301
6.7. STAUFF Oil Level & Temperature Gauge���������������������������������������������������������������������������������� . 303
6.8. SMC Air Regulator���������������������������������������������������������������������������������������������������������������������� . 316
6.9. HYDROLEDUC Main Pump �������������������������������������������������������������������������������������������������������� . 340
6.10. HYDRO CONTROL Hydro Valve 5 Bank ���������������������������������������������������������������������������������� . 351

Table of Content v
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

1
SPECIFICATION & GENERAL
ARRANGEMENT DRAWING

Specification and General Arrangement Drawing 1


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

1.1. Specification of Lube Service Truck

DIMENSION : Length : Approx. - mm

Width : Approx. - mm

Height of Sides : Approx. - mm

MODULE : SAE 10 : 2000 lt

SAE 30 : 2000 lt

SAE 40 : 2000 lt

SAE 90 : 2000 lt

COOLANT : 1000 lt

WASTE OIL : 2000 lt

GREASE POD : 500 lt

STRUCTURE

Tray Body : Heavy duty Main-runners, cross-bearers, and 6mm plate floor,
Heavy duty Cab-Rack (bulkhead), Additional Ladder to be provided

Cabinet/Compartment : Lockable and provide drainage outlet at base of cabinet, construct from
3 mm mild steel completed with lock and rubber seals

Tank : All tanks are fabricated with 6 mm steel plate, flexible mounting and a
throw-over manhole completed with vent/breather. Tank designed for
bottom filling/loading. 2 (two) sight level glass only for each tank

AIRSUPPLY

Compressor : INGERSOLL-RAND 2545 series 10 HP coupled with hydraulic vane motor


vickers 26M30

Regulator & Lubricator : Regulator Assy SMC AR40-03-A AL40-03-A Air Lubricator

OIL SYSTEM

Oil Tank s : Construct from 6 mm mild steel and fill/discharge ports are provided.
Fabricated main hole completed with vent/breather is fitted. FASTFILL
receiver fitted into base of tank for filling/bottom loading

Oil Dispensing : Vickers 25VQ-21 Hydraulic Pump


OGM A25 Flow Meter
GRACO Hose Reel XD Series 1/2” x 15m
INTEGRAL Pressure Filter Oil
COOLANT SYSTEM

Tank : Construct from 6 mm mild steel and fill/discharge ports are provided.
Fabricated mainhole completed with vent/breather is fitted. FASTFILL
receiver fitted in to base of tank for fillling/bottom loading.

Dispensing : GRACO 716 Diaphragm Pump

Hose Reel : GRACO Hose Reel XD Series 1/2” x 15m

Specification and General Arrangement Drawing 2


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

GREASE SYSTEM

Tank : Construct from 6 mm mild steel and fill/discharge ports are provided.
Fabricated main hole completed with vent/breather is fitted. FASTFILL
receiver fitted into base of tank for filling/bottom loading

Grease Pump : GRACO Fireball 425 Ratio 50:1

Hose Reel : GRACO Hose Reel XD 20 3/8” x 15m High Pressure

WASTE SYSTEM

Tank : Construct from 6 mm mild steel and fill/discharge ports are provided.
Fabricated main hole completed with vent/breather is fitted. FASTFILL
receiver fitted into base of tank for filling/bottom loading

Pump : GRACO Diaphragm Pump Waste Oil 1040

Hose Reel : GRACO Hose Reel XD Series 1” x 15m

ELECTRICAL SYSTEM

Lamp : Tray Body to be fitted with rear lamp combination, top/tail/turn light
mounted at rear of tray with repeated set of light mounted high at rear.

Strobe Lamp : 2 (two) only strobe lamp on front and rear.

Work Light : 4 (four) 24 VDC work light (2 at right hand side and 2 at left hand side)

All wiring to be conduit with junction boxed for ease maintenance.

ACCESSORIES
• Elect. safety device
• Safety top Hand Rail

PAINT

Type of Paint : PRU Standard Paint

Primer : Zinc type

Second Coat : Epoxy

Top Coat : Polyurethane type

Color : Customer Request


WARRANTY TERMS & POLICY

Equipment/structure manufactured by PT. PORTER REKAYASA UNGGUL is guaranteed for one year from
date of shipment and will rectify any fault which in the opinion of the company needs rectification by
reason of defective materials, workmanship or design.

Components such as Axles, Cylinders, Pumps, Motors, Valves and etc. that are manufactured by other
vendors will be subject to the warranty terms of those manufacturers. Also excluded from general
guarantee are normal wear items, including seals, hoses / fittings, and paint finish.

We reserve the right to modify or alter materials, dimensions, design, and construction when necessary
to improve the performance of the equipment and/or accessories, or to meet customer requirements.

We expressly disclaim any liability for damage or injuries resulting from the use, operation, service,
maintenance, or failure of equipment.

Specification and General Arrangement Drawing 3


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

1.2. General Arrangement Drawing

Specification and General Arrangement Drawing 4


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

2
OPERATING
INSTRUCTIONS

Operating Intructions 5
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

2.1. Introduction

This manual is purposed to give you good and unequivocal information for the use and maintenance of your
vehicle. We strongly advise to store this manual in a save place in the vehicles cabin for later consultation.
Before operating your vehicle it is necessary to get familiar with the use and working of this hydraulic system.
Therefore you have to read this manual carefully in order to use the system in a safe and proper way. Defects
and injuries are often related to inexpertness use and incomplete maintenance of your vehicle system inside.
We hardly stressed cannot admit any complaints and claims caused by and or to due to unskilled use,
incomplete maintenance and or inexpert repairs.
Throughout ongoing development to further improvement of our system design, it is possible that some
modifications took place on your system which is not mentioned in this manual.

If you obey the instructions in this manual, we are sure that you will have an efficient use of your system
throughout many years.

This specification describes the general features of a lube service body unit suitable for fitment to an
VOLVO FMX 440 6x6 truck cab/chassis to provide lube service to mine-site equipment. This configuration
is based around RAASM lubrication components and utilizes an INGERSOLL-RAND diesel-driven package
compressor unit to provide power for the product pumps.

2.2. General Operating Procedure

2.2.1. Pre-Start Checks


Before starting, please check the following item:

 Check wholly electrical circuit, oil dispense line and hydraulic connections are securely attached.

 Ensure the compressor and the dispensing system in normal condition.

2.2.2. Compressor Operation


After performing pre-start checks, the compressor generator may be started by:

 Make sure emergency push button release, located at the right side

 Start unit

 Step on clutch

 Press PTO button, hold 5 seconds

Picture 1. PTO button on Volvo

Operating Intructions 6
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

 Loosen the clutch slowly

 Setting RPM on 800

 Activate the solenoid for compressor

 Make sure the Ball Valve Drain is closed

 Make sure the ball valve for supply to manifold is open, located in the cabinet

 Turn the master air valve on the compressor outlet to “open” position

Picture 3. Master Air Valve

Check the air regulator in the dispenser container is set to max 10 bar (145 psi)

Picture 4. Air Regulator

Operating Intructions 7
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

2.2.3. Filling an Oil to Tank by Bottom Loading


The four oil tanks are labeled with the type of oil to be filled, they are SAE 10; SAE 30; SAE 40; SAE
90 and the other tanks are Waste Oil; Coolant and Grease Tank which have bottom filling point for each
except waste oil tank.

Picture 5. Bottom Loading/Filling Receiver

CAUTION !

When taking hoses from the station for filling and fitting to the receiver connectors ensure that
the coupler are not allowed to contact the ground. Cleanliness is essential to achieve the objective of clean
oil.

1. Open the quick coupler cap from the tank need to filling.

2. Connect the appropriate hose-coupler to the inlet of oil module. Note that the quick release
coupler has a lock the connection once it is in place.

3. Set the oil dispense ball valves located under the tank on “Closed” position.

4. Monitor the oil level flow through to the tank filled by sight glass / oil level indicator and stop
filling after required level reached.

5. Disconnect the connection hose-coupler and return it to its storage, taking care not to allow dirt
to enter the couplers. Reinstall the protector cap on the couplers.

2.2.4. Dispensing Oil, Coolant and Grease


Dispensing clean oil to the equipment is of paramount importance. Always ensure that dispensing
nozzle / gun for each oil type are stored in their holsters, and are not allowed to contact dirt on the
machines before beginning to fill. Wipe the dispensing nozzle and also the receiver before inserting.

To dispense oil the steps are as follows:

1. Check the pressure gauge of the compressor and ensure the air inside adequate to running /
dispense oil. If not enough to dispense oil, just switch ON the PTO to start up the main pump to
fill air compressor.

2. Set position the master air line ball valve out of the compressor to “OPEN”.

3. Press the reset button on the flow meter located in the cabinet / compartment near the hose reel
to set the readout to 00.00.

Operating Intructions 8
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Picture 6. Flow Meter

4. Take the dispense nozzle from its holster and pull enough hose to reach the machine to be serviced.

5. Insert the nozzle in to the machine and squeeze it to begin filling. Open the control valve (ball
valve) for desired oil to dispense by turning the lever anticlockwise.

Picture 7. Control Valve

6. When the machine has been filled, remove the nozzle and return in to its holster.

7. Read off the quantity of oil dispensed from the meter and record in accordance with local
instructions. Note that the total of oil dispensed through the meter may be read by pressing the
TOTAL button.

2.2.5. Waste Oil Operating Instruction

A diaphragm pump is provided to evacuate oil from machines and to pump oil from the container
sumps.

To evacuate oil from machine, follow these steps:

1. Set the four way valve to “Fill Tank” position by turning the lever clockwise.

Operating Intructions 9
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Picture 8. Four Way Valve

2. Attach the waste oil nozzle to the machine desired to evacuate.

3. Turn the waste oil airline ball valve to “ON” position.

Note : The sump under the dispenser container holds approximately 2000 liters of
oil. Check the remaining capacity before beginning to evacuate oil from a machine.
The diaphragm pump is protected by a runaway valve in the airline. When the flow of fluid in to
the pump ceases, usually because the supply is exhausted, the pump will automatically shut down.
This prevents the pump from “running away” when there is no fluid being pumped. The valve was
set on installation and the setting should not be disturbed.

4. When the oil has been evacuated :

a. Turn Off the waste oil diaphragm pump air line ball valve.

b. Disconnect and store the hose.

To discharge waste oil out from the tank, use the following steps:

1. Set the four way valve to “Empty Tank” position by turning the lever clockwise.

2. Replace the male coupler to female quick coupling to open the check valve inside it.

3. Attach the waste oil hose to the delivery line quick release coupler to the waste oil receptacle used at
site.

4. Turn On the waste oil diaphragm pump air line ball valve

Note : The diaphragm pump is protected by a runaway valve in the airline. When the flow of fluid
in to the pump ceases, usually because the supply is exhausted, the pump will automatically shut
down. This prevents the pump from “running away” when there is no fluid being pumped. The
valve was set on installation and the setting should not be disturbed.

5. When the oil has been fully discharged :

a. Turn Off the waste oil diaphragm pump air line ball valve.

b. Disconnect and store the hose in the compartment.

Operating Intructions 10
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

3
MAINTENANCE
SCHEDULE

Maintenance Schedule 11
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

3.1. General

Our products are built to high standards and are engineered to give years of dependable service, but
regular attention is recommended for continuous efficient running.

Maintenance procedures are carefully set out in this booklet to enable the operator to obtain the
most satisfactory performance from the equipment and operators are expected to perform these
recommended maintenance procedures as a condition of our warranty.

When renewing parts, use only genuine parts, as they are correctly designed and manufactured to
exacting standards of quality control to ensure optimum performance.

When ordering parts, always quote the component or equipment serial number and type designation.
Illustrated parts lists are available on request.

The following schedule refers to Lube Service System for running under normal conditions. During
servicing, replace defective items with genuine parts.

3.2. Maintenance Attention Sign

 An eventual maintenance contract for your vehicle


does not release you of your obligation to take care
of good maintenance.

 Filling the oil tank above the maximum level can


result in overflow of the tank.

 Grease all turning points prior to long lasting


standstill to avoid sticking turning points by rust.

 If there is direct eye contact with hydraulic oil then


rinse it out with plenty of water for at least 15
minutes. Then consult a physician.

 Maintenance near or on rotating parts is


dangerous

Maintenance Schedule 12
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

3.3. Maintenance Schedule Chart

Six-Monthly
Initially and
after 2 wks

Comments
Bi-Weekly

Quarterly

Annually
Monthly

2-Yearly
Weekly

Other
Daily
 
days
Item TASK 1 7 14 30 90 180 365 730  
>>

1. Lubricate

  Hose Reels - Bearing & Spring              


  Monitor Lube Capsule ( Replace )                
                         

2. Check / Adjust

A. Lines
Oil Level for each tanks
  Oil Dispensing Lines for Leaks                    
  Pneumatic Lines for Leaks                  
  Water Lines for Leaks                    
  Condition of Hoses                    
Check Condition of all Caps & Plug
for Receiver Nozzles
  B.  Electrical Circuit
  Electrical Lines for Fretting                  
  Strobe Light Operation                      
  Work Light Operation                      
  Rear Brake & Turn Lights                      
  Control Panel Lights                  
Control Box Fuses
  C.  Tank & Cabinet
  Check Seals on Manholes              
  Check Operation of Vents                  
Check Cabinet Door Seal
Check Tank Structure for Cracks
D. Air Regulator
Drain Condensate from Air
                       
Regulator
Test Pressure Relief of Air Regulator
Check Air Filter Regulator from
Clogging
E. Compressor
Check V-Belt of Compressor             
Check Cut-in and Cut-out pressure
and adjust as required
Change Air Filter

Maintenance Schedule 13
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

  Check Oil Level Lubricator          


Drain Receiver Tank Condensate
Check Unusual Noise and Vibration
Ensure Safety/Relief Valve is
working properly
Inspect Air Filter Element, Clean if
necessary
Replace Oil Filter and Change
Lubricant on pressure lubricated
model
Fuel Level Check and Refilling
Fuel Tank Draining
Fuel Filter Element cleaning
Replace Fuel Filter Element
Lubricating Oil System
Crank Case Oil Level Check & Refill
Lubricating Oil Change
Lubricating Oil Strainer cleaning
Cooling Water System
Cooling Water refill
Water leakage check
Radiator Screen cleaning
Radiator Fin cleaning
V-Belt tension adjustment
Air Cleaner
Air Cleaner Element Cleaning
Replace Air Cleaner Element
Others
All Nut & Bolt Torque
All Pump - Bearings & Seals

                         

NOTES:
1. The life expectancies of the various components are estimates only
2. If the product fails any portion of the weekly inspection, it must be internally inspected immediately.
3. Please refer to the appropriate detailed parts and maintenance manual on each product in “Supporting Parts
Manual” Section.

Maintenance Schedule 14
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

4
SCHEMATIC
DIAGRAM

Schematic Diagram 15
17
MANIFOLD FROM
AIR COMPRESSOR
16
27 27 27 27
07
24 26 27 28 24 26 27 24 26 27 24 26 27
04 05 04 03 25 25 25 25
Optional
Manifold Drain
01
04
03
06
07

09 08 02
GRACO
4.1. Schematic of Pneumatic System

13 14 15 15 14 13 08
FIRE-BALL 425
P/N : 205395 24
08 12
09

24
29

24 Tyre Inflator
with air Chuck
18
3/8"BSPf
22
19 20
1/2" NPT.f

1/2" NPT.f
09 21
11
07 10
100.psi
16.gpm
23
GRACO Air Blow Gun
Note : The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

16
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

PT. PORTER REKAYASA UNGGUL


MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037

Schematic Diagram 17
05
08

Cap. 2000.Ltr 09

01 07

10
06 09
11 12 13
21 39 40 41
22 ” ”
1 1/2" 1"
28
34 38
21 04 03 02 27
23 1 1/2"

27 35 36 62
61
24
27

47
25 30 44 27 47
46
4.2. Schematic of SAE10 Oil Dispensing

17
35 35
60 47
26
30 30 30

30
33 48 60

27

35
TANK
28 35 PUMP
35 28
OUTLET

PUMP
INLET
27 14
FILL
Tank
HOSE
29 29
FLOWMEC
63 28 041 5 1 3
27 35 27 0 41 5 1 3 28
27
49 27

27
30

29
19 20 43
GRACO
1/2"

18
15 16
42
31
32
30

30 27 35 36 37

3/4"NPT BANLAW receiver AUS41A NOTE : The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

18
05
08

Cap. 2000.Ltr 09

01 07

10
06 09
11 12 13
21 39 40 41
22 ” ”
1 1/2" 1"
28
34 38
21 04 03 02 27
23 1 1/2"

27 35 36 62
61
24
27

47
25 30 44 27 47
4.3. Schematic of SAE30 Oil Dispensing

46
17
35 35
60 47
26
30 30 30

30
33 48 60

27

35
TANK
28 35 PUMP
35 28
OUTLET

PUMP
27 14
INLET
FILL
Tank
HOSE
29 29
FLOWMEC
63 28 041 5 1 3
27 35 27 0 41 5 1 3 28
27
49 27

27
30

29
19 20 43
GRACO
1/2"

18
15 16
42
31
32
30

30 27 35 36 37

3/4"NPT BANLAW receiver AUS29W NOTE : The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

19
05
08

Cap. 2000.Ltr 09

01 07

10
06 09
11 12 13
21 39 40 41
22 ” ”
1 1/2" 1"
28
34 38
21 04 03 02 27
23 1 1/2"

27 35 36 62
61
24
27

47
25 30 44 27 47
4.4. Schematic of SAE90 Oil Dispensing

46
17
35 35
60 47
26
30 30 30

30
33 48 60

27

35
TANK
28 35 PUMP
35 28
OUTLET

PUMP
INLET
27 14
FILL
Tank
HOSE
29 29
FLOWMEC
63 28 041 5 1 3
27 35 27 0 41 5 1 3 28
27
49 27

27
30

29
19 20 43
GRACO
1/2"

18
15 16
42
31
32
30

30 27 35 36 64 37

1/2"NPT BANLAW receiver AUS33W


NOTE : The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

20
05
08

Cap. 2000.Ltr 09

01 07

10
06 09
11 12 13
21 39 40 41
22 ” ”
1 1/2" 1"
28
21 34 38
04 03 02 27
23 1 1/2"

27 35 36 62
61
24
27

47
25 30 44 27 47
46
17
35 35
47
4.5. Schematic of 15 W 40 Oil Dispensing

26 60
30 30 30

30
33 48 60

27

35
TANK
28 35 PUMP
35 28
OUTLET

PUMP
INLET
27 14
FILL
Tank
HOSE
29 29
FLOWMEC
63 28 041 5 1 3
27 35 27 0 41 5 1 3 28
27
49 27

27
30

29
19 20 43
GRACO
1/2"

18
15 16
42
31
32
30

30
27 35 36 37

3/4"NPT BANLAW receiver AUS29W NOTE : The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

21
06
18

Cap. 1000.Ltr 25 33

01

34
4.6. Schematic of Coolant Dispensing

Add Filter (Oil Strainer) on Suction 26


02.b 02 02.a 25 28 27 29 30 31 32
05 35
04 1 1/2" 08
23 24
09

03 09 12 20 37

07 ”

10 14
08 09

10
09 12
PUMP 12
INLET 12 19
HOSE
08 TANK

FILL
Tank
09 PUMP
08
OUTLET
12 36
12 09 09
08 10
1 1/16 " 1 1/16 "
JIC JIC
13
11
14 09 08
100.psi
16.gpm 16 17
GRACO

1/2" NPT.f

12 1/2" NPT.f 1/2" 1/2" NPT.f


GRACO 15

10 10

14 09 12 21
Note : The need to adjust the amount of detail the actual installation
22
Kebutuhan detail menyesuaikan dengan aktual pemasangan 1/2"NPT BANLAW receiver AUS37W
20

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

22
06 16

18
Cap. 2000.Ltr
01
4.7. Schematic of Waste Oil Dispensing

02.b 02 20
04 27 26 19 23 24 22
05 1 1/2" 1"
02.a


04
03 1 1/2" 08

07 11 12

08
14 Hydraulic hose 1" One wire
14 Hydraulic hose 1" One wire

10 09
12
08
09 12
PUMP
INLET ”
09 12
HOSE
10 TANK

FILL
Tank
10
PUMP
OUTLET
10 08 12
15
13 09 12 09 14 Hydraulic hose 1" One wire
10
GRACO

14 09 12 1" NPT.f
17
Note : The need to adjust the amount of detail the actual installation 14 Hydraulic hose 1" One wire - 24 25
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

23
02

GRACO
03
05 FIRE-BALL 425
P/N : 205395 04
3/8"
06

Cap. 500.Ltr
01
4.8. Schematic of Grease Dispensing System

3/8" NPT.f 15

Graco. 3/8"with coupler & extend


3/8" Graco. 242058 (assy)
3/8" NPT.f

3/8"
3/8"
18 GRACO 16
10 11 12 13 14 21 22
06
Hydraulic hose
3/8" Two wire

7/8" JIC 7/8" JIC

20 1 1/16 "
JIC
20 1 1/16 " 1 1/16 " 1 1/16 " 1 1/16 "
19
JIC JIC JIC JIC

25
1 1/16 "
JIC 1 1/16 "
JIC

26 1 1/16 "
JIC 07 1/2" NPT.f 23
19
18 Hydraulic hose 3/8" Two wire

24 1/2"
GRACO
17
09
08 Hydraulic hose 1/2" Two wire

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

24
WORK LIGHT STROBE LIGHT
STROBE LIGHT

ORIGINAL TRUCK
4.9. Schematic of Electric

<HORZ.XQLQJ /DPSX6HLQ.LUL /
%ODFN+LWDP /DPSX0DODP
%OXH%LUX /DPSX$ODUP0XQGXU
*UHHQ+LMDX /DPSX6HLQ.DQDQ 5
5HG0HUDK /DPSX0DODP
:KLWH3XWLK *URXG3RZHU'&

CABINET LAMP CABINET LAMP

SWITCH
On Cabinet
08 15 01 01 15 08

 SWITCH
CLOSE-OPEN DOOR
12
15 01 15 18 01

01
V.DC (Battery /Accu)
Connect To Truck System 08 15 01 15 08
Spare Electrical with Fuse
FUSE 15.A
CABINET LAMP CABINET LAMP
Strobe Light Strobe Light Work Lamp Rear
- + In Cabrak On Rear On Cabinet
01 04 06 
- + 

12 01 10
01 04 06 01 11 15 01 11 15 10 15
FUSE 10.A
01 07 04
15 01
POWER SWITCH FUSE 10.A
GROUND /
86 85
14 14
MASA KEYS ON OFF

30
POWER V.DC
ACCU / BATTERY
87 POWER BEBAN
04 16 16 04
01 04 06 12
Black /Hitam
Red /Merah
Blue /Merah
Blue /Biru
Red /Merah
Black /Hitam

Yellow /Kuning
Green /Hijau

White /Putih
White /Putih
White /Putih
White /Putih
White /Putih
White /Putih

Relay 17 17

 Junction Box
Terminal Cable

Grond REAR STOP/TAIL LAMP ORIGINAL TRUCK REAR STOP/TAIL LAMP ORIGINAL TRUCK
FUSE 15.A
V.DC (Battery /Accu) 15 09
Connect To Truck System 15 09
Switch Keys with Fuse
01 Black 01 CHEK ORIGINAL ON TRUCK
Black
White White

<HORZ.XQLQJ CHEK ORIGINAL ON TRUCK <HORZ.XQLQJ


%ODFN+LWDP
03 16 %ODFN+LWDP
%OXH%LUX %OXH%LUX
*UHHQ+LMDX *UHHQ+LMDX
5HG0HUDK 5HG0HUDK
:KLWH3XWLK Junction Box 17 03 13 Junction Box 17 03 13 :KLWH3XWLK
Terminal Cable Terminal Cable
Black Black
White White
01 01
Note : The amount of work lamp is depending on the suitable lighting expossure needed on the unit
15 09 15 09
Jumlah lampu kerja menyesuaikan penempatan yang di butuhkan untuk penerangan untuk unit

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

25
Floating Switch 17 26 29 04
Fuel Low Level EMERGENCY
STOP ON WORK STROBE RUNNING OIL SAE 10 OIL SAE 30 OIL SAE 90 OIL 15 W 40 COMPRESSOR 05
OFF LAMP LAMP PUMP
Recomended For Fuel
E F 09
PUSH
Liquid Float Level 11
PANEL ELECTRICAL
KAIDI (KDS-M.20E) ON FAN COOLER

C
Stainles steel 24.V DC

BAZZER Alarm Low Level / 10


POWER AUTO
FAN COOLER
Empty Tank indicator
V.DC (Battery /Accu) 30 14 26 IN CABIN
Connect To Truck System
Spare Electrical with Fuse FUSE 15.A
LED Indicator
POWER V.DC POWER BEBAN
ACCU / BATTERY
Low Level (RED) GROUND / POWER SWITCH
MASA KEYS ON OFF
25 26 17 22
17 29 29
17 28
29
+
+ -
-
29
27 20
12 29
GROUND / POWER SWITCH
86 85 KEYS ON OFF
MASA
14 26 AIR TANK
30
POWER V.DC FUSE 15.A
87 POWER BEBAN
ACCU / BATTERY 07 08
29 26 Relay
27 20 CABINET LAMP CABINET LAMP 01 01
12 14 26
OFF
ON GROUND / POWER SWITCH
26 26
86 85 EMERGENCY
PTO MASA KEYS ON OFF
Connect ToSwitch 1 2 STOP
3
PTO System 30 4 5
POWER V.DC
ACCU / BATTERY 87 POWER BEBAN
FUSE 15.A 19 29 19 29
ROCKER SWITCH ROCKER SWITCH
09 02 LED INDICATOR LED INDICATOR
RED LAMP RED LAMP
21 03
05 26 05 26
Relay 17 17
CABINET LAMP CABINET LAMP
27 20 12 14 26
OFF / ROCKER SWITCH
ON 26 26 04 04 LED INDICATOR
GROUND / POWER SWITCH
86 85
MASA KEYS ON OFF RED LAMP

POWER V.DC
30 FUSE 15.A 19 29 19 29
ACCU / BATTERY 87 POWER BEBAN 05 26
05 29 26 Relay

20 10 17
26 01 01
06 04 06 04
ROCKER SWITCH IN CABINET ROCKER SWITCH ROCKER SWITCH
RUNNING PUMP LED INDICATOR LED INDICATOR
GROUND / POWER SWITCH 07 07
86 85 RED LAMP
MASA KEYS ON OFF OFF / RED LAMP
ON 09 05
30
POWER V.DC
12 14 26
87 POWER BEBAN
ACCU / BATTERY
08 05 26 08 05 26
Relay FUSE 15.A 18 26 29 12 29 06
17 17 08
06 06 07
Connected To pneumatic Control Valve
SWITCH OFF/ON
CLOSE-OPEN DOOR 07 08
07
08 08 08
08 Connected To pneumatic Control Valve Connected To pneumatic Control Valve

08 08
Connected To pneumatic Control Valve Connected To pneumatic Control Valve

Strobe Light Strobe Light Work Lamp Rear


In Cabrak On Rear On Cabinet


05
24 24
26 23 17 29 29
26 20 17 26 25 29 26 25 29
FUSE 10.A

26 26
GROUND / POWER SWITCH FUSE 10.A
86 85 KEYS ON OFF
MASA

30
POWER V.DC 87
ACCU / BATTERY POWER BEBAN
26 23 17 05
Relay


V.DC (Battery /Accu)

Connect To Truck System 14 29 Note :
Switch Keys with Fuse
FUSE 15.A Grond
The need to adjust the amount of detail the actual installation
Kebutuhan detail menyesuaikan dengan aktual pemasangan

Schematic Diagram
PT. PORTER REKAYASA UNGGUL
MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

26
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

PNEUMATIC
PNEUMATIC

BRONZE
PNEUMATIC

PNEUMATIC

PNEUMATIC

ESTIMATE

PRIMER

PRIMER

ESTIMATE
ESTIMATE

ESTIMATE

PRIMER

Primer L

FESTO
KAIDI stainles steel

PT. PORTER REKAYASA UNGGUL


MANUFACTURE OF ENGINEERED TRANSPORT EQUIPMENT
WORKSHOP:
Jl. Gatot Subroto KM. 8, Jatake, Tangerang, Banten - Indonesia
Telp. (62-21) 591 8951 Fax. (62-21) 591 9037

Schematic Diagram 27
LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5
PART LIST
COMPONENTS

Part List Components 28


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.1. Pneumatic Part List

No. Part no. Description/Picture Qty

1 2545 1pc

INGERSOLL-RAND 2545 series Compressor

2 AL40-03-A 1pc

SMC AR40-03 Air Regulator-AL40-03 Air Lubricator

3 07-351 1pc

SELLERY Air Gun

4 AT-001 1pc

TOYODA Tyre Inflator

5 240959 1pc

GRACO Hose Reel XD Series 3/8” x 15m

6 205395 1pc

GRACO Fireball 425 Ratio 50:1

Part List Components 29


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

No. Part no. Description/Picture Qty

7 D51277 1pc

GRACO 515 Diaphragm Pump

8 647666 1pc

GRACO Diaphragm Pump Waste Oil 1050

Part List Components 30


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.2. Hydraulic System Part List

No. Part no. Description/Picture Qty

1 56281108 1pc

HYVA 132L/108L Hydraulic Tank

2 147 80 306 1pc

HYVA Return Line Filter

3 081 02 116 1pc

HYVA Breather Filter

4 26M-42A-1C-20 1pc

Vickers 26M65 vane motor

5 0512520 1pc

HydroLeduc Txv 92 main pump

6 5827007007 1pc

Parker Fan Cooler

7 90306 1pc

Hydro Control HC-D16 Hydro Valve 5 bank

Part List Components 31


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.3. Oil Dispensing System Part List

No. Part no. Description/Picture Qty

1 25VQ-21A-1C-20 4pcs

Vickers 25VQ-21 Hydraulic Pump

2 M2-210-35-1C-13-JA-J 4pcs

TOKIMEC M2-210 Vane Motor

3 KC-5014 4pcs

Chain Coupling

4 F025-3S4 4pcs

Macnaught Flow Meter

5 HSM6DB 4pcs

GRACO Hose Reel XD Series 1/2” x 15m

6 TA80 7pcs

MP FILTRI Filter Breather 1”

7 1910000112 12pcs

STAUFF Oil Level & Temperature Gauge

Part List Components 32


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

8 CT06 FV50 4pcs

Vickers Relief Valve

9 247-723 4pcs

GRACO XDV20 Oil Gun

10 78205155 4pcs

MAHLE Pressure Filter Oil

11 - 4pcs

RAASM 4-Way Evacuation Valve 3/4” npt (f)

Part List Components 33


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.4. Coolant System Part List

No. Part no. Description/Picture Qty

1 D51277 1pc

GRACO 515 Diaphragm Pump

2 HSL65B 1pc

GRACO Hose Reel XD Series 1/2” x 15m

3 - 1pc

LINCOLN Water Bib Cock 846

4 - 1pc

RAASM 4-Way Evacuation Valve 3/4” npt (f)

Part List Components 34


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.5. Grease System Part List

No. Part no. Description/Picture Qty

1 205395 1pc

GRACO Fireball 425 Ratio 50:1

2 HSH55B 1pc

GRACO Hose Reel XD 20 3/8” x 15m High Pressure

3 HSHC5B 1pc

GRACO Hose Reel XD 20 1/2” x 15m High Volume

4 242056 1pc

GRACO Grease Dispense Valve

Part List Components 35


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.6. Waste System Part List

No. Part no. Description/Picture Qty

1 647666 1pc

GRACO Diaphragm Pump Waste Oil 1050

2 - 1pc

GRACO Hose Reel XD Series 1” x 15m

3 - 1pc

RAASM 4-Way Evacuation Valve 1” npt (f)

Part List Components 36


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.7. Lighting Part List

No. Part no. Description/Picture Qty

1 PL1511 3pcs

PRIMER LIGHT Work Lamp PL1511

2 PL.AE01190C 2pcs

LED Cabinet Lamp

3 200.257.FIRE.09 1pc

9 Kg Fire Extinguisher

4 PL4224.AH 1pc

PRIMER LIGHT PL4224-AH 12-36VDC Strobe Lamp

5 KW20ARW 2pcs

Tail Lamp

Part List Components 37


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

5.8. Accessories Part List

No. Part no. Description/Picture Qty

1 200.299.L001 1set

Ladder

2 300.338.FLAP950.700.2 2pcs

Mud Flap Standard PRU

3 300.360.BELT.06 2pcs

Mud Guards

Part List Components 38


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

6
SUPPORTING PARTS
MANUAL

Supporting Parts Manual 39


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

6.1. INGERSOLL RAND


IR-2545 Series
Air Compressor

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Breakdown Part List 

 
 
 
 

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

6.2. GRACO
Parts and Accessories
PMG Buyer’s Guide
Innovative Product Solutions for the Lubrication Marketplace

Supporting Parts Manual 70


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Fire-Ball 425, 50:1 ®

Air-Powered Grease Pumps and Packages

Features and Benefits


• Non-corrosive air motor design for long life
• Double-acting pump ensures smooth fluid flow
• Robust grease inlet cage withstands the most abusive handling

Typical Applications
Pump Performance
• Medium pressure, low to medium
volume grease dispense Cycles per minute
13 27 41 53 Inlet Air Pressures:
7500
• Automotive dealerships (510)
A =150 psi
(10.3 bar)
6000 40
• Heavy-duty dealerships
Fluid Presure (psi)

(408) (1.1) B =100 psi

Air Flow (scfm)


(6.9 bar)

(m³/min)
• Fast lube and service centers 4500 30
(bar)

(306) (.85) TEST FLUID:


#10 Weight Oil
• Fleet service facilities 3000
(204)
20
(0.56)

• Lube trucks 0 10
0 1 2 3 4 (0.28)
• Mining (0.45) (.9) (1.4) (1.8)
Fluid Flow (lb/min)
• In-plant (kg/min)

Typical Fluids Handled


• Grease up to NLGI #2

Technical Specifications
Continuous-Duty Flow Rate ....................................................................................................3.35 lb/min (1.5 kg/min.)
Maximum Fluid Pressure ................................................................................................................ 7500 psi (517 bar)
Air Motor Effective Diameter.............................................................................................................. 4.25 in (10.8 cm)
Operating Range ................................................................................................................. 40-150 psi (2.8-10.4 bar)
Approximate Air Use ..........................................................................................................19 cfm @ 70 psi (4.8 bar)
Wetted Materials ....................................................................................................................................... CS, Leather
Air Inlet Port Size ....................................................................................................................................... 1/2 in npt(f)
Material Inlet ....................................................................................................................................................Slotted
Material Outlet........................................................................................................................................... 3/8 in npt(f)
Line Length‡ .........................................................................................................................Up to 250 ft (76.2 m)
Dispense Points ..................................................................................................................................... 4 or more
Annual Usage ............................................................................................................ 20,000 lb or more (9,072 kg)

Ordering Information
Fire-Ball 425 50:1 Pumps
205394 120 lb (55 kg) Grease Pump - 50:1
205395 400 lb (180 kg) Grease Pump - 50:1

‡ Consult your local authorized Graco representative for line or pipe sizing

www.graco.com Supporting Parts Manual 71 3


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Instructions - Parts List

50:1 Fire-Ball®
425 Pumps 306674W
EN

For pumping non-corrosive and non-abrasive greases and lubricants only. For
professional use only.
Model 205394, Series E
Model 205395, Series N
7500 psi (51.7 MPa, 517 bar) Maximum Working
Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure

Important Safety Instructions


Read all warnings and instructions in this
manual. Save these instructions.

This pump is designed to be used only in pumping


non-corrosive and non-abrasive oils and lubricants.
Any other use of the pump can cause unsafe
operating conditions and component rupture, which
can result in fluid injection or other serious injury or
fire or explosion.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Warnings

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 or on warning labels, 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.

WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in the work area.
• Use only grounded hoses.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

2 306674W

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Warnings

WARNING
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.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.

MOVING PARTS HAZARD


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

TOXIC FLUID OR FUMES HAZARD


Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT


Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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

306674W 3

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation

Installation

Grounding To ground the pump: Remove the ground screw (Z)


and insert through the eye of the ring terminal at end of
ground wire (Y). Fasten the ground screw back onto the
pump and tighten securely. Connect the other end of the
ground wire to a true earth ground. See FIG. 1. To order
The equipment must be grounded to reduce the risk a ground and wire clamp, order Part No. 222011.
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Mounting the Pump
Grounding provides an escape wire for the electric
current.

Pump: Use a ground wire and clamp as shown in FIG. 1.


Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in personal injury or equipment damage.

• Select a convenient location for the equipment to


ensure easy operator access to the pump air con-
Z Y
trols, sufficient room to change supply containers,
and a secure mounting platform.

• If you are mounting the pump directly on the supply


tank, position the pump so its intake valve is no
more than 1 inch (25 mm) from the bottom of the
container. Mount the pump to the cover or other suit-
able mounting device.
FIG. 1

Air and fluid hoses: Use only electrically conductive Typical Installation
hoses.
Mount the pump to suit the type of installation planned.
Air compressor: Follow manufacturer’s recommenda- Very heavy lubricant may require an inductor plate. See
tions. page 17 for the mounting hole layout and dimensions.

Dispense valve: Ground through connection to a prop- Install the airline accessories in the approximate order
erly grounded fluid hose and pump. shown in FIG. 2. Install a bleed-type master air valve (B)
within easy reach of the pump, upstream from the air
Object being dispensed: follow local code. regulator. Install an air filter (C) to remove harmful dirt
and moisture from your compressed air supply. For
Solvent pails used when flushing: Follow local code. automatic air motor lubrication, install an air line oiler (D)
Use only conductive metal pails, placed on a grounded close to the pump air inlet. Install an air regulator (E) to
surface. Do not place the pail on a nonconductive sur- control pump speed.
face, such as paper or cardboard, which interrupts
grounding continuity.

To maintain grounding continuity when flushing or


relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.

4 306674W

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation

Be sure the air hose is properly sized to deliver an ade-


quate supply of air to the motor. Refer to the Technical
Data on page 16.
A bleed-type master air valve (B) is required to shut
off an relieve air pressure that may be trapped in the Connect a dispensing hose to the 3/8 npt(f) pump outlet.
air motor. Trapped air could cause the pump to cycle Install an appropriate gun or dispense valve to the hose.
unexpectedly and cause serious bodily injury,
including amputation. Ground the pump as explained on page 4.

A C D

B E
G

FIG. 2: Typical Installation

Key:
A Grounded air line
B Bleed-type master air valve
C Air filter
D Air line oiler
E Air regulator
F Grounded dispensing hose
G Dispensing valve
H Elevator assembly with inductors
J Ground wire

306674W 5

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Operation

Operation

Pressure Relief Procedure Startup and Adjustment


Follow the Pressure Relief Procedure whenever
you see this symbol.

Open the bleed-type air master valve (B). Open the dis-
pensing valve (G), and slowly open the air regulator (E)
until the pump is running smoothly. After all the air is
This equipment stays pressurized until pressure is purged, close the dispensing valve. The pump will start
manually relieved. To help prevent serious injury from and stop as the valve is opened and closed.
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before NOTICE
cleaning, checking, or servicing the equipment. Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
1. Close the air regulators (E). sped and may damage itself. If your pump acceler-
ates quickly or is running too fast, stop it immediately
2. Close the supply pump’s bleed-type air master valve and check the fluid supply. If the supply container is
(B, required in system). empty and air has been pumped into the lines, prime
the pump and the lines with fluid, or flush the pump
3. Open the dispensing valve (G) until pressure is fully
and leave it filled with a compatible solvent. be sure to
relieved.
eliminate all air from the fluid system.
NOTE: If you suspect that the dispensing valve, exten-
sion, or grease fitting coupler is clogged, or that pres- Use the air regulator (E) to control the pump speed and
sure has not been fully relieved after following the steps fluid pressure. See FIG. 2. Always use the lowest pres-
above, VERY SLOWLY loosen the coupler or hose end sure necessary to obtain the desired results.
coupling and relieve pressure gradually, then loosen
completely and clear the clog. When you are finished using the pump for the day
always follow the Pressure Relief Procedure.

Maintenance
The accessory air line oiler (D) provides automatic air
motor lubrication. Four daily manual lubrication, discon-
nect the air hose, place about 15 drops of light machine
oil in the air inlet, reconnect the hose, and turn on the air
supply to blow oil into the motor.

6 306674W

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Troubleshooting

Troubleshooting
1. Follow Pressure Relief Procedure, page 6, before
checking or repairing gun.

2. Check all possible problems and causes before dis-


assembling gun.

Problem Cause Solution

Inadequate air supply pressure or


Increase air supply; clear
restricted air lines.
Closed or clogged valves Open; clean
Pump fails to operate Clogged fluid lines, hoses, valve,
Clear*
etc.
Damaged air motor Service air motor
Exhausted fluid supply Refill and reprime, or flush
Worn or damaged air motor gasket,
Continuous air exhaust Service air motor
packing, seal, etc.
Exhausted fluid supply Refill and reprime, or flush
Erratic pump operation Held open or worn intake valve or
Clear; service
piston packings
Pump operates, but output low on Held open or worn piston or pack-
Clear; service
upstroke ings
Pump operates, but output low on
Held open or worn intake valve Clear; service
downstroke
Inadequate air supply or restricted
Increase air supply; clear
air lines
Closed or clogged valves Open; clean

Pump operates, but output low on Exhausted fluid supply Refill and reprime, or flush
both strokes Clogged fluid lines, hoses, valves,
Clear*
etc.
Packing nut too tight Loosen
Loose packing nut or worn packings Tighten; replace

* Follow the Pressure Relief Procedure (see page 6), and disconnect the fluid line. If the pump starts when the air is
turned back on, the fluid line, hose, valve, etc. was clogged.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service

Service
77

Ref. 63 (copper gasket) and


Ref. 60 (cotter pin),
64 see Parts Drawing on page 16.
15

80

68 59
62

65

74 66 1

59
61
62 68

67

72

79 2
69
75
73 1
76
70

1/4” ROD

72
78

71

FIG. 3

8 306674W

Supporting Parts Manual 79


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service

Displacement Pump in (6 mm) diameter rod through the holes in the


tube. Handle the tube carefully to avoid marring the
surface. Remove the ball, seat, and gasket.

7. Unscrew the intake valve housing (67) from the pis-


ton valve housing (64). Remove the ball and pack-
Before starting: ings.

• To reduce down time, be sure you have all neces- 8. Clean all parts thoroughly. Grease all parts except
sary repair parts available. Recommended spare threads when reassembling.
parts are listed in the parts list on page 15.
Reassembly
• The balls (59) in the intake and piston valves cannot
be reseated on the hardened seats (68). 1. One at a time, place the female gland (74), five
leather v-packings (66) with the lips of the packings
• Repair Kit 239320 is available. If you have a repair facing up, and the male gland (65) on the intake
kit, use all the new parts for the best results. housing (67). Place the gasket (62), seat (68), and
ball (59) on the housing (67).
• Whenever replacing packings, also replace the
glands and bearing. 2. If the pins (80) were removed from the piston valve
housing (64), replace them. Hold the piston valve
• When cleaning parts, use a compatible solvent. housing with a wrench and screw in the intake valve
Inspect parts for wear or damage and replace as housing.
necessary. Scoring or irregular surfaces on the
priming tube (72) or polished inner wall of the riser 3. Place a gasket (62), seat (68), and ball (59) on the
tube (79) causes premature packing wear and leak- priming tube (72). Holding the piston valve housing
ing. Check these parts by rubbing a finger on the (67) with a wrench, screw the priming tube into it.
surface and by holding the parts up to the light at a using a 1/4 in. diameter rod through the tube for
slight angle. leverage.

4. Guide the riser tube (79) over the priming tube and
• Use light, waterproof grease whenever grease is
screw it into the motor base, making sure the gasket
mentioned.
(63) is in place. Torque to 50 to 70 ft-lb (68 to 95
N.m).
Disassembly
5. One at a time, place the female gland (76), five
1. Flush the pump if possible. Follow the Pressure
leather packings (73) with lips of packings facing up,
Relief Procedure on page 6. Disconnect all air and
a male gland (75), and a bearing (69) in the packing
fluid hoses.
housing (70). Screw the housing firmly into the riser
2. Clamp the motor base in a vise. Unscrew the prim- tube.
ing cylinder (78).
6. Screw the priming piston (71) firmly onto the priming
3. Hold the priming tube (72) with a 1/4 in (6 mm) tube (72). Screw the intake cylinder (78) firmly onto
diameter rod through the holes in the tube. Grip the the riser tube.
flats of the priming position (71) with a wrench and
7. Reconnect the ground wire if it was disconnected
unscrew the piston.
during repair.
4. Loosen the packing housing (70). Unscrew the riser
tube (79) from the air motor.

5. Remove the packing housing (70) from the riser


tube (79), and remove the packings from the hous-
ing.

6. Hold the intake valve housing (67) with a wrench,


and unscrew the priming tube (72) by inserting a 1/4

306674W 9

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service

Air Motor and Throat Service NOTICE


Before starting: Do not damage the plated surface of the trip rod.
Damaging the surface of the trip rod can result in
• Be sure to have all necessary parts on hand. Air erratic air motor operation. Use the special padded
Motor Repair kit, 207385, includes repair parts for pliers, 207579, to grasp the rod.
the motor. Pump Repair Kit, 239320, includes repair
parts for the pump and the air motor throat area. 4. Remove the eight screws (7) holding the cylinder
Use all the parts in the kits for the best results. (32) to the base (56). Carefully pull the cylinder
straight up off the piston. (FIG. 4)
• Two accessory tools should be used. Padded Pliers,
207579, is used to grip the trip rod without damag- 5. Use a screw driver to push down on the trip rod
ing its surface. Gauge, 171818, is used to ensure yoke (14) and snap the toggle assemblies (k) down.
the proper clearance between the poppets and seat Remove the lockwires (28) from the adjusting nuts
of the transfer valve. (27) of the transfer valves (M). Screw the top adjust-
ing nuts (27) off. Screw the valve stems (30) out of
Disassembly the grommets (18) and lower adjusting nuts (27).
Take the valve poppets (37) off the stems and
squeeze them firmly to check for cracks. (FIG. 5)

6. Grip the toggle rockers (16) with a pliers. Compress


the springs (17) and swing the toggle assembly (K)
1. Flush the pump. Follow the Pressure Relief Proce- up and away from the piston lugs (L), and remove
dure, page 6. the parts. Check that the valve actuator (13) is sup-
ported by the spring clips (4), but slides easily into
2. Disconnect the air hose from the motor. If neces-
them. (FIG. 5)
sary, disconnect the motor from the pump. Clamp
the air motor base in a vise. 7. Remove the trip rod yoke (14), valve actuator (13)
and trip rod (1). Check the exhaust valve poppets
3. Manually push on the piston rod to move the piston
(38) for cracks.
assembly to the top of its stroke. Unscrew the cylin-
der cap nut (31) from the cylinder (32). Pull up on NOTE: To remove the exhaust valve poppets (38),
the cap nut. Grip the trip rod (1) with a padded pli- stretch them out and cut with a sharp knife.
ers, 207579, and screw the cap nut off the trip rod.
(FIG. 4) 8. Pull the piston (5) up and out of the base (56) and
inspect the piston o-ring (20) and the o-ring base
31 casting.
1
Hold trip rod with
padded pliers
207579, to prevent
damage to rod
32

56

36

FIG. 4

10 306674W

Supporting Parts Manual 81


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service

Push toggles (K) in


and then up. 1 14 28* Cut off tops of
poppets (x) as
17 Turn wires up.
indicated by dotted
K 27* lines
16 1
L 38*
30* 4
30*
13 27*
18*
27*
18*

27*
M 20*

0.125 in.
(3.18 mm)

5
37*

56 5

CUTAWAY VIEW

4 13 38* 37*
FIG. 5

Reassembly 7. Before installing the lockwires (28) in the adjusting


nuts (27), use the special gauge, 171818, to adjust
1. Clean all the parts carefully in a compatible solvent the transfer valve (M) so there is 0.125 in (3.68 mm)
and inspect for wear or damage. Use all the repair clearance between the poppets (37) and the piston
kit parts during reassembly and replace other parts (5) when the toggle assemblies are in the down
as necessary. position. (FIG. 5)
2. Check the polished surfaces of the piston, piston rod 8. Snap the toggle assemblies (K) to the up position.
and cylinder wall for scratches or wear. A scored rod Reinstall the cylinder (32) and cap nut (31). Reas-
will cause premature packing wear and leaking. semble the air motor to the displacement pump.
3. Lubricate all parts with a light, waterproof grease. 9. Before remounting the pump, connect an air hose
and run the pump slowly, at about 40 psi (0.28 MPa,
4. Be sure the o-rings are in place. Slide the piston rod
2.8 bar) to ensure that it operates smoothly.
down through the throat bearing and lower the pis-
ton (5) into the air motor base (56). 10. Reconnect the ground wire before regular operation.
5. Pull the exhaust valve poppets (38) into the valve
actuator (13) and clip off the top part shown with
dotted lines. (FIG. 5)
Throat Packing
6. Install the transfer valve poppets (37) onto the valve
stems (30), then reassemble the valve stems (30),
bottom adjusting nuts (27), grommets (18), and top
adjusting nuts (27) on the piston (5). Assemble the See FIG. 6 and the parts drawing and list on pages 14
trip rod (1), valve actuator (13), trip rod yoke (14) and 15 for further information.
and toggle assemblies (K) on the piston. (FIG. 5)
1. Clamp the pump in a vise and unscrew the riser
tube (80) from the air motor base (56). Pull the riser
tube away from the air motor until the cotter pin (60)
which secures the displacement pump connecting
rod to the air motor piston rod (52) is visible.

306674W 11

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service

2. Remove the cotter pin (60) and unscrew the pump NOTE: Make sure the packing (25) lips face down and
connecting rod (79) from the air motor piston rod make sure the wiper (22) lips face up.
(52). Remove the cylinder (32) from the air motor
base (56) as described under Disassembly on page 8. Insert the bearing (46) and the washer (44) into the
10. base. Assemble the female gland (48), v-packings
(49), and the male gland (47) into the packing nut
3. Remove one louvered air exhaust plate (36) and (45).
unscrew the throat packing nut (45), using a span-
ner wrench or a 0.22 in (5.6 mm) diameter rod. 9. Reinstall the spacer and packing in the base and
packing nut (45). Screw the packing nut into the
4. Remove the packing nut (45), male and female base and tighten it securely. Carefully slide the pis-
glands (47, 48), v-packings (49), washer (44), bear- ton rod (52) down through the throat packing and
ing (46), retainer (24), wiper (22), o-ring (23), u-cup lower the piston into the base. Reinstall the plate
(25), and washer (26) from the base. (36) and cylinder (32). Reassemble the air motor to
the displacement pump.
5. Clean the throat packing area in the base and the
packing nut. Clean and inspect all parts and replace 10. Torque the outlet adapter (42) to 45 to 55 ft-lb (61 to
as necessary. 75 N.m).

6. Lubricate the packings, piston rod, and piston flange NOTE: When reinstalling the cotter pin (60), always
with a light, waterproof grease. spread and flatten the pin (both the head and prongs)
around the rod to within 1 inch (25 mm) total diameter.
7. Install the washer (26) into the base. Assemble the see Detail A of FIG. 6.
packing (25) and the wiper (22) into the retainer
(24). Install the o-ring (23) onto the retainer, and
insert the retainer assembly into the base.

32

DETAIL A
56

45 52

60
79

1 in.
(25 mm)
SEE DETAIL A

36

80
FIG. 6

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Parts

Parts

45
48
31

9
49
47
44
32
46

22
28* 72
15 13 14 23
27*
29 24
17
25
16 38*
18* 26
58
3 21*
1 33
2 4 19
27*
56
5 79
40

53
*20 69
1 42
7 75

8 *37
63 73
*30
60 76
57
33
52 6 70
36
71
77

80 78
64

59
68
62
65
66
74

67
61
59
68
62

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts

Model 205394, Series E, 120 lb. (55 kg) drum length


Model 205395, Series N, 400 lb. (180 kg) drum length
Ref. Part Description Qty. Ref. Part Description Qty.
1 207150 TRIP ROD 1 53 116343 SCREW, grounding 1
2 207391 PISTON, includes items 3 to 5 (also 1 56 165362 BASE, motor, air 1
includes repair kit 207385 when 58 177843 PLATE, warning 1
ordered as a replacement part) 59‡ 100170 BALL, steel, 3/8” dia. 2
3 102975 SCREW, rd hd mach, 6-32 x 1/4 in. 2 60‡ 100579 PIN, cotter, 7/64” dia., 1” long 1
4 158361 CLIP, spring 2 61 108513 PIN, roll, 0.135” dia. 7/8” long 1
5 BARE PISTON (not sold sepa- 1 62‡ 150451 GASKET, copper 2
63 158314 GASKET, copper 1
rately)
64 162555 HOUSING, piston valve 1
6 100078 SCREW, hex head, 8-32 x 3/8 in. 20
65‡ 162556 GLAND, male 1
7 101578 SCREW, hex head Nylock, 8-32 x 8
66‡ 162557 V-PACKING, 5
3/8 in. 67 162558 HOUSING, intake valve 1
8 150647 GASKET, copper 1 68 162559 SEAT, valve 2
9 156698 O-RING, buna-N 1 69‡ 162560 BEARING, brass 1
13 158359 ACTUATOR, valve 1 70 162561 HOUSING, packing 1
14 158360 YOKE, rod, trip 1 71 162562 PISTON, priming 1
15 158362 PIN, toggle 2 72 162564 TUBE, priming 1
16 158364 ROCKER, toggle 2 73‡ 162566 V-PACKING, leather 5
17 167585 SPRING, helical compression 2 74‡ 162568 GLAND, female 1
18* 158367 GROMMET, rubber 2 75‡ 162602 GLAND, male 1
19 158377 SEAL, flat ring, nitrile rubber 1 76‡ 162603 GLAND, female 1
20* 158378 SEAL, o-ring, nitrile rubber 1 77 164234 ROD, connecting, 12.47” (317 mm) 1
21* 158379 SEAL, o-ring, nitrile rubber 1
long, model 205394
22† 113935 WIPER, rod 1
164231 ROD, connecting, 19-13/32” (493 1
23† 113944 PACKING, o-ring 1
24† 192172 RETAINER, packing 1 mm) long, model 205395
25† 113936 PACKING, u-cup 1 78 164233 CYLINDER, intake primer 1
26† 192173 WASHER, packing 1 79 165381 TUBE, rise, 21.31” (541 mm) long, 1
27* 160261 NUT, adjusting 4 model 205394
28* 160618 LOCKWIRE, transfer valve 2 165382 TUBE, riser, 28-1/4” (817 mm) long, 1
29 160623 ARM, toggle 2 model 205395
30* 160896 STEM, valve 2 80 102180 PIN, spring, 0.135” dia. 1” long 2
31 161435 NUT, cylinder cap 1
32 15E954 CYLINDER, motor, air 1  Replacement Danger and Warning labels, tags, and
33 178270 PLATE, muffler 2 cards are available at no cost.
36 15E555 PLATE, identification 1
37* 170708 POPPET, valve, urethane 2 * Parts included in Kit 207385 (purchase separately).
38* 170709 POPPET, valve, urethane 2 Parts included in Kit 239320 (purchase separately),
40 150461 GASKET, copper 1 includes parts to service the air motor throat area
42 158409 ADAPTER, outlet 1
and the power lower.
44† 158697 WASHER, thrust 1
45† 159047 NUT, packing 1 † Parts for the air motor throat area.
46† 159048 BEARING, brass 1
47† 159306 GLAND, male 1 ‡ Parts for the power lower.
48† 159307 GLAND, female 1  Recommended spare parts. Keep on hand to reduce
49† 159308 V-PACKING, nitrile rubber 4
down time.
52 162553 ROD, piston 1

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Technical Data

Technical Data
.
50:1 Fire-Ball 425 Pumps
US Metric
Maximum fluid working pressure 7500 psi 51.7 MPa, 517 bar
Air pressure operating range 40 to 150 psi 0.3 to 1 MPa, 3 to 10 bar
Fluid pressure ratio 50:1
Maximum delivery 0.5 gpm 1.9 lpm
Cycles per gallon (per liter) 110 28
Maximum recommended pump speed 60 cycles per minute
Air motor effective diameter 4.25 in. 108 mm
Stroke 4 in. 102 mm
Air consumption approximately 19 cfm at 1 approximately 0.53 m3/min at
gpm at 70 psi 3.8 lpm at 0.48 MPa, 4.8 bar
Wetted parts Steel, brass, aluminum, leather
Weight
Model 205394 34 lb 15 kg
Model 205395 37 lb 17 kg

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Dimensions

Dimensions

3/8 npt
3/8 npt Fluid
Fluid Outlet
Outlet
14–9/16” 14–9/16”
(369.9 mm) (369.9 mm)

6–1/2” 6–1/2”
(165.1 mm) (165.1 mm)
Diameter Diameter
41–1/4”
1/2 npt(f) (1048 mm)
1/2 npt(f) 48–3/16”
Air Inlet Air Inlet (1224 mm)

26–11/16” 33–5/8”
(678 mm) (854.1 mm)

Priming Piston Priming Piston

Model 205394, Series E Model 205395, Series N


Weight 36 lb (16 kg) Weight 36 lb (16 kg)

Mounting Holes

306674W 17

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Instructions--Parts List

ALUMINUM

Huskyt 716 Air--operated


Diaphragm Pumps 308797R
Used to evacuate and transfer fluids.
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure

Part No. 241407, Series D


with two--direction manifolds

Part No. 241408, Series D


with single--direction manifolds

Patents Pending

Important Safety Instructions


Read all warnings and instructions in this manual.
Save these instructions.

9246A

Model No. 241407

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Diaphragm Pumps and Accessories


Air-Operated Double Diaphragm Transfer Pumps
Diaphragm Pumps and Accessories

D31255 241906 647648 DB3525 DF3525


652002

Ordering Information and Technical Specifications


Key OT = Oil Transfer OE = Oil Evacuation WA = Water, Anti-Freeze FD = Fuel Dispense (with 50 psi relief valve) FT = Fuel Transfer WWS = Windshield Wash Solution
Max. Air Max. Fluid Air Valve Kits
Part Typical Free Flow Diaphragm
Body/Diaphragm Description Air Inlet psi Inlet/ Replace- (Seats, Balls, Manual
Number Application gpm (lpm) Diaphragms) Kit
SCFM NPT (bar) Outlet ment Kit
307 3/8 in Diaphragm Pump OT, WA, 100
D31255 7(1) 1/4 3/8 7 (31.8) 239952 D03255 D03005 308553
Acetal/TPE WWS (7)
515 3/4 in Diaphragm Pump 50/50 100
243669 28(1) 1/4 3/4 16 (60.6) 241657 D05277 D05007 309204
Acetal/Buna Dual Inlet WWS, WA (7)
716 3/4 in Diaphragm Pump OT, OE, 100
241906 28(1) 1/4 3/4 16 (61) 241657 D05277 D05007 308573
Aluminum/Buna N WA, WWS (7)
OE, WA,
1 in Diaphragm Pumps 120
647016 FT (leaded 67 1/2 1 50 (189) 313597
1050A Aluminum/TPE (UL) fuel only)
(8.2)
Seats-24B634
50 24B766 and 24B624
1050A Aluminum/TPE (UL) 647648 FD 20(2) 1/2 1 32 (121) 313597
(3.4) Balls-24B639
OT, OE, 125
1050A Aluminum/TPE 647666 67(2) 1/2 1 50 (189) 312877
WA (8.6)
1590 1-1/2 in Diaphragm Pump OT, OE, 120
DB3525 90(3) 1/2 1 1/2 90 (341) 236273 D0B525 D0B005 308441
Aluminum/TPE WA (8.3)
2150 2 in Diaphragm Pump OT, OE, 120
DF3525 175(3) 1/2 2 150 (567) 236273 D0F525 D0F005 308368
Aluminum/TPE WA (8.3)
3300 3 in Diaphragm Pump OT, OE, 125 280 Seats-24K932
652002 335(3) 3/4 3 24K855 24K901 3A0410
Aluminum/TPE WA (8.6) (1,060) Balls-24K937
(1) (2) (3)
NOTE: All pumps are 1:1 ratio Max air use at 100 psi (7.0 bar) Max air use at 125 psi (8.6 bar) Max air use at 120 psi (7.0 bar)

Mounting Accessories
Pump 307 515/716 1050 1590 2150 3275
Air Line Filter 110146 106148 106149 106150 106150
Air Regulator and Gauge 110147 110147 244844 202858 206199 207651
Air Quick-Connect Coupler 208536, 1/4 npt(f) 110199, 1/2 npt(f) N/A
Air Quick-Connect Nipple 169970, 1/4 npt(m) 110196, 1/2 npt(f) N/A
Bleed Type Air Valve 110223 110224 110225 110226
Wall Bracket 224835 24C637 N/A N/A N/A
Thermal Relief Kit 238899 238428 N/A N/A N/A
Thermal Relief Valves
113497 al/bn, 112119 ss/tf 113497 al/bn , 112119 ss/tf
150 psi (10.3 bar)
Grounding Wire and Clamp 222011
Suction Hose Kit 236054 N/A N/A N/A
Flange Adapter Kit N/A N/A N/A N/A N/A N/A
Dual Inlet Manifold N/A 243669* 24D205 N/A N/A N/A
308573 and 308326 and
Instruction Manual 308553 308441 308368 308639
308981 308479
*Includes the dual inlet manifold.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Table of Contents Symbols


Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Warning Symbol
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARNING
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 This symbol alerts you to the possibility of serious
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 injury or death if you do not follow the instructions.
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Caution Symbol
241407 and 241408 Repair Kits . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CAUTION
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 26 This symbol alerts you to the possibility of damage to
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 or destruction of equipment if you do not follow the
instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7 MPa,
7 bar) maximum incoming air pressure.
D Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below --40_C (--40_F).
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Do not use 1.1.1--trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.

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WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.

D Know the specific hazards of the fluid you are using.

D Do not lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
Pressure Relief Procedure on page 10 before lifting the pump.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

D Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If
the diaphragm fails, the fluid is exhausted along with the air. Read Air Exhaust Ventilation on
page 6.

D Never use an acetal pump to pump acids. Take precautions to avoid acid or acid fumes from
contacting the pump housing exterior. Stainless steel parts will be damaged by exposure to acid
spills and fumes.

FIRE AND EXPLOSION HAZARD


Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.

D Ground the equipment. Refer to Grounding on page 8.

D If there is any static sparking or you feel an electric shock while using this equipment, stop pump-
ing immediately. Do not use the equipment until you identify and correct the problem.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.

D Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails,
the fluid is exhausted along with the air. Read Air Exhaust Ventilation on page 6.

D Keep the work area free of debris, including solvent, rags, and gasoline.

D Electrically disconnect all equipment in the work area.

D Extinguish all open flames or pilot lights in the work area.

D Do not smoke in the work area.

D Do not turn on or off any light switch in the work area while operating or if fumes are present.

D Do not operate a gasoline engine in the work area.

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Installation
General Information
CAUTION
D The Typical Installations in Fig. 2 are only guides
for selecting and installing system components. Safe Operating Temperatures
Contact your Graco distributor for assistance in Minimum: 40_ F (4_ C)
planning a system to suit your needs. Maximum: 225_ F (107_ C)
These temperatures are based upon mechanical stress
D Always use Genuine Graco Parts and Accessories. only and may be significantly altered by pumping certain
chemicals. Consult engineering guides for chemical com-
D Use a compatible, liquid thread sealant on all male patibilities and temperature limits, or contact your Graco
threads. Tighten all connections firmly to avoid air distributor.
or fluid leaks.

Tightening Threaded Fasteners Before Mountings


First Use
D These pumps can be used in a variety of installa-
Before using the pump for the first time, check and
tions. Be sure the mounting surface can support
retorque all external fasteners. See Torque Se-
the weight of the pump, hoses, and accessories, as
quence, page 20. After the first day of operation,
well as the stress caused during operation.
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
D Fig. 2 shows some installation examples. On all
installations, mount the pump using screws and
Toxic Fluid Hazard nuts.

Read Toxic Fluid Hazard


on page 3. Pumping High-Density Fluids

Use fluids and solvents that are compatible with the High density fluids may prevent the lighter non-metallic
equipment wetted parts. Refer to the Technical Data check valve balls from seating properly, which reduces
section of all equipment manuals. Read the fluid and pump performance significantly. Stainless steel balls
solvent manufacturer’s warnings. should be used for such applications.

4 308797

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Installation
Air Line 2. Install an electrically conductive, flexible air hose
(C) between the accessories and the 1/4 npt(f)
pump air inlet. Use a minimum 1/4 in. (6.3 mm) ID
WARNING air hose. Screw an air line quick disconnect cou-
pler (D) onto the end of the air hose (C), and
A bleed-type master air valve (B) is required in your screw the mating fitting into the pump air inlet
system to relieve air trapped between this valve snugly. Do not connect the coupler (D) to the fitting
and the pump. See Fig. 2. Trapped air can cause yet.
the pump to cycle unexpectedly, which could result
in serious injury, including splashing in the eyes or Fluid Suction Line
on the skin, injury from moving parts, or contamina-
tion from hazardous fluids. D If using a conductive (acetal) pump, use conductive
hoses. If using a non-conductive pump, ground the
fluid system. Read Grounding on page 8. The
CAUTION fluid inlet port is 3/4 in.

The pump exhaust air may contain contaminants. D At inlet fluid pressures greater than 15 psi
Ventilate to a remote area if the contaminants could (0.1 MPa, 1 bar), diaphragm life will be shortened.
affect your fluid supply. Read Air Exhaust Ventila-
tion on page 6. Fluid Outlet Line

1. Install the air line accessories as shown in Fig. 2. WARNING


Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the acces- A fluid drain valve (H) is required in your system to
sories is electrically conductive. relieve pressure in the hose if it is plugged. See
Fig. 2. The drain valve reduces the risk of serious
a. The fluid pressure can be controlled in either injury, including splashing in the eyes or on the
of two ways. To control it on the air side, install skin, or contamination from hazardous fluids when
an air regulator (G). To control it on the fluid relieving pressure. Install the valve close to the
side, install a fluid regulator (J) near the pump pump fluid outlet.
fluid outlet (see Fig. 2).
1. Use electrically conductive fluid hoses (K). The
pump fluid outlet is 3/4 in. Screw the fluid fitting
b. Locate one bleed-type master air valve (B)
into the pump outlet snugly. Do not overtighten.
close to the pump and use it to relieve trapped
air. Read the WARNING above. Locate the 2. Install a fluid regulator (J) at the pump fluid outlet
other master air valve (E) upstream from all air to control fluid pressure, if desired (see Fig. 2).
line accessories and use it to isolate them See Air Line, step 1a, for another method of
during cleaning and repair. controlling pressure.

c. The air line filter (F) removes harmful dirt and 3. Install a fluid drain valve (H) near the fluid outlet.
moisture from the compressed air supply. Read the WARNING above.

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Installation
Fluid Pressure Relief Valve Air Exhaust Ventilation

CAUTION
Read Toxic Fluid Hazard on
Some systems may require installation of a pressure
page 3.
relief valve at the pump outlet to prevent overpres-
surization and rupture of the pump or hose.
See Fig. 1. Read Fire and Explosion
Hazard on page 3.
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when using
Be sure the system is properly ventilated for your
long fluid lines exposed to sunlight or ambient heat,
type of installation. You must vent the exhaust to a
or when pumping from a cool to a warm area (for
safe place, away from people, animals, food handl-
example, from an underground tank).
ing areas, and all sources of ignition when pumping
Overpressurization can also occur if the Husky pump flammable or hazardous fluids.
is being used to feed fluid to a piston pump, and the
Diaphragm failure will cause the fluid being pumped
intake valve of the piston pump does not close,
to exhaust with the air. Place an appropriate con-
causing fluid to back up in the outlet line.
tainer at the end of the air exhaust line to catch the
fluid. See Fig. 2 .
1 Install valve between fluid inlet and outlet ports.
2 Connect fluid inlet line here.
3 Connect fluid outlet line here. The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
3 erratic pump operation.

See Venting Exhaust Air in Fig. 2. Exhaust to a


remote location as follows:

1. Remove the muffler (W) from the pump air exhaust


1
port.

2. Install an electrically conductive air exhaust hose


2 (X) and connect the muffler to the other end of the
hose. The minimum size for the air exhaust hose
is 3/8 in. (10 mm) ID. If a hose longer than 15 ft
(4.57 m) is required, use a larger diameter hose.
Avoid sharp bends or kinks in the hose.

3. Place a container (Z) at the end of the air exhaust


9073A
line to catch fluid in case a diaphragm ruptures.
Fig. 1 See Fig. 2.

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Installation
ABOVE-GROUND TRANSFER INSTALLATION KEY
J A Pump
K B Bleed-type master air valve
A
C (required for pump)
D
C Electrically conductive
air supply line
H D Air line quick disconnect
E Master air valve (for accessories)
E F Air line filter
B G Pump air regulator
F G H Fluid drain valve (required)
J Fluid regulator (optional)
Y N K Electrically conductive
fluid supply hose
L Fluid suction line
M Underground storage tank
N Wall mounting bracket
Y Ground wire (required; see page 8
for installation instructions)
L 9074A

55-GALLON BUNG PUMP INSTALLATION K

KEY A
A Pump C D
C Electrically conductive air supply line H
D Air line quick disconnect
H Fluid drain valve (required)
K Electrically conductive fluid supply hose Y
L Fluid suction line
Y Ground wire (required; see page 8
for installation instructions)

9075A

VENTING EXHAUST AIR


KEY
Z
W Muffler
X Electrically Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust
All wetted and non-wetted pump parts must be
compatible with the fluid being pumped. W
X
04054
Fig. 2
308797 7

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation
Grounding
Ground all of this equipment:
WARNING D Pump: The metal pump has a grounding strip in
front of the center housing. Connect the non-clamp
FIRE AND EXPLOSION HAZARD
end of the ground wire to the grounding strip and
This pump must be grounded. Before
connect the clamp end of the ground wire to a true
operating the pump, ground the system
earth ground. To order a ground wire and clamp,
as explained below. Also read the sec-
order Part No. 222011.
tion Fire and Explosion Hazard on
page 3. D Air and fluid hoses: Use only electrically conductive
hoses.
The metal Husky 716 pumps have a grounding
strip connecting the vee clamps (109). Attach a D Air compressor: Follow the manufacturer’s recom-
ground wire to the grounding strip with the screw, mendations.
lockwasher, and nut as shown in the Grounding D Solvent pails used when flushing: Follow the local
Detail on page 18. code. Use only grounded metal pails, which are
When pumping conductive flammable fluids, al- conductive. Do not place the pail on a non-conduc-
ways ground the entire fluid system by making tive surface, such as paper or cardboard, which
sure the fluid system has an electrical path to a interrupts the grounding continuity.
true earth ground (see Fig. 3). D Fluid supply container: Follow the local code.
US Code (NFPA 77 Static Electricity) recommends
a conductivity greater than 50 x 10--12 Siemans/me- GROUNDING A PUMP
ter (mhos/meter) over your operating temperature KEY
range to reduce the hazard of fire. Consult your A Pump
fluid supplier to determine the conductivity or H Fluid drain valve (required)
S Dispense valve
resistivity of your fluid. The resistivity must be less T Fluid drain line
than 2 x 1012 ohm-centimeters. Y Fluid section grounding via grounding strip or grounding
screw (required for metal and acetal pumps)
Z Container ground wire (required)
To reduce the risk of static sparking, ground the pump
and all other equipment used or located in the pumping 1 Hose must be conductive.
area. Check your local electrical code for detailed
2 Dispense valve nozzle must be in contact with container.
grounding instructions for your area and type of equip- Y
ment. A
H
NOTE: See the WARNING above. Fig. 3 shows a Y
recommended method of grounding flammable fluid
containers during filling. T 1

S 2

9079A
Fig. 3

8 308797

Supporting Parts Manual 96


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation
Changing the Orientation of the Fluid Inlet 1 Torque to 80 to 90 in-lb (9 to 10 NSm). See
and Outlet Ports Torque Sequence, page 20.
outlet

Fig. 4. You can change the orientation of the fluid inlet 1 105
and outlet ports by repositioning the manifolds.

Relieve the pressure. See Pres-


1. sure Relief Procedure on page 10.

2. Remove four manifold bolts (105).

3. Turn manifold to desired position, reinstall bolts,


and torque to 80 to 90 in-lb (9 to 10 NSm). See
Torque Sequence, page 20.
inlet

NOTE: Make sure all manifold o-rings are posi- 1 105


tioned correctly before you fasten the manifold. 9071A
Manifold o-rings (139) are shown in Fig. 6. Fig. 4

308797 9

Supporting Parts Manual 97


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Operation
Pressure Relief Procedure NOTE: If the inlet fluid pressure to the pump is more
than 25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in inefficient
WARNING pump operation.
PRESSURIZED EQUIPMENT HAZARD
6. Place the end of the fluid hose (K) into an appro-
The equipment stays pressurized until pressure is
priate container.
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray, or
7. Close the fluid drain valve (H).
splashing fluid, follow this procedure whenever you
D Are instructed to relieve pressure 8. With the pump air regulator (G) closed, open all
D Stop pumping bleed-type master air valves (B, E).
D Check, clean, or service any system equipment
D Install or clean fluid nozzles 9. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
1. Shut off the air to the pump. Slowly open the air regulator (G) until the pump
starts to cycle. Allow the pump to cycle slowly until
2. Open the dispensing valve, if used. all air is pushed out of the lines and the pump is
primed.
3. Open the fluid drain valve to relieve all fluid pres-
If you are flushing, run the pump long enough to
sure, and have a container ready to catch the
thoroughly clean the pump and hoses. Close the
drainage.
air regulator. Remove the suction tube from the
solvent and place it in the fluid to be pumped.
Flush Pump Before First Use
The pump was tested with water. If water could contai- Operation of Remote Piloted Pumps
minate the fluid you are pumping, flush the pump
1. Fig. 2 and Parts Drawings. Follow preceding steps
thoroughly with a compatible solvent before using the
1 through 8 of Starting and Adjusting Pump.
equipment. Follow the steps under Starting and
Adjusting Pump.
2. Open air regulator (G).
Starting and Adjusting Pump
WARNING
1. Read Toxic Fluid Hazard
on page 3. The pump may cycle once before the external sig-
nal is applied. Injury is possible. If pump cycles,
wait until end before proceeding.

2. If lifting the pump, follow the Pres-


3. Pump will operate when air pressure is alternately
sure Relief Procedure above.
applied to push type connectors (16).

Be sure the pump is NOTE: Leaving air pressure applied to the air motor for
properly grounded. extended periods when the pump is not running may
3. Read Fire and shorten the diaphragm life. Using a 3--way solenoid
Explosion Hazard valve to automatically relieve the pressure on the air
on page 3. motor when the metering cycle is complete prevents
this from occurring.
4. Check all fittings to be sure they are tight. Use a
compatible liquid thread sealant on all male Pump Shutdown
threads. Tighten the fluid inlet and outlet fittings
snugly. Do not overtighten the fittings into the At the end of the work shift, relieve
pump. the pressure as described in Pres-
sure Relief Procedure at left.
5. Place the suction tube (if used) in the fluid to be
pumped.
10 308797

Supporting Parts Manual 98


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance
Lubrication Tightening Threaded Connections
The air valve is lubricated at the factory to operate Before each use, check all hoses for wear or damage
without additional lubrication. If you want to provide and replace as necessary. Check to be sure all
additional lubrication, remove the hose from the pump threaded connections are tight and leak-free.
air inlet and add two drops of machine oil to the air
inlet every 500 hours of operation or every month. Check fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to
CAUTION retorque fasteners every two months. See Torque
Sequence, page 20.
Do not over-lubricate the pump. Oil is exhausted
through the muffler, which could contaminate your Preventive Maintenance Schedule
fluid supply or other equipment. Excessive lubrication
can also cause the pump to malfunction. Establish a preventive maintenance schedule, based
on the pump’s service history. This is especially impor-
Flushing and Storage tant for prevention of spills or leakage due to dia-
phragm failure.
Flush the pump to prevent the fluid you are pumping
from drying or freezing in the pump and damaging it.
Use a compatible solvent.
Always flush the pump and relieve the pressure
before you store it for any length of time.

Read Pressure Relief Procedure


on page 10.

308797 11

Supporting Parts Manual 99


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Troubleshooting
Read Pressure Relief Procedure on page 10, and relieve the pressure before you check or service
the equipment. Check all possible problems and causes before disassembling the pump.

PROBLEM CAUSE SOLUTION


Pump will not cycle, or cycles once Air valve is stuck or dirty. Use filtered air.
and stops.
Pump cycles at stall or fails to hold Leaky check valves or o-rings. Replace.
pressure at stall.
Worn check balls or duckbill valves Replace.
or guides.
Check ball wedged in guide. Repair or replace.
Worn diaphragm shaft seals. Replace.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace.
Loose manifolds or damaged man- Tighten manifold bolts or nuts; re-
ifold o-rings. place o-rings.
Loose fluid side diaphragm plates. Tighten.
Fluid in exhaust air. Diaphragm ruptured. Replace.
Loose fluid side diaphragm plates. Tighten.
Worn diaphragm shaft seals. Replace.
Pump exhausts air from clamps Loose clamps. Tighten clamp nuts.
(metal pumps).
Air valve o-ring is damaged. Inspect; replace.
Pump leaks fluid from check valves. Worn or damaged check valve Inspect; replace.
o-rings.

12 308797

Supporting Parts Manual 100


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service
Air Valve
NOTE: Air Valve Repair Kit 241657 is available. Parts included in the kit are marked with a dagger ({) in Fig. 5 and
in the Parts Drawings and Lists. A tube of general purpose grease 111920 is supplied in the kit. Service the air
valve as follows. See Fig. 5.

1. Relieve the pressure. See NOTES:


Pressure Relief Procedure on D When you install each u-cup packing (2) on each
page 10. carriage plunger (7), make sure the lips of the
u-cup packing face toward the clip end (the
2. Remove the cover (10) and the o-ring (4). smaller end) of the carriage plunger.

3. Remove the carriage plungers (7), carriages (8), D When you slide the carriage plungers (7) into the
carriage pins (9), and valve plate (14) from the bores, slide them in with the clip ends (the smaller
center housing (11). ends) facing toward the center of the center hous-
ing (11).
4. Clean all the parts, and inspect them for wear or
damage. 7. Grease the carriage pins (9), and slide the carriage
pins into the carriage pin bores.
NOTE: If you are installing the new Air Valve
Repair Kit 241657, use all the parts in the kit. 8. Install the carriages (8). Make sure the carriages
engage the clip ends of the carriage plungers (7)
5. Grease the lapped surface of the valve plate (14), and carriage pins (9).
and install the valve plate with the lapped surface
facing up.
9. Grease the o-ring (4), and seat it in the groove
6. Grease the bores of the center housing (11), install around the cover opening of the center hous-
the u-cup packings (2) on the carriage plungers ing (11).
(7), and slide the carriage plungers into the car-
riage plunger bores. See the following important 10. Screw the cover (10) into the center housing, and
installation notes: torque the cover to 80 to 100 in-lb (9.0 to 13.6 N-m).

NOTE: Center housing (11) is {8


shown separated from the air 1 10
covers, but it is not necessary to
remove the air covers for this 5 4 2{ 3 14{
5 4
service. Leave the center {2 4 6 7{
housing and air covers 4 6 {7
assembled for this service.

{ Included in Air Valve Repair Kit 241657 4 2

1 Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).

2 Apply grease.

3 Apply grease to lapped face. 11


4 Apply grease to bores of center housing (11) before installing.

5 Seal lips face clip end (the smaller end) of carriage plunger (7).
9{ 2
Install with the clip ends (the smaller ends) facing toward center
8{
6
of center housing (11). 9{ 2
9069A
Fig. 5
308797 13

Supporting Parts Manual 101


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service
Ball Check Valves 3. Remove all parts shown with a dagger (}) Fig. 6.

NOTE: Fluid Section Repair Kit D05977 is available.


See page 21 to order the correct kit for your pump.
4. Clean all parts, and replace worn or damaged
Parts included in the kit are marked with a double
parts.
dagger (}) in Fig. 6 and in the Parts Drawings and
Lists. General purpose grease 111920 and Adhesive
113500 are supplied in the kit.
5. Reassemble the pump.
1. Relieve the pressure. See
Pressure Relief Procedure on
page 10. NOTE: Torque the manifold bolts (105) to 80 to 90
in-lb (9 to 10 NSm). See Torque Sequence, page
2. Remove the top and bottom manifolds (102, 103). 20.

14 308797

Supporting Parts Manual 102


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service
1 105

107

102

}139

}202
}301

}201

}139
106

101

106

}139

}202

}301

}201
}139

102

1 105

1 Torque to 80 to 90 in-lb (9 to 10 NSm). See


Torque Sequence, page 20. 9081A
Fig. 6

308797 15

Supporting Parts Manual 103


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service
Diaphragms
NOTE: Fluid Section Repair Kit D05977 is available. Parts included in the kit are marked with a double dagger (})
in Fig. 7 and in the Parts Drawings and Lists. General purpose grease 111920 and Adhesive 113500 are supplied
in the kit. Service the diaphragms as follows. See Fig. 7.
Disassembly 3. Position the exhaust cover (13) and o-ring (4) on
the center housing (11).
1. Relieve the pressure. See
Pressure Relief Procedure on 4. Repeat steps 1 and 2 for the other end of the
page 10. center housing and the remaining air cover.

2. Remove the manifolds (102) and fluid cov- 5. Apply medium-strength (blue) Loctite or equivalent
ers (101). to the threads of the screws (140). Install on one
end of the diaphragm shaft (15) the following parts
NOTE: Make sure all the check valve parts stay in (see proper order in Fig. 7): air-side diaphragm
place. See Fig. 6 on page 15. plate (6), diaphragm (401), fluid-side diaphragm
plate (133), o-ring (115), and screw (140).
3. Remove the grounding strip from the vee clamps
(109), and remove the vee clamps. NOTE: The words “AIR SIDE” on the diaphragm
(401) and the flat side of the air-side diaphragm
4. Remove one of the fluid-side diaphragm plates plate (6) must face toward the diaphragm
(133) (whichever one comes loose first when you shaft (15).
use a wrench on the hex of each), and pull the
diaphragm shaft out of the center housing (11). 6. Put grease on the diaphragm shaft (15), and
carefully (do not damage the shaft u-cups) run the
5. Use a wrench on the flats of the diaphragm shaft diaphragm shaft (15) through the center housing
(15) to remove the other fluid-side diaphragm plate (11) bore.
(133) from the diaphragm shaft.
7. Repeat step 5 for the other end of the diaphragm
shaft (15), and torque the diaphragm shaft screws
6. Remove the screws (141) and air covers (136),
(140) to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm
and remove all old gasket (12) material from the
maximum.
ends of the center housing (11) and the surfaces of
the air covers.
8. Install the muffler (3).
7. Remove the diaphragm shaft u-cups (16) and pilot When you install the vee clamps in step 10, orient the
pin o-rings (1). center housing (11) so the air inlet is approximately
45_ above horizontal and the muffler (3) is approxi-
8. Inspect all parts for wear or damage, and replace mately horizontal.
as necessary.
9. Apply thin, even film of grease to inside of vee
Reassembly clamp (109).

1. Insert a diaphragm shaft u-cup (16) and a pilot pin 10. Position the fluid covers (101), install the vee
o-ring (1) into the end of the diaphragm shaft bore clamps (109) around the fluid and air covers,
of the center housing (11). install the grounding strip on the vee clamps, and
torque the vee clamp nuts to 80 to 90 in-lb (9 to 10
NOTE: Make sure the lips of the u-cup face out of NSm). See Torque Sequence, page 20.
the center housing.
11. Make sure all the check valve parts are in place.
2. Line up the holes in the gasket (12) with the holes See Fig. 6 on page 15.
in the end of the center housing (11), and use six
screws (141) to fasten an air cover (136) to the 12. Install the manifolds (102), and torque the manifold
end of the center housing (11). Torque the screws bolts (105) to 80 to 90 in-lb (9 to 10 NSm). See
to 35 to 45 in-lb (4.0 to 5.1 N-m). Torque Sequence, page 20.

16 308797

Supporting Parts Manual 104


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Service
Diaphragms

11
105 16} 1
7
4
13
102
2 141
3

12}

136
3

101
109 4 }402 5 6

4 }401
15 3

102 }16 1
}115 133

6 140

105
7
} Included in Fluid Section Repair Kit D05977

1 Install with lips facing out of center housing (11).

2 Torque to 35 to 45 in-lb (4.0 to 5.1 N-m).

3 Apply grease.

4 The words “AIR SIDE” on diaphragm and backup diaphragm must face
toward diaphragm shaft (15).

5 Flat side of the air-side diaphragm plate must face


toward diaphragm shaft (15).

6 Apply medium-strength (blue) LoctiteR or equivalent


to threads, and torque to 80 to 90 in-lb (9 to 10 N-m) at
100 rpm maximum.

7 Torque to 80 to 90 in-lb (9 to 10 NSm). See


Torque Sequence, page 20.
9072A
Fig. 7

308797 17

Supporting Parts Manual 105


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

241407 and 241408 Parts Drawing


{ Included in Air Valve Repair Kit 241657
10 8{ 7{
} Included in Fluid Section Repair Kit D05977 2{

4
105 102 {14
103
{9
107

112 11

}1 16}
}12
134
}139

}202
4
}301
13
}201
3
}139
106 141 15
}402 6 }16

}401
101
117
106 109
133
}115
}139
140
}202 Grounding Detail
}301

}201

}139 123
102 122
112

121
110
105 108
9070A

18 308797

Supporting Parts Manual 106


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

241407 and 241408 Parts List


Fluid Section Parts List
Ref. Part Description Qty 6 195025 PLATE, diaphragm, air side 2
No. No.
7{ 15Y825 PLUNGER, carriage 2
101 185622 COVER, fluid; aluminum 2
8{ 192595 CARRIAGE 2
102 185624 MANIFOLD; aluminum; NPT 2
9{ 192596 PIN, carriage 2
103 189220 LABEL, warning 1
10 192597 COVER, valve chamber 1
105 112912 SCREW; 3/8--16; 2.25 in. (57.2 8
mm) 11 192602 HOUSING, center 1
106 112913 NUT, hex; 3/8--16; sst 8
12} 192765 GASKET 2
107 112914 WASHER, flat; 3/8 in.; sst 4
13 194247 COVER, exhaust 1
108 186207 BASE, feet 2
14{ 194269 PLATE, valve 1
109 189540 CLAMP, vee 2
15 192601 SHAFT, diaphragm 1
110 112499 NUT, clamp; 1/4--28 2
111 191079 STRIP, grounding 1
112* 102726 PLUG, steel; NPT 2 Guide Parts List
115} 110004 O-RING; PTFE 2
Ref.
117 186205 LABEL, warning 1 No. Part No. Description Qty
121 102790 SCREW; 10--24; 0.31 in. (8 1 201} 186776 GUIDE, polypropylene 4
mm)
202} 186777 STOP, polypropylene 4
122 100718 LOCKWASHER; #10 1
123 100179 NUT, hex; 10--24 1
125* 100896 BUSHING, 3/4 X 1/2 npt 4 Ball Parts List
133 191837 PLATE, diaphragm, fluid side; 2 Ref.
sst No. Part No. Description Qty
134 290045 PLATE, designation 1
301} 108944 BALL, buna-N 4
136 194246 COVER air 2
139} 110636 O-RING; PTFE 8
140 113747 SCREW, flange; hex head 2 Diaphragm Parts List
141 114882 SCREW, machine, torx 12 Ref.
No. Part No. Description Qty
142 111183 RIVET (for plate 134) 2
16} 108808 PACKING, u-cup 2
401} 190148 DIAPHRAGM, buna-N 2
Air Motor Parts List
Ref.
No. Part No. Description Qty * Item 112, 102726 used on 241408, item 125, 100896
used on 241407
1} 114866 PACKING, o-ring 2

2{ 108808 PACKING, u-cup 2


{ Included in Air Valve Repair Kit 241657
3 112933 MUFFLER 1

4{ 162942 PACKING, o-ring 2


} Included in Fluid Section Repair Kit D05977

308797 19

Supporting Parts Manual 107


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Torque Sequence
Always follow torque sequence when instructed to torque fasteners.

1. Left/Right Fluid Covers 3. Outlet Manifold


Torque bolts to 80--90 in--lb (9--10 NSm). Torque bolts to 80--90 in--lb (9--10 NSm).
9
7

2 1

8 10

FRONT VIEW
TOP VIEW

2. Inlet Manifold
Torque bolts to 80--90 in--lb (9--10 NSm).
5
3

4 6

BOTTOM VIEW

20 308797

Supporting Parts Manual 108


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)
Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 100 psi (0.2 to 0.7 MPa, 2.1 to 7 bar )
Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 scfm (0.672 cubic meters/min.)
Maximum free flow delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 gpm (61 l/min)
Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 cpm
Gallons (Liters) per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04(0.15)
Maximum suction lift (water w/buna balls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft (4.5 m) dry,
25 ft (7.6 m) wet
Maximum size pumpable solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/32 in. (2.5 mm)
Sound power level (measured per ISO standard 9614--2)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dBa
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 dBa
Sound pressure level (measured 1 meter from pump)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 dBa
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 dBa
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)
Air exhaust port size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Fluid inlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Fluid outlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Wetted parts (in addition to ball, seat, and diaphragm materials, which vary by pump)
Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, stainless steel, PTFE, zinc-plated steel
Stainless steel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 stainless steel, PTFE
Non-wetted external parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . polypropylene, stainless steel, polyester (labels),
nickel-plated brass, epoxy-coated steel (feet)
Weight (approximate)
Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 lb (3.9 kg)
Stainless steel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 lb (8.2 kg)
Santoprener is a registered trademark of the Monsanto Company.
Loctiter is a registered trademark of the Loctite Corporation.

241407 and 241408 Repair Kits


NOTE: Order Repair Kits separately.

To order the Air Valve Repair Kit, order Part No. 241657.
To order the Fluid Section Repair Kit, order Part No. D05977.

308797 21

Supporting Parts Manual 109


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Husky 716 Dimensions

FRONT VIEW
4.25 in. 4.44 in.
(108.0 mm) (112.8 mm) 3/4 npt(f)
Fluid Outlet *

1/4 npt(f)
Air Inlet

10.43 in.
(264.9
mm)
9.18 in.
(233.2
mm)

7.37 in. 7.80 in.


(187.2 mm) (198.1
mm)

1.38 in.
(35.1 mm)

6.62 in.
(168.1 mm)
SIDE VIEW 3/4 npt(f)
Fluid Inlets * 3/4 npt(f)
2.76 in. Fluid Outlet *
3/4 npt(f) (62.5 mm)
Fluid Outlets *

PUMP MOUNTING HOLE PATTERN


Four 0.28 in.
(7.1 mm)
Diameter Slots

4.29 in.
(109.0 mm)

6.62 in.
(168.1 mm)
4.29 in.
(109.0 mm) 3/4 npt(f)
Fluid Inlets *
6.04 in.
(153.4 mm)

9078A

22 308797

Supporting Parts Manual 110


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Performance Charts
Fluid Outlet Pressure
Test Conditions: Pump tested in water with inlet submerged.
100
(0.7, 7)

A
Fluid Pressure Curves
FLUID OUTLET PRESSURE-- --psi (MPa, bar)

A at 100 psi (0.7 MPa, 7 bar) air pressure


80
(0.55, 5.5) B at 70 psi (0.48 MPa, 4.8 bar) air pressure
C at 40 psi (0.28 MPa, 2.8 bar) air pressure

B
60
(0.41, 4.1)

40
(0.28, 2.8)
C

20
(0.14, 1.4)

0
0 2 4 6 8 10 12 14 16
(7.6) (15.2) (22.7) (30.3) (37.9) (45.4) (53.0) (60.6)

FLUID FLOW-- --gpm (lpm)

To find Fluid Outlet Pressure (psi/MPa/bar) at a


specific fluid flow (gpm/lpm) and operating air
pressure (psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Follow vertical line up to intersection with selected
fluid outlet pressure curve.
3. Follow left to scale to read fluid outlet pressure.

308797 23

Supporting Parts Manual 111


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Performance Charts
Air Consumption
Test Conditions: Pump tested in water with inlet submerged.
30
(0.84) A
Air Consumption Curves
AIR CONSUMPTION-- --scfm (cubic meters/min)

A at 100 psi (0.7 MPa, 7 bar) air pressure


25 B at 70 psi (0.48 MPa, 4.8 bar) air pressure
(0.70)
C at 40 psi (0.28 MPa, 2.8 bar) air pressure

20
(0.56) B

15
(0.42)

C
10
(0.28)

5
(0.14)

0
0 2 4 6 8 10 12 14 16
(7.6) (15.2) (22.7) (30.3) (37.9) (45.4) (53.0) (60.6)

FLUID FLOW-- --gpm (lpm)

To find Pump Air Consumption (scfm or m#/min) at a


specific fluid flow (gpm/lpm) and air pressure
(psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Read vertical line up to intersection with selected air
consumption curve.
3. Follow left to scale to read air consumption.

24 308797

Supporting Parts Manual 112


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

INSTRUCTIONS–PARTS LIST 308788


KEEP FOR REFERENCE. Rev. C
See instruction manual 308479 (supplied) for
important safety warnings and installation, First choice when
operation, and service instructions. quality counts.
INSTRUCTIONS

Husky 1040 Air-Operated


Diaphragm Pumps
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure

Model No. 240623


With BSP manifolds and Tri-Clamp adapters

Model No. 240624


With bare BSP manifolds

US and Foreign Patents Pending

Model No. 240623 shown




GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441


COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

Supporting Parts Manual 113


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts Drawing
3
29
2
11 10
4

17
5
16
6
18 115 
3 7
116 
8
110
9
106
16
17 12
28 10 103
11 22
26 23
25
15 24 117
*402
1 19 104 401* 301*
20 21
403* 202*
105 201*
108*
107 202*

106

101 114

27
* These parts are included in the Pump Repair Kit, which
115 
may be purchased separately. Refer to the Repair Kit 301*
Matrix in instruction manual 308479 to determine the 116 
correct kit for your pump. 202*

 These parts are included in Air Valve Repair Kit 236273, 201*
which may be purchased separately.
202*
 Supplied with Model 240623 only.
 Replacement Danger and Warning labels,
102
tags and cards are available at no cost.



106

 

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts List
Ref. Ref.
No. Part No. Description Qty No. Part No. Description Qty
1 188838 HOUSING, center; alum. 1 101 188860 COVER, fluid; sst 2
2 188854 COVER, air valve; alum. 1 102 193419 MANIFOLD, inlet, BSP thread; 1
sst
3 112179 SCREW, torx, thread forming; 9
M5 x 0.8; 12 mm (0.47 in.) 103 193421 MANIFOLD, outlet, BSP thread; 1
sst
4 188618 GASKET, cover; foam 1
104 188607 PLATE, air side; aluminum 2
5 188855 CARRIAGE; aluminum 1
105 188960 PLATE, fluid side; sst 2
6 108730 O-RING; nitrile 1
106 112178 SCREW; M8 x 1.25; 24
7 188616 BLOCK, air valve; acetal 1 25 mm (1 in.)
8 188615 PLATE, air valve; sst 1 107 189044 BOLT; M12 x 1.75; 2
35 mm (1.38 in.); sst
9 188617 SEAL, valve plate; buna-N 1
108* 104319 O-RING;PTFE  2
10 112181 PACKING, u-cup; nitrile 2
110 188621 LABEL, warning 1
11 188612 PISTON, actuator; acetal 2 
12 188613 BEARING, piston; acetal 2 114 112257 NUT, hex; M8 x 1.25; sst 8
15 188611 BEARING, pin; acetal 2 115 193427 ADAPTER, Tri-Clamp; 1.5 in. 2
16 188610 PIN, pilot; stainless steel 2 Model 240623 only

17 157628 O-RING; buna-N 2 116 193422 GASKET; PTFE  2


Model 240623 only
18 188614 BLOCK, pilot; acetal 1
117 115608 SPRING, compression 2
19 188609 BEARING, shaft; acetal 2
201* 188707 SEAT; 316 stainless steel 4
20 104029 STUD, grounding 1
202* 109205 O-RING;PTFE  8
21 104582 WASHER, tab 1
301* 103869 BALL; 316 stainless steel 4
22 188603 GASKET, air cover; foam 2
401* 188606 DIAPHRAGM; Hytrel 2
23 188839 COVER, air; aluminum 2
402* 112181 PACKING, u-cup; nitrile 2
24 188608 SHAFT, diaphragm; sst 1
403* 188605 DIAPHRAGM;PTFE  2
25 112178 SCREW; M8 x 1.25; 12
25 mm (1 in.)
26 290045 PLATE, designation 1
27 188620 LABEL, identification 2
28 111183 RIVET 2
29 189989 LABEL, CE 1

 

Supporting Parts Manual 115


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

GENUINE GRACO PARTS AND ACCESSORIES

Fluid Section Repair Kits 406266E


®
Husky 1040 Diaphragm Pumps EN

Important Safety Instructions


Read all warnings and instructions in the Husky®
1040 Diaphragm Pump Repair/Parts manual.
Save all instructions.

C 6

402* 1 B

3 401* 4
301*

201* 9

25 6 202* 8

A 7
1 Lips face out of housing (C).
2 Grease.

403* 6
3 Rounded side faces diaphragm (401). 3 108*
4 5 10
4 Air Side must face center housing (C).
8
5 Used on Models with PTFE diaphragms only.
301*
6 Apply medium-strength (blue) Loctite or equivalent. Torque to 120 to
150 in-lb (14 to 17 N•m).
201* 9
7 Arrow (A) must point toward outlet manifold (B).

8 Not used on some models. 202* 8

9 Beveled seating surface must face ball (301).

10 Apply medium-strength (blue) Loctite or equivalent. Torque to 20 to 25


ft-lb (27 to 34 N•m) at 100 rpm maximum. 6

Loctite® is a registered trademark of the Loctite Corporation. 4406a


NOTE: Reference numbers refer to the parts list in manual 308479. See manual for Metal Pumps
torque sequences.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 1994, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
406266, Rev. E, July 2015

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

402* 1

3 401* 4
301*
201* 9

202* 8

25 6
A 7

403* 10
10
4 5

11 11

1 Lips face out of housing (C). 301*


2 Grease.

3 Rounded side faces diaphragm (401).


201* 9

4 Air Side must face center housing (C). 202* 8

5 Used on Models with PTFE diaphragms only.

6 Apply medium-strength (blue) Loctite or equivalent. Torque to 80 to 90


in-lb (9 to 10 N•m).
7 Arrow (A) must point toward outlet manifold (B).

8 Not used on some models. 6


4334a
9 Beveled seating surface must face ball (301).
Plastic Pumps
10 Apply medium-strength (blue) Loctite or equivalent. Torque to 20 to 25
ft-lb (27 to 34 N•m) at 100 rpm maximum.

11 Apply medium-strength (blue) Loctite or equivalent. Torque to 130 to


150 in-lb (14 to 17 N•m).

Loctite® is a registered trademark of the Loctite Corporation.


NOTE: Reference numbers refer to the parts list in manual 308443. See manual for
torque sequences.

2 406266E

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Instructions

SD and XD Series
Hose Reels 313431V
EN

For dispensing air, water, antifreeze, windshield washer solvent, transmission fluid, oil and
grease. For professional use only.
Not approved for use in European explosive atmosphere locations.

A complete list of Models, including Maximum Working


Pressure, begins on page 2. Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

SD Series XD Series XD Series


(HP Models) (HS Models) (HN Models)

Table of Conents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mounting Channel Dimensions . . . . . . . . . . . . . . . 42
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Graco Hose Reel Warranty . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts SD Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts XD Series; HS Models . . . . . . . . . . . . . . . . . 28
Parts XD Series; HN Models . . . . . . . . . . . . . . . . . 31
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Supporting Parts Manual 118


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

XD 10 , XD 20 and XD 30 Hose Reels


™ ™ ™

Hose Reels and Packages

Features and Benefits


• Designed for robust/heavy-duty applications such as mobile lube trucks or large equipment
service, yet with a narrow footprint to fit more reels into small spaces
• Dual pedestal frame provides increased strength for extreme-duty applications
• Long lasting spring is sealed for protection against the weather
• Durable steel spool rides on sealed roller bearings to ensure trouble-free performance
• Available in four colors. Metallic blue is standard
• Available with arms removed for bulkhead mounting

Typical Applications Dimensions


• Heavy-duty truck dealers XD 10
• Fleet maintenance A 7.5 in (196 mm)
• Mining maintenance B 16.2 in (412 mm)
XD 10
• Public works garages C 21.0 in (533 mm)
• Construction vehicle maintenance D 18.0 in (457mm)
• Heavy-duty mobile service trucks
E 18.5 in (470 mm)
• Mining
F 22.5 in (571 mm)

Typical Fluids Handled


XD 20
Reels and Packages

• Petroleum- and synthetic-based oils


A 7.5 in (196 mm)
• Grease
B 18.1 in (460 mm)
• Fuel
C 23.4 in (594 mm)
• Pressure wash
• Air D 20.0 in (508 mm)

• Water E 21.0 in (533 mm)


• Anti-freeze F 25.2 in (640 mm)
• Windshield washer
XD 30
• Waste oil
A 9.0 in (229 mm)
Note: Hose Inlet Kit for all XD Reels sold separately.
B 21.50 in (546.00 mm)
C 25.96 in (659.45 mm) XD 20
D 22.12 in (561.73 mm)
E 23.10 in (588.00 mm)
F 27.60 in (700.82 mm)

A F
E

XD 30

B
C

64 www.graco.com

Supporting Parts Manual 119


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

XD 10 , XD 20 and XD 30 Hose Reels


™ ™ ™

Hose Reels and Packages

Ordering Information Technical Specifications


Model numbers by color Pressure Hose Connection Size
Operating
Applications id Length Inlet Outlet
Metallic Blue White Yellow Desert Sand psi (bar) Temp.
in ft (m) in in
HSL25B HSL25A HSL25F HSL25G 3/8 50 (15) 3/8 npt(m)
XD 10

HSL33B HSL33A HSL33F HSL33G 1/2 35 (11) 1/2 npt(m) -20–190º F


Air, Water, (-28–87º C)
HSL56B HSL56A HSL56F HSL56G 3/8 65 (20) 1/2 npsm(m) 3/8 npt(m)
Anti-Freeze,
XD 20

300 (20.7)
Windshield HSL65B HSL65A HSL65F HSL65G 1/2 50 (15) 1/2 npt(m)
Washer Fluid
HSLC8B HSLC8A HSLC8F HSLC8G 1/2 75 (23) 1/2 npt(m) -40–180º F
XD 30

HSLD5B HSLD5A HSLD5F HSLD5G 3/4 50 (15) 3/4 npsm(m) 3/4 npt(m) (-40–82º C)

HSM33B HSM33A HSM33F HSM33G 35 (11) 1/2 npt(m)


XD 10

HSM3BB* HSM3BA* HSM3BF HSM3BG 35 (11) 1/2 npt(f) -20–190º F


2,000 (138)
(-28–87º C)
HSM65B HSM65A HSM65F HSM65G 50 (15) 1/2 npt(m)
XD 20

1/2 1/2 npsm(m)


Petroleum– HSM6DB* HSM6DA* HSM6DF* HSM6DG 50 (15) 1/2 npt(f)
and Synthetic–
Based Oils HSMC8B HSMC8A HSMC8F HSMC8G 1,500 (103) 75 (23) 1/2 npt(m)

Reels and Packages


HSMCFB* HSMCFA* HSMCFF* HSMCFG* 2,000 (138) 75 (23) 1/2 npsm(f) -40–180º F
XD 30

HSMD5B HSMD5A HSMD5F HSMD5G 1,250 (86) 3/4 3/4 npt(m) (-40–82º C)
50 (15) 3/4 npsm(m)
HSMDDB* HSMDDA* HSMDDF* HSMDDG* 2,000 (138) 3/4 3/4 npsm(f)

HSH15B HSH15A HSH15F HSH15G 1/4 50 (15) 3/8 npsm(m) 1/4 npt(m)
XD 10

8,000 (552)
HSH1DB* HSH1DA* HSH1DF* HSH1DG* 3/8 35 (11) 3/8 npt(f) -40–200º F
(-40º–93º C)
HSH55B HSH55A HSH55F HSH55G 4,000 (276) 1/4 npt(m)
XD 20

3/8
Grease HSH5DB* HSH5DA* HSH5DF* HSH5DG* 8,000 (552) 3/8 npsm(f)
50 (15) 1/2 npsm(m)
HSHC5B HSHC5A HSHC5F HSHC5G 1/2 npt(m)
1/2 -40–180º F
XD 30

HSHCDB* HSHCDA* HSHCDF* HSHCDG* 5,000 (345) 1/2 npsm(f)


(-40–82º C)
HSHB7B HSHB7A HSHB7F HSHB7G 3/8 75 (23) 3/8 npt(f)

HSPB8B HSPB8A HSPB8F HSPB8G 3/8 npt(m)


4,000 (276) 3/8 75 (23)
-20–225º F
XD 30

Pressure Wash HSHFFB* HSHFFA* HSHFFF* HSHFFG* 1/2 npsm(m) 3/8 npsm(f)
(-28–107º C)
HSPC5B HSPC5A HSPC5F HSPC5G 4,500 (310) 1/2 50 (15) 1/2 npt(m)

-40–120º F
XD 30

Fuel/Evacuation HSLE3B HSLE3A HSLE3F HSLE3G 125 (8.6) 1 30 (9) 3/4 npsm(m) 1 npt(m)
(-40–49º C)

HSDD5B HSDD5A HSDD5F NA 12–140º F


XD 30

DEF 50 (3.4) 3/4 50 (15) 3/4 bspp(m) 3/4 bspp ORB


HSDDDB* HSDDDA HSDDDF NA (-11–60º C)

Maximum dry weight with hose: XD10 = 54 lbs (24.5 kg), XD20 = 59 lbs (27 kg), XD30 = 98 lbs (44.5 kg)
Wetted parts–Bare hose reel only: zinc plated steel, anodized aluminum, nitrile rubber
Instruction Manuals: XD10 and XD20: 313431, XD30: 3A0138
* Bare reel–hose sold separately

www.graco.com 65

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

XD 10 , XD 20 and XD 30 Hose Reel Accessories


™ ™ ™

Hose Reels and Packages

Ordering Information
XD Enclosure Kits Provides protection to extend the life of hose and bearings for XD reels Mounting Channel

Reel Enclose kits for White Metallic Blue Red Black Dark Blue Yellow
One Reel
XD 10 Enclosure 24N331 24N332 24N333 24N334 24N335 24N336
XD 20 Enclosure 24N337 24N339 24N340 24N341 24N342 24N343
XD 10 End Caps (2) — — — 24A950 — —
XD 20 End Caps (2) — — — 24A951 — —
Enclosed Reel
Enclosure mounting channel kits include all parts for mounting hose reels to walls or ceilings
Mounting Channel
Description 1 Reel 2 Reels 3 Reels 4 Reels 5 Reels 6 Reels
Retrofit Bracket to
XD Enclosed 24N323 24N324 24N325 24N326 24N327 24N328
fit 500 Series
Open Reel Accommodates one, two, three, four, five or six reels (includes all parts for wall or ceiling mounts)
Mounting Channel
1 Reel 2 Reels 3 Reels 4 Reels 5 Reels 6 Reels
XD 10/XD 20 Open 24A219 24A220 24A221 — — 24A222
Retrofit Adapter Kits
24A224 Includes all parts to mount hose reel to existing 500 series mounting pattern
24C100 Includes all parts to convert SD10 hose reels to fit existing 250 series enclosures
Mounting Bracket
Reels and Packages

Mounting Bracket
Secures mounting channel to I-beam without drilling. Two brackets are required for 1-3 hose
204741
reels; three brackets for 4-6 hose reels
Ball Stop Kits Typical Hose I.D.
222225 For 1/4 in (6.4 mm) I.D. hose (Not for use with XD30, 700 or 750)
218340 For 1/4-3/8 in (6.4-9.5 mm) I.D. hose (Not for use with XD30, 700 or 750)
218341 .782 I.D. used for 3/8 in and 1/2 in (9.5 mm and 12.7 mm) hose (Not for use with XD 30, 700 or 750) Ball Stop Kit
237872 1.0 I.D. used for 5/8 in (15.9 mm) hose
237873 1.123 I.D. used for 3/4 in (19.1 mm) hose
237874 1.374 I.D. used for 1 in (25.4 mm) hose
24D132 For 3/8 in (9.5 mm) O.D. hose
24D133 For 1/2 in (12.7 mm) O.D. hose
Hose Inlet Kits for XD 10 and XD 20 Pressure psi (bar) Hose id in (mm) Length in (mm) Hose Inlet
218549 Low/medium pressure 2000 (137) 1/2 (12) 24 (610) npt(m)
218550 High pressure 4000 (276) 3/8 (10) 24 (610) npt(m)
224417 High pressure 5000 (345) 1/4 (6) 24 (610) npt(m)
Hose Inlet Kits for XD 30 Pressure psi (bar) Hose id in (mm) Length in (mm) Hose Inlet
24E283 High pressure 5000 (345) 1/2 (12) 24 (610) npt(m)
24E284 Low/medium pressure 1250 (86) 3/4 (19) 24 (610) npt(m)
24E285 Low pressure (for fuel) 125 (8.6) 1/2 (12) 24 (610) npt(m)
DEF Hoses
124875 DEF hose, 2 ft, 3/4 in BSPP (M) x cut end (inlet hose) Hose Reel Enclosure
124581 DEF hose, 6 ft, 3/4 in BSPP (M) x cut end (inlet hose)
Valve Hanger Kit
224444 Mounts to side of reel to allow hanging of non-metered and high flow dispensing valves
Metal Label Kits (includes one 3/4 in x 4-1/4 in (1.9 cm x 10.8 cm) metal label and mount)
218670 Motor oil 218675 Air 218674 Hydraulic Oil
218671 Grease 218676 Water 218673 ATF
218672 Gear lube 218677 Anti-Freeze 218678 Evacuation
Self Adhesive Identification Label Set
Set includes: 1 in x 5 in (25.4 mm x 127 mm) hose reels labels for Anti-Freeze, Water, SAE 5-40,
180698
SAE 10-40, SAE 20W, Hydraulic, Gear, SAE 10W, SAE 10-30, SAE 30W, Dexron, Air, Chassis, ATF

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Models

Models
SD Series (Part List page 25)
*Each HP Model hose reel shown in the tables below is available in several colors. The last character of each Model
No. indicates the hose reel color. For example: A = white + NPT, B = metallic blue + NPT, C = red + NPT, D = black +
NPT, E = Mercedes blue + NPT, F = yellow + NPT, J = white + BSPP, K = metallic blue + BSPP, L = red + BSPP, M =
black + BSPP, N = yellow + BSPP, P = white + BSPT, R = metallic blue + BSPT, S = red + BSPT, T = black + BSPT, or
U = yellow + BSPT. (Other color choices may be available from your Graco Distributor.) On the table below this last
character is represented by the generic # symbol. For example, to show the complete model number for a white
HPL56# model hose reel, the # symbol in the table is replaced with “A”. The complete model number is: HPL56A.

Pressure Connection Size


Rating Line Size Length
Model No.* Size Type psi (MPa, bar) Media Inlet Outlet (inches) (feet)

Air/Water 3/8 npsm(m) 1/2 npsm(f) 3/8 50


HPL2D# 10 Bare 300 (2.1, 20.7)
3/8 bspp(m) 1/2 bspp(f)
Air/Water 1/2 npsm(m) 1/2 npsm(f) 1/2 50
HPL6D# 20 Bare 300 (2.1, 20.7)
1/2 bspp(m) 1/2 bspp(f)
Air/Water 3/8 npt(m) 3/8 35
1/2 npsm(m)
HPL23# 10 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 3/8 npt(m) 3/8 50
1/2 npsm(m)
HPL25# 10 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 3/8 npt(m) 3/8 65
1/2 npsm(m)
HPL56# 20 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 3/8 npt(m) 3/8 65
1/2 npsm(m)
HPL5J# 20 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 1/2 npt(m) 1/2 35
1/2 npsm(m)
HPL33# 10 Hose 300 (2.1, 20.7) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Air/Water 1/2 npt(m) 1/2 50
1/2 npsm(m)
HPL65# 20 Hose 300 (2.1, 20.7) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Air/Water 1/2 npt(m) 1/2 50
1/2 npsm(m)
HPL6H# 20 Hose 300 (2.1, 20.7) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Oil 1/2 npsm(m) 1/2 npsm(f) 1/2 35
HPM3B# 10 Bare 2000 (14, 138)
1/2 bspp(m) 1/2 bspp(f)
Oil 1/2 npsm(m) 1/2 npsm(f) 1/2 50
HPM6D# 20 Bare 2000 (14, 138)
1/2 bspp(m) 1/2 bspp(f)
Oil 1/2 npt(m) 1/2 35
1/2 npsm(m)
HPM33# 10 Hose 2000 (14, 138) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Oil 1/2 npt(m) 1/2 50
1/2 npsm(m)
HPM65# 20 Hose 2000 (14, 138) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Oil 1/2 npt(m) 1/2 50
1/2 npsm(m)
HPM6H# 20 Hose 2000 (14, 138) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Grease 3/8 npsm(m) 3/8 npsm(f) 1/4 50
HPH1D# 10 Bare 5000 (35, 344.7)
3/8 bspp(m) 3/8 bspp(f)
Grease 3/8 npsm(m) 3/8 npsm(f) 3/8 50
HPH5D# 20 Bare 5000 (35, 344.7)
3/8 bspp(m) 3/8 bspp(f)

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Models

Pressure Connection Size


Rating Line Size Length
Model No.* Size Type psi (MPa, bar) Media Inlet Outlet (inches) (feet)

Grease 1/4 npt(m) 1/4 50


3/8 npsm(m)
HPH15# 10 Hose 5000 (35, 344.7) 1/4 bspp(m)
3/8 bspp(m)
1/4 bspt(m)
Grease 1/4 npt(m) 3/8 35
3/8 npsm(m)
HPH23# 10 Hose 4800 (33, 331) 1/4 bspp(m)
3/8 bspp(m)
1/4 bspt(m)
Grease 1/4 npt(m) 3/8 50
3/8 npsm(m)
HPH55# 20 Hose 4800 (33, 331) 1/4 bspp(m)
3/8 bspp(m)
1/4 bspt(m)
Grease 1/4 npt(m) 3/8 50
3/8 npsm(m)
HPH5H# 20 Hose 4800 (33, 331) 1/4 bspp(m)
3/8 bspp(m)
1/4 bspt(m)

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Models

XD Series (Parts List page 28)


**Each HS or HN Model hose reel shown in the table below is available in either white, metallic blue or yellow. The
last character of each Model No. indicates the hose reel color. For example: A = white + NPT, B = metallic blue +
NPT, F = yellow + NPT, J = white + BSPP, K = metallic blue + BSPP, N = yellow + BSPP, P= white + BSPT, R = metal-
lic blue + BSPT, or U = yellow + BSPT. (Other color choices may be available from your Graco Distributor.) On the
table below this last character is represented by the generic # symbol. For example to show the complete model
number for a white HSL2D# model hose reel, the # symbol in the table is replaced with “A”. The complete model
number is: HSL2DA.

Pressure Connection Size


Rating Line
Model psi (MPa, Size Length
No.** Size Type bar) Media Inlet Outlet (inches) (feet)

HSL2D# 10 Bare 300 (2.1, 20.7)


Air/Water 1/2 npsm(m) 3/8 npsm(f) 3/8 50
1/2 bspp(m) 3/8 bspp(f)

HSL6D# 20 Bare 300 (2.1, 20.7)


Air/Water 1/2 npsm(m) 1/2 npsm(f) 1/2 50
1/2 bspp(m) 1/2 bspp(f)
Air/Water 1/2 npsm(m)
3/8 npt(m) 3/8 50
HSL25# 10 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 1/2 npsm(m)
1/2 npsm(m) 1/2 35
HSL33# 10 Hose 300 (2.1, 20.7) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt (m)
Air/Water 1/2 npsm(m)
3/8 npt(m) 3/8 65
HSL56# 20 Hose 300 (2.1, 20.7) 3/8 bspp(m)
1/2 bspp(m)
3/8 bspt(m)
Air/Water 1/2 npsm(m)
1/2 npt(m) 1/2 50
HSL65# 20 Hose 300 (2.1, 20.7) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)

HSM3B# 10 Bare 2000 (14, 138)


Oil 1/2 npsm(m) 1/2 npsm(f) 1/2 35
1/2 bspp(m) 1/2 bspp(f)

HSM6D# 20 Bare 2000 (14, 138)


Oil 1/2 npsm(m) 1/2 npsm(f) 1/2 50
1/2 bspp(m) 1/2 bspp(f)
Oil 1/2 npsm(m)
1/2 npt(m) 1/2 35
HSM33# 10 Hose 2000 (14, 138) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)
Oil 1/2 npsm(m)
1/2 npt(m) 1/2 50
HSM65# 20 Hose 2000 (14, 138) 1/2 bspp(m)
1/2 bspp(m)
1/2 bspt(m)

5000
Grease 3/8 npsm(m)
1/4 npt(m) 1/4 50
HSH15# 10 Hose 1/4 bspp(m)
(34, 344.7) 3/8 bspp(m)
1/4 bspt(m)

HSH1D# 10 Bare
8000 Grease 3/8 npsm(m) 3/8 npsm(f) 1/4 50
(55, 551.6) 3/8 bspp(m) 3/8 bspp(f)

HSH5D# 20 Bare
8000 Grease 3/8 npsm(m) 3/8 npsm(f) 3/8 50
(55, 551.6) 3/8 bspp(m) 3/8 bspp(f)
Grease 3/8 npsm(m)
1/4 npt(m) 3/8 50
HSH55# 20 Hose 4800 (33, 331) 1/4 bspp(m)
3/8 bspp(m)
1/4 bspt(m)
HNL56# 20 Hose 300 (2.1, 20.7) Air/Water 1/2 npsm(m) 3/8 npt(m) 3/8 65

HNL65# 20 Hose 300 (2.1, 20.7) Air/Water 1/2 npsm(m) 1/2 npt(m) 1/2 50

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Models

Pressure Connection Size


Rating Line
Model psi (MPa, Size Length
No.** Size Type bar) Media Inlet Outlet (inches) (feet)
HNM65# 20 Hose 2000 (14, 138) Oil 1/2 npsm(m) 1/2 npt(m) 1/2 50

HNH55# 20 Hose 4800 (33, 331) Grease 3/8 npsm(m) 1/4 npt(m) 3/8 50

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.

WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in the work area.
• Use only grounded hoses.
• 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.

EQUIPMENT MISUSE HAZARD


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

SKIN INJECTION HAZARD


High-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispense valve at anyone or at any part of the body.
• Do not put your hand over the end of the dispense nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

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Warnings

WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

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 Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Typical Installation

Typical Installation

A ground wire (G), bleed-type master air valve (E) and


fluid drain valve (H) are required in your system installa-
tion. These components help reduce the risk of serious
injury, including electric shock and splashing in your eyes
or on the skin.
• The ground wire must be connected to the pump
grounding lug and to a true each ground according to
your local code.
• The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is shut
off. Trapped air can cause the pump to cycle unexpect-
edly Locate the valve close to the pump.
• The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose and gun. Trigger-
ing the valve to relieve pressure may not be sufficient.

Overhead-Mounted Hose Reel

A
J
K

F L
B
D E
C G P

H
N

03791

FIG. 1: Typical Installation

Key:
A Main air supply line H Fluid drain valve (required)
B Pump air supply line J Fluid shutoff valve
C Air filter K Fluid line
D Air regulator L Hose reel fluid inlet kit
E Bleed-type master air valve (required) M Hose reel
F Pump N Dispensing valve
G Pump grounding wire (required) P Mounting channel/base

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Installation

Installation
The typical installations shown in FIG. 1 is only a guide Fluid Line Components
for selecting and installing a hose reel system. The com-
ponents shown are the minimum requirements for all Install the following components in the order shown in
systems. However, it is not an actual system design. FIG. 1, using adapters if necessary.
Contact your Graco distributor for assistance in design-
ing a system to suit your needs. • Fluid Drain Valve (H): install the drain valve point-
ing down but so the handle points up when the valve
NOTE: The air and fluid accessories required for your is open.
pump must be properly sized to that pump. Refer to your
specific pump manual for selecting pump accessories. • Fluid Shutoff Valve (J): shuts off fluid to hose reel.

• Dispensing Valve (N): dispenses the fluid or air.


Air Line Components
Required Components
Be sure you have the following components before you
begin the installation.

Install the following components in the order shown in • Hose inlet kit (L)
FIG. 1, using adapters if necessary.
• Reel mounting bases, mounting brackets and
• Bleed-type Master Air Valve (E): locate down- mounting channels (P)
stream from the air regulator and for easy access
from the pump. • Dispense valves (N)

• Air Regulator (D): controls pump speed and outlet


pressure by adjusting the air pressure to the pump.
Locate the regulator close to the pump but upstream
from the bleed-type master air valve.

• Air Line Filter (C): removes harmful dirt and mois-


ture from the compressed air supply.

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Installation

Installation Mounting Options All Mountings

Mounting Adapter Kit for Replacing Series


500 Reels
To reduce the risk of injury, be sure the mounting sur-
A Mounting Adapter Kit is available for installing an XD face is strong enough to support the reels, weight of
Series Hose Reel in the same location that a Series 500 the lubricants and stress caused by hard pulls on the
Hose Reel was previously installed. Order Graco Kit No. service hoses. See Technical Data, page 38 for
24A224. See FIG. 2 and page 36. weights of hose reel assemblies.
A = Original Series 500 holes in mounting surface.
B = Holes on the bottom of adapter bracket, predrilled to NOTE: Reels perform best when arm allows hose to pull
match original Series 500 hole configuration (A). straight off the spool as shown in FIG. 3.
C = Holes on the top of the adapter bracket, predrilled to
match new XD Series Hose Reel base. HP, HS Models

A B

Adapter 24A224

XD base

C
ti13258
mounting
surface
ti13795 Panel Mount (HN) Models
FIG. 2

FIG. 3

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Installation

NOTE: Always use all 4 large flat washers with 4 bolts to • HS Model Reels
mount the hose reel pedestal to any surface.
a. Secure spool against pedestal with C-Clamp.

All Models b. Remove 8 nuts (b) (4 from each side) and


rotate arm (a) to desired position.
Select the reel bank mounting location.
c. Check pawl to make sure it is not wedged.
• For high ceilings, suspend a suitable support See FIG. 5.
structure for the reels, so the hoses will be long
enough to reach your service area.
• A reel bank mounted in a one-lift service bay DD a
should be at least 6-ft (1.9m) from the center
line of the lift (FIG. 6). AA*

• In a one-lift bay, mount the reel bank at least 6


EE
feet (1.9 m) from the center line of the lift. In a
two-lift bay, mount the bank equal distance
between the lifts.
BB
• A bank of all motor oil reels should be mounted
about 5 ft (1.5m) from the center of the lift,
toward the front of the lift rails (FIG. 6).
FF
HP or HS Models Only b
1. Determine the desired position of the roller support
arm (a) (FIG. 4). CC

The hose reel is factory-assembled and shipped ti12199a


with the roller support arm (a) in either the AA or EE AA Shipping Position
position:
a DD
• AA for HP Models that do not have an H or J in
the 5th number position of the model number AA
• EE for HP Models showing an H or J in the 5th
number position of the model number **EE

• EE for all HS Models

If shipping position AA or EE is desired, skip BB


step 2.

FF
b

2. To reposition roller support arm to any other position


than the Ship Position (AA or EE): CC

• HP Model Reels ti13394


EE Shipping Position
a. Secure spool against pedestal with C-Clamp.
FIG. 4
b. Remove 4 nuts (b) and rotate arm (a) to
desired position.

c. Check pawl to make sure it is not wedged.


See FIG. 5.

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Installation

Overhead Installations 4. Bolt hose reel to its mounting. Be sure it is secure


before lowering the lift truck.

To reduce the risk of injury, when you are mounting a


hose reel overhead, always use a lift truck.
1

HS Models Only
1. Reposition guide arm to position AA. See Step 2 for
HS Model Reels (above). 3

Incorrect

ti13351

1 5 ft (1.5m) minimum for motor oil

2 6 ft (1.9m) minimum for 1 lift

3 Center between two lifts

FIG. 6

Correct
5. Connect inlet supply line to inlet hose of the reel.
See Hose Installation, page 17.

NOTE: None of the hose reels listed in this manual


come with a Hose Inlet Kit.

6. Flush system.

FIG. 5 To avoid contaminating the fluid with line-scale,


chips or other installation debris, before installing
2. Position the hose reel so the pedestal is facing up. meter or dispense valve to end of hose, flush the
equipment with a compatible solvent such as Stod-
3. Using the lift truck, raise the reel as close to the dard solvent or mineral spirits.
mounting location as possible.
a. Secure the end of the hose in a waste bucket.

b. Blow out entire lubricant supply line with air.

c. Pump solvent through line until fluid runs clear


and is debris free.

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Installation

d. Pump lubricant through line until all solvent is 8. Install meter or dispense valve to end of hose follow-
flushed out. ing instructions provided with the dispense equip-
ment. (NOTE: If installing an enclosure around hose
7. Re-position hose stop if needed so hose extends far reel, install the enclosure before installing dispense
enough for all operators to reach dispensing valve valve or meter to hose end.)
and tighten nuts to securely hold hose stop in place.
9. Adjust spring tension, page 18.

Other Mounting Options


Ceiling Mounting Without an I-Beam - Open Channel (All Models)
• For HP Model Reels Order Mounting Kit: 24A934, 24A935, 24A936, 24A937, 24A938 or 24A939. For HS or HN
Model Reels Order Mounting Kit: 24A219, 24A220, 24A221, 24A222.
• See page 42 for mounting channel dimensions.

HP Models: Open Channel Mounting Kits HS Models: Mounting Kits


24A934 24A935 24A936 24A937 24A938 24A939 24A219 24A220 24A221 24A222
FN Description 1 Reel 2 Reels 3 Reels 4 Reels 5 Reels 6 Reels 1 Reel 2 Reels 3 Reels 6 Reels
101 PLATE, hold down 1 2 3 4 5 6
SCREW, 3/8” - 16 x
102 5 10 15 20 25 30 4 8 12 24
5/8”
103 WASHER, lock, 3/8” 5 10 15 20 25 30 4 8 12 24
104 BASE, reel 1 2 3 4 5 6
105 BASE, reel, channel 1 1 1 1 1 1 1 1 1 1

1. Install the mounting channel (105) and (HP Models)


base plate (104) as shown in FIG. 7.

104 105
2. Slide hose reel into the base plate (104) and install
101
103 the hold-down plate (101), washer (103) and cap-
screw (102). Tighten the screw firmly (FIG. 7, page
102 13).

3. If you are installing permanent supply lines, drill 1.5


in. (38 mm) diameter holes through the ceiling
toward the inlet side of the reels.

4. Continue installation following steps 5 - 9 of Over-


head Installations instructions, beginning on page
12.

ti13185

FIG. 7

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Installation

Ceiling Mounting Directly to an Ceiling Mounting to I-Beam without Drilling


Holes - All models
I-Beam - HP Models Only
(Order Mounting Bracket Kit: 204741 for open or
1. Using the template (B), provided, drill holes in the enclosed reels.)
I-Beam (C) (FIG. 8).
NOTE: For mounting 1-3 reels, two kits are required. For
mounting 4-6 reels, three kits are required.

2. Bolt reel to I-Beam.

3. If you are installing permanent supply lines, drill 1.5


in. (38 mm) diameter holes through the ceiling FN Description Qty
toward the inlet side of the reels. 201 WASHER, lock, 1/2” 4
202 SCREW, 1/2” - 13 x 1” 2
203 SCREW, 1/2” - 13 x 1-3/4” 2
204 NUT 1/2” - 13 2
NUT, spring clamp (not
205 2
shown)
206 CLAMP, beam 2
A 207 CHANNEL, unistrut 1
C
1. Secure mounting brackets (D) to the channel. Use
B two mounting brackets for each 1- to 3 capacity
mounting channel (103). (Use 3 brackets for 4-6 reel
channels.)
ti13186
FIG. 8 2. Position the adjustable clamps (206) of the mount-
ing brackets over the I-Beam (A), and tighten them
securely (FIG. 9).
4. Continue installation following steps 5 - 9 of Over-
head Installations instructions, beginning on page 3. HP Model Reels only (FIG. 7, page 13): Slide hose
12. reel onto the base plate (104) and install the
hold-down plate (101), washer (103) and capscrew
(102). Tighten the screw firmly.

4. If you are installing permanent supply lines, drill 1.5


in. (38 mm) diameter holes through the ceiling
toward the inlet side of the reels.

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Installation

5. Connect inlet supply line to inlet hose of the reel. c. Pump solvent through line until fluid runs clear
See Hose Installation, page 17. and is debris free.

202 201 203


d. Pump lubricant through line until all solvent is
flushed out.
206
7. Position hose stop so hose extends far enough for
all operators to reach dispensing valve and tighten
nuts to securely hold hose stop in place.

8. Install meter or dispense valve to end of hose follow-


204
ing instructions provided with the dispense equip-
D ment. (NOTE: If installing an enclosure around hose
reel, install the enclosure before installing dispense
valve or meter to hose end.)
103
9. Adjust spring tension, page 18.

ti13188

A
203
206 201

205

207
D
201 / 202 / 204 ti13187

FIG. 9

NOTE:

• The hose reels listed in this manual do not come


with a Hose Inlet Kit.

6. Flush system.

To avoid contaminating the fluid with line-scale,


chips or other installation debris, before installing
meter or dispense valve to end of hose, flush the
equipment with a compatible solvent such as Stod-
dard solvent or mineral spirits.

a. Secure the end of the hose in a waste bucket.

b. Blow out entire lubricant supply line with air.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation

Wall Mounting
(For HP Model Reels Order Mounting Kit: 24A934, 24A935, 24A936, 24A937, 24A938 or 24A939.
For HS or HN Model Reels Order Mounting Kit: 24A219, 24A220, 24A221, 24A222.)

HP Models: Open Channel Mounting Kits HS / HN Models: Mounting Kits


24A934 24A935 24A936 24A937 24A938 24A939 24A219 24A220 24A221 24A222
FN Description 1 Reel 2 Reels 3 Reels 4 Reels 5 Reels 6 Reels 1 Reel 2 Reels 3 Reels 4 Reels
101 PLATE, hold down 1 2 3 4 5 6
SCREW, 3/8” x 16 x
102 5 10 15 20 25 30 4 8 12 24
5/8”
103 WASHER, lock,3/8” 5 10 15 20 25 30 4 8 12 24
104 BASE, reel 1 2 3 4 5 6
105 BASE, reel channel 1 1 1 1 1 1 1 1 1 1

1. Adjust guide arm to desired position, FIG. 4, page NOTE:


11.
• The hose reels listed in this manual do not come
2. Select the reel bank mounting location. Mount the with a Hose Inlet Kit.
reel to a wall, using the provided template (B) for
laying out the holes you drill. 5. Flush system.

You can mount the base plate (104) to the wall for To avoid contaminating the fluid with line-scale,
easier installation and removal of the hose reel for chips or other installation debris, before installing
servicing (FIG. 10). meter or dispense valve to end of hose, flush the
equipment with a compatible solvent such as Stod-
dard solvent or mineral spirits.

a. Secure the end of the hose in a waste bucket.

3. Slide hose reel onto the base plate (104) and install b. Blow out entire lubricant supply line with air.
the hold-down plate (101), washer (103) and cap-
screw (102). Tighten the screw firmly (FIG. 10). c. Pump solvent through line until fluid runs clear
and is debris free.
103 101
104 d. Pump lubricant through line until all solvent is
102
flushed out.
B
6. Position hose stop so hose extends far enough for
all operators to reach dispensing valve.

7. Insert screws through hose stop and tighten nuts to


securely hold hose stop in place.

8. Install meter or dispense valve to end of hose follow-


ing instructions provided with the dispense equip-
ment.

NOTE: If installing an enclosure around hose reel,


ti13189 install the enclosure before installing dispense valve
FIG. 10 or meter to hose end.

4. Connect inlet supply line to inlet hose of the reel. 9. Adjust spring tension, page 18.
See Hose Installation, page 17.

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Installation

Hose Installation • Stop only at latching locations.


• Stop reel where there is access to hose swivel
Installing a Hose on a Bare Reel (A) (FIG. 12) and where reel is securely latched.
1. Locate length of your hose in table below. Note how
many times you must turn the spring to properly pre-
set spring tension.

Hose Length No. of Reel Turns


35 ft (10.7 m) 17

50 ft. (15.2 m) 21

65 ft. (19.8 m) 23

2. Before you install hose, attach a C-Clamp (D, FIG.


11) to reel flange to help prevent the reel from unin-
tentionally becoming unlatched and spinning freely.
D

ti13191

FIG. 11
SPRING HAZARD
The spring is always under great tension, which if
released in an uncontrolled manner could cause seri- 5. Uncoil and extend hose.
ous injury.
6. Install hose stop (C) to end of hose. If hose has a
• Never allow the reel to spin freely. Uncontrolled warning tag (F), hose stop should be installed on
spinning could cause serious injury if you are hit the same end of the hose as the warning tag.
by the hose.
NOTE: If hose is equipped with a kink guard, this end
• Always grasp the adjusting tool firmly with both must be on the same end as the hose stop.
hands when adjusting tension. Spring tension
can cause the tool to move violently.
• Bolt the reel securely in place when making A
adjustments. E

3. Place a piece of tape on the side of the reel flange


to use as a visual reference to help you count the
number of reel turns.
B

Always wear heavy gloves when adjusting the spring C


tension to protect your hands from being cut on hose F
reel. Air/Water Reel, Oil reel or
Grease Reel ti13190

4. Wearing heavy gloves, firmly grab the outside edge


of the reel flange with both hands. Wind the reel the
FIG. 12
proper number of turns (See reference table follow-
ing Step 1), rotating it in the direction shown in FIG.
11. 7. Run the end of the hose (B) through the hose guide
(G) and then the hole (E) in reel (FIG. 12).

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Installation

8. Attach hose end (B) to hose reel swivel (A). Then d. Pump lubricant through line until all solvent is
carefully remove C-Clamp (D) (FIG. 11). flushed out.

9. Pull hose hard enough to release the latch, and


11. Reposition hose stop if needed so hose extends far
slowly allow the hose to retract.
enough for all operators to reach dispensing valve.
10. Flush system.
12. Insert screws through hose stop and tighten nuts to
securely hold hose stop in place.
To avoid contaminating the fluid with line-scale,
chips or other installation debris, before installing 13. Install meter or dispense valve to end of hose follow-
meter or dispense valve to end of hose, flush the ing instructions provided with the dispense equip-
equipment with a compatible solvent such as Stod- ment. (NOTE: If installing an enclosure around hose
dard solvent or mineral spirits. reel, install the enclosure before installing dispense
valve or meter to hose end.)
a. Secure the end of the hose in a waste bucket.
14. Adjust spring tension, page 18.
b. Blow out entire lubricant supply line with air.

c. Pump solvent through line until fluid runs clear


and is debris free.

Increasing and Decreasing Spring Tension


Single Pedestal HP Model Hose Reels
Increasing Spring Tension
1. Pull out hose, 1 to 2 turns and engage latch.
SPRING HAZARD 2. Pull hose back through hose rollers.
The spring is always under great tension, which if
released in an uncontrolled manner could cause seri- 3. Wrap a loop of hose onto the reel flange.
ous injury.
4. Check the spring tension; the hose must pull out
• Never allow the reel to spin freely. Uncontrolled fully and retract fully. Wrap more loops, one at a
spinning could cause serious injury if you are hit time around the reel flange until the spring has the
by the hose. desired tension.
• Always grasp the adjusting tool firmly with both NOTE: Do not put so many loops onto the reel that the
hands when adjusting tension. Spring tension spring winds up tightly before the hose is fully extended.
can cause the tool to move violently.
• Bolt the reel securely in place when making Decreasing Spring Tension
adjustments.
Remove loops to decrease tension.

The hose reel spring is not a serviceable part. Do not


attempt to replace or service the hose reel spring.

18 313431V

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation

Dual Pedestal HS or HN Model Hose Reels


Increasing Spring Tension
(spring is too loose, hose does not retract completely or
C retraction is sluggish)

1. Loosen screw (A) 3-5 turns. Do not completely


remove it.

2. Use a hex wrench to loosen, the two screws (B). Do


not completely remove them.

3. Insert a 3/8” square drive breaker bar in opening (C)


on the spring adjustment plate (D).
B
4. While holding the breaker bar securely, completely
D remove the two screws (B).
A
B 5. Firmly grasp the breaker bar with both hands and
turn it clockwise one turn at a time to increase
ti12201 (tighten) spring tension.

FIG. 13 6. Replace and partially tighten both screws (B). You


can now remove the breaker bar. Pull out a section
of hose and allow it to retract to test the tension
adjustment.

7. If additional tension is required, insert the breaker


SPRING HAZARD bar in the bracket again and remove screws (B).
The spring is always under great tension, which if Then repeat steps 5 - 6.
released in an uncontrolled manner could cause seri-
ous injury. 8. When you are satisfied with the new setting, tighten
screws A and B.
• Never allow the reel to spin freely. Uncontrolled
spinning could cause serious injury if you are hit
by the hose.
• Always grasp the adjusting tool firmly with both
hands when adjusting tension. Spring tension
can cause the tool to move violently.
• Bolt the reel securely in place when making
adjustments.

If hose is not retracting sufficiently or is wound too tight,


the tension can be increased or decreased using one of
the following procedures:

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Supporting Parts Manual 139


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance

Decreasing Spring Tension 6. Replace and partially tighten both screws (B). You
(spring is too tight, hose retracts too fast) can now remove the breaker bar. Pull out a section
of hose and allow it to retract to test the tension
1. Loosen screw (A) 3-5 turns. Do not completely adjustment.
remove it.
7. If additional adjustment is required, insert the
2. Use a hex wrench to loosen, the two screws (B). Do breaker bar in the bracket again and remove screws
not completely remove them. (B). Then repeat steps 5 and 6.

3. Insert a 3/8” square drive breaker bar in opening (C) 8. When you are satisfied with the new setting, tighten
on the spring adjustment plate (D). screws A and B.

4. While holding the breaker bar securely, completely 9. Match holes (e) in end panel (403) to mating holes
remove the two screws (B). (f) in side panel. Install and tighten screws (402) to
join the end and side panels together.
5. Firmly grasp the breaker bar with both hands and
turn it counter-clockwise one turn at a time to 10. Clean and dry off surface of each end panel. Attach
decrease (loosen) spring tension. a Graco label (404) to the center of each end panel.

11. Position hose stop so hose extends far enough for


all operators to reach dispensing valve.

Maintenance
Pressure Relief Procedure 3. Open the fluid valve at the pump fluid outlet. Leave
the drain valve open until you are ready to use the
Follow the Pressure Relief Procedure whenever system again.
you see this symbol.
If you suspect that the dispensing valve, extension, or
grease fitting coupler is clogged, or that pressure has
not been fully relieved after you have followed the steps
above, very slowly loosen the coupler or hose end cou-
pling to relieve the pressure gradually, then loosen it
This equipment stays pressurized until pressure is completely. Then clear the clog.
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing Replacing Spool - HP models (single
fluid and moving parts, follow the Pressure Relief pedestal)
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment. A complete list of replacement Spool Kits is available on
page 33. Use all new parts included in kit.
1. Close the supply pump’s bleed-type master air valve
(required for pneumatic systems).

2. Open the dispensing valve until pressure is fully


relieved.
1. Relieve pressure, page 20.

2. Release spring tension, page 18.

20 313431V

Supporting Parts Manual 140


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance

3. Remove capscrew (102), washer (103) and hold 6. Completely remove guide arm and pedestal assem-
down plate (101). Then slide hose reel out of base bly (16 / 18) as one piece and set it aside to reinstall
plate (104) (FIG. 14). on the new spool. These parts do not have to be dis-
assembled.
104
7. Remove spool assembly (5).
101

103 NOTE: Inspect inside of guide arm to make sure


102 washer (5j) is not adhering to the inside of the guide
arm. Washer (5j) should be discarded with the old
spool. A new washer (5j) is installed on the new
spool and is part of the new spool assembly.

8. Install new spool assembly (5).

9. Install guide arm and pedestal assembly (16 / 18)


ti13185 over spool (5) and install nut (5g). Tighten and
FIG. 14 torque nut to 85-105 ft. lbs (378 - 467 N.m).

10. Slide hose reel onto the base plate (104) and install
4. Completely remove hose from spool (5h) and set it
the hold-down plate (101), washer (103) and cap-
aside to reinstall on the new spool.
screw (102). Tighten the screw firmly.

11. Install hose on spool following the Hose Installation


instructions, page 17.
5 12. Flush hose following flushing instructions starting
with Step10, page 18.

13. Set spring tension following Increasing and


Decreasing Spring Tension instructions on page 18.

18 Replacing Spool - HS or HN models (dual


pedestal)
A complete list of replacement Spool Kits is available on
5g page 33. Use all new parts included in kit.

16

5j

1. Relieve pressure, page 20.


FIG. 15 2. Release spring tension, page 19

5. Remove and discard nut (5g). 3. Remove reel from service.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance

4. Completely remove hose from spool and set it aside 8. Lay hose reel on its side so you can easily access
to reinstall on the new spool. the guide arm and pedestal (24 / 30). Remove long
bolt (18) and washers (15 / 17) (FIG. 16 and FIG.
17).
27 29 5
11 9. Remove snap ring (5e) (FIG. 17).
30
10. Remove guide arm and pedestal base (24 / 30) as
one piece. These parts do not have to be disass-
15 sembled.

NOTE: Inspect inside of guide arm to make sure


washer (5j) is not adhering to the inside of the guide
arm. Washer (5j) should be discarded with the old
26 17 18 spool. A new washer (5j) is part of the new swivel
assembly.

11. Remove and discard old spool.


27 24
FIG. 16 To Reassemble Spool:

12. Place new spool (5) on its side on a work bench.


5. Remove large nut (11) (FIG. 16).
Make sure the flat side of the spool faces down on
6. Remove two screws (27) holding pedestal (26) to the table and the ratchet side is facing up, as shown
base (24) and two screws (27) holding guide arm in FIG. 17.
(29) to guide arm (30) (FIG. 16).
13. Position guide arm and pedestal base (24 / 30)
assembly over spool. Adjust as needed to correctly
NOTE: HN models do not have a guide arm.
align parts.
Guide Arm and related parts are not included.

7. Completely remove guide arm and pedestal assem- NOTE: It is easier to reattached the guide arm and
bly (26 / 29) and set it aside to reinstall on the new pedestal assembly to the spool if the spool is sup-
spool (FIG. 16). These parts do not have to be disas- ported and somewhat level. Placing a couple blocks
sembled. of 1” thick scrap wood under the spool as shown in
FIG. 17 (page 22) will help support the spool during
the arm installation.
30 5e 24
14. Replace snap ring (5e).

15. Install new swivel assembly in spool (see parts page


28).

16. Install washers (15 / 17) and long bolt (18), but do
NOT tighten bolt.

17. Turn the spool over.

16

FIG. 17

22 313431V

Supporting Parts Manual 142


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance

18. Install guide arm and pedestal assembly (26 / 29) Replacing the Service Hose
over swivel assembly and spool.

Note shape (a) of swivel assembly end shown in


FIG. 18 and the correct alignment of swivel to the
key hole in the pedestal. For the hose reel to oper-
ate correctly, these parts must be aligned correctly.
1. Relieve the pressure.
NOTE: HN models do not have a guide arm.
2. Fully extend the hose (B) and latch the reel.
Guide Arm and related parts are not included.
3. Attach a C-Clamp (A) to the reel flange to help pre-
vent the reel from unintentionally becoming
unlatched and spinning freely (FIG. 19).

SPRING HAZARD
The spring is always under great tension, which if
released in an uncontrolled manner could cause
serious injury.

• Never allow the reel to spin freely. Uncontrolled


spinning could cause serious injury if you are hit
by the hose.
a • Always grasp the adjusting tool firmly with both
hands when adjusting tension. Spring tension
can cause the tool to move violently.
FIG. 18
• Bolt the reel securely in place when making
adjustments.
19. Install large nut (11) (FIG. 16, page 22). Tighten and
torque nut to 85-105 ft. lbs (378 - 467 N.m).

20. Tighten bolt (18).

21. Align guide arm (29) and guide arm (30). Install A
screws (27). Tighten and torque screws to 20-30 ft.
lbs (89 - 133 N.m).

22. Align pedestal assembly (26) to base (24). Install 2


screws (27). Tighten and torque screws to 20-30 ft.
lbs (89 - 133 N.m).

23. Re-install reel to ceiling or wall.

24. Install hose on spool following the Hose Installation


instructions, page 17.
B
25. Flush hose following flushing instructions starting
with Step10, page 18.

26. Set spring tension following Increasing and


Decreasing Spring Tension instructions on page 19. ti13184
FIG. 19

313431V 23

Supporting Parts Manual 143


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Maintenance

4. Remove hose stop from hose end and put all the 8. Run the end of hose (B), through the hose guide (G)
parts in a safe place to reinstall on the new hose and then the hole (E) in reel (FIG. 21).
later (FIG. 20).
9. Attach hose end (B) to hose reel swivel (C). Then
a. Loosen and remove screws (aa) and nuts (bb). carefully remove C-Clamp (D) (FIG. 11).
b. Separate two hose stop components (cc) to
10. Pull the hose hard (B) enough to release the latch
remove from end of hose.
and slowly allow the hose to retract.

11. If used, reassemble hose reel enclosure

12. Flush system.

To avoid contaminating the fluid with line-scale,


chips or other installation debris, before installing
meter or dispense valve to end of hose, flush the
aa equipment with a compatible solvent such as Stod-
dard solvent or mineral spirits.

a. Secure the end of the hose in a waste bucket.

b. Blow out entire lubricant supply line with air.


bb
cc c. Pump solvent through line until fluid runs clear
FIG. 20
and is debris free.

5. Disconnect hose (B) from swivel (C). (Fig FIG. 21) d. Pump lubricant through line until all solvent is
6. Install hose stop (D) to end of hose. If hose has a flushed out.
warning tag, hose stop should be installed on the
same end as the warning tag (F). 13. Re-position hose stop (D) so hose extends far
enough for all operators to reach dispensing valve.
NOTE: If hose is equiped with a kink guard this end Securely tighten nuts (bb) to keep hose stop in
must be on the same end as the hose stop. place.

7. Insert screws (aa) through hose stop (cc) and hand 14. Install meter or dispense valve to end of hose follow-
tighten nuts (bb) to hold hose stop in place. ing instructions provided with the dispense equip-
ment.

15. Adjust spring tension, page 18.


C

D
F

er Reel, Oil reel or Grease ti13190

FIG. 21

24 313431V

Supporting Parts Manual 144


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts SD Series

Parts SD Series
Ref Part No. Description Qty Ref Part No. Description Qty
5 KIT, spool (includes 5a-5j) (see page 1 15V158 ARM, guide (Mercedes Blue) HPL56,
33) HPL65, HPM65, HPM6D, HPH55,
5a WASHER, 26 mm (all HPL and HPM 1 HPH5D models
models) 15V159 ARM, guide (Yellow)HPL56, HPL65,
WASHER,23 mm (all HPH models) 1 HPM65, HPM6D, HPH55, HPH5D mod-
5b RING, backup 1 els
5c O-RING 1 15V160 ARM, guide (Red) HPL56, HPL65,
5d SWIVEL, elbow 1 HPM65, HPM6D, HPH55, HPH5D mod-
5e 155470 FITTING, swivel, 90°, npsm HPL3B, 1 els
HPL6D, HPL33, HPL65, HPM3B, 15V161 ARM, guide (White) HPL56, HPL65,
HPM6D, HPM33, HPM65 models HPM65, HPM6D, HPH55, HPH5D mod-
161037 FITTING, swivel, 90°, npsm HPL23, 1 els
HPL25, HPL56 models 15V162 ARM, guide (Black) HPL56, HPL65,
15Y397 FITTING, swivel, 90°, npsm HPH mod- 2 HPM65, HPM6D, HPH55, HPH5D mod-
els els
125593 FITTING, swivel, 90°, bspt x bspp, 1 24 BUSHING, pawl 1
HPL6D, HPL33, HPM3B, HPM6D mod- 25 PAWL, ratchet 1
els 26 218591 KIT, roller, (includes 25a - 25d) (see 1
125594 FITTING, swivel, 90°, 3/8 bspt x 3/8 1 page 36)
bspp, HPH1D, HPH5D, HPH23 models 26a BRACKET, roller 1
125595 FITTING, swivel, 90°, bspt x bspp, 1 26b PIN, roller 4
HPL2D, HPL23, HPL56, models 26c ROLLER, hose 4
5f 186579 NUT, hex, 3/8” x 18 npsm HPH models) 26d SCREW, M6 x 1.0 x 20 4
186580 NUT, hex, 1/2” - 14 npsm HPL and 1 30 KIT, stop, hose (see page 37) 1
HPM models
16J893 NUT, hex, 1/2”-14 bspp, HPL2D, 1
HPL6D, HPL23, HPL56, HPL33,
HPM3B, HPM6D models
16J894 NUT, hex, 3/8”-19 bspp. HPH1D, 1
HPH5D, HPH23 models
5g SPOOL 1
5h WASHER, 30 mm 1
13 NUT, lock, M8 x 1.25 4
15 SPRING, ratchet, pawl 1
16 BASE 1
17 BOLT, M10 x 1.50 x 25 1
18 15V139 ARM, guide (Metallic Blue) HPL23,
HPL25, HPL33, HPM33, HPM3B,
HPH15, HPH1D, HPH23 models
15V140 ARM, guide (Mercedes Blue) HPL23,
HPL25, HPL33, HPM33, HPM3B,
HPH15, HPH1D, HPH23 models
15V141 ARM, guide (Yellow) HPL23, HPL25,
HPL33, HPM33, HPM3B, HPH15,
HPH1D, HPH23 models
15V142 ARM, guide (Red) HPL23, HPL25,
HPL33, HPM33, HPM3B, HPH15,
HPH1D, HPH23 models
15V143 ARM, guide (White) HPL23, HPL25,
HPL33, HPM33, HPM3B, HPH15,
HPH1D, HPH23 models
15V144 ARM, guide (Black) HPL23, HPL25,
HPL33, HPM33, HPM3B, HPH15,
HPH1D, HPH23 models
15V157 ARM, guide (Metallic Blue) HPL56,
HPL65, HPM65, HPM6D, HPH55,
HPH5D models

313431V 25

Supporting Parts Manual 145


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts SD Series

Ref Part No. Description Qty Ref Part No. Description Qty
33 109158 HOSE, 50 ft, npt (Models- HPH15A, 1 24J811 HOSE, 50 ft, bspt (Models- HPH55P, 1
HPH15B, HPH15C, HPH15D, HPH15E, HPH55R, HPH55S, HPH55T, HPH55U)
HPH15F) 24K199 HOSE, 65 ft, bspp (Models- HPL56J, 1
124461 HOSE, 50 ft, npt (Models- HPH55A, 1 HPL56K, HPL56L, HPL56M, HPL56N)
HPH55B, HPH55C, HPH55D, HPH55E, 24K200 HOSE, 65 ft, bspt (Models- HPL56P, 1
HPH55F) HPL56R, HPL56S, HPL56T, HPL56U)
253848 HOSE, 35 ft, npt (Models- HPL23A, 1 24K193 HOSE, 50 ft, bspp (Models- HPL65J, 1
HPL23B, HPL23C, HPL23D, HPL23E, HPL65K, HPL65L, HPL65M, HPL65N)
HPL23F) 24K194 HOSE, 50 ft, bspt (Models- HPL65P, 1
253849 HOSE, 50 ft, npt (Models- HPL25A, 1 HPL65R, HPL65S, HPL65T, HPL65U)
HPL25B, HPL25C, HPL25D, HPL25E, 24J798 HOSE, 50 ft, bspp (Models- HPM65J, 1
HPL25F) HPM65K, HPM65L, HPM65M,
253850 HOSE, 65 ft, npt (Models- HPL56A, 1 HPM65N)
HPL56B, HPL56C, HPL56D, HPL56E, 24J799 HOSE, 50 ft, bspt (Models- HPM65P,
HPL56F) HPM65R, HPM65S, HPM65T,
253852 HOSE, 35 ft, npt (Models- HPL33A, 1 HPM65U)
HPL33B, HPL33C, HPL33D, HPL33E, 34 15W036 LABEL, warning 1
HPL33F)  Replacement Danger and Warning labels, tags and cards
253853 HOSE, 50 ft, npt (Models- HPL65A, 1 are available at no cost.
HPL65B, HPL65C, HPL65D, HPL65E,
HPL65F) A complete list of all available kits begins on page 33.
253857 HOSE, 35 ft, npt (Models- HPM33A, 1
HPM33B, HPM33C, HPM33D,
HPM33E, HPM33F)
256864 HOSE, 50 ft, npt (Models- HPM65A, 1
HPM65B, HPM65C, HPM65D,
HPM65E, HPM65F)
124470 HOSE, 35 ft, npt (Models- HPH23A, 1
HPH23B, HPH23C, HPH23D, HPH23E,
HPH23F)
24J794 HOSE, 50 ft, bspp (Models- HPH15J, 1
HPH15K, HPH15L, HPH15M,
HPH15N)
24J795 HOSE, 50 ft, bspt (Models- HPH15P, 1
HPH15R, HPH15S, HPH15T, HPH15U)
24J812 HOSE, 35 ft, bspp (Models- HPH23J, 1
HPH23K, HPH23L, HPH23M,
HPH23N)s
24J813 HOSE, 35 ft, bspt (Models- HPH23P, 1
HPH23R, HPH23S, HPH23T, HPH23U)
24K195 HOSE, 35 ft, bspp (Models- HPL23J, 1
HPL23K, HPL23L, HPL23M, HPL23N)
24K196 HOSE, 35 ft, bspt (Models- HPL23P, 1
HPL23R, HPL23S, HPL23T, HPL23U)
24K197 HOSE, 50 ft, bspp (Models- HPL25J, 1
HPL25K, HPL25L, HPL25M, HPL25N)
24K198 HOSE, 50 ft, bspt (Models- HPL25P, 1
HPL25R, HPL25S, HPL25T, HPL25U)
24K191 HOSE, 35 ft, bspp (Models- HPL33J, 1
HPL33K, HPL33L, HPL33M, HPL33N)
24K192 HOSE, 35 ft, bspt (Models- HPL33P, 1
HPL33R, HPL33S, HPL33T, HPL33U)
24J796 HOSE, 35 ft, bspp (Models- HPM33J, 1
HPM33K, HPM33L, HPM33M,
HPM33N)
24K797 HOSE, 35 ft, bspt (Models- HPM33P, 1
HPM33R, HPM33S, HPM33T,
HPM33U)
24J810 HOSE, 50 ft, bspp (Models- HPH55J, 1
HPH55K, HPH55L, HPH55M,
HPH55N)

26 313431V

Supporting Parts Manual 146


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts SD Series

HPH, HPP, HPL, HPM Models 33 33


Air/Water Reel, Oil Reel or 30
Grease Reel
26d
5d
26a
5a 5b

26b
5c
26c 5e
34

18

13 5g

5f 5h 15 17
24 25
16

ti13194

ti13194-2

313431V 27

Supporting Parts Manual 147


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Parts XD Series; HS Models

Parts XD Series; HS Models


Ref Part No. Description Qty Ref Part No. Description Qty
5 KIT, spool (see page 33) (includes parts 1 253853 HOSE, 50 ft, npt (models HSL65A, 1
5a-5j) HSL65B, HNL65F, HNL65A, HNL65B,
5e RING, retaining 1 HNL65F)
5h SPOOL 1 253857 HOSE, 35 ft, npt (models (HSM33A, 1
5j WASHER, 30 mm 1 HSM33B, HSM33F)
5k WASHER, square center 1 256864 HOSE, 50 feet, npt (models HSM65A, 1
6 RING, backup 2 HSM65B, HNM65F, HNM65A,
7 O-RING 2 HNM65B, HNM65F)
8 SWIVEL, elbow 1 24J794 HOSE, 50 ft, bspp (models HSH15J, 1
9 WASHER 1 HSH15K, HSH15N)
10 155470 FITTING, swivel, 90° npsm HSL33, 1 24J795 HOSE, 50 ft, bspt (models HSH15U, 1
HSM33, HSM3B, HSL65, HSL6D, HSH15P, HSH15R)
HSM65, HSM6D, HNL65, HNM65 mod- 24J810 HOSE, 50 ft, bspp (models HSH55J, 1
els HSH55K, HSH55N)
15Y397 FITTING, swivel, 90° npsm HSH, 1 24J811 HOSE, 50 ft, bspt (models HSH55P, 1
HNH55 models HSH55R, HSH55U)
161037 FITTING, swivel, 90° npsm HSL25, 1 24K193 HOSE, 50 ft, bspp (models HSL65J, 1
HSL2D, HSL56, HSL5D, HNL56 mod- HSH65K, HSH65N)
els 24K194 HOSE, 50 ft, bspt (models HSL65P, 1
125593 FITTING, swivel, 90°, bspt x bspp, 1 HSL65R, HSL65U)
HSL56, HSL65, HSL6D, HSM33, 24K197 HOSE, 50 ft, bspp (models HSL25J, 1
HSM3B, HSM65, HSM6D models HSL25K, HSL25N)
125594 FITTING, swivel, 90° 3/8 bspt x 3/8 1 24K198 HOSE, 50 ft, bspt (models HSL25P, 1
bspp, HSH models HSL25R, HSL25U)
125595 FITTING, swivel, 90°, bspt x bspp, 1 24K191 HOSE, 35 ft, bspp (models HSL33J, 1
HSL25, HSL2D, HSL33 models HSL33K, HSL33N)
11 186579 NUT, hex 3/8” - 18 npsm, models 1 24K192 HOSE, 35 ft, bspt (models HSL33P, 1
HSH15, HSH1D, HSH55, HSH55B, HSL33R, HSL33U)
HNH55 24K796 HOSE, 35 ft, bspp (models HSM33J, 1
186580 NUT, hex, 1/2” - 14 npsm, HNL56, 1 HSM33K, HSM33N)
HNL65, HSL25, HSL33, HSL56, 24K797 HOSE, 35 ft, bspt (models HSM33P, 1
HSL65, HSL2D, HSL6D, HSM3B, HSM33R, HSM33U)
HSM6D, HSM33, HSM65, models 24K199 HOSE, 65 ft, bspp (models HSL56 J, 1
16J893 NUT, hex, 1/2-14 bspp, HSL25,HSL2D, 1 HSL56K, HSL56N)
HSL33, HSL56, HSL65, HSL6D, 24K200 HOSE, 65 ft, bspt (models HSL56P, 1
HSM33, HSM3B, HSM65, HSM6D HSL56R, HSL56U)
16J894 NUT, hex, 3/8-19 bspp, HSH15, 1 24J798 HOSE, 50 ft, bspp (models HSM65J, 1
HSH1D, HSH55, HSH5D models HSM65K, HSM65N)
14 ADJUSTER, power spring 1 24J799 HOSE, 50 ft, bspt (models HSM65P,
17 WASHER, 8 mm 1 HSM65R, HSM65U)
18 SCREW, M8 x 1.25 x 120 1 29 15V145 ARM, guide, dual (Metallic Blue)
19 SCREW, M5 x .80 x 20 2 HSL25, HSL33, HSM33,
24 BASE, dual 1 HSH15,HSH1D,HSM3B models (not
25 SHAFT, swivel 1 included on HN models)
26 PEDESAL 1 15V146 ARM, guide, dual (White) HSL25,
27 SCREW, M8 X 1.25 x 20 4 HSL33, HSM33,
28 109158 HOSE, 50 feet, npt (models HSH15A, 1
HSH15,HSH1D,HSM3B models (not
HSH15B)
included on HN models)
124461 HOSE, 50 feet, npt (models HSH55A, 1
15X939 ARM, guide, dual (Yellow) HSL25,
HSH55B, HNH55f, HNH55A, HNH55B,
HSL33, HSM33,
HNH55F)
HSH15,HSH1D,HSM3B models (not
253849 HOSE, 50 ft, npt (models HSL25A, 1
included on HN models)
HSL25B, HSL25F)
15Z003 ARM, guide, dual (Desert Sand)
253850 HOSE, 65 ft, npt (models HSL56A, 1
HSL25, HSL33, HSM33,
HSL56B, HNL56F, HNL56A, HNL56B,
HSH15,HSH1D,HSM3B models (not
HNL56F)
included on HN models)

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Parts XD Series; HS Models

Ref Part No. Description Qty Ref Part No. Description Qty
15V163 ARM, guide, dual (Metallic Blue) 16A124 ARM, guide (Desert Sand) HSHC5,
HSL56, HSL65, HSM65, HSH55, HSHFF, HSLC8, HSLD5, HSLE3,
HSH5D, HSM6D models (not included HSMC8, HSMD5, HSMDD, HSPB8,
on HN models) HSHCD, HSMCF, HSDD5, HSDDD
15V164 ARM, guide, dual (White) HSL56, models (not included on HN models)
HSL65, HSM65, HSH55, HSH5D, 32 NUT, lock, M8 x 1.25 8
HSM6D models (not included on HN 33 218591 KIT, roller (includes 33a-33d) (page 36)
models) (not included on HN models)
15X942 ARM, guide, dual (Yellow) HSL56, 33a BRACKET, roller 1
HSL65, HSM65, HSH55, HSH5D, 33b PIN, roller 4
HSM6D models (not included on HN 33c ROLLER, hose 4
models) 33d SCREW, M6 x 1.0 x 20 4
15Z007 ARM, guide, dual (Desert Sand) 34 15W036 LABEL, warning 1
HSL56, HSL65, HSM65, HSH55, 37 BUSHING, pawl 1
38 PAWL, ratchet 1
HSH5D, HSM6D models (not included
39 BOLT, M10 x 1.5 x 25 lg 1
on HN models) 40 SPRING, ratchet pawl 1
30 15V143 ARM, guide (White) HSL25, HSL33, 1 48 KIT, stop, hose (page 37) 1
HSM33, HSH15, HSH1D, HSM3B mod-  Replacement Danger and Warning labels, tags and cards
els (not included on HN models) are available at no cost.
15V139 ARM, guide (Metallic Blue) HSL25,
HSL33, HSM33, HSH15, HSH1D, A complete list of all available kits begins on page 33.
HSM3B models (not included on HN
models)
15V141 ARM, guide (Yellow) HSL25, HSL33,
HSM33, HSH15, HSH1D, HSM3B mod-
els (not included on HN models)
15Z004 ARM, guide (Desert Sand) HSL25,
HSL33, HSM33, HSH15, HSH1D,
HSM3B models (not included on HN
models)
15V161 ARM, guide (White) HSL56, HSL65,
HSM65, HSH55, HSH5D, HSM6D mod-
els (not included on HN models)
15V157 ARM, guide (Metallic Blue) HSL56,
HSL65, HSM65, HSH55, HSH5D,
HSM6D models (not included on HN
models)
15V159 ARM, guide (Yellow) HSL56, HSL65,
HSM65, HSH55, HSH5D, HSM6D mod-
els (not included on HN models)
15Z008 ARM, guide (Desert Sand) HSL56,
HSL65, HSM65, HSH55, HSH5D,
HSM6D models (not included on HN
models)
16A121 ARM, guide (White) HSHC5, HSHFF,
HSLC8, HSLD5, HSLE3, HSMC8,
HSMD5, HSMDD, HSPB8, HSHCD,
HSMCF, HSDD5, HSDDD models
16A122 ARM, guide (Metallic Blue) HSHC5,
HSHFF, HSLC8, HSLD5, HSLE3,
HSMC8, HSMD5, HSMDD, HSPB8,
HSHCD, HSMCF, HSDD5, HSDDD
models (not included on HN models)
16A123 ARM, guide (Yellow) HSHC5, HSHFF,
HSLC8, HSLD5, HSLE3, HSMC8,
HSMD5, HSMDD, HSPB8, HSHCD,
HSMCF, HSDD5, HSDDD models (not
included on HN models)

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Parts XD Series; HS Models

33d
33a 39
5h
37 40

48 28

33b
33c 38 34

30
14 5j
27

29
19
5k
5e
17 10
18 24 32
25
7
11
28
26
Air/Water Reel, Oil Reel or Grease Reel
6
8 ti13196
9

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Parts XD Series; HN Models

Parts XD Series; HN Models


Ref Part No. Description Qty
5 KIT, spool (see page 33) (includes parts 1
5a-5j)
5e RING, retaining 1
5h SPOOL 1
5j WASHER, 30 mm 1
5k WASHER, square center 1
6 RING, backup 2
7 O-RING 2
8 SWIVEL, elbow 1
9 WASHER 1
10 155470 FITTING, swivel, 90° (all HNL65 and
HNM65 models)
15Y397 FITTING, swivel, 90° (all HNH55 mod-
els)
161037 FITTING, swivel, 90° (all HNL56 mod- 1
els)
11 186579 NUT, hex 3/8” - 18 npsm (models 1
HNH55)
186580 NUT, hex, 1/2” - 14 npsm (all models 1
except: HNH55)
14 ADJUSTER, power spring 1
17 WASHER, 8 mm 1
18 SCREW, M8 x 1.25 x 120 1
19 SCREW, M5 x .80 x 20 2
24 BASE, dual 1
25 SHAFT, swivel 1
26 PEDESAL 1
27 SCREW, M8 X 1.25 x 20 4
28 124461 HOSE, 50 feet, (model HNH55) 1
253850 HOSE, 65 ft (model HNL56) 1
253853 HOSE, 50 ft (model HNL65) 1
256864 HOSE, coupled, 50 feet (mode HNM65) 1
32 NUT, lock, M8 x 1.25 8
34 15W036 LABEL, warning 1
37 BUSHING, pawl 1
38 PAWL, ratchet 1
39 BOLT, M10 x 1.5 x 25 lg 1
40 SPRING, ratchet pawl 1
48 KIT, stop, hose (page 37) 1

 Replacement Danger and Warning labels, tags and cards


are available at no cost.

A complete list of all available kits begins on page 33.

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Parts XD Series; HN Models

5h

48
28
5j
40

14
39
38
37
19
5k
5e
17 24
18 10 32
25
7
11
28
26
6
Air/Water Reel, Oil reel or Grease Reel
8 ti13196
9

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Kits

Kits
Spool Assembly Kits
NPT/BSP
Part No. Model. Models Size Media Line Size (inches) Length (feet)

HPL2D#
15Y486 NPT 10 Air/Water 3/8 50
HPL25#

24K432 HPL2D# BSP 10 Air/Water 3/8 50

HPL6D#
15Y487 HPL65# NPT 20 Air/Water 1/2 50
HPL6H#

24K433 HPL6D# BSP 20 Air/Water 1/2 50

15Y488 NPT
HPL23# 10 Air/Water 3/8 35
24L864 BSP

15Y489 HPL56# NPT


20 Air/Water 3/8 65
24L865 HPL5J# BSP

15Y490 NPT
HPL33# 10 Air/Water 1/2 35
24L866 BSP

HPM3B#
15Y491 NPT 10 Oil 1/2 35
HPM33#

24K434 HPM3B# BSP 10 Oil 1/2 35

HPM6D#
15Y492 HPM65# NPT 20 Oil 1/2 50
HPM6H#

24K435 HPM6D# BSP 20 Oil 1/2 50

HPH1D#
15Y493 NPT 10 Grease 1/4 50
HPH15#

24K436 HPH1D# BSP 10 Grease 1/4 50

HPH5D#
15Y494 HPH55# NPT 20 Grease 3/8 50
HPH5H#

24K437 HPH5D# BSP 20 Grease 3/8 50

15Y495 NPT
HPH23# 10 Grease 3/8 35
24L867 BSP

HSL2D# NPT
15Y496‡ 10 Air/Water 3/8 50
HSL25# BSP

HSL6D#
NPT
15Y497‡ HSL65# 20 Air/Water 1/2 50
BSP
HNL56#

HSL56#
15Y498‡ NPT 20 Air/Water 3/8 65
HNL65#

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Kits

NPT/BSP
Part No. Model. Models Size Media Line Size (inches) Length (feet)

HSL33# Air/Water
NPT
15Y499‡ HSM3B# 10 / 1/2 35
BSP
HSM33# Oil

HSM6D#
NPT
15Y500‡ HSM65# 20 Oil 1/2 50
BSP
HNM65#

HSH15# NPT
15Y501‡ 10 Grease 1/4 50
HSH1D# BSP

HSH5D#
NPT
15Y502‡ HSH55# 20 Grease 3/8 50
BSP
HNH55#

‡ Kit does not include swivel. Order swivel kit separately. See page 34 for complete list of swivel kits.

Swivel Kits
(See Instruction Manual: 313432)

Series A All Other Series All Other Series


SD Models SD Models XD Models

NPT BSP NPT BSP NPT BSP


Description Thread Thread Thread Thread Thread Thread

Low & Medium


Pressure 24Z552 24Z555 24Z553 24Z556 24Z554 24Z557
Swivel Kit

High Pressure
26A155 26A156 26A155 26A156 26A153 26A154
Swivel Kit

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Kits

Label, Fluid Identification: 24A223 Swivel Seal Kits: 24A952,


24A953
(Instruction Manual: 313432)

24A952 Used with Low and Medium


Pressure Reels
Description Qty
WASHER, 8 mm 1
NUT, M8 x 1.25 4
RING, retaining 1
RING, backup 2
WASHER, 16 mm 1
O-RING 2
SCREW, M8 x 1.25 x 120 1
SCREW, M8 x 1.25 x 20 4

24A953 Used with High Pressure Single


Pedestal (SD) Reels
Swivel Kits are not available for high pressure, dual
pedestal (XD) reels. If replacement is required use
BSPP Hose Seal Kit: 24M713 Swivel Kit 26A153 or 26A154, page 34.

Description Qty. Description Qty


SEAL, elastomeric, 1/4-19 1 WASHER, 8 mm 1
SEAL, elastomeric, 3/8-19 1 NUT, M8 x 1.25 4
SEAL, elastomeric, 1/2-14 1 O-RING 2
SEAL, elastomeric, 1”- 19 1 RING, retaining 1
RING, backup 2
WASHER, 23 mm 1
WASHER, 16 mm 1
SCREW, M8 x 1.25 x 120 1
SCREW, M8 x 1.25 x 20 4

Latch Kit: 15Y503


(Instruction Manual: 406801)
H

Description Qty
SCREW, M8 x 1.25 x 20 2
PAWL, ratchet 1
SPRING, ratchet, pawl 1
SCREW, M10 x 1.50 x 25 1
BUSHING 1
NUT, M8 x 1.25 4
SCREW, M8 x 1.50 x 40 1
NUT, M10 x 1.50 1

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Kits

Enclosure Retrofit Kit: 24C100 3/8” BSPP Inlet: 24M230


(Instruction Manual: 313902) Description Qty.
HOSE, 3/8” x 36”, 5000 psi 1
Description Qty CONNECTOR, hose, 3/8” ID x 3/8-19 BSPP 1
ARM, hose guide 1 SEAL, elastomeric, 3/8-19 BSPP 1
BASE, reel, enclosed 1 FERRULE, hose, 3/8”, grease 1
NUT, lock 4 CONNECTOR, hose, 3/8” ID, swivel, elbow 1
SCREW 4 TAG, hose 1
WASHER, flat 3
BOLT, m10 x 40lg 1 1/2” NPT Inlet: 218549
NUT, hex 1
WASHER, lock, spring 1 Description Qty
NUT, lock 4 HOSE, coupled, 24” 1
SCREW 4 FITTING, swivel, union, 90° 1
NUT, hex 5
WASHER, lock 1
SCREW, shoulder, #10 1 1/2” BSPT Inlet: 24C441
Description Qty
HOSE, coupled, 1/2” ID x 3 ft oil 1
Hose Inlet Kit: 224417, 218550, FITTING, 1/2” BSPP to 1/2” BSPT 1

218549 1/2” BSPP Inlet: 24J256


(Instruction Manual 406741)
Description Qty
1/4” NPT Inlet: 224417 HOSE, 1/2” ID x 3 ft oil 1

Description Qty
HOSE, coupled, 24” 1
FITTING, union, adapter, 90° 1 Mounting Adapter: 24A224 (page
10)
1/4” BSPT Inlet: 24C442
Description Qty
Description Qty BASE, adapter 1
HOSE, 1/4” ID x 3 ft grease 1 SCREWS, 3/8” - 16 x 3/4” 4
FITTING, 3/8” BSPP to 1/4” BSPT 1

1/4” BSPP Inlet: 24J257 Hose Guide Kits


Description Qty
HOSE, 1/4” ID x 3 ft grease 1 Roller Bracket Repair: 218591
(Instruction Manual: 406743)
3/8” Inlet: 218550 Description Qty
Description Qty BRACKET, hose guide 1
HOSE, coupled, 24” 1 PIN, roller 4
FITTING, union, adapter, 90° 1 ROLLER, hose 4
NUT, lock, #10 - 32 4
SCREW, #10 - 32 x 3/4” 4
3/8” BSPT Inlet: 24M231 SCREW, M6 x 1.0 x 20 4

Description Qty
FITTING, swivel, 90°, 3/8” BSPP x BSPT 1
HOSE, coupled, 36”, 3/8 BSPT 1

36 313431V

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Kits

Cabinet Mounting Kit: 15Y478


Description Qty
BRACKET, hose guide 1
PIN, roller 4
ROLLER, hose 4
PLATE, mounting 1
NUT, lock, #10 - 32 4
SCREW, #10 - 32 x 3/4” 4

Hose Reel Stop Kit: 218340,


218341, 222225
(Instruction Manual: 406742)

1/4” and 3/8” ID Hoses: 218340


Description Qty
NUT, hex, jam 2
SCREW, machine, phillips 2
STOP, hose, 0.656” ID 2

3/8” and 1/2” ID Hoses: 218341


Description Qty
NUT, hex, jam 2
SCREW, machine, phillips 2
STOP, hose, 0.782” ID Kit 2

1/4” ID Hoses: 222225


Description Qty
NUT, hex, jam 2
SCREW, machine, phillips 2
STOP, hose, 0.53” ID Kit 2

Intermediate Hose and Fitting


Repair Kit: 24N719
Used with
Model Series
HSH15* B-D
HSH55* D-F
HPH15* A-C
HPH23* C-E
‘HPH55* C-E

Description Qty.
HOSE, coupled 15 IN, 3/8” ID 1
FITTING, swivel, 90° 1

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Technical Data

Technical Data
Low Pressure Hose Reels and Hoses
Fluid Pressure
Air/Water, all hose diameters 300 psi (20.7 bar, 2.07 MPa)
Inlet 1/2” NPSM Male; 1/2” BSPP Male
Outlet 1/2”or 3/8” NPT Male; 1/2” or 3/8” BSPP Male; 1/2” or 3/8” BSPT
Male
Operating Temperature -20°F to 190°F (-28°C to 87°C)
Wetted parts - Bare Hose Reel Only Zinc plated steel, anodized aluminum, Nitrile rubber
Dimensions Page 39

Medium Pressure Hose Reels


Fluid Pressure
Oil 2000 psi (172 bar, 17.2 MPa)
Inlet 1/2” NPSM Male; 1/2” BSPP Male
Outlet 1/2” or 3/8” NPT Male; 1/2” or 3/8” BSPP Male; 1/2” or 3/8”
BSPT Male
Operating Temperature -20°F to 190°F (-28°C to 87°C)
Wetted parts - Bare Hose Reel Only Zinc plated steel, anodized aluminum, Nitrile rubber
Dimensions Page 39

High Pressure Hose Reels


Fluid Pressure
Grease, 1/4” diameter hose 5000 psi (344 bar, 34.4 MPa)
Grease, 3/8” diameter hose 4800 psi (331 bar, 33.1 MPa)
Inlet 3/8” NPSM Male; 3/8” BSPP Male
Outlet 1/4” NPT Male; 1/4” BSPP Male, 1/4” BSPT Male
Operating Temperature -40°F to 200°F (-40°C to 93°C)
Dry Weight HP Model (for example HPH55B): 52 lbs (23.5 kg)
HS Model (for example HSH55B): 59 lbs (26.5 kg)
HN Model (for example HNL56A): 52 lbs (23.5 kg)
Wetted parts - Bare Hose Reel Only Zinc plated steel, polyurethane, steel
Dimensions
HS Models Page 40
HN Models Page 41

Sound Data: All Hose Reels


Sound Pressure* HP Model: 80 dB(A)
HS Model: 78 dB(A)
Sound Power** HP Model: 87 dB(A)
HS Model: 88 dB(A)

*All readings taken at assumed retraction rate, from assumed operator position.
**Sound Power tester per ISO 9614-2.

38 313431V

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Technical Data

Dimensions

HP Models

B A
D C

Pressure Size A B* C D E† F G
Low 10
3.5 inches 7.5 inches 4.7 inches 9 inches 19.5 inches 7.0 inches 17.1 inches
Medium 10
(89 mm) (191 mm) (120 mm) (229 mm) (498 mm) (177 mm) (435 mm)
High 10
Low 20
3.5 inches 7.5 inches 4.7 inches 9 inches 21.8 inches 7.0 inches 19.2 inches
Medium 20 (89 mm) (191 mm) (120 mm) (229 mm) (554 mm) (177 mm) (487 mm)
High 20

* Measurement taken from center to center of bolt slot/hole.


† Measurement taken from base to top of bolts.
 Measurement taken from edge of spool to front of arm.

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Technical Data

HS Models

A B

C D

Pressure Size A B* C D E† F G
Low 10
6.5 inches 7.5 inches 7.7 inches 9 inches 18.5 inches 7.5 inches 18 inches
Medium 10
(165 mm) (191 mm) (196 mm) (229 mm) (473 mm) (196 mm) (460 mm)
High 10
Low 20
6.5 inches 7.5 inches 7.7 inches 9 inches 21 inches 7.5 inches 20 inches
Medium 20 (165 mm) (191 mm) (196 mm) (229 mm) (533 mm) (196 mm) (508 mm)
High 20

*Measurement taken from center to center of bolt slots.


† Measurement taken from base to top of bolts.
 Measurement taken from edge of spool to front of arm.

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Technical Data

HN Models

A B

C D

Pressure Size A B* C D E G
Low 10
6.5 inches 7.5 inches 7.7 inches 9 inches 18.2 inches 20 inches
Medium 10
(165 mm) (191 mm) (196 mm) (229 mm) (463 mm) (508 mm)
High 10
Low 20
6.5 inches 7.5 inches 7.7 inches 9 inches 18.2 inches 20 inches
Medium 20 (165 mm) (191 mm) (196 mm) (229 mm) (463 mm) (508 mm)
High 20

*Measurement taken from center to center of bolt slots.

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Mounting Channel Dimensions

Mounting Channel Dimensions


(Side dimension for all kits, page 47)

1 Reel Base - Included in Kits 24A934 / 203521


9.0 inch/228.6 mm
4 x 3/8-16 UNC-2B
Weld Nut
7.50 inch/ 190.5 mm
0.50 inch/12.7 mm

8 x 4 .562 in
4 14.28 mm

6.75 inch
171.4 mm
7.75 inch
196.8 mm

4.00 in
101.6 mm
0.75 inch/19.05 mm
2.5 in
63.5 mm

2 Reel Base - Included in Kits 24A935 / 203522

18.0 inch/457.2 mm

7.50 inch/190.5 mm 7.50 inch/190.5 mm

0.50 inch/
12.7 mm 1.5 inch/38.1 mm 7.75 inch
2.00 inch 196.8 mm
50.8 mm
6.75 inch
171.4 mm
4.0 inch
101.6 mm

8 x 39=16 UNC=2B Weld Nut

3.50 in 10.00 in
88.9 mm 254.0 mm

42 313431V

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Mounting Channel Dimensions

3 Reel Base Weldment 4-Reel Base Weldment


Included in Kits 24A936, 203523 Included in Kits 24A937, 203524
7.75 in. / 7.75 in. /
196.8 mm 196.8 mm

0.75 inch/
0.75 inch/
19.05 mm
19.05 mm

27.00 inch/685.8 mm
7.50 inch/190.5 mm
1.5 inch/38.1 mm

36.00 inch/914.4 mm
1.5 inch/38.1 mm

7.50 inch/190.5 mm
12 x 3/8-16 UNC-2B Weld Nut

16 x 3/8-16 UNC-2B Weld Nut

6.75 in/
171.4 mm 0.50 inch/
12.7 mm
6.75 in/ 171.4 mm
0.50 inch/
12.7 mm

313431V 43

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Mounting Channel Dimensions

5 Reel Base Weldment 6-Reel Base Weldment


Included in Kits 24A938, 203525 Included in Kits 24A939, 203526
7.75 in. /
196.8 mm
7.75 in. /
196.8 mm

0.75 inch/
19.05 mm
0.75 inch/
19.05 mm 7.50 inch/190.5 mm

45.00 inch/1143 mm
1.5 inch/38.1 mm

54.00 inch/1372 mm
1.5 inch/38.1 mm

7.50 inch/190.5 mm
20 x 3/8-16 UNC-2B Weld Nut

24 x 3/8-16 UNC-2B Weld Nut

6.75 in/
171.4 mm
0.50 inch/
12.7 mm
6.75 in/171.4 mm 0.50 inch/
12.7 mm

44 313431V

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Mounting Channel Dimensions

1 Reel Channel Base - Included in Kit 24A219


11.36 inch/288.5 mm

2.43 inch/ 2.43 inch/


6.50 inch/ 190.5 mm
61.72 mm 61.72 mm

0.75 inch/
19.05 mm

9.0 inch
228.6 mm

7.5 inch
190.5 mm

4 x 3/8-16 UNC-2B
Weld Nut

2 Reel Channel Base - Included in Kits 24A220

22.72 inch/577.1 mm
11.36 inch/288.5 mm
2.43 inch
61.72 mm 6.50 inch/ 6.50 inch/
190.5 mm 190.5 mm

0.75 inch/
19.05 mm 9.0 inch
228.6 mm

7.5 inch/
190.5 mm

8 x 39=16 UNC=2B Weld Nut

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Mounting Channel Dimensions

3 Reel Channel Base Weldment 6-Reel Channel Base Weldment


Included in Kits 24A221 - XD (HSXXXX Models) Included in Kits 24A222 - XD (HSXXXX Models)
9.0 in. /
9.0 in. / 228.6 mm
228.6 mm
2.43 inch/
61.72 mm
2.43 inch/

5 x 11.36/288.5 mm
61.72 mm
6 x 6.50 inch/
190.5 mm
3 x 6.50 inch/
190.5 mm
2 x 11.36/288.5 mm
12 x 3/8-16 UNC-2B Weld Nut

34.08 inch/856.6 mm

68.16 inch/1731 mm
24 x 3/8-16 UNC-2B Weld Nut

7.5 inch/190.5 mm

0.75 inch/ 7.5 inch/


19.05 mm 0.75 inch/
190.5 mm 19.05 mm

46 313431V

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Mounting Channel Dimensions

Side Dimension (All Models)

2.5 inch/63.5 mm

313431V 47

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Instructions

Pro-Shot™ Grease
Dispense Valve 309032L
EN

For high pressure grease dispense. For professional use only.


Model No. 242055, Series B, 1/4 npt Fluid Inlet
Model No. 242056, Series B, 1/4 npt Fluid Inlet with Coupler
Model No. 242057, Series B, 3/8 npt Fluid Inlet
Model No. 242058, Series B, 3/8 npt Fluid Inlet with Coupler
Model No. 24H399, Series A, 1/4-19 bspt Fluid Inlet
Model No. 24H400, Series A, 1/4-19 bspt Fluid Inlet with Coupler
Model No. 24H401, Series A, 3/8-19 bspt Fluid Inlet
Model No. 24H402, Series A, 3/8-19 bspt Fluid Inlet with Couple
Model No. 24H403, Series A, 1/4-19 bspp Fluid Inlet
Model No. 24H404, Series A, 1/4-19 bspp Fluid Inlet with Coupler
Model No. 24H405, Series A, 3/8-19 bspp Fluid Inlet
Model No. 24H406, Series A, 3/8-19 bspp Fluid Inlet with Coupler
8000 psi (55.2 MPa, 552 bar) Maximum Working
Pressure

Important Safety Instructions


Read all warnings and instructions in this
manual. Save these instructions.

Supporting Parts Manual 168


LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Grease Dispense Valves


Dispense Meters and Control Valves

Pro Shot™ Non-Metered Grease Valves


• Rugged design for harsh environments
• Pressure-assisted trigger for ease of operation
• Easy top adjustment with locking nut
• Pro-Shot adjustment nut protected by rigid guard

Typical Applications
• Service shops 242056
• Heavy-duty dealerships
• Fast lube centers
• Automotive dealerships
• In-plant
• Lube trucks
• Mining

Typical Fluids Handled


• Grease up to NLGI #2

Dispense Meters and Control Valves


Ordering Information
Pro-Shot Grease Dispense Valve
242056 1/4 npt(f) inlet with coupler and extension 200389
242055 1/4 npt(f) inlet without coupler or extension
242058 3/8 npt(f) inlet with coupler and extension 200389
242057 3/8 npt(f) inlet without coupler or extension
224872 Includes 30 in (76.2 cm) whip hose (109148), Z-Swivel (202577) and grease valve (242056)

Accu-Shot™ Metered Grease Valves


• Accurate grease metering within ±3%
• Easy-to-read LCD display
• Handles pressure up to 5000 psi (345 bar) and flow up to 36 oz/min (1 kg/min)

Typical Applications
• Lube trucks 233807
• Heavy-duty dealerships
• In-plant
• Fleet service facilities
• Mining

Typical Fluids Handled


• Grease up to NLGI #2

Ordering Information
Accu-Shot Electronic Metered Grease Valve
233807 U.S. Measurement, includes extension and hydraulic coupler
233933 Metric Measurement, includes extension and hydraulic coupler

www.graco.com 89
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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Warnings

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 or on warning labels, 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.

WARNING
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.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.

SKIN INJECTION HAZARD


High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARD


Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

2 309032L

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Operation

Operation

Pressure Relief Procedure NOTE: If you suspect the dispensing valve, extension,
or grease fitting coupler is clogged, or the pressure has
Follow the Pressure Relief Procedure whenever not been fully relieved after following the previous steps,
you see this symbol. using a rag VERY SLOWLY loosen the coupler or hose
end coupling and allow pressure to be relieved gradu-
ally, then loosen the part completely then clear the clog.

This equipment stays pressurized until pressure is Adjustment


manually relieved. To help prevent serious injury from The dispense valve provides positive control of high
pressurized fluid, such as skin injection, splashing pressure lubricants. When supplied with air the pump
fluid and moving parts, follow the Pressure Relief will start when the valve is triggered and still stall against
Procedure when you stop spraying and before pressure when the trigger is released.
cleaning, checking, or servicing the equipment.

1. Close the supply pump’s bleed-type master air valve


(required in pneumatic systems).

2. Open the dispensing valve until pressure is fully 1. Relieve the pressure, see Pressure Relief Proce-
relieved. dure.

3. Open the fluid drain valve at the pump fluid outlet. 2. To adjust the clearance, loosen the top nut (5, Fig 1)
Leave the drain valve open until you are ready to and turn the bottom nut (5) in or out as needed. To
use the system again. increase grease flow turn bottom nut in. To reduce
grease flow turn bottom nut out. Hold the bottom nut
in place and securely tight the top nut.

7
Yoke
5

Rod Guide

11

Torque 90 – 110 ft. lbs.

FIG. 1

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Service

Service
Refer to Parts Drawing, page 5, for following instruc- 9. Push plunger rod (15) through seal (4). Be careful;
tions. seat (14), ball (2), and copper gasket (6) will fall out
bottom.

10. Replace all parts included in service kit 243446.

Disassembly 11. Reassemble valve.

1. Relieve the pressure. See Pressure Relief Proce-


dure on page 3.

2. Check all parts thoroughly when disassembling and To reduce the risk of serious injury after servicing
carefully replace any worn or damaged parts. valve, always make sure the valve is in the closed
position with trigger released.
3. Remove bottom seat adapter (10) from grease fun
body (9). 12. With trigger in free position tighten bottom nut (5)
until yoke bottoms out on rod guide (this is the max-
4. Remove acorn nuts (1) and bolts (17) from trigger imum flow setting. (FIG. 1) Back off nut approxi-
guard (12). Remove trigger guard (12). mately 1/8 turn. Hold bottom nut in place and
securely tighten top nut.
5. Remove outlet adapter (7).
13. If additional adjustment is desired, follow adjustment
6. Remove hex nuts (5).
procedure on page 3.
7. Remove yoke (16). 14. For specific operational problems, see Trouble
Shooting.
8. Remove rod guide (18) from grease gun body (9).

Troubleshooting
Problem Cause Solution

Damaged Ball Install Service Kit


Damaged Seat Install Service Kit
Grease Flows with trigger release
Out of Adjustment Readjust, see Adjustment, page 3
Missing Ball Install Service Kit
Out of Adjustment Readjust, see Adjustment, page 3
No grease flow when trigger pulled Plugged Seat Clean seat
Disassembled Plunger and Rod Reassemble
Loose Bottom Adapter Tighten adapter (FIG. 1)
Grease is leaking out of bottom of gun Missing Copper Gasket Install Service Kit
Worn Copper Gasket Install Service Kit
Grease is leaking out of the top of gun Worn Seal in top of gun Install Service Kit
Short seal life Worn plunger rod Install Service Kit
Bent guard Replace guard
Trigger will not move Bent pivot pin Install Service Kit
Damaged handle Replace trigger

4 309032L

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Parts

Parts
12

17*

18*
1*
4* 6*
5*
2*
16* 15* 14*
8a
6

9**
10
8b

3*

11

Ref. Part Description Qty. Ref. Part Description Qty.


1 † NUT, self-locking, 10-32 2 16G884 ADAPTER, 1/4”-19 bspt, seat, 1
2 † BALL, carbide 1 model 24H399 and 24H400
3 † SPRING, compression 1 16G885 ADAPTER, 1/4”-19 bspp, seat, 1
4 † SEAL 1 model 24H403 and 24H404
5 † NUT, hex, 10-32 2 16G886 ADAPTER, 3/8”-19 bspt, seat, 1
6 † GASKET, copper 2 model 24H401 and 24H402
7 196783 ADAPTER, outlet, 1/8 npt 1 16G887 ADAPTER, 3/8”-19 bspp, seat, 1
8 200389 NOZZLE 1 model 24H405 and 24H406
Includes items 8a and 8b, model 11 196999 TRIGGER 1
242056 and 242058 only 12 195612 GUARD, trigger 1
8a TUBE, adapter (not sold sepa- 1 14 † SEAT, valve 1
rately) 15 † PLUNGER/ROD ASSEMBLY 1
8b 200325 COUPLER, model 242056 and 1 16 † YOKE 1
242058 only 17 † SHAFT, pivot 2
9** BODY, grease gun 1 18 † GUIDE, rod 1
10 195610 ADAPTER, 1/4” npt, seat, model 1
242055 and 242056 ** Not available
195620 ADAPTER, 3/8” npt, seat, model 1
† Parts included in Kit 243446 (purchase separately).
242057 and 242058

Technical Data
.
Pro-Shot™ Grease Dispense Valve
US Metric
Maximum fluid working pressure 8000 psi 55.2 MPa, 552 bar
Inlet Size 1/4” or 3/8”
Wetted Parts Chrome Vanadium, Polyurethane, Brass, Carbon Steel, Alloy Steel

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6.3. VICKERS
Parts and Accessories

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Applying Vane Units

Pump Characteristics The maximum pressure obtainable in a system using a


Maximum Speed motor as a retarder (pumping) is dependent upon speed. At
speeds below 1000 r/min, maximum obtainable pressure
Maximum rated pump speeds are based on one atmosphere is proportionally diminished relative to speed as speed
of inlet pressure (14.7 psia) with the pump at sea level and approaches stall.
operating with SAE 10W oil at 38° to 82° C (100° to 180° F),
unless otherwise specified. When a motor is used as a retarder, adequate pressure must
be provided at the inlet port to prevent cavitation. Consult
Minimum Speed your Vickers representative before using motors as retarders.
Minimum recommended starting speed, under fluid
conditions stated above, is generally 600 r/min. However, Drives
the pump size, system characteristics and environmental Recommended Drives
conditions can raise or lower this speed. A lower speed can
often be achieved after the pump has primed. Vickers units are designed for use on direct coaxial drives
using spline connections and/or flexible couplings. If drives
If low starting or operating speeds are required, consult your imposing radial or axial loads, or key drives, are being
Vickers representative. considered, consult your Vickers representative for additional
Inlet Pressure information.
Recommended inlet pressure is 0 to 0,34 bar (0 to 5 psi) Drive Alignment
gauge. Inlet pressure should not exceed 1,38 bar (20 psi). Concentricity and angular alignment of shafts are important
Inlet depressions should not exceed 0,17 bar (5” of Hg or to pump life. Misalignment can induce heavy loads on
12.2 psia). bearings, causing premature failure. Flexible coupling halves
Rated Pressure must be aligned according to the coupling manufacturer’s
recommendations.
Pumps should not be operated at or near rated pressures at
idle speeds for extended periods. Localized overheating and Universal Joints
damage can result. When using double universal joint couplings, the shafts must
Never assume pumps in a double, triple or thru-drive pump be parallel and the yokes must be in line. The offset should
assembly can be simultaneously loaded to rated pressure. be kept as low as possible. Maximum allowable offset will, of
Shaft loading must be checked for excessive torque and side course, vary with application conditions. The pump shaft to
loads. universal joint diametral fit should be close (major diameter
fit) with no looseness.
Pump Supercharge Pressure
Mounting Pad Accessory Drives
A pressurized reservoir system does not always assure a
positive(supercharge) pressure at the pump inlet. Vacuum A splined shaft is recommended on applications where the
at the pump inlet can result during cold start-ups. Avoid pump shaft is coupled directly into a transmission or gearbox.
high speeds until the circuit has warmed and supercharge Spline drives should be lubricated.
pressure actually exists at the pump inlet. When vacuum The possibility of interference between the shaft and
breaker pressure caps are used on the reservoir, exercise transmission splines, due to tolerance stack-up, can exist. To
implements to obtain reservoir precharge. reduce this possibility, side tooth spline fits should be used.
Motor Characteristics A side tooth fit and short length of engagement permits more
Minimum Speed flexibility and less tendency for side loading than does a major
diameter fit spline or long spline engagement.
Normal operating motor speeds can be as low as 50 to 100 r/
min. Lower operating speeds are permissible depending on Mounting Dimensions
torque requirements of the motor and characteristics of the
driven load. Requirements

Stall Torque Dimensional control requirements of the customer’s


mounting pad to which the pump or motor is affixed are as
Motor stall torque ranges between 65% and 100% of 1200 r/ follows.
min running torque for a given pressure differential across the
motor. This is dependent on the specific angular position of Pilot Diameter
the shaft at stall and the volume supply of fluid to the motor. Concentricity of the customer’s female pilot diameter relative
Hydraulic Braking to the effective axis of the female drive must be within 0,10
mm (.004 in.) total indicator reading. The clearance between
Motors may be used as retarders but may not be used the male and female pilot diameters must be +0,01 to +0,05
as hydraulic brakes. Systems requiring positive holding mm (+.0005 to +.0020 in.).
capabilities must be provided with externally operated
mechanical holding devices.

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Mounting Face A neater installation is usually obtainable by using extra


The customer’s mounting face to which the pump or motor is fittings to minimize unusually long loops in a line. Hoses
affixed must be square to the axis of the female drive within should be clamped to prevent rubbing and entanglement
0,0381 mm per mm (.0015 inch per inch). with moving parts. Where hoses are subject to chafing, they
should be run through protective neoprene hose or shielded
Shafts metallic guards.
Dimensions of keyed shaft receivers must be between
+0,003 and +0,03 mm (+.0001 and +.0010 in.) of the Fluid Considerations
maximum shaft diameter shown on the Vickers installation Preferred Viscosity
drawing.
Normal pump operation (at rated conditions) is based on the
Circuitry Requirements use of SAE 10W oil in the 38° to 82° C (100° to 180° F) range
(or comparable viscosities).
Valves
Permissible Viscosity
In the event of acceleration or deceleration of the drive or
driven members, overrunning loads or system bleed-off, When operating with SAE 10W oil in the 860 to 40 cSt (4000
control valves and circuitry must provide a continuous supply to 180 SUS) range (-12° to 35° C or 10° to 95° F oil temp.),
of oil to the pump or motor. This supply should be sufficient the speed and pressure of the pump should be limited to
to prevent transient or continuous cavitation, but not so large 50% or less of their respective rated value until the system
as to result in speeds beyond the published maximum speed. has warmed up. Caution must be used in starting units when
fluid viscosity is greater than 860 cSt (4000 SUS). Care should
Protect against hydraulic surge pressures (inlet, outlet or be exercised to warm up the entire system (fluid). Remote
drain) applied to or generated by the pump or motor. Relief components (cylinders, motors) should be actuated during the
valves must prevent these surges from exceeding published warm-up process.
pressure ratings.
Fluid viscosities must not be less than 60 SUS, and
Never assume a relief valve setting is the maximum pressure temperatures should not exceed 99° C (210° F), because
a pump experiences. Shock conditions may exist which can the life expectancy of rotating groups and elastomers will
exceed circuit and pump limitations. decrease.
Piping Care should be taken to change to appropriate oil viscosities
Hydraulic lines should be as short and have as large an inside when climatic conditions change. See recommendations for
diameter as possible. Where lines are long, it is desirable to mobile hydraulic systems on pages 122 and 123. Consult your
adapt to a larger capacity line than a unit’s ports specify. Inlet, Vickers representative for applicable decreases in ratings,
outlet and drain lines should not be smaller than the nominal and modifications, if fluids other than SAE type oils are
port size shown on installation drawings. A “Y” haped inlet considered.
should not be used to feed two separate pumps because one Fluid Cleanliness
may be starved and cavitate.
Proper fluid condition is essential for long and satisfactory
There should be as few bends and fittings in lines as possible. life of hydraulic components and systems. Hydraulic fluid
High-pressure lines and fittings are restrictive to flow and may must have the correct balance of cleanliness, materials, and
result in excessive pressure drop through the system. They additives for protection against wear of components, elevated
should be used only where necessary in a pressure line. viscosity and inclusion of air.
Hose Essential information on the correct methods for treating
Because steering components move during operation, their hydraulic fluid is included in Vickers publication 561; “Vickers
working hydraulic lines consist mainly of flexible hoses. Long Guide to Systemic Contamination Control,” available from
lines may be partly flexible hose and partly tubing where your local Vickers distributor or by contacting Vickers,
flexibility is not required. Incorporated. Recommendations on filtration and the
When installing a hose, allow enough slack to avoid kinking. selection of products to control fluid condition are included in
A taut hose will not allow movement with pressure surges. this publication.
Slack in the line compensates for surges, relieving strain. Recommended cleanliness levels using petroleum oil under
The hose should not be twisted during installation or while common conditions are based on the highest fluid pressure
in operation. Twisting will weaken the hose and loosen levels in the system. See Figure 1.
connections. Fluids other than petroleum, severe service cycles or
For power steering pumps using a remote reservoir, temperature extremes are cause for adjustment of these
connecting hoses should not exceed three feet in length. It is cleanliness codes. See Vickers publication 561 for exact
highly desirable to design the reservoir-pump relationship so details.
that there is always a static head on the pump inlet port.

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Applying Vane Units

Product System Pressure Level the tank is cleaned. The seals used on all suction line connec-
1000 psi 2000 psi 3000+ psi tions should be such that they will not deteriorate and leak.
Vane Pumps - fixed 20/18/15 19/17/14 18/16/13 Baffle Plate
Vane Pumps - variable 8/16/14 17/15/13
A baffle plate in the reservoir is desirable to separate the suc-
Piston Pumps - fixed 19/17/15 18/16/14 17/15/13
tion and return lines. The plate causes return oil to circulate
Piston Pumps - variable 18/16/14 17/15/13 16/14/12
around the outer wall of the reservoir for cooling before it
Directional Valves 20/18/15 20/18/15 19/17/14
re-enters the pump. It also helps provide time for entrained
Proportional Valves 17/15/12 17/15/12 15/13/11
air to separate from the oil. Baffle plate openings should be
Pressure/Flow Controls 19/17/14 19/17/14 19/17/14 designed so that cascade effects and resultant air entrain-
Cylinders 20/18/15 20/18/15 20/18/15 ment are minimized.
Vane Motors 20/18/15 19/17/14 18/16/13
Magnets
Axial Piston Motors 19/17/14 18/16/13 17/15/12
Radial Piston Motors 20/18/14 19/17/13 18/16/13 Magnets in a reservoir should be able to pick up ferrous par-
ticles not retained by filters or strainers. Magnets should be
Figure 1 assembled to the support bars located between suction and
return lines, and be accessible for cleaning.
Aeration
Filler/Breather
Reservoir and circuit design must prevent aeration of the
fluid. Particular care must be used to employ joints, seals and Most reservoirs are vented to the atmosphere through an
gaskets that will not leak or deteriorate. This is especially im- opening that lets air leave or enter the space above the oil as
portant in low pressure and suction lines. Connections should the oil level rises or falls. A filler/breather unit containing an air
always be tight to prevent air from entering the system. filtering element, such as shown on page 120, is often used
as the vent. It must be large enough to handle the air flow
It is best to use windows and sight glasses in the reservoir required to maintain atmospheric pressure whether the tank
and inlet lines during prototype evaluation to determine is full or empty.
whether significant amounts of air are present in the fluid.
Any opaqueness or milky appearance of the fluid in the lines
or reservoir indicates excessive aeration. Bubbles on the sur-
face of the reservoir fluid may indicate that excessive aeration
is present.

Reservoirs
Oil Level
The oil level of the reservoir should be as high as possible
above the pump suction line opening. All return lines should
discharge near the tank bottom, always below the oil level,
and as far from the pump inlet as possible.
For power steering pumps using a remote reservoir, the oil
level should not be lower than one foot below the pump shaft
centerline.
Reservoirs should incorporate a sight gauge, dipstick or
other means for easy checking of the oil level. Without these
devices, the oil level often goes unchecked and, should a leak
occur, the pump can be starved and damaged from loss of
lubrication.
Location
Preferably, reservoirs should be located above pumps. This
creates a flooded pump inlet which reduces the possibility of
pump cavitation.
Line Connections
Pump suction and tank return lines should be attached to the
reservoir by flanges or welded heavy-duty coupling. If the suc-
tion line is connected to the bottom of the reservoir, the cou-
pling should extend above the bottom inside the tank. This
prevents residual dirt from getting into the suction line when

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Pump Start-up Procedure Pump Start-up


Preparation Prior to Start-up All controls should be placed in the neutral position so the
The reservoir and circuit should be clean and free of dirt and pump is unloaded when started.
debris prior to filling with fluid. Start the engine and run at low idle.
Circuit Cleanup Once the pump is started, it should prime and pump within
The reservoir should be charged with filtered hydraulic fluid. a few seconds. If it does not, make sure there are no restric-
The fluid level should be sufficient to prevent vortexing at the tions between the reservoir and the inlet to the pump, and
suction connection to the pump inlet. It is good practice to that there are no air leaks in the inlet line and connections.
clean the system by flushing and filtering, using an external Also, make sure that trapped air can escape from the outlet.
slave pump. Run at low engine idle for approximately five minutes. Then,
Filling Pump and Removing Air while observing the reservoir fluid level, operate the imple-
ments. Extend all actuators to maximum safe limits to com-
If the pump is mounted above the fluid level, it should be pletely fill the system with fluid.
filled with fluid through the outlet port.
Do not run with the fluid level below the “low” limit.
If the pump is mounted below the fluid level, the pump outlet
fitting (or other downstream fitting or plug) can be loosened Add fluid to the reservoir to bring the fluid to the proper fill
to allow fluid to displace the air. It may be necessary to level.
loosen the fill cap on the reservoir to allow the fluid to flow
freely. When a solid stream of fluid with no observed air
begins to drain through the loosened fitting, the fitting should
be retightened.
An air bleed valve in the outlet circuit is also recommended to
remove trapped air. If such a device is used, the pump should
be filled with fluid before start-up.
In some cases, it may be possible to prime the pump by
running the engine starter for five to ten seconds with the
throttle and/or ignition switch in the “off” position. It will be
necessary to loosen a fitting or plug in the pump outlet to al-
low air to escape.

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VQ Series High Speed, High Presure Pumps

Design Features Durability


In all pumps, except the rear pump of triple pumps, fluid flow Vickers high speed-high pressure pumps give more staying
is developed in a cartridge which consists principally of a cam power – they last. Their workhorse ruggedness has been
ring, rotor, ten vanes, and unique side plates and support proved on the newest types of giant earth-moving equipment.
plates. The bimetallic flexible side plates are located on each Reliability & Efficiency
side of the rotor with their bronze face toward the rotor and
their steel face toward the support plate. Two cavities in each Axial and radial running clearances, along with lubricating oil
support plate hold high pressure oil against the flexible side film on the rotor and vanes, are optimized over the entire
plate, thereby hydrostatically balancing the flexible plate and operating pressure range. Excellent cold-start capability and
providing optimum clearance with the rotor. superior resistance to seizure make Vickers VQ pumps highly
reliable and efficient.
Performance
For a combination of maximum horsepower in a small pack-
age, high efficiency, serviceability and economy, Vickers
“high output” pumps are unequalled anywhere in industry.

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Replaceable Cartridge
The pump cartridge described under design features is easy
to service and can normally be replaced in ten minutes or
less, without removing the pump from its mounting. A small
stock of cartridges can serve many pump models on a variety
of vehicles.
Hydraulic Balance
Pump inlet and outlet pressure chambers are diametrically op-
posed as shown in Figure 2. As a result, the rotor is hydrauli-
cally balanced. Bearings thus encounter no hydraulic loads,
assuring long life.
Figure 3 shows an insert fitted into a slot in the vane. Outlet
pressure is applied continuously only to the space between
the vane and insert. Top and bottom areas of the vane are
subject to either inlet or outlet pressure, depending upon the
vane’s location during rotor rotation. See Figure 2. Complete
hydraulic balance is effected in the outlet pressure areas. Out-
ward thrust by the vane in the inlet area is equal to the outlet
pressure times the projected area of the end of the insert.
Double Pumps
Double pumps provide a single power source capable of serv-
ing two separate hydraulic circuits, or of providing greater vol-
ume through the combined delivery of both sections. In either
type of application, two pumps in a single housing result in a
more compact, simple installation and can be driven through a
single shaft coupling.
Triple Pumps
Because triple pumps have three pumps in a single housing,
they offer even more application versatility than do the double
pumps described above.
Thru-Drive Pumps
These versions of single and double pumps have a rear pad
for directly mounting and driving an additional pump. Many
different multi-pump arrangements are thus possible. A typical application for the flow control is power steering,
where it provides a constant supply of oil throughout the
Integral Valve Options vehicle engine’s mid to high speed range.
Single, double, and triple pumps are available with flow con- The priority valve cover maintains a nearly constant flow to
trol and priority valve covers. a primary circuit and diverts remaining flow to a secondary
The flow control cover limits flow to the operating system to circuit. The amount of flow going to the secondary circuit is
the desired maximum. Excess flow is diverted to tank. On determined by pump delivery. The primary circuit is protected
double and triple pumps, the deliveries of the shaft-end and by an integral relief valve, but an external relief valve must be
center pumps are proportional to speed. provided for the secondary and any additional circuit.
The flow control cover also includes a relief valve to limit
maximum operating pressure. Operating pressures of the
shaft-end and center pumps of double and triple pumps must
be controlled by separate, external relief valves.

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Single Pump Operating Specifications

Typical del. Typical


L/min input
Delivery USgpm Displ. (USgpm) kW (hp)
Model @ 1200 r/min cm3/r Max. Max. @ max. speed @ max. speed Weight
Series 7 bar (100 psi) (in3/r) r/min bar (psi) & pressure & pressure kg (lb)

20VQ 5 18,0 (1.10) 2700 210 (3000) 42,3 (11) 17,9 (24)
8 27,4 (1.67) 2700 210 (3000) 65,4 (17) 26,1 (35)
11 36,4 (2.22) 2700 210 (3000) 88,5 (23) 35,4 (47.5) 11,8 (26)
12 39,5 (2.41) 2700 160 (2300) 98,1 (25.5) 28,4 (38)
14 45,9 (2.80) 2700 140 (2000) 115,4 (30) 29,1 (39)
25VQ 12 40,2 (2.45) 2700 210 (3000) 88,5 (23) 41,0 (55)
14 45,4 (2.77) 2700 210 (3000) 103,8 (27) 46,6 (62.5)
17 55,2 (3.37) 2500 210 (3000) 119,2 (31) 51,8 (69.5) 14,5 (32)
21 67,5 (4.12) 2500 210 (3000) 146,2 (38) 61,9 (83)
35VQ 25 81,6 (4.98) 2500 210 (3000) 173,1 (45) 75,3 (101)
30 97,7 (5.96) 2500 210 (3000) 211,5 (55) 87,7 (117.5)
35 112,8 (6.88) 2400 210 (3000) 230,8 (60) 98,5 (132) 22,7 (50)
38 121,6 (7.42) 2400 210 (3000) 250,0 (65) 104,4 (140)
45VQ 42 138,7 (8.46) 2200 175 (2500) 255,8 (66.5) 91,4 (122.5)
50 162,3 (9.90) 2200 175 (2500) 303,8 (79) 105,2 (141) 34,1 (75)
60 193,4 (11.80) 2200 175 (2500) 369,2 (96) 126,8 (170)
Performance constants: SAE 10W fluid @ 82° C (180° F), and pump inlet @ 0 PSIG (14.7 PSIA)

Note: Outlet pressure must always be higher than inlet pressure.


See page 7 for details.

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Model Codes
Single Pump

(F3) - 20VQ - F - 5 - A - S - 1 - C - 2 - K - 30 - L

1 2 3 4 5 6 7 8 9 10 11 12

1 F3 – Viton seals 6 Mounting & shaft seal assembly 10 Relief valve setting
Omit if not required. F– Foot mount with single shaft (20VQF & 20VQP)
seal bar (psi)
S – Flange mount and double shaft A – 17 (250) F – 100 (1500)
2 Intravane pump series seal B – 35 (500) G – 121 (1750)
Omit for flange mount with single shaft C – 52 (750) H – 140 (2000)
seal. D – 70 (1000) J – 155 (2250)
3 Integral valve options E – 86 (1250) K – 175 (2500)
Omit if not required
F – Flow control and relief 7 Shaft type
P – Priority valve and relief 1 – Straight keyed 11 Design
151 – Splined Subject to change. Installation
dimensions remain the same for
4 Geometric displacement designs –30 through –39.
Code = SAE rating (USgpm) at 8 Outlet positions
1200 r/min, 7 bar (100 psi) (Viewed from cover end of pump)
Code cm3/r in3/r A – Opposite inlet port 12 Shaft Rotation
5 18,0 1.10 B – 90° CCW from inlet (Viewed from shaft end of pump)
8 27,4 1.67 C – In line with inlet L – Left hand or counterclockwise.
11 36,4 2.22 D – 90° CW from inlet Omit for right hand.
12 39,5 2.41
14 45,9 2.80
9 Controlled flow rate
(20VQF & 20VQP)
5 Port connections 3 – 11 L/min (3 USgpm)
Series Code Inlet Outlets 4 – 15 L/min (4 USgpm)
20VQ A SAE SAE 6 – 23 L/min (6 USgpm)
4-bolt flg. 4-bolt flg. 7 – 27 L/min (7 USgpm)
20VQ AM* Metric Metric 8 – 30 L/min (8 USgpm)
4-bolt flg. 4-bolt flg. 10 – 38 L/min (10 USgpm)
20VQF&P B SAE SAE 11 – 42 L/min (11 USgpm)
Str. thd. Str. thd. 12 – 45 L/min (12 USgpm)
20VQF&P C SAE SAE
4-bolt flg. Str. thd.
* Same as code “A” port connections, except
metric threads for fastening flanges.

NOTE: For options other than listed above, i.e. shafts, ports, displacements,
and mountings, contact your Vickers representative.

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Model Codes
Single Pump

(F3) - 25VQ (S) 21 A (S) - 11 C 20 (L)

1 2 3 4 5 6 7 8 9 10

1 F3 - Viton seals 5 Port connections 8 Outlet positions


Omit if not required. Series Code Inlet Outlets (Viewed from cover end of pump)
All A SAE SAE A – Opposite inlet
4-bolt flg. 4-bolt flg. B – 90° CCW from inlet
2 Intravane pump series C – In line with inlet
Standard Heavy duty All AM* Metric Metric D – 90° CW from inlet
bearing bearing 4-bolt flg. 4-bolt flg.
25VQ 26VQ
35VQ 36VQ 25VQ B SAE SAE 9 Design
45VQ – str. thd. str. thd. Subject to change. Installation
dimensions remain the same for de-
25VQ C SAE SAE signs –20 through –29
3 Pilot designation 4-bolt flg. str. thd.
S – SAE per ISO 3019/1 (SAE J744)
Omit for standard pilot. 25VQ D SAE SAE 10 Rotation
str. thd. 4-bolt flg. (Viewed form shaft end of pump)
L – Left hand (counterclockwise)
4 Geometric displacement *Same as code “A” port connections, except Omit for right hand.
Code = SAE rating (USgpm) at 1200 metric threads for fastening flanges.
r/min and 7 bar (100 psi)
Frame
Size Code cm3/r in3/r 6 Mounting & shaft seal assembly
25V 12 40,2 2.45 F– Foot mounting with single shaft
14 45,4 2.77 seal
17 55,2 3.37 S – Flange mount and double shaft
21 67,5 4.12 seal
Omit for flange mount with single shaft
35V 25 81,6 4.98 seal.
30 97,7 5.96
35 112,8 6.88
38 121,6 7.42 7 Shaft type
With standard pilot, single shaft seal
45V 42 138,7 8.46 1 – Straight keyed
50 162,3 9.90 11 – Splined
60 193,4 11.80 86 – Straight keyed, heavy duty

With standard pilot, double shaft seal


123 – Splined (not available on 45VQ)
130 – Splined (for 45VQ only)

With SAE pilot, single or double shaft


seal
203 – Straight keyed, heavy duty
297 – Splined

NOTE: For options other than listed in the model code, i.e. shafts, ports,
displacements and mountings, contact your Vickers representative.

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Installation Dimensions

20VQ Series .375-16 UNC OR M10


19,0 (.75) DEEP
Dimensions in millimeters (inches).
50,8
(2.00)

SEE PAGE 121 FOR SELECTION OF 101,60 (4.000)


SAE 4-BOLT FLANGES FOR PORT 101,55 (3.998)
CONNECTION PADS.

101,6
(4.00)
OPTIONAL
.500-13 UNC-2B, 1.625-12UN-2B
OUTLET CONNECTION INLET CONNECTION STRAIGHT THD
OPTIONAL 1.0625- ∅ 19,0 (.75) OR M12, ∅ 38,1 (1.50)
21,0 (.83) DEEP CONNECTION
12 UN-2B STRAIGHT FOR SAE
THD. CONNECTION HYD FITTINGS
FOR SAE HYD. FITTING

155,4
(6.12) 132,6
(5.22) SEE SHAFT OPTIONS STARTING ∅ 146
63,5 9,5 ON PAGE 19. (5.75)
(2.5) (.375)
∅ 14,2 (.56)
THRU
76,2 2 HOLES
(3.00)

55,4
(2.18)

12,7 174,6
(.50) (6.875)

20VQF Series .750-16UNF –2B THD.


FOR SAE HYD. FITTINGS
Additional dimensions are shown above.
3,2
(.125)

23,1
(.91)

20,6 .875-14 UNF-2B THD


(.81) FOR SAE HYD. FITTINGS
PRIMARY OUTLET PORT
170,9
TANK PORT (6.73)
113,5
(4.47)

12,7
(.50)

99,1
(3.90)
SEE SHAFT
OPTIONS
STARTING
ON PAGE 19.

50,0
(1.97)

153,7
50,8 78,5 (6.05)
(2.00) (3.09)

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Installation Dimensions

20VQP Series
Dimensions in millimeters (inches) 181,6
(7.15)
16,0 (.63)
See preceding page for 16,0 (.63)
additional dimensions. 55,4 (2.18)

SEE SHAFT OPTIONS STARTING


ON PAGE 19 .
56,4 (2.22)
.750-16 UNF-2B THD. FOR SAE HYD. FITTINGS
157,7
(6.21)

TANK PORT PRIMARY OUTLET PORT

62,0
(2.44)

62,0
(2.44)

46,0
(1.81)
SECONDARY OUTLET PORT
.875-14 UNF-2B THD.
FOR SAE HYD. FITTINGS

25VQ Series
Dimensions in millimeters (inches)
.500-13 UNC OR M12
22,3 (.88) DEEP

58,7
(2.31)
PORT CONNECTION PADS ARE FOR
USE WITH 4-BOLT FLANGES.
SEE PAGE 121 FOR SELECTION.
58,7
(2.31)

.375-16 UNC OR M10


19,0 (.75) DEEP

INLET CONNECTION
∅ 38,1 (1.50) OUTLET CONNECTION
∅ 25,4 (1.00)

76,2 (3.00) FOR SAE 4-BOLT


FLANGE PADS. 85,9 (3.38) FOR
1.875-12 STRAIGHT THREADED
INLET AND 1.312-12 OUTLET. 164,1
SEE MODEL CODE, PAGE 15. SEE SHAFT OPTIONS STARTING
(6.46) 120,7 ON PAGE 19.
(4.75) 174,5
C 38,1
(6.87)
(1.50)

146,1

101,6 (5.75)

D B ∅ 101,5
(4.000)
(3.998)
63,5
(2.50)

12,7
A (.50) 60,5
R.
(2.38)
9,53
(.375)
∅ 14,2 (.56)
THRU 2 HOLES

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

35VQ Series
15,7
Dimensions in millimeters (inches) ∅ 50,8 (2.00) INLET (.62)

.4375-14 UNC-2B, OR M12, THD.


22,3 (.88) DEEP – 4 HOLES

PORT CONNECTION PADS ARE FOR


USE WITH 4-BOLT FLANGES.
SEE PAGE 119 FOR SELECTION.

.500-13 UNC-2B OR M12 THD.


22,4 (.94) DEEP – 4 HOLES
OUTLET CONNECTION
∅ 31,75 (1.25)

186,9
(7.36) SEE SHAFT OPTIONS STARTING
125,5 ON PAGE 17.
(4.94) 212,7
C 38,1 (8.38)
(1.50)
82,6
(3.25) 181,0
∅ (7.125)
127,0
D B ∅ 126,9
(5.000)
69,9 (4.998)
(2.75)

147,6
A ∅(5.81)
9,5
69,9 69,9 (.375) ∅ 17,5 (.69) 2 HOLES
(2.75) (2.75)
FOR MOUNTING

45VQ Series 15,7


(.62)
Dimensions in millimeters (inches) .500-13 UNC-2B OR M14 THD.
23,8 (.94) DEEP – 4 HOLES

PORT CONNECTION PADS ARE FOR


USE WITH 4-BOLT FLANGES.
SEE PAGE 121 FOR SELECTION.

.625-11 UNC-2B OR M16 THD.


22,3 (.88) USEABLE THD. ∅ 38,1 (1.50) OUTLET
ENGAGEMENT – 4 HOLES
∅ 76,2 (3.00) INLET

216,9
(8.54) SEE SHAFT OPTIONS STARTING
153,2
ON PAGE 19.
(6.03)
42,9 212,7
C (1.69) (8.38)

93,7 181,0
(3.69) ∅(7.13)
127,0
∅ 126,9
D B (5.000)
(4.998)
82,6
(3.25)

147,6
12,7 ∅(5.81)
A
79,4 (.50) ∅ 17,5 (.69) 2 HOLES
(3.125) FOR MOUNTING
158,8
(6.25)

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Optional Shafts

Splined Shafts
Dimensions in millimeters (inches)
A

D
∅E

See spline data table below

Shaft Spline Data


Pump Code A B C D ØE (See below.)

20VQ,
20VQF, 151 44,1 (1.62) 9,53 (.375) 11,9 (.468) 4,1 (.16) 27,8 (1.09) A
20VQP
11 44,5 (1.75) 9,53 (.375) 11,1 (.437) 4,1 (.16) 27,8 (1.09) A
25VQ 123 44,5 (1.75) 9,53 (.375) 15,7 (.62) 4,1 (.16) 27,8 (1.09) A
297 41,1 (1.62) 9,53 (.375) 7,9 (.31) 4,1 (.16) 27,8 (1.09) C
11 58,7 (2.31) 9,53 (.375) 11,1 (.437) 6,4 (.25) 35,1 (1.38) D
35VQ 123 58,7 (2.31) 9,53 (.375) 15,2 (.60) 5,5 (.21) 35,1 (1.38) D
297 55,5 (2.19) 12,7 (.500) 7,9 (.31) 6,4 (.25) 35,1 (1.38) E
11 61,9 (2.44) 12,7 (.500) 14,3 (.565) 9,7 (.38) 39,6 (1.56) D
45VQ 130 61,9 (2.44) 12,7 (.500) 15,2 (.60) 9,9 (.39) 40,4 (1.59) D
297 55,5 (2.19) 12,7 (.500) 7,9 (.31) 9,7 (.38) 39,6 (1.56) E

Spline Data Table


(Involute splines from above chart)
Spline Data Number of
Reference Teeth Pitch Major Diameter Form Diameter Minor Diameter Minor Diameter

A 13 16/32 22,17 (.873) 19,03 (.749) 18,16 (.715) Major dia. fit
22,15 (.872)
C 13 16/32 21,8 (.858) 19,03 (.749) 18,16 (.715) Side fit
21,6 (.852)
D 14 12/24 31,70 (1.248) 27,4 (1.08) 26,42 (1.040) Major dia. fit
31,67 (1.247)
E 14 12/24 31,2 (1.229) 27,4 (1.08) 26,42 (1.040) Side fit
31,1 (1.223)

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Straight Key Shafts B


Dimensions in millimeters (inches)
F

∅D

1,5 (.06) x 45
C
A

Shaft F key width


Pump Code A B C ØD E x length

20VQ,
20VQF, 1 58,7 (2.31) 9,53 (.375) 11,9 (.468) 22,23 (.875) 24,5 (.966) 4,75 (.187)
20VQP 22,20 (.874) 24,4 (.961) x 32 (1.25)
1 58,7 (2.31) 9,53 (.375) 11,1 (.435) 22,23 (.875) 24,5 (.966) 4,75 (.187)
22,20 (.874) 24,4 (.961) x 32 (1.25)
25VQ 86 77,7 (3.06) 9,53 (.375) 11,1 (.435) 25,37 (.999) 28,3 (1.11) 6,36 (.250)
25,35 (.998) 28,1 (1.10) x 50,8 (2.00)
203 77,7 (3.06) 9,53 (.375) 7,9 (.31)  25,40 (1.00) 28,20 (1.11) 6,36 (.250)
25,35 (.998) 27,94 (1.10) x 49,2 (1.938)
1 73,2 (2.88) 9,53 (.375) 11,1 (.435) 31,75 (1.250) 35,36 (1.39) 7,94 (.313)
31,70 (1.248) 34,10 (1.38) x 38,1 (1.50)
35VQ 86 85,9 (3.38) 9,53 (.375) 11,1 (.435) 34,90 (1.374) 38,6 (1.52) 7,92 (.312)
34,87 (1.373) 38,3 (1.51) x 54 (2.13)
203 84,1 (3.31) 12,7 (.500) 7,9 (.31)  34,90 (1.374) 38,6 (1.52) 7,92 (.312)
34,87 (1.373) 38,3 (1.51) x 54 (2.125)
1 62,0 (2.44) 12,7 (.500) 14,22 (.560) 31,75 (1.250) 35,36 (1.39) 7,92 (.312)
31,70 (1.248) 34,10 (1.38) x 28,5 (1.12)
45VQ 86 87,4 (3.44) 12,7 (.500) 14,22 (.560) 38,07 (1.499) 42,4 (1.67) 9,53 (.375)
38,05 (1.498) 42,1 (1.66) x 50,8 (2.00)
203 90,4 (3.56) 12,7 (.500) 7,9 (.31)  38,07 (1.499) 42,4 (1.67) 9,53 (.375)
38,05 (1.498) 42,1 (1.66) x 57,1 (2.25)
 Shaft shoulder inside recess in pilot.

20 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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Typical Performance

20VQ Single Pumps


Performance Constants:
SAE 10W fluid @ 82° C (180° F) CODE 12 & 14 PUMPS bar (psi) CODE
136 (36)
Pump inlet @ 0 psig (14.7 psia)
129 (34)
7 (100)
121 (32) 70 (1000)
14
114 (30) 140 (2000)
CODE 5, 8 & 11 PUMPS bar (psi) CODE
106 (28) 7 (100)
106 (28) 70 (1000) 12
98 (26) 140 (2000)
7 (100) 98 (26)
160 (2300)
70 (1000)
91 (24) 11 91 (24)
140 (2000)
210 (3000)

– L/min (USgpm)
83 (22) 83 (22)
76 (20)
DELIVERY – L/min (USgpm)

7 (100) 76 (20)
70 (1000)
68 (18) 8 68 (18)
140 (2000)
210 (3000)
61 (16) 61 (16)

53 (14) DELIVERY 53 (14)


7 (100)
45 (12) 70 (1000) 45 (12)
140 (2000) 5
38 (10) 210 (3000) 38 (10)
30 (8) 30 (8)

23 (6) 23 (6)
15 (4) 15 (4)
8 (2) 8 (2)
0 0
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800

bar (psi) CODE bar (psi) CODE


37,3 (50)
210 (3000) 11
33,6 (45) 33,6 (45)

29,8 (40) 29,8 (40) 140 (2000) 14


160 (2300) 12
26,1 (35) 210 (3000) 8
26,1 (35) 70 (1000) 12
INPUT – kW (hp)

INPUT – kW (hp)

140 (2000) 11
22,4 (30) 22,4 (30)

18,6 (25) 210 (3000) 5 18,6 (25)


140 (2000) 8
14,9 (20) 14,9 (20) 70 (1000) 14
70 (1000) 11 70 (1000) 14
11,2 (15) 140 (2000) 5 11,2 (15)
70 (1000) 8
7,5 (10) 7,5 (10)
70 (1000) 5
3,7 (5) 3,7 (5) 7 (100) 14
7 (100) 11
7 (100) 8 7 (100) 12
0 7 (100) 5 0
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800
SPEED – r/min SPEED – r/min

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25VQ Single & 25VQT*S Thru–drive Pumps


Performance Constants:
SAE 10W fluid @ 82o C (180o F)
Pump inlet @ 0 psig (14.7 psia) MAXIMUM OPERATING SPEED CORRECTION
Maximum operating speeds shown on performance curves FACTORS BASED ON PUMP INLET CONDITIONS
are for pumps operating at 0 psi inlet condition. To compute 0,14 0,07
0,17 0,10 0 ,0 7 0,14 0,21 0,28 0 ,3 4
maximum operating speeds at other inlet conditions, use ap-
propriate speed rating correction factor. 1.14
1.12 SPEED RATING
Example: 1.10
CORRECTION
FACTOR
Max. speed @ 0 psi inlet 2700 r/min 1.08
Correction factor @ 5 in. Hg x .93 1.06

Max. speed @ 5 in. Hg inlet 2511 r/min 1.04


1.02
Pump inlet suction should not exceed 5 in. Hg vacuum. Posi- in. Hg 5 4 3 2
tive pressure on inlet should not exceed 1,4 bar (20 psi). 1.0 2 3 4 5 psi
VACUUM 0.98 SUPERCHARGE PRESSURE
0.96
0.94
0.92
0.90
0.88
0.86

CODE 14 & 21 PUMPS bar (psi) CODE


bar (psi) CODE 170 (45) 7 (100)
CODE 12 & 17 PUMPS 70 (1000)
151 (40) 151 (40) 140 (2000) 21
7 (100) 210 (3000)
DELIVERY – L/min (USgpm)

133 (35) 70 (1000) 133 (35)


17 7 (100)
140 (2000)
70 (1000) 14
DELIVERY – L/min (USgpm)

114 (30) 210 (3000) 114 (30)


7 (100) 140 (2000)
70 (1000) 95 (25) 210 (3000)
95 (25) 12
140 (2000)
76 (20) 210 (3000) 76 (20)

57 (15) 57 (15)

38 (10) 38 (10)

19 (5) 19 (5)

0 0
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800

67,1 (90)
210 (3000) 21
59,7 (80) 59,7 (80)

52,2 (70) 210 (3000) 17 52,2 (70)


210 (3000) 14
INPUT – kW (hp)

44,7 (60) 44,7 (60) 140 (2000) 21


INPUT – kW (hp)

210 (3000) 12
37,3 (50) 140 (2000) 17 37,3 (50)
140 (2000) 14
29,8 (40) 140 (2000) 12 29,8 (40)

22,4 (30) 22,4 (30) 140 (2000) 21


70 (1000) 17
140 (2000) 14
14,9 (20) 70 (1000) 12 14,9 (20)

7,5 (10) 7 (100) 17 7,5 (10)


7 (100) 21
7 (100) 12 7 (100) 14
0 0
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800
SPEED – r/min SPEED – r/min

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Typical Performance

35VQ Single & 35VQT*S Thru–drive Pumps


Performance Constants:
SAE 10W fluid @ 82o C (180o F) MAXIMUM OPERATING SPEED CORRECTION
FACTORS BASED ON PUMP INLET CONDITIONS
Pump inlet @ 0 psig (14.7 psia)
0,14 0,07
Maximum operating speeds shown on performance curves bar 0,17 0,10 0,07 0,14 0,21 0,28 0,34 bar

are for pumps operating at 0 psi inlet condition. To compute


1.14
maximum operating speeds at other inlet conditions, use ap- 1.12 SPEED RATING
propriate speed rating correction factor. 1.10
CORRECTION
FACTOR
Example: 1.08
1.06
Max. speed @ 0 psi inlet 2500 r/min
1.04
Correction factor @ 5 in. Hg x .92
1.02
Max. speed @ 5 in. Hg inlet 2300 r/min in. Hg 5 4 3 2
1.0 2 3 4 5 psi
Pump inlet suction should not exceed 5 in. Hg vacuum. Posi- VACUUM 0.98 SUPERCHARGE PRESSURE
tive pressure on inlet should not exceed 1,4 bar (20 psi). 0.96
0.94
0.92

CODE 25 & 35 PUMPS bar (psi) CODE CODE 30 & 38 PUMPS bar (psi) CODE
284 (75) 284 (75) 7 (100)

265 (70) 265 (70) 70 (1000)


7 (100) 38
140 (2000)
246 (65) 246 (65) 210 (3000)
70 (1000) 35
140 (2000) 7 (100)
227 (60) 210 (3000) 227 (60)
70 (1000) 30
208 (55) 208 (55) 140 (2000)
210 (3000)
7 (100)
DELIVERY – L/min (USgpm)

DELIVERY – L/min (USgpm)

189 (50) 70 (1000) 189 (50)


25
140 (2000)
170 (45) 210 (3000) 170 (45)

151 (40) 151 (40)

133 (35) 133 (35)

114 (30) 114 (30)

95 (25) 95 (25)

76 (20) 76 (20)

57 (15) 57 (15)

38 (10) 38 (10)

19 (5) 19 (5)
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800
111,9 (150) 111,9 (150)

104,4 (140) 104,4 (140) 210 (3000) 38


210 (3000) 35
96,9 (130) 96,9 (130)

89,5 (120) 89,5 (120) 210 (3000) 30


82,0 (110) 82,0 (110)
210 (3000) 25
74,6 (100) 74,6 (100)
140 (2000) 38
INPUT – kW (hp)

67,1 (90) 140 (2000) 35 67,1 (90)


INPUT – kW (hp)

59,7 (80) 59,7 (80) 2000 PSI 30

52,2 (70) 140 (2000) 25 52,2 (70)

44,7 (60) 44,7 (60)

37,3 (50) 37,3 (50) 70 (1000) 38


70 (1000) 35
29,8 (40) 29,8 (40) 70 (1000) 30
70 (1000) 25
22,4 (30) 22,4 (30)

14,9 (20) 14,9 (20)

7,5 (10) 7 (100) 35 7,5 (10) 7 (100) 38


7 (100) 25 7 (100) 30
(0) (0)
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800
SPEED – r/min SPEED – r/min

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

45VQ Single & 45VQT*S Thru–drive Pumps


Performance Constants:
SAE 10W fluid @ 82o C (180o F)
Pump inlet @ 0 psig (14.7 psia)
0,14 0,07
Maximum operating speeds shown on performance curves 0,17 0,10 0 ,0 7 0,14 0,21 0,28 0 ,3 4
are for pumps operating at 0 psi inlet condition. To compute
maximum operating speeds at other inlet conditions, use ap-
propriate speed rating correction factor.
Example:
Max. speed @ 0 psi inlet 2200 r/min
Correction factor @ 5 in. Hg x .91
Max. speed @ 5 in. Hg inlet 2002 r/min
Pump inlet suction should not exceed 5 in. Hg vacuum. Posi-
tive pressure on inlet should not exceed 1,4 bar (20 psi).

bar (psi) CODE


416 (110)
7 (100)
398 (105) 70 (1000) 60
140 (2000)
379 (100) 175 (2500)
bar (psi) CODE
360 (95) 360 (95)

341 (90) 341 (90) 7 (100)

322 (85) 322 (85)


70 (1000) 50
303 (80) 303 (80) 140 (2000)
7 (100) 175 (2500)
284 (75) 284 (75)
70 (1000)
DELIVERY – L/min (USgpm)

42
265 (70) 140 (2000) 265 (70)

246 (65) 175 (2500) 246 (65)

227 (60) 227 (60)


DELIVERY – L/min (USgpm)

208 (55) 208 (55)

189 (50) 189 (50)

170 (45) 170 (45)

151 (40) 151 (40)

133 (35) 133 (35)

114 (30) 114 (30)

95 (25) 95 (25)

76 (20) 76 (20)

57 (15) 57 (15)

38 (10) 38 (10)

19 (5) 19 (5)

134,2 (180)
175 (2500)
119,3 (160) 119,3 (160)

140 (2000) 175 (2500) 50


104,4 (140) 104,4 (140)
INPUT – kW (hp)

175 (2500)
89,5 (120) 89,5 (120) 140 (2000) 50
INPUT – kW (hp)

74,6 (100) 140 (2000) 74,6 (100)

59,7 (80) 59,7 (80)


70 (1000)
44,7 (60) 44,7 (60) 70 (1000) 50
70 (1000)
29,8 (40) 29,8 (40)

14,9 (20) 7 (100) 14,9 (20)


7 (100) 50
7 (100)
0 0
SPEED – r/min SPEED – r/min

24 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Double Pump Operating Specifications

Shaft End Pump Cover End Pump

Typical Typical Typical Typical


del. input del. input
Delivery L/min kW Delivery L/min kW
USgpm @ (USgpm) (hp) USgpm @ (USgpm) (hp)
1200 r/min Displ. Max. @ max. @ max. 1200 r/min Displ. Max. @ max. @ max. Wt.
Model 7 bar cm3/r Max. bar speed & speed & 7 bar cm3/r Max. bar speed & speed & kg
Series (100 psi) (in3/r) r/min (psi) pressure pressure (100 psi) (in3/r) r/min (psi) pressure pressure (lb.)
2520VQ 12 40,2 (2.45) 2700 210 (3000) 88,5 (23) 41,0 (55) 5 18,0 (1.10) 2700 210 (3000) 42,3 (11) 17,9 (24)
14 45,4 (2.77) 2700 210 (3000) 103,8 (27) 46,6 (62.5) 8 27,4 (1.67) 2700 210 (3000) 65,4 (17) 26,1 (35) 20,5
17 55,2 (3.37) 2500 210 (3000) 119,2 (31) 51,8 (69.5) 11 36,4 (2.22) 2700 210 (3000) 88,5 (23) 35,4 (47.5) (45)
21 67,7 (4.12) 2500 210 (3000) 146,2 (38) 61,9 (83) 12 39,5 (2.41) 2700 160 (2300) 98,1 (25.5) 28,4 (38)
14 45,9 (2.80) 2700 140 (2000) 115,4 (30) 29,1 (39)
3520VQ 25 81,6 (4.98) 2500 210 (3000) 173,1 (45) 75,3 (101) 5 18,0 (1.10) 2500 210 (3000) 38,5 (10) 16,5 (22)
30 97,7 (5.96) 2500 210 (3000) 211,5 (55) 87,7 (117.5) 8 27,4 (1.67) 2500 210 (3000) 61,5 (16) 24,0 (32.5) 34,0
35 112,8 (6.88) 2400 210 (3000) 230,8 (60) 98,5 (132) 11 36,4 (2.22) 2500 210 (3000) 80,8 (21) 33,0 (44) (75)
38 121,6 (7.42) 2400 210 (3000) 250,0 (65) 104,4 (140) 12 39,5 (2.41) 2500 160 (2300) 90,4 (23.5) 26,1 (35)
14 45,9 (2.80) 2500 140 (2000) 105,8 (27.5) 26,8 (36)
3525VQ 25 81,6 (4.98) 2500 210 (3000) 173,1 (45) 75,3 (101) 12 40,2 (2.45) 2500 210 (3000) 79,5 (21) 38,0 (51)
30 97,7 (5.96) 2500 210 (3000) 211,5 (55) 87,7 (117.5) 14 45,4 (2.77) 2500 210 (3000) 91,0 (24) 43,0 (58) 34,5
35 112,8 (6.88) 2400 210 (3000) 230,8 (60) 98,5 (132) 17 55,2 (3.37) 2500 210 (3000) 119,2 (31) 51,5 (69) (76)
38 121,6 (7.42) 2400 210 (3000) 250,0 (65) 104,4 (140) 21 67,5 (4.12) 2500 210 (3000) 146,2 (38) 61,9 (83)
4520VQ 42 138,7 (8.46) 2200 175 (2500) 255,8 (66.5) 91,4 (122.5) 5 18,0 (1.10) 2200 210 (3000) 32,0 (8.5) 14,5 (19.5)
50 162,3 (9.90) 2200 175 (2500) 303,8 (79) 105,2 (141) 8 27,4 (1.67) 2200 210 (3000) 51,0 (13.5) 21,0 (28.5) 43,0
60 193,4 (11.80) 2200 175 (2500) 369,2 (96) 126,8 (170) 11 36,4 (2.22) 2200 210 (3000) 68,0 (18) 28,5 (38.5) (94)
12 39,5 (2.41) 2200 160 (2300) 77,5 (20.5) 23,0 (31)
14 45,9 (2.80) 2200 140 (2000) 91,0 (24) 24,0 (32)
4525VQ 42 138,7 (8.46) 2200 175 (2500) 255,8 (66.5) 91,4 (122.5) 12 40,2 (2.45) 2200 210 (3000) 68,0 (18) 33,0 (44) 46,0
50 162,3 (9.90) 2200 175 (2500) 303,8 (79) 105,2 (141) 14 45,4 (2.77) 2200 210 (3000) 79,5 (21) 38,0 (51) (101)
60 193,4 (11.80) 2200 175 (2500) 369,2 (96) 126,8 (170) 17 55,2 (3.37) 2200 210 (3000) 100,0 (26.5) 45,5 (61)
21 67,5 (4.12) 2200 210 (3000) 125,0 (33) 54,5 (73)
4535VQ 42 138,7 (8.46) 2200 175 (2500) 255,8 (66.5) 91,4 (122.5) 25 81,6 (4.98) 2200 210 (3000) 145,5 (38.5) 66,5 (89) 53,6
50 162,3 (9.90) 2200 175 (2500) 303,8 (79) 105,2 (141) 30 97,7 (5.96) 2200 210 (3000) 178,0 (47) 77,5 (104) (118)
60 193,4 (11.80) 2200 175 (2500) 369,2 (96) 126,8 (170) 35 112,8 (6.88) 2200 210 (3000) 211,5 (55) 89,5 (120)
38 121,6 (7.42) 2200 210 (3000) 223,0 (59) 97,0 (130)
Performance constants: SAE 10W fluid @ 82oC (180o F); pump inlet @ 0 PSIG (14.7 PSIA)

Note: Outlet pressure must always be higher than inlet pressure. See page 7 for details.

EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011 25

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Model Codes
Double Pump (without integral valves)

(F3) - 2520VQ (S) 12 A 11 (S) - 123 CC 20 (L)

1 2 3 4 5 6 7 8 9 10 11

1 F3 - Viton seals 6 Geometric displacement - 9 Port orientation


Omit if not required. cover end pump (Viewed from cover end of pump)
Code = SAE rating (USgpm) at 1200 All series except 4535VQ
r/min and 7 bar (100 psi) With No.1 outlet opposite inlet:
2 Intravane pump series Frame Code AA - No. 2 outlet 135o CCW from inlet
2520VQ 3525VQ 4525VQ Size (USgpm) cm3/r in3/r AB - No. 2 outlet 45o CCW from inlet
3520VQ 4520VQ 4535VQ **20VQ 5 18,0 1.10 AC - No. 2 outlet 45o CW from inlet
8 27,4 1.67 AD - No. 2 outlet 135o CW from inlet
11 36,4 2.22 With No.1 outlet 90o CCW from inlet:
3 Pilot designation 12 39,5 2.41 BA - No. 2 outlet 135o CCW from inlet
S – SAE per ISO 3019/1 (SAE J744) 14 45,9 2.80 BB - No. 2 outlet 45o CCW from inlet
Omit for standard pilot. BC - No. 2 outlet 45o CW from inlet
**25VQ 12 40,2 2.45 BD - No. 2 outlet 135o CW from inlet
14 45,4 2.77 With No.1 outlet inline with inlet:
4 Geometric displacement shaft 17 55,2 3.37 CA - No. 2 outlet 135o CCW from inlet
end pump 21 67,5 4.12 CB - No. 2 outlet 45o CCW from inlet
Code = SAE rating (USgpm) at 1200 CC - No. 2 outlet 45o CW from inlet
r/min and 7 bar (100 psi) 4535VQ 25 81,6 4.98 CD - No. 2 outlet 135o CW from inlet
Frame Code 30 97,7 5.96 With No.1 outlet 90o CW from inlet:
Size (USgpm) cm3/r in3/r 35 112,8 6.88 DA - No. 2 outlet 135o CCW from inlet
2520VQ 12 40,2 2.45 38 121,6 7.42 DB - No. 2 outlet 45o CCW from inlet
14 45,4 2.77 DC - No. 2 outlet 45o CW from inlet
17 55,2 3.37 DD - No. 2 outlet 135o CW from inlet
21 67,5 4.12 7 Mounting & shaft seal assembly
S– Flange mount and double shaft Series 4535VQ
35**VQ 25 81,6 4.98 seal With No.1 outlet opposite inlet:
30 97,7 5.96 Omit for flange mount with single shaft AA - No. 2 outlet opposite inlet
35 112,8 6.88 seal. AB - No. 2 outlet 90o CCW from inlet
38 121,6 7.42 AC - No. 2 outlet inline with inlet
AD - No. 2 outlet 90o CW from inlet
45**VQ 42 138,7 8.46 8 Shaft type With No.1 outlet 90o CW from inlet:
50 162,3 9.90 With standard pilot, single shaft seal BA - No. 2 outlet opposite inlet
60 193,4 11.80 1 – Straight keyed BB - No. 2 outlet 90o CCW from inlet
11 – Splined BC - No. 2 outlet inline with inlet
Note: For options other than listed in the model
86 – Straight keyed, heavy duty BD - No. 2 outlet 90o CW from inlet
code, i.e. shafts, ports, displacements and mount-
With No.1 outlet inline with inlet:
ings, contact your Vickers representative.
With standard pilot, double shaft seal CA - No. 2 outlet opposite inlet
123 – Splined (not available on 45**VQ) CB - No. 2 outlet 90o CCW from inlet
130 – Splined (for 45**VQ only) CC - No. 2 outlet inline inlet
CD - No. 2 outlet 90o CW from inlet
With SAE pilot, single or double shaft With No.1 outlet 90o CW from inlet:
seal DA - No. 2 outlet opposite inlet
203 – Straight keyed, heavy duty DB - No. 2 outlet 90o CCW from inlet
297 – Splined DC - No. 2 outlet inline with inlet
DD - No. 2 outlet 90o CW from inlet
5 Port connections
Pump series Code Inlet Outlet no.1 Outlet no. 2 10 Design
All A SAE 4-bolt flg SAE 4-bolt flg. SAE 4-bolt flg.
All AM* Metric 4-bolt flg. Metric 4-bolt flg. Metric 4-bolt flg.
2520VQ C SAE 4-bolt flg. SAE str. thd. SAE str. thd. 11 Shaft Rotation
All but 4535VQ E SAE 4-bolt flg. SAE 4-bolt flg. SAE str. thd. (Viewed form shaft end of pump)
2520VQ F SAE 4-bolt flg. SAE str. thd. SAE 4-bolt flg. L – Left hand (counterclockwise)
*Same as code “A” port connections, except metric threads for fastening flanges. Omit for right hand.

26 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Model Codes
Double Pump (without integral valves)

(F3) - 2520VQ (S) F 12 E 11 (S) - 297 CC 6 D 20 (L)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 F3 - Viton seals 7 Geometric displacement - 10 Port orientation


Omit if not required. cover end pump (Viewed from cover end of pump)
Code = SAE rating (USgpm) at 1200 With No.1 outlet opposite inlet:
r/min and 7 bar (100 psi) AA - No. 2 outlet 135o CCW from inlet
2 Intravane pump series Frame Code AB - No. 2 outlet 45o CCW from inlet
2520VQ 3525VQ 4525VQ Size (USgpm) cm3/r in3/r AC - No. 2 outlet 45o CW from inlet
**20VQ 5 18,0 1.10 AD - No. 2 outlet 135o CW from inlet
8 27,4 1.67 With No.1 outlet 90o CCW from inlet:
3 Pilot designation 11 36,4 2.22 BA - No. 2 outlet 135o CCW from inlet
S – SAE per ISO 3019/1 (SAE J744) 12 39,5 2.41 BB - No. 2 outlet 45o CCW from inlet
Omit for standard pilot. 14 45,9 2.80 BC - No. 2 outlet 45o CW from inlet
BD - No. 2 outlet 135o CW from inlet
With No.1 outlet inline with inlet:
4 Integral valve options 8 Mounting & shaft seal assembly CA - No. 2 outlet 135o CCW from inlet
F – Flow control and relief S– Flange mount and double shaft CB - No. 2 outlet 45o CCW from inlet
P – Priority valve and relief seal CC - No. 2 outlet 45o CW from inlet
Omit for flange mount with single shaft CD - No. 2 outlet 135o CW from inlet
seal. With No.1 outlet 90o CW from inlet:
5 Geometric displacement shaft DA - No. 2 outlet 135o CCW from inlet
end pump DB - No. 2 outlet 45o CCW from inlet
Code = SAE rating (USgpm) at 1200 9 Shaft type DC - No. 2 outlet 45o CW from inlet
r/min and 7 bar (100 psi) With standard pilot, single shaft seal DD - No. 2 outlet 135o CW from inlet
Frame Code 1 – Straight keyed
Size (USgpm) cm3/r in3/r 11 – Splined
2520VQ 12 40,2 2.45 86 – Straight keyed, heavy duty 11 Controlled flow rate – USgpm
14 45,4 2.77 2, 4, 6, 7, 8, 10 or 12 USgpm
17 55,2 3.37 With standard pilot, double shaft seal
21 67,5 4.12 123 – Splined (not available on 4520VQ)
130 – Splined (for 4520VQ only) 12 Relief valve setting – bar (psi)
3520VQ 25 81,6 4.98 C – 52 (750) G – 121 (1750)
30 97,7 5.96 With SAE pilot, single or double shaft D – 70 (1000) H – 140 (2000)
35 112,8 6.88 seal E – 86 (1250) J – 155 (2250)
38 121,6 7.42 203 – Straight keyed, heavy duty F – 100 (1500) K – 175 (2500)
297 – Splined
4520VQ 42 138,7 8.46
50 162,3 9.90 13 Design
60 193,4 11.80 (Viewed form shaft end of pump)
L - Left hand (counterclockwise)
Omit for right hand.

6 Port connections
Pump series Code Inlet Outlet no. 1 Outlet(s) no. 2 Tank 14 Shaft Rotation
2520VQ only C SAE 4-bolt flg. SAE str. thd. SAE str. thd. SAE str. thd. (Viewed form shaft end of pump)
All pumps E SAE 4-bolt flg. SAE 4-bolt flg. SAE str. thd. SAE str. thd. L – Left hand (counterclockwise)
Omit for right hand.

Note: For options other than listed in the model


code, i.e. shafts, ports, displacements and mount-
ings, contact your Vickers representative.

EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011 27

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Installation Dimensions

2520VQ Series
Dimensions in millimeters (inches)
.375 UNC-2B OR M10 THD.
19,05 (.75) DEEP – 4 HOLES

∅ 63,5 (2.50)
4-BOLT PORT CONNECTION PADS ARE INLET CONN.
FOR USE WITH 4-BOLT FLANGES.
SEE PAGE 121 FOR SELECTION.
101,6 OPTIONAL STRAIGHT
∅ 101,5 THREAD CONNECTION
OPTIONAL STRAIGHT THREAD CONNECTION (4.000) 1.3125-12 UN –2B
1.0625-12 UN-2B THREAD (3.998) THREAD FOR SAE HYD.
FOR SAE HYD. FITTINGS FITTINGS
SEE SHAFT OPTIONS
STARTING ON PAGE 32.
12,7
.500-13 UNC-2B OR M12 (.50) 9,53
∅ 19,1 (.75) THD. 23,8 (.938) DEEP (.38)
OUTLET 4 HOLES ∅ 25,4 (1.00)
CONN. NO. 2 OUTLET CONN. NO. 1

C .375-16 UNC-2B OR M10 THD.


19,05 (.75) DEEP – 4 HOLES
∅ 120,7 (4.75)
45 88,1 101,6 174,8
Z (3.47) (4.00) 38,1 (6.88)
VIEW Z-Z (1.50)

85,9
53,8 (3.38) 84,1 ∅ 146,1(5.75)
Z (3.31)
(2.12)
B D
11,9 107,7 76,2
R. (4.24) (3.00)
(.47)
76,2 HEIGHT OF
(3.00) STRAIGHT
252,5 THREAD ∅ 14,2 (.56) – 2 HOLES
53,8 (9.94) CONNECTION
A
107,7 (2.12)
(4.24)

3520VQ Series
Dimensions in millimeters (inches) 15,7
(.62)
.625 UNC-2B OR M16 THD.
28,5 (1.125) DEEP – 4 HOLES

127,0
4-BOLT PORT CONNECTION PADS ARE
FOR USE WITH 4-BOLT FLANGES. ∅ 126,9
(5.000)
SEE PAGE 121 FOR SELECTION. (4.998)
OPTIONAL STRAIGHT THREAD CONNECTION
1.0625-12 UN-2B THREAD
FOR SAE HYD. FITTINGS SEE SHAFT OPTIONS STARTING
∅ 76.2 (3.00) ON PAGE 32.
INLET CONN.
9,7
.375-16 UNC-2B OR M10 THD. (.38)
19,05 (.75) DEEP – 4 HOLES ∅ 31,8 (1.25)
.437-14 UNC-2B OR M12 THD OUTLET CONN. NO. 1
22,2 (.875) DEEP – 4 HOLES
VIEW Z-Z
C
∅ 19,1 (.75) 276,6
45 OUTLET (10.89)
CONN. NO. 2 99,6 114,3 38,1 212,9
Z (3.92) (4.50) (1.50) (8.38)

88,9
(3.50) 82,6 181,1

Z (3.25) (7.13)

B D
69,9
R.
(2.75)
76,2
(3.00)
A ∅ 17,5 (.69) – 2 HOLES ∅ 147.6 (5.81)

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Installation Dimensions

3525VQ Series
Dimensions in millimeters (inches)
.437-14 UNC-2B OR M12
4-BOLT PORT CONNECTION PADS ARE THD. 22,2 (.875) DEEP
FOR USE WITH 4-BOLT FLANGES. 9,53
SEE PAGE 121 FOR SELECTION. .625-11 UNC-2B OR M16 (.375)
THD. 28,5 (1.125) DEEP
OPTIONAL STRAIGHT
THREAD CONNECTION
1.3125-12 UN-2B THREAD
FOR SAE HYD. FITTINGS 127,0
∅ 126,9
(5.000)
(4.998)
SEE SHAFT OPTIONS STARTING
ON PAGE 32.

∅ 76.2 (3.00)
.375-16 UNC-2B OR M10 THD INLET CONN. 15,7
16,7 (.66) DEEP ∅ 31,8 (1.25) (.62)
OUTLET CONN. NO. 1
82,6
293,9 (3.25)
58,7 R. (11.57)
VIEW Z-Z 109,5 114,3 38,1 212,9
(2.31) Z (8.38)
C (4.31) (4.50) (1.50)
∅ 25,4 (1.00)
OUTLET CONN.
12,7 R. Z NO. 2 88,9 181,1
(.50) (3.50) ∅
45 (7.13)

B D
122,4
(4.82)
74,7
(2.94) ∅ 147.6 (5.81)
61,2
61,2 81,0 ∅ 17,5 (.69) – 2 HOLES
(2.41)
(2.41) (3.19)
122,4
(4.82) HEIGHT OF STR. THD. CONNECTION
A

4520VQ Series .500-13 UNC-2B OR M12 THD.


23,8 (.938) DEEP – 4 HOLES
Dimensions in millimeters (inches)
.625-11 UNC-2B OR M16 THD.
31,7 (1.25) DEEP – 2 HOLES

4-BOLT PORT CONNECTION


PADS ARE FOR USE WITH
4-BOLT FLANGES. SEE PAGE ∅ 88,9 (3.50)
121 FOR SELECTION. INLET CONN.

OPTIONAL STRAIGHT
THREAD CONNECTION
1.0625-12 UN-2B THREAD
FOR SAE HYD. FITTINGS
SEE SHAFT OPTIONS STARTING
ON PAGE 32.

12,7
∅ 19,1 (.75) ∅ 38,1 (1.50) (.50)
OUTLET CONN. 15,7
OUTLET CONN. NO. 1 (.62)
NO. 2
.375-16 UNC-2B OR M10 THD.
19,05 (.75) DEEP – 4 HOLES
162,1 127,0
(6.38) 306,8
Z (12.08) ∅ 126,9
(5.000)
81,0 119,9 119,4 42,9 (4.998) 212,9
VIEW Z-Z (8.38)
(3.19) (4.72) (4.70) (1.69)
C Z

93,7
79,2 (3.69)
(3.12) 45 102,4
(4.03)
D
B

76,2 84,1 181,1



(3.00) (3.31) (7.13)

A ∅ 17,5 (.69) – 2 HOLES ∅ 147.6 (5.81)

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

4525VQ Series
Dimensions in millimeters (inches)
4-BOLT PORT CONNECTION PADS ARE
FOR USE WITH 4-BOLT FLANGES. SEE
PAGE 121 FOR SELECTION. ∅ 38,1 (1.50)
OUTLET CONN. NO. 1
.625-11 UNC-2B OR M16 THD. SEE SHAFT OPTIONS STARTING
31,7 (1.25) DEEP – 4 HOLES ON PAGE 32.
OPTIONAL STRAIGHT
THREAD CONNECTION
1.3125-12 UN-2B THREAD
FOR SAE HYD. FITTINGS 127,0
∅ 126,9
(5.000)
(4.998)

∅ 88,9 (3.50) 15,7


.375-16 UNC-2B OR M10 THD. (.62) .500-13 UNC-2B OR M12 THD.
INLET CONN.
16,6 (.656) DEEP – 4 HOLES 23,8 (.938) DEEP – 4 HOLES
∅ 25,4 (1.00)
VIEW Z-Z OUTLET CONN.
162,1 NO. 2 329,9
(6.38) Z (12.99) 93,7 212,9
81,0 135,9 119,4 42,9 (3.69) (8.38)
(3.19) C (5.35) (4.70) (1.69)
Z
84,1 102,4
79,2 (3.31) (4.03)
(3.12)
D
181,1

(7.13)
∅ 17,5 (.69) – 2 HOLES
A 79,2 FOR MOUNTING
45 74,7 12,7
(3.12) ∅ 147.6 (5.81)
(2.94) (.50)
HEIGHT OF STRAIGHT
THREAD CONNECTION

4535VQ Series
Dimensions in millimeters (inches)

.500-13UNC-2B OR M12 THD.


23,8 (.94) DEEP – 4 HOLES
.625-11 UNC-2B OR M16 THD. SEE SHAFT OPTIONS STARTING
31,7 (1.25) DEEP – 4 HOLES ON PAGE 32.
.437-14 UNC-2B OR M12 THD.
22.3 (.88) DEEP – 4 HOLES

127,0
PORT CONNECTION PADS ARE
FOR USE WITH 4-BOLT FLANGES. ∅ 126,9
(5.000)
SEE PAGE 121 FOR SELECTION.
(4.998)

∅ 31,8 (1.25)
OUTLET CONN. NO. 2
∅ 101,6 (4.00)
15,7
INLET CONN.
(.62)
∅ 38,1 (1.50)
OUTLET CONN. NO. 1

C
162,1
(6.38) 353,1 (13.90)
148,3 133,4 42,9 212,9
81,0 (5.84) (5.25) (1.69) (8.38)
(3.19)

102,4
(4.03)
101,6 93,7
(4.00) (3.69)

B D
181,1
∅ (7.13)
84,1 ∅ 17,5 (.69)
(3.31) – 2 HOLES
12,7
(.50) ∅ 147.6 (5.81)
A

30 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Installation Dimensions

Pumps with flow control cover


Dimensions in millimeters (inches)
OUTLET CONNECTION NO. 2
.750-16 UNF-2B THD.

Model Dimensions
series A B C D E

2520VQF 265,9 108,7 88,1 101,6 38,1


(10.47) (4.28) (3.47) (4.00) (1.50)
3520VQF 289,8 120,1 99,6 114,3 38,1
(11.41) (4.73) (3.92) (4.50) (1.50)
4520VQF 320,3 140,5 119,9 119,4 42,9 INLET
(12.61) (5.53) (4.72) (4.70) (1.69) CONNECTION
OUTLET CONNECTION NO. 1
TANK CONNECTION
.875-14 UNF-2B THD.

A
45 B
3,2 C D E
(.125)

23,0
(.906)

98,6
(3.88)

Note: For installation dimensions and performance 114,3


(4.50)
data of basic pump series, refer to preceding pages.

INLET CONNECTION OUTLET


Pumps with priority valve cover CONNECTION
NO. 1

Dimensions in millimeters (inches) SECONDARY OUTLET PORT


.875-14 UNF-2B THD PORT
MACHINED TO .62 TUBE SIZE
PER SAE SPEC FOR STRAIGHT
THD “O ” RING BOSS.
Model Dimensions
series A B C D

2520VQP 276,6 113,0 101,6 38,1


(10.89) (4.45) (4.00) (1.50)
3520VQP 300,7 124,5 114,3 38,1
(11.84) (4.90) (4.50) (1.50)
4520VQP 331,0 144,8 119,4 42,9
(13.03) (5.70) (4.70) (1.69)
A
62,0 56,4 B C D
(2.44) (2.22)
124,0 55,4
(4.88) (2.18)

#2 PRIMARY OUTLET PORT


.750-16 UNF-2B THD. PORT MACHINED
TO .50 TUBE SIZE PER SAE SPEC.
FOR STRAIGHT THREAD “O ” RING BOSS

16,0 (.63)
16,0 (.63)
TANK PORT FOR PRESSURE RELIEF
OF PRIMARY OUTLET PORT
.750-16 UNF-2B THD. PORT MACHINED
TO .50 TUBE SIZE PER SAE SPEC.
FOR STRAIGHT THREAD “O ” RING BOSS.

EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011 31

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Optional Shafts

Splined Shafts
Dimensions in millimeters (inches) A

D
∅E

See spline data table below.

Shaft Spline Data


Pump Code A B C D ØE (See below.)

2520VQ 11 44,5 (1.75) 9,53 (.375) 11,1 (.437) 4,1 (.16) 27,8 (1.09) A
2520VQF, 123 44,5 (1.75) 9,53 (.375) 15,7 (.62) 4,1 (.16) 27,8 (1.09) A
2520VQP 297 41,1 (1.62) 9,53 (.375) 7,9 (.31) 6,4 (.25) 27,8 (1.09) C
3520VQ,
3520VQF, 11 58,7 (2.31) 9,53 (.375) 11,1 (.437) 6,4 (.25) 35,1 (1.38) D
3520VQP, 123 58,7 (2.31) 9,53 (.375) 15,2 (.60) 5,5 (.21) 35,1 (1.38) D
3525VQ 297 55,5 (2.19) 12,7 (.500) 7,9 (.31) 5,5 (.21) 35,1 (1.38) E
4520VQ,
4520VQF,
4520VQP, 11 61,9 (2.44) 12,7 (.500) 14,3 (.565) 9,7 (.38) 39,6 (1.56) D
4525VQ, 130 61,9 (2.44) 12,7 (.500) 15,2 (.60) 9,9 (.39) 40,4 (1.59) D
4535VQ 297 55,5 (2.19) 12,7 (.500) 7,9 (.31) 6,4 (.25) 39,6 (1.56) E

Spline Data Table


(Involute splines from above chart)
Spline Data Number of
Reference Teeth Pitch Major Diameter Form Diameter Minor Diameter Minor Diameter

A 13 16/32 22,17 (.873) 19,03 (.749) 18,16 (.715) Major dia. fit
22,15 (.872)
C 13 16/32 21,8 (.858) 19,03 (.749) 18,16 (.715) Side fit
21,6 (.852)
D 14 12/24 31,70 (1.248) 27,4 (1.08) 26,42 (1.040) Major dia. fit
31,67 (1.247)
E 14 12/24 31,2 (1.229) 27,4 (1.08) 26,42 (1.040) Side fit
31,1 (1.223)

32 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Optional Shafts

Straight Key Shafts


Dimensions in millimeters (inches) B

∅D

1,5 (.06) x 45
C
A

Shaft F key width


Pump Code A B C ØD E x length

2520VQ, 1 58,7 (2.31) 9,53 (.375) 11,1 (.435) 22,23 (.875) 24,5 (.966) 4,75 (.187)
22,20 (.874) 24,4 (.961) x 32 (1.25)
2520VQF, 86 77,7 (3.06) 9,53 (.375) 11,1 (.435) 25,37 (.999) 28,3 (1.11) 6,35 (.250)
25,35 (.998) 28,1 (1.10) x 50,8 (2.00)
2520VQP 203 77,7 (3.06) 9,53 (.375) 7,9 (.31) 25,40 (1.00) 28,20 (1.11) 6,35 (.250)
25,35 (.998) 27,94 (1.10) x 49,2 (1.938)
3520VQ, 1 73,2 (2.88) 9,53 (.375) 11,1 (.435) 31,75 (1.250) 35,36 (1.39) 7,94 (.313)
31,70 (1.248) 34,10 (1.38) x 38,1 (1.50)
3520VQF, 86 85,9(3.38) 9,53 (.375) 11,1 (.435) 34,90 (1.374) 38,6 (1.52) 7,92 (.312)
3520VQP, 34,87 (1.373) 38,3 (1.51) x 54 (2.13)
3525VQ 203 84,1 (3.31) 12,7 (.500) 7,9 (.31) 34,90 (1.374) 38,6 (1.52) 7,92 (.312)
34,87 (1.373) 38,3 (1.51) x 54 (2.125)
4520VQ, 1 62,0 (2.44) 12,7 (.500) 14,22 (.560) 31,75 (1.250) 35,36 (1.39) 7,92 (.312)
4520VQF, 31,70 (1.248) 34,10 (1.38) x 28,5 (1.12)
4520VQP, 86 87,4 (3.44) 12,7 (.500) 14,22 (.560) 38,07 (1.499) 42,4 (1.67) 9,53 (.375)
4525VQ, 38,05 (1.498) 42,1 (1.66) x 50,8 (2.00)
4535VQ 203 90,4 (3.56) 12,7 (.500) 7,9 (.31) 38,07 (1.499) 42,4 (1.67) 9,53 (.375)
38,05 (1.498) 42,1 (1.66) x 57,1 (2.25)
 Shaft shoulder inside recess in pilot.

EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011 33

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Typical Performance

Shaft End Pumps


2520VQ Double Pumps & 2520VQV10 Triple Pumps
Performance Constants:
SAE 10W fluid @ 82o C(180o F)
Pump inlet @ 0 psig (14.7 psia)

CODE 12 & 17 PUMPS bar (psi) CODE CODE 14 & 21 PUMPS bar (psi) CODE
151 (40) 170 (45)
7 (100)
70 (1000)
136 (36) 7 (100) 151 (40) 21
140 (2000)
70 (1000) 210 (3000)
17
121 (32) 140 (2000) 133 (35)

DELIVERY – L/min (USgpm)


210 (3000)
7 (100)
DELIVERY – L/min (USgpm)

106 (28) 7 (100) 114 (30) 70 (1000)


14
70 (1000) 140 (2000)
91 (24) 12 95 (25) 210 (3000)
140 (2000)
210 (3000)
76 (20) 76 (20)

61 (16) 57 (15)

45 (12) 38 (10)

30 (8) 19 (5)

15 (4) 0
400 800 1200 1600 2000 2400 2800
0
400 800 1200 1600 2000 2400 2800

74,6 (100)

67,1 (90)
210 (3000) 21
59,7 (80) 59,7 (80)

52,2 (70) 210 (3000) 17 52,2 (70)


INPUT – kW (hp)

210 (3000) 14
44,7 (60) 44,7 (60) 140 (2000) 21
INPUT – kW (hp)

210 (3000) 12
37,3 (50) 37,3 (50)
140 (2000) 17 140 (2000) 14
29,8 (40) 29,8 (40)
140 (2000) 12
22,4 (30) 22,4 (30) 70 (1000) 21
70 (1000) 17 70 (1000) 14
14,9 (20) 70 (1000) 12 14,9 (20)

7,5 (10) 7,5 (10) 7 (100) 21


7 (100) 17 7 (100) 14
0 7 (100) 12 0
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800
SPEED – r/min SPEED – r/min

34 EATON Vickers® Vane Pump & Motor Design Guide 353 November 2011

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LUBE SERVICE HYDRAULIC SYSTEM on VOLVO FMX 440 HP 6x6

Typical Performance

Shaft End Pumps


3520VQ & 3525VQ Double Pumps, 352*VQV10 Triple Pumps,
3525VQT Double Thru-drive Pumps
Performance Constants:
SAE 10W fluid @ 82o C (180o F)
Pump inlet @ 0 psig (14.7 psia)

CODE 25 & 35 PUMPS bar (psi) CODE CODE 30 & 38 PUMPS bar (psi) CODE
273 (72) 288 (76)
7 (100)
257 (68) 7 (100) 273 (72)
70 (1000)
242 (64) 257 (68) 38
70 (1000) 35
140 (2000)
140 (2000)
227 (60) 242 (64) 210 (3000)
210 (3000)
7 (100)
212 (56) 227 (60)
70 (1000) 30
197 (52) 7 (100) 212 (56) 140 (2000)
210 (3000)
182 (48) 70 (1000) 35 197 (52)
140 (2000)
DELIVERY – L/min (USgpm)

DELIVERY – L/min (USgpm)

167 (44) 210 (3000) 182 (48)

151 (40) 167 (44)

136 (36) 151 (40)

121 (32) 136 (36)

106 (28) 121 (32)

91 (24) 106 (28)

76 (20) 91 (24)

61 (16) 76 (20)

45 (12) 61 (16)

30 (8) 45 (12)

15 (4) 30 (8)

0 15 (4)
400 800 1200 1600 2000 2400 2800 400 800 1200 1600 2000 2400 2800