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PMC PHDX-2 Service Manual

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PHDX-2 Proportioner
Service Manual
Ref. # 202266
Revision 1.1
FOR PROFESSIONAL USE ONLY
Not approved for use in European explosive atmosphere locations
1 Komo Dr.
Lakewood, NJ 08701
Phone: 732-415-4400
URL: http://www.polymacusa.com

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Summary of Contents for PMC PHDX-2

  • Page 1 PHDX-2 Proportioner Service Manual Ref. # 202266 Revision 1.1 FOR PROFESSIONAL USE ONLY Not approved for use in European explosive atmosphere locations 1 Komo Dr. Lakewood, NJ 08701 Phone: 732-415-4400 URL: http://www.polymacusa.com...

  • Page 2: Table Of Contents

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY TABLE OF CONTENTS CORPORATION Table of Contents WARRANTY SAFETY AND HANDLING CHARACTERISTICS PRINCIPAL HEATING SYSTEM ..... .
  • Page 3 15.16 FINAL ASSEMBLY ......15.17 PHDX-2 HOSES ....... .
  • Page 4 Motor-Line Assembly - 3 Phase ......PHDX-2 Final Assembly - A ......
  • Page 5 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY LIST OF FIGURES CORPORATION Proportioner Hoses - Back ......

  • Page 6: Warranty

    Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return the Product to PMC as directed by PMC, freight prepaid. If PMC deter- mines that the Product is Defective and that such Defect is covered by this Warranty, PMC will credit Customer for the reasonable freight charges incurred by Customer in returning the Defective Product to PMC, and PMC (or its authorized agent) will, at PMC’s option,...
  • Page 7 Period or for three (3) months from the repair or replacement date, whichever is longer. No Rights Implied: Nothing in the sale, lease or rental of any Product by PMC shall be construed to grant any right, interest or license in or under any patent, trademark, copyright, trade secret or other proprietary right or material owned by anyone;...

  • Page 8: Safety And Handling

    Keep this Operations Manual for future consultation of useful information at all times. If you lose this manual, ask for a new copy from your PMC Service Center or go on line at our web site (www.polymacusa.com).
  • Page 9 Always use liquids and solvents that are compatible with the unit. If in doubt, consult your authorized PMC distributor. When working with the PHD Series Proportioner, it is recommended that the opera- tor wear suitable clothing and elements of personal protection, including, without limitation, gloves, protective goggles, safety footwear and face masks.

  • Page 10: Characteristics

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 3. CHARACTERISTICS CORPORATION CHARACTERISTICS The PHD Series Proportioner has been designed and built for the application of polyurea chemical systems, polyurethane foam chemical systems, and some specific two- component epoxy systems. PRINCIPAL HEATING SYSTEM The Proportioner consists of one (1) Material Heater without internal seals. The Low Pressure Heater has three (3) Heating Elements per fluid side rated at 1,250, 1,500,...

  • Page 11: Double Acting Opposed Piston Metering Pumps

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 3. CHARACTERISTICS CORPORATION DOUBLE ACTING OPPOSED PISTON METERING PUMPS The opposed double acting Pump-Line is driven by a double ended Hydraulic Cylin- der. The in-line pump system with opposed piston pumps provides a constant volume and guarantees uniform pressures in both directions of pump movement.

  • Page 12: Technical Specifications

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 4. TECHNICAL SPECIFICATIONS CORPORATION TECHNICAL SPECIFICATIONS ELECTRICAL PHDX-2, Single Phase, 208-240V Pressure Heater Size Electrical Consumption 9.0kW(4.5kW/side) 3,000PSI 10.5kW(5.25kW/side) 14.0kW(7.0kW/side) 105A PHDX-2, Three Phase, 208-240V Pressure Heater Size Electrical Consumption 9.0kW(4.5kW/side) 3,000PSI 10.5kW(5.25kW/side) 14.0kW(7.0kW/side) PHDX-2, Three Phase, 400V...

  • Page 13: Mechanical

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 4. TECHNICAL SPECIFICATIONS CORPORATION MECHANICAL 123 Pumps Maximum Working Pressure 2,000PSI(14MPa, 138bar) Maximum Production 31lb/min(14kg/min) Minimum Production 2lb/min(1kg/min) Gallons per Stroke 0.01859gal/stroke(0.07037L) Strokes per 55gal(200L) Drum 2,958strokes Maximum Hose Length 2kVA Transformer 210ft(64m) 3kVA Transformer...

  • Page 14: Description

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION DESCRIPTION Figure 3: Component Identification - Front REVISION 1.1...

  • Page 15: Component Identification - Back

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION Figure 4: Component Identification - Back REVISION 1.1...

  • Page 16: Strainer Components

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION A. Control Panel - Controls and regulates the operation of the PHD Series Proportioner. B. Isocyanate (Iso, A) Metering Pump - Meters the Isocyanate material. C. Polyol (Poly, R) Metering Pump - Meters the Polyol material.

  • Page 17: Front Panel Description

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION Figure 6: Front Panel Description N. Main Power - Turns ON and OFF main power to the control panel. It must be turned ON for any operation to be performed with the unit. When turned ON, the red pilot will light.

  • Page 18: Operation Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION OPERATION MENU Figure 7: HMI Operation Menu 1 - A SIDE HEATER ON/OFF 2 - INPUT A SIDE HEATER TEMPERATURE 3 - R SIDE HEATER ON/OFF 4 - INPUT R SIDE HEATER TEMPERATURE...

  • Page 19: Options Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION OPTIONS MENU Figure 8: HMI Options Menu 12 - PRESSURE BALANCE CONTROL ON/OFF 13 - PRESSURE BALANCE ALARM RESET 14 - INPUT PRESSURE BALANCE CONTROL VALUE 15 - INPUT COUNTDOWN COUNTER 16 - SET COUNTDOWN COUNTER...

  • Page 20: Alarms Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION ALARMS MENU Figure 9: HMI Alarms Menu 19 - REPLACE PUMP LUBE ALARM RESET 20 - REPLACE HYDRAULIC OIL ALARM RESET 21 - SERVICE Y-STRAINER ALARM RESET 22 - PUMP REBUILD ALARM RESET...

  • Page 21: Chemical Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION CHEMICAL MENU Figure 10: HMI Chemical Menu 25 - CHEMICAL COUNTDOWN COUNTER ON/OFF 26A - RATIO ALARM ON/OFF 26B - INPUT CHEMICAL RATIO HIGH LIMIT 26C - INPUT CHEMICAL RATIO LOW LIMIT...

  • Page 22: Process Data Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION PROCESS DATA MENU Figure 11: HMI Process Menu 29 - INPUT JOB NUMBER 30 - INPUT DATE OF JOB 31 - DATA DISPLAY 32 - ALARM DISPLAY 33 - USB EJECT REVISION 1.1...

  • Page 23: Setup Menu

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION SETUP MENU Figure 12: HMI Setup Menu 34 - INPUT USER NAME 35 - INPUT PASSWORD 36 - LOGIN 37 - LOGOUT 38 - INPUT LEVEL PASSWORD REVISION 1.1...

  • Page 24: Button Appearance

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 5. DESCRIPTION CORPORATION BUTTON APPEARANCE CONTROL Heater A (Figure 7, Item 1) Heater R (Figure 7, Item 3) Hose Heat (Figure 7, Item 5) Motor (Figure 7, Item Standard Button #1 Standard Button #2 REVISION 1.1...

  • Page 25: Installation

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 6. INSTALLATION CORPORATION INSTALLATION WARNING! Use suitable protection and follow the recommenda- tions in the Safety Information enclosed and provided by material suppliers when installing or working with the Proportioner. CAUTION! Make sure the power cable is disconnected from the main power source before connecting to the Terminal Strip in the Console.

  • Page 26: Component Identification - Misc

    Ensure Main Power Switch is OFF and in- coming power is locked OFF before reversing power leads. Recheck rotation before proceeding with Installation. 5. Fill the Lube Reservoir with PMC Pump Lube or suitable diluents. It is not necessary to prime the system. REVISION 1.1...

  • Page 27: Heated Hose Installation

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 6. INSTALLATION CORPORATION HEATED HOSE INSTALLATION CAUTION! The material delivery Heated Hoses are color coded Red and Blue, allowing the user to recognize them. The Red cor- responds to the Isocyanate (Iso, A) and the Blue to the Polyol (Poly, R).

  • Page 28: Temperature Sensing Unit

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 6. INSTALLATION CORPORATION CAUTION! Ensure the proper mechanical and electri- cal connections of the Heated Hoses are made to avoid possible material leakage and Hose heat problems. 6. It is recommended the TSU be installed between the last section of Heated Hose and the Gun Whip.
  • Page 29 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 6. INSTALLATION CORPORATION 7. Ensure the Manual Valves are CLOSED and connect the Coupling Block to the Heated Gun Whip. CAUTION! Excessive force closing or opening the Man- ual Valves may result in damage to the Manual Valves and/or Coupling Block.

  • Page 30: Hose Heat Transformer

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 6. INSTALLATION CORPORATION HOSE HEAT TRANSFORMER The Hose Heat Transformer offers the ability of connecting to different output voltages depending on the total length of the Heated Hose in use, maximizing the heating ability of the Heated Hose. The factory setting is 18 volts for use with 60 feet of Heated Hose.

  • Page 31: Proportioner Purging

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 7. PROPORTIONER PURGING CORPORATION PROPORTIONER PURGING WARNING! Use suitable Personal Protection Equipment (PPE) and follow the recommendations in the Safety Informa- tion provided by product suppliers when installing or working with the unit. WARNING! Do not turn the Temperature Controllers ON until the Proportioner purging procedure is complete and the Primary Heaters and Heated Hoses are filled with material.
  • Page 32 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 7. PROPORTIONER PURGING CORPORATION 6. Turn Hydrualic Pressure Control (Item K, Figure 4) fully COUNTERCLOCKWISE. 7. Turn ON Main Power (Item N, Figure 6). 8. Turn ON Motor Power (Item 9, Figure 7). Button will turn green when activated.

  • Page 33: Pressure Balance Control

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 8. PRESSURE BALANCE CONTROL CORPORATION PRESSURE BALANCE CONTROL The PHD Series Proportioner has been designed with a pressure balance control system. This system will give the operator of this machine the ability to control a pressure imbalance within certain predetermined parameters.

  • Page 34: Temperature Controls

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 9. TEMPERATURE CONTROLS CORPORATION TEMPERATURE CONTROLS WARNING! Do not turn the Temperature Controllers ON until the Proportioner Purging procedure is complete and the Primary Heaters and Heated Hoses are filled with material. OPERATION The Temperature Controller menu is located in the ”Operation” tab. This screen is detailed in Section 5.1 on page 17.

  • Page 35: Start-Up

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 10. START-UP CORPORATION START-UP NOTE! Follow the recommended procedure in the order shown. CAUTION! The Start-up procedures assume that all steps in Pro- portioner purging (Section 7) have been performed and no prob- lems were found.
  • Page 36 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 10. START-UP CORPORATION 10. Using the Hydraulic Pressure Control (Item K, Figure 4), adjust to the required stall pressure and check each Material Pressure Gauge. 11. Countdown Counter - Follow the steps below to set the Auto Shut Down Counter: a.

  • Page 37: Shut-Down

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 11. SHUT-DOWN CORPORATION SHUT-DOWN 11.1 SHORT-TERM Follow the procedure below for temporary shut-downs, such as lunch breaks: 1. Turn OFF pump RETRACT. The button should appear as when inactive. 2. Turn OFF pump NORMAL. The button should appear as when inactive.

  • Page 38: Troubleshooting

    PHD Series Proportioner. The information provided will serve as a guideline to detect and resolve problems. In any case, feel free to contact your authorized PMC distributor, where a qualified technician will advise you. WARNING! Only qualified personnel should perform troubleshoot-...
  • Page 39 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION When the proportioner experiences an error an alarm will flash on the current menu in use. This alarm is shown below. Upon activation of this alarm the machine will cease to function. The proportioner will only allow further usage once the parameter that is causing the fault has been fixed.

  • Page 40: Heaters

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 12.1 HEATERS WARNING! Only qualified personnel should perform troubleshoot- ing; unqualified personnel may cause damage to the unit, personnel, or property and put the operator at risk. The Heaters are compo- nents that reach high temperatures; you must wait until they cool before handling.
  • Page 41 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION Problem: Primary heater does not heat and the display on the HMI shows ambient temperature. Solutions: 1. Check the heater breaker in the main console and reset the breaker. If it continues to trip, wrap an Amp Clamp around one of the wires coming off...
  • Page 42 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION Problem: Primary heater does not heat and the display on the HMI shows #### for ambient temperature. Solutions: 1. Open the console and check PLC slice TS3101. Make sure that the wires in spots 5A, 5B, 7A, and 7B are securely fastened.

  • Page 43: Hydraulic Drive System

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 12.2 HYDRAULIC DRIVE SYSTEM Frequent Hydraulic Drive System Problems Hydraulic Pump does not develop pressure and the electric motor is not Page 43 running. Low or zero hydraulic pressure with unusual Hydraulic Pump noises.
  • Page 44 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION Problem: Hydraulic Pump does not develop pressure and the electric motor is not running. Solutions: Hydraulic Power Package - With the Pump in the NORMAL position, the failure of the Hydraulic Pump to develop pressure is loss of pump suction (this is called ”prime”).

  • Page 45: Metering Pump-Line

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 12.3 METERING PUMP-LINE Figure 17: Metering Pump-Line (PL-10) Frequent Pump-Line Problems Metering pumps do not change direction and the pressures on both of Page 44 chemical gauges are lower than normal. Pump Cavitation.

  • Page 46: Phdx-2 Console - Bottom Plate

    Power up the unit with the pump in the normal position and the motor OFF. If the directional light comes on replace the defective solid state relay. If not replace the Latching relay. Figure 18: PHDX-2 Console - Bottom Plate REVISION 1.1...
  • Page 47 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 3. Safety Pressure Switch - Each Metering Pump has a Safety Pressure Switch set to 2,200 psi for #123 pumps, 3,200 psi for #61 pumps. When the material system reaches this pressure, the Safety Pressure Switch will remove power from the Directional Valve and Direction Indicator Lights (arrows for RETRACT and NORMAL, Figure 7).
  • Page 48 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION Problem: Cavitation. Solutions: 1. Cavitation occurs when the Metering Pump requires a larger volume of material than the supply system (Transfer Pump) can furnish. This creates a ”void” of material in the Metering Pump. The most common causes of cavitations are: a.

  • Page 49: Hose Heating

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 12.4 HOSE HEATING WARNING! Before correcting any kind of defect, make sure the Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Propor- tioner power supply ON.
  • Page 50 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION 5. To check the secondary side of the transformer, you must take an AC volt reading across the two leads coming out of the transformer that are connected to the “A” and “R” hose leads. If you are reading voltage (your volt reading will vary depending on what tap setting is used), most likely the problem is in the heated hose.
  • Page 51 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 12. TROUBLESHOOTING CORPORATION Problem: Hose heater shows excessive temperature. Solutions: 1. Set the temperature set point at least 20 degrees lower than the temperature shown on the controller. Briefly turn on the hose and look for the led light on the solid state relay to be on.

  • Page 52: Maintenance

    CAUTION! All repairs performed by unqualified personnel or the use of parts other than supplied by PMC may cause damage to the unit and put the operator at risk. REVISION 1.1...
  • Page 53 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION The first four alarms in the alarms menu are simple maintenance warnings. These alarms will not automatically stop the proportioner from functioning. They are, however, critical features that require maintenance and, if neglected, could compromise the integrity of the proportioner.

  • Page 54: Inlet Material Screens

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION 13.1 INLET MATERIAL SCREENS CAUTION! Make sure the Main Power Switch is OFF and incom- ing power is locked OFF. NOTE! Inspect and clean Inlet Material Screens before Propor- tioner start-up. They should not be cleaned after the days’ oper- ation as the Proportioner should be purged (see page 30) immedi- ately after inspection and cleaning.

  • Page 55: Iso Lubrication System

    ISO LUBRICATION SYSTEM DAILY: Check the condition of the PMC Lube Oil in the Iso Lube Reservoir. Replace the PMC Lube Oil if you see significant changes in the color or signs of solidification. Ensure inside of Reservoir is wiped clean.

  • Page 56: Hydraulic Drive System

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION 13.3 HYDRAULIC DRIVE SYSTEM WARNING! Before performing any maintenance, make sure the Main Power Switch is OFF and incoming power is locked OFF. The Hydraulic Unit is a component that works under pressure. Do not open any connection or carry out maintenance on components subject to pressure until all pressure has been bled to zero.

  • Page 57: Metering Pump-Line

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION 13.4 METERING PUMP-LINE WARNING! Before performing any maintenance, make sure the Main Power Switch is OFF and incoming power is locked OFF. Al- low material temperature to cool below 80 F and bleed all material pressure to zero.

  • Page 58: Material Heater

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION 13.6 MATERIAL HEATER WARNING! Before performing any maintenance, make sure the Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Propor- tioner power supply ON.
  • Page 59 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 13. MAINTENANCE CORPORATION WARNING! Before performing any maintenance, make sure the Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Propor- tioner power supply ON. The Heaters are components that reach high temperatures;...

  • Page 60: Hydraulic Oil Specifications

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 14. HYDRAULIC OIL SPECIFICATIONS CORPORATION HYDRAULIC OIL SPECIFICATIONS Recommended Hydraulic Oil Specification: ISO/ASTM Viscosity Grade 32 Viscosity: 28.8 – 35.2 SSU at 104 F Rust and Oxidation Inhibited 14.1 MANUFACTURERS Mobil DTE24 (Recommended) Cook’s Albavis 8 Ashland - Valvoline AW15 Shell –...

  • Page 61: Parts Identification

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PARTS IDENTIFICATION 15.1 FRAME ASSEMBLY Figure 19: Frame Assembly (FR-10) REVISION 1.1...
  • Page 62 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION FRAME ASSEMBLY (FR-10) ITEM QTY PART NUMBER DESCRIPTION 200950 GROMMET, 1.750” GD, 0.375” GW, 1.500” ID 200951 GROMMET, 1.000” GD, 0.125” GW, 0.813” ID 201060 WASHER, LOCK, 1/4, 18-8 SS 201328 GROMMET, 2.250”...

  • Page 63: Prox Sensor Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.2 PROX SENSOR ASSEMBLY Figure 20: Prox Sensor Assembly (RM-243) PROX SENSOR ASSEMBLY (RM-243) ITEM QTY PART NUMBER DESCRIPTION 201060 WASHER, LOCK, 1/4, 18-8 SS 201621 WASHER, FLAT, 1/4, 18-8 SS 201930 HHCS, 1/4-20 X 1.0, ZP GRD8...

  • Page 64: Hydraulic Manifold Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.3 HYDRAULIC MANIFOLD ASSEMBLY Figure 21: Hydraulic Manifold Assembly (HI-05335) HYDRAULIC MANIFOLD ASSEMBLY (HI-05335) ITEM QTY PART NUMBER DESCRIPTION HI-05070-3 HYDRAULIC MANIFOLD HI-05007 6 ORB X 6 JIC HI-05324 6 ORB X 1/2 JIC; 90 DEG...

  • Page 65: Exit Manifold Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.4 EXIT MANIFOLD ASSEMBLY Figure 22: Exit Manifold Assembly (HI-05343) EXIT MANIFOLD ASSEMBLY (HI-05343) ITEM QTY PART NUMBER DESCRIPTION HI-05307 OUTLET MANIFOLD HI-05011 6 ORB X 6 JIC NIPPLE HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG...

  • Page 66: Hydraulic Seal Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.5 HYDRAULIC SEAL ASSEMBLY Figure 23: Hydraulic Seal Assembly HYDRAULIC SEAL ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION HI-05025-13 BUSHING,ROD HI-05025-4 WIPER, ROD HI-05025-5 SHAFT SEAL HI-05025-6 BACK UP RING, BUSHING OR-00039A...

  • Page 67: Hydraulic Piston Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.6 HYDRAULIC PISTON ASSEMBLY Figure 24: Hydraulic Piston Assembly HYDRAULIC PISTON ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION HI-05300 HYDRAULIC PISTON HI-05025-3 WEAR RING HI-05025-2 BACK-UP RING, PISTON HI-05025-1 U-CUP REVISION 1.1...

  • Page 68: Hydraulic Cylinder Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.7 HYDRAULIC CYLINDER ASSEMBLY Figure 25: Hydraulic Cylinder Assembly (HI-05336) REVISION 1.1...

  • Page 69: Hydraulic Cylinder Rebuild Kit

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION HYDRAULIC CYLINDER ASSEMBLY (HI-05336) ITEM QTY PART NUMBER DESCRIPTION HYDRAULIC PISTON ASSEMBLY (SEE PAGE 66) HI-05301 HYDRAULIC CYLINDER HI-05200-3 PORT BLOCK, HYDRAULIC HYDRAULIC SEAL ASSEMBLY (SEE PAGE 65) HI-05302 FEMALE CLEVIS...

  • Page 70: A & R Single Pump Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.8 A & R SINGLE PUMP ASSEMBLY Figure 26: A & R Single Pump Assembly (202192) REVISION 1.1...

  • Page 71: A & R Single Pump Cross Section

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION A & R SINGLE PUMP ASSEMBLY (202192) ITEM QTY PART NUMBER DESCRIPTION 200700 INLET BODY, LP 200701 INLET VALVE, LP 201625 SHCS, 3/8 X 4.0, 18-8 SS OR-035 O-RING, -035, VITON...

  • Page 72: Pump-Line Seal Orientation

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.9 PUMP-LINE SEAL ORIENTATION Figure 28: A & R Single Pump Assembly Detail A Figure 29: A & R Single Pump Assembly Detail B REVISION 1.1...

  • Page 73: Pump-Line Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.10 PUMP-LINE ASSEMBLY Figure 30: Pump-Line Assembly (PL-10) REVISION 1.1...

  • Page 74: Pump Rebuild Kit

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PUMP LINE ASSEMBLY - HIGH PRESSURE (PL-10) ITEM QTY PART NUMBER DESCRIPTION PAX-044 SINGLE PL-PAX PUMP PU-07002 BRACKET, PAX 201589 SHCS, 1/4-20 X 1.000, 18-8 SS HI-05338 FLANGE, PAX 201584 SHCS, 3/8-16 X 3.000, 18-8 SS...

  • Page 75: A" Inlet Manifold Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.11 ”A” INLET MANIFOLD ASSEMBLY Figure 31: ”A” Inlet Manifold Assembly (YS-6-PHX) ”A” INLET MANIFOLD ASSEMBLY (YS-6-PHX) ITEM QTY PART NUMBER DESCRIPTION HI-05305 INLET MANIFOLD HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG...

  • Page 76: R" Inlet Manifold Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.12 ”R” INLET MANIFOLD ASSEMBLY Figure 32: ”R” Inlet Manifold Assembly (YS-7-PHX) ”R” INLET MANIFOLD ASSEMBLY (YS-7-PHX) ITEM QTY PART NUMBER DESCRIPTION HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG HI-05325 12 ORB X 12 JIC...

  • Page 77: Heater Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.13 HEATER ASSEMBLY Figure 33: Heater Assembly, 6 Rod - A Figure 34: Heater Assembly, 6 Rod - B REVISION 1.1...
  • Page 78 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PREHEATER ASSEMBLY PH-21 (3750W) PH-22 (4500W) PH-23 (5250W) ITEM QTY PART NUMBER DESCRIPTION 201560 BHCS, 1/4-20 X 0.500, 18-8 SS 201899 BHCS, 1/4-20 X 0.750, 18-8 SS 201561 BHCS, #6-32 X 0.375, 18-8 SS...

  • Page 79: Heater Assembly, 8 Rod - A

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION Figure 35: Heater Assembly, 8 Rod - A Figure 36: Heater Assembly, 8 Rod - B REVISION 1.1...
  • Page 80 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PREHEATER ASSEMBLY PH-33 (7000W) ITEM QTY PART NUMBER DESCRIPTION 201560 BHCS, 1/4-20 X 0.500, 18-8 SS 201899 BHCS, 1/4-20 X 0.750, 18-8 SS 201561 BHCS, #6-32 X 0.375, 18-8 SS EL-00006A...

  • Page 81: Motor-Line Assembly (1 Phase)

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.14 MOTOR-LINE ASSEMBLY (1 PHASE) Figure 37: Motor-Line Assembly - 1 Phase REVISION 1.1...
  • Page 82 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION MOTOR-LINE ASSEMBLY (1 PHASE) ML-2 (3HP, 1PH, 60HZ) ML-3 (5HP, 1PH, 60HZ) ITEM QTY PART NUMBER DESCRIPTION 201620 SHCS, 3/8-16 X 1.500, 18-8 SS 201628 WASHER, LOCK, 3/8, 18-8 SS 201629...

  • Page 83: Motor-Line Assembly (3 Phase)

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.15 MOTOR-LINE ASSEMBLY (3 PHASE) Figure 38: Motor-Line Assembly - 3 Phase REVISION 1.1...
  • Page 84 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION MOTOR-LINE ASSEMBLY (1 PHASE) ML-2 (3HP, 1PH, 60HZ) ML-3 (5HP, 1PH, 60HZ) ITEM QTY PART NUMBER DESCRIPTION 201620 SHCS, 3/8-16 X 1.500, 18-8 SS 201628 WASHER, LOCK, 3/8, 18-8 SS 201629...

  • Page 85: Final Assembly

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.16 FINAL ASSEMBLY Figure 39: PHDX-2 Final Assembly - A REVISION 1.1...

  • Page 86: Phdx-2 Final Assembly - B

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION Figure 40: PHDX-2 Final Assembly - B Figure 41: PHDX-2 Final Assembly - C REVISION 1.1...

  • Page 87: Phdx-2 Final Assembly - D

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION Figure 42: PHDX-2 Final Assembly - D REVISION 1.1...
  • Page 88 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PHDX-2 FINAL ASSEMBLY (HIGH PRESSURE) ITEM QTY PART NUMBER DESCRIPTION 201057 NUT, HEX #8-32 201060 WASHER, LOCK, 1/4, 18-8 SS 201242 LIGHT UNIT, RED, 120VAC 201243 LIGHT UNIT, WHITE, 120VAC 201529 FHCS, 1/4-20 X 0.750, 18-8 SS...
  • Page 89 POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION ITEM QTY PART NUMBER DESCRIPTION EL-192 TERMINAL BLOCK EL-193 INRUSH CURRENT LIMITER EL-195 0-5000 PRESS TRANSDUCER EL-35 HOSE HEAT RELAY EL-35-1 HEAT SINK EL-37 TRANSFORMER, SIGNAL EL-42-3200 PRESSURE SWITCH FR-10 FRAME ASSY, PH-2...

  • Page 90: Phdx-2 Hoses

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.17 PHDX-2 HOSES Figure 43: Proportioner Hoses - Front Figure 44: Proportioner Hoses - Back REVISION 1.1...

  • Page 91: Half Inch Hose Kit

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION PROPORTIONER HOSES ITEM QTY PART NUMBER DESCRIPTION HI-05047-2 HOSE 9” HYD PUMP TO TANK HI-05340-1 HOSE ASSY, PHX-2 HI-05047-6 HOSE 13” TOP PUMP CYL TO LEFT M HI-05047-7 HOSE ASSY HYDRAULIC PUMP TO TA...

  • Page 92: Lube Bottle Components

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.18 LUBE BOTTLE COMPONENTS Figure 45: Lube Bottle Assembly LUBE BOTTLE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION MQ-01009-01A LUBE BOTTLE MQ-01009-02A LUBE BOTTLE LID MA-00024A 1/2” X 3’ PLASTIC TUBING, SUPPLY MA-00025A 3/8”...

  • Page 93: Exit Manifold Accessory

    POLYURETHANE PHDX-2 SERVICE MANUAL MACHINERY 15. PARTS IDENTIFICATION CORPORATION 15.19 EXIT MANIFOLD ACCESSORY Figure 47: In-Trailer Option Figure 46: In-Plant Option Figure 48: Exit Manifold Accessory EXIT MANIFOLD ACCESSORY ITEM QTY PART NUMBER DESCRIPTION HI-05011 6 ORB X 6 JIC...

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