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Fluke Calibration 4322-SYS-NAVAIR Service Manual

Automated pressure calibrator
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4322-SYS-NAVAIR
Automated
Pressure
Calibrator
Service Manual

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Summary of Contents for Fluke Calibration 4322-SYS-NAVAIR

  • Page 1 4322-SYS-NAVAIR Automated Pressure Calibrator Service Manual...
  • Page 2 Reproduction and Distribution Notice In accordance Section 130 of title 10, United States Code, a DoD Distribution marking system for technical data has been established by DoD Directive 5230.24. IAW this directive and NAVAIR METCAL Policy, the below distribution statement needs to be added to the covers of all Technical Manuals acquired by the NAVAIR METCAL Program: DISTRIBUTION STATEMENT C.
  • Page 3 4322 Automated Pressure Calibrator Service Manual Reproduction and distribution of this technical manual is authorized for U.S. Government purposes. PN 4133214 September 2013 Rev. 2, 2/15 © 2013-2014 Fluke Corporation. All rights reserved. Specifications are subject to change without notice. All product names are trademarks of their respective companies.
  • Page 4 LIMITED WARRANTY AND LIMITATION OF LIABILITY Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is one year and begins on the date of shipment. Parts, product repairs, and services are warranted for 90 days.

  • Page 5: Table Of Contents

    Table of Contents Chapter Title Page Introduction and Specifications ............1-1 Introduction ......................1-3 Product Overview ....................1-3 Safety Information ..................... 1-4 The Product Manual Set ..................1-5 General Specifications ..................1-6 Pressure Limits ....................1-6 Measurement Specifications ................1-8 Pressure Control Specifications .................
  • Page 6 4322 Service Manual Calibration and Alignment ..............3-1 Introduction ......................3-3 Fundamentals ..................... 3-3 Required Equipment ..................3-4 Environmental Conditions ................. 3-4 Equipment Setup ....................3-5 Preliminary Operations ..................3-5 Module Calibration Procedure ................3-7 Module Alignment Procedure ................3-8 Controller Maintenance...............
  • Page 7 Contents (continued) Intensifier Maintenance............... 5-1 Introduction ......................5-3 Safety ......................... 5-3 Standard Torque Look-Up Table ............... 5-4 Intensifier Hour Meter ..................5-5 Maintenance Procedures ..................5-7 Front-Panel and Case Cleaning ..............5-7 Pressure Generation and Leak Test ............... 5-7 Electronic Pressure Sensor Alignment ............5-8 Seal Replacements ..................
  • Page 8 4322 Service Manual Electrical Problems ..................8-6 Pressure Selection and LED Indications ............8-7 Abnormal Noises ................... 8-7 Pressure Generation and Indication Problems ..........8-8 Valves and Quick-Connect Problems ............8-8 Wiring Schematics ................9-1 Introduction ......................9-3 Controller Wiring Schematics ................9-3 Intensifier Wiring Schematics ................
  • Page 9 List of Tables Table Title Page 1-1. Symbols ........................1-4 2-1. Valve and Solenoid Positions ................. 2-9 3-1. Calibration Equipment ................... 3-4 4-1. Controller Maintenance Time Schedule ..............4-3 4-2. Standard Hardware Torque Values ................ 4-3 4-3. Leak Test Parameters ..................... 4-5 4-4.
  • Page 10 4322 Service Manual...
  • Page 11 List of Figures Figure Title Page 1-1. The 4322 Automated Pressure Calibrator .............. 1-3 2-1. Location of the Pressure Valves ................2-5 2-2. Pressure Valve Schematic ..................2-8 2-4. Contamination Prevention System (CPS) .............. 2-12 2-5. CPS Pressure Routing (Cross-Section View) ............2-14 2-6.
  • Page 12 4322 Service Manual 5-3. Housing Assembly Removal .................. 5-13 5-4. Pump Cam Assembly Removal ................5-15 5-5. Cam Assembly Replacement ................. 5-18 5-6. Motor Controller Replacement ................5-19 5-7. Planetary Gear Replacement .................. 5-21 5-8. ICM Shaft Assembly ....................5-22 5-9.
  • Page 13 Chapter 1 Introduction and Specifications Title Page Introduction ......................1-3 Product Overview ....................1-3 Safety Information ..................... 1-4 The Product Manual Set ..................1-5 General Specifications ..................1-6 Pressure Limits ....................1-7 Measurement Specifications ................1-8 Pressure Control Specifications ................. 1-8 Pressure Switch Testing Specifications (Handheld) ..........
  • Page 14 4322 Service Manual...

  • Page 15: Introduction And Specifications

    Cylinder Handheld Control gxj039.eps Figure 1-1. Main Components of 4322-SYS-NAVAIR Configuration of 4322 Automated Pressure Calibrator For maximum versatility and portability, the Calibrator consists of a Pressure Controller (the Controller), a Pressure Intensifier (the Intensifier), a Nitrogen Cylinder, and an Accessory Kit that can be used in three different configurations.

  • Page 16: Safety Information

    4322 Service Manual Safety Information A Warning identifies condition and procedures that are dangerous to the user. A Caution identifies conditions and procedures that can cause damage to the Product or the equipment under test. See Table 1-1 for a list of symbols used in this manual and on the Calibrator. Table 1-1.

  • Page 17: The Product Manual Set

    CD in the Accessory Kit. www.flukecal.com Note Not all available components are included in every configuration of a 4322 system. Both manuals assume model 4322-SYS-NAVAIR, which includes all major components available, except for the 4322-REM Handheld Control, which is ordered separately. •...

  • Page 18: General Specifications

    4322 Service Manual General Specifications Power Requirements ..........100 V ac to 240 V ac (-15 %, +10 %), 50 Hz to 60 Hz Maximum Power Consumption Controller ............110 VA Intensifier ............250 VA Operating Temperature Range ......0 °C to 50 °C Storage Temperature Range ........

  • Page 19: Pressure Limits

    20 MPa (3,000 psi) Assembly Regulator Outlet Miniature QC female coupler 20 MPa (3,000 psi) Note: IQC70 is a Fluke Calibration interlocking quick connection nominally rated to 70 MPa (10,000 psi). Adaptor Kit Fittings Maximum Working Name Type of Fittings Pressure Limit...

  • Page 20: Measurement Specifications

    QC male stem at the other. Notes: IQC70 is a Fluke Calibration interlocking quick connection nominally rated to 70 MPa (10,000 psi). Hose limited to 3,000 psi due to miniature QC used to connect to the fitting on the regulator.

  • Page 21: Pressure Switch Testing Specifications (Handheld)

    Introduction and Specifications Pressure Switch Testing Specifications (Handheld) Typical Control Set Times Measure Mode Range Time (seconds) [1] [6] <28 kPa (4 psi) 28 kPa to 700 kPa (4 to 100 psi) Gauge 700 kPa to 7 MPa (100 to 1,000 psi) 7 to 70 MPa (1,000 to 10,000 psi) [1] [6] <14 kPa (2 psi)
  • Page 22 4322 Service Manual 1-10...

  • Page 23: Theory Of Operation

    Chapter 2 Theory of Operation Title Page Introduction ......................2-3 Controller ......................2-3 Pressure Control .................... 2-4 External Supply Pressure Control ............. 2-6 Internal Pump Pressure Generation and Control ........2-7 Removable Components ................2-10 Pressure Transducer Modules ..............2-10 Barometer ....................
  • Page 24 4322 Service Manual...

  • Page 25: Introduction

    Theory of Operation Introduction Introduction This chapter contains theory of operation principles and information for the Controller and the Intensifier. Controller The main function of the Controller is to have a user set a target pressure then accurately control and measure applied pressure to a unit under test (UUT). When a user sets a target pressure, the Controller uses the user supply selection to determine whether to use the internal pump, an external source, or both as follows: •...

  • Page 26: Pressure Control

    4322 Service Manual Pressure Control The Controller offers three different control modes to set pressure: Static Mode sets the target pressure and stops controlling, adjusting only when the measured pressure has exceeded specific limits. Dynamic Mode sets the target pressure and constantly adjusts to maintain the target.
  • Page 27 Theory of Operation Controller CPS Dock Pump Head Assembly Assembly View from Bottom hbx077.eps Figure 2-1. Location of the Pressure Valves...

  • Page 28: External Supply Pressure Control

    4322 Service Manual External Supply Pressure Control The Controller can set pressure from 28 kPa to 70 MPa gauge (4 psig to 10,000 psig) using external supply gas, such as from the nitrogen cylinder or Intensifier. The sequence below describes pressure control and measurement processes when using an external pressure source.

  • Page 29: Internal Pump Pressure Generation And Control

    Theory of Operation Controller Controller. Table 2-1 shows the configurations of the isolation valves, solenoids, and piezo-electric valves at different phases or pressures. Internal Pump Pressure Generation and Control The internal pump is used to control pressures below 4 psig. Between 4 psig and 300 psig, either the pump or external supply can be selected.
  • Page 30 4322 Service Manual hbx064.eps Figure 2-2. Pressure Valve Schematic...

  • Page 31: Valve And Solenoid Positions

    Theory of Operation Controller Table 2-1. Valve and Solenoid Positions Phase or BARO Pressure Ctrl Ctrl VENT VENT VENT 3-WAY Pressure Vented CLSD CLSD CLSD Pressure between 4 psig to CTRL CTRL CLSD CLSD CLSD CLSD CLSD CLSD 7.6 psig (External Source) Pressure between 4 psig to...

  • Page 32: Removable Components

    4322 Service Manual Removable Components Read the subsequent sections to learn more about the removable components in the Controller. Pressure Transducer Modules To measure pressure, the Controller uses four Pressure Transducer Modules (pressure module). A pressure module (shown in Figure 2-3), is a serviceable and replaceable pressure measurement component that is installed behind the display which allows for easy access to calibrate or replace a failed pressure module.

  • Page 33: Barometer

    Theory of Operation Controller Barometer The barometer module (shown in Figure 2-3), supplies the Controller with an atmospheric pressure value for absolute measurements. The barometer gets an atmospheric pressure reading through the ATM port on the front panel on the Controller. The barometer is a serviceable and replaceable module that must be regularly calibrated.

  • Page 34: Contamination Prevention System

    4322 Service Manual Contamination Prevention System To prevent damage to the Controller from contaminates that can be in the UUT and hoses such as water, dirt, oil and grease, the Controller is equipped with an integrated Contamination Prevention System (CPS). The CPS consists of an electronically controlled vent, a male and female QC fitting, a filter, and a purge port with a 60 ml plastic waste container (see Figure 2-4).
  • Page 35 Theory of Operation Controller Note The test medium exhausted through the CPS is sent through an additional coalescing filter. The filter can be identified as an externally visible white filter which is inserted into the waste bottle when the CPS is mounted into the Controller.
  • Page 36 4322 Service Manual To UUT Pressure Applied Fine Up Control Valve = OPEN Fine Down Control Valve = CLOSED Pressure in from CPS Dock Waste Fine Coalescing Filter Coarse Coalescing Filter Pressure Vented Fine Up Control Valve = CLOSED Fine Down Control Valve = CLOSED Waste Fine Coalescing Filter Coarse Coalescing Filter...

  • Page 37: Calcheck

    Theory of Operation Controller CalCheck Each pressure module features three redundant pressure sensing elements. Measurement uncertainty is reduced during normal operation by averaging the output of the three elements to determine the final pressure measurement used by the Controller. The Controller also monitors the individual pressure measurement of the elements and compares them to each other.

  • Page 38: Emergency Pressure Relief

    4322 Service Manual • Gauge and vacuum pressure measurement with the intrinsically absolute pressure module (A150K): AutoZero tares the reading to zero gauge pressure at vent. At all other pressures, the output is dynamically compensated for small changes in atmospheric pressure measured by the barometer module. •...

  • Page 39: Intensifier

    Theory of Operation Intensifier Intensifier The Pressure Intensifier (the Intensifier) is an electric pressure booster system that can boost a gas pressure (nitrogen) supply of (500 to 2,000) psig up to 10,000 psig. Note The Intensifier requires at least 500 psi from the Nitrogen Cylinder to boost pressure.
  • Page 40 4322 Service Manual Boost pressure selection is dependent on the pressure necessary to complete the UUT calibration. For a typical UUT calibration, select a set pressure equal to or greater than the maximum pressure necessary in the calibration sequence. For multiple UUT calibrations in the same location, set the boost pressure to the lowest available selection that is equal to or higher than the highest pressure necessary to complete the UUT calibrations.

  • Page 41: Overpressure Relief

    Theory of Operation Intensifier Overpressure Relief The Intensifier is fitted with an automatic pressure relief valve that automatically and instantaneously vents excess pressure if the pressure goes above 11,500 psi. This pressure relief valve is a safety feature and it resets automatically once pressure has decreased to the working range of the Intensifier.
  • Page 42 4322 Service Manual 2-20...

  • Page 43: Calibration And Alignment

    Chapter 3 Calibration and Alignment Title Page Introduction ......................3-3 Fundamentals ..................... 3-3 Required Equipment ..................3-4 Environmental Conditions ................. 3-4 Equipment Setup ....................3-5 Preliminary Operations ..................3-5 Module Calibration Procedure ................3-7 Module Alignment Procedure ................3-8...
  • Page 44 4322 Service Manual...

  • Page 45: Introduction

    Calibration and Alignment Introduction Introduction This chapter supplies information and instructions on how to calibrate and align the G70M, G10M, G700K, A150K, and barometer modules in the Controller. Note This chapter does not contain information on the Intensifier because the Intensifier does not require a calibration procedure.

  • Page 46: Required Equipment

    4322 Service Manual Required Equipment The equipment in Table 3-1 is required to complete the calibration procedure. Table 3-1. Calibration Equipment Primary Reference Classifications Minimum Use Specifications Suggested Equipment Automated Pressure See Required Components Supplied with Fluke 4322 Calibrator (APC) Range: 0.5 psia to 10,000 psia Pressure Controller Supplied with Fluke 4322...

  • Page 47: Equipment Setup

    Calibration and Alignment Equipment Setup Equipment Setup The operator can choose to calibrate all installed modules or only selected ranges. A pressure supply sufficient to reach the selected modules’ maximum pressure must be connected. For example, to calibrate the G10M (1500 psig) module, a gas cylinder with approximately 2000 psi could be used, or a gas supply with a minimum pressure of 500 psig and the 4322 Intensifier could be used.
  • Page 48 4322 Service Manual d. Fully open the Nitrogen Cylinder regulator to supply pressure. Note Close the Nitrogen Cylinder regulator when the Intensifier is not in use. 4. Connect the Intensifier to the Controller as follows (see Figure 3-1): a. Connect the two male ends of the system interconnect hose to the OUTPUT port on the Intensifier and the SUPPLY port on the Controller.

  • Page 49: Module Calibration Procedure

    Calibration and Alignment Module Calibration Procedure Module Calibration Procedure This procedure supplies instructions on how to perform the Calibration procedure on the G70M, G10M, G700K, A150K, and barometer modules. As mentioned in the Fundamentals section, Calibration is a performance verification procedure that tests to see if the module is within tolerance.

  • Page 50: Module Alignment Procedure

    4322 Service Manual hbx070.jpg Figure 3-3. Calibration Menu Configuration 7. Select . This starts the calibration procedure. The Calibration procedure is an automated process. The Controller automatically sets pressure, dwells, and takes measurements. As the test runs, the Controller reads the measurements from the modules and receives measurements data from the KN 3689 over the GPIB connection.
  • Page 51 Calibration and Alignment Module Alignment Procedure hbx067.jpg Figure 3-4. Module Selection 6. Fill in the Run Calibration menu as follows (see Figure 3-5): Note Text enclosed in [brackets] denotes a custom user entry. a. Test type: Alignment b. Adjustment Tol % : [user entry] c.
  • Page 52 4322 Service Manual 7. Select . This starts the Alignment procedure. The Alignment procedure is an automated process. The Controller automatically sets pressure, dwells, and takes measurements. As the test runs, the Controller reads the measurements from the modules and receives measurements data from the KN 3689 over the GPIB connection.

  • Page 53: Controller Maintenance

    Chapter 4 Controller Maintenance Title Page Introduction ......................4-3 Safety ......................... 4-3 Standard Torque Look-Up Table ............... 4-3 Maintenance Procedures ..................4-4 Event Log ...................... 4-4 Front-Panel and Case Cleaning ..............4-4 Pressure Leakage Test ................... 4-5 Pressure Generation Test (On-Board Motor) ..........4-6 Fuse Replacement ..................
  • Page 54 4322 Service Manual...

  • Page 55: Introduction

    Controller Maintenance Introduction Introduction This chapter supplies maintenance procedures and part replacement procedures for the Controller. Warning To prevent injury to personnel or damage to the Product, Controller maintenance is to only to be completed by maintenance personnel who have been formally trained on how to complete the maintenance procedures.

  • Page 56: Maintenance Procedures

    4322 Service Manual Maintenance Procedures This section supplies maintenance information and procedures for the Controller. The Controller is easy to maintain and troubleshoot. The onboard software monitors the system status and provides error messages to the user if any of the internal components fail.

  • Page 57: Pressure Leakage Test

    Controller Maintenance Maintenance Procedures Pressure Leakage Test Leak Test is a function of the Controller that checks the Controller and UUT connection for pressure leaks. To detect leaks, the Controller generates pressure and monitors the rate of pressure change over a specified time period. The total change in pressure (dP) and average rate of change is shown on the Leak Test menu and stays on the menu until the test is reaccomplished.

  • Page 58: Pressure Generation Test (On-Board Motor)

    4322 Service Manual Bubbles Show a Leak Spray Bottle hbx026.eps Figure 4-1. Spray Test Pressure Generation Test (On-Board Motor) Use the following instructions to test the internal piston pump. The internal piston pump generates pressure and also can create a vacuum. To fully test, both functions should be checked.

  • Page 59: Fuse Replacement

    Controller Maintenance Maintenance Procedures Fuse Replacement The Controller has a replaceable fuse located inside the power module on the front panel that protects against drawing excessive current from the mains supply. See Table 4-4. Warning To prevent possible electrical shock, fire, or personal injury, use only specified replacement parts.
  • Page 60 4322 Service Manual Controller Fuse Holder Intensifier gxj081.eps Figure 4-2. Controller Fuse Replacement...

  • Page 61: Controller Part Replacement

    Controller Maintenance Controller Part Replacement Controller Part Replacement This section supplies instructions on how to replace specific parts within the Controller. Note The replacement procedures in this chapter only contain specific instructions on how to replace a part and do not list part numbers. For a full list of part numbers, see Chapter 7 “List of Replaceable Parts”.

  • Page 62: Control Panel Separation

    4322 Service Manual Reinstall the chassis and control panel as follows (see Figure 4-3). Skip step 1 if the control panel was not removed. 1. Reinstall the control panel on the chassis as follows (see Figure 4-4): a. Connect the keypad ribbon cable () and feed the display ribbon cable () and the backlight power cable () through the control panel ().
  • Page 63 Controller Maintenance Controller Part Replacement 10. Remove the t-fitting () shown in Figure 4-6 by pressing in on the plastic ring around the tube and pulling the TEE away from the bulkhead fitting. 11. Remove tubeweld () shown in Figure 4-6. To do this, remove the two screws () and washers () that secure the tubeweld () to the manifold.
  • Page 64 4322 Service Manual f. Connect the CPS isolation valve VH3 cable to (J8) on the main PCA. 10. Connect the cable from (J14) of main PCA and connect (P4) and (P5) on power supply to allow for installation of the electronics cover/power supplies (see Figure 4-5).
  • Page 65 Controller Maintenance Controller Part Replacement CPS Dock To Keypad To CPS To Display Dock To Display Backlight hbx068.eps Figure 4-4. Control Panel Removal 4-13...
  • Page 66 4322 Service Manual View of the Electronics Box Wiring Connections Keypad (J16) Display Backlight (J7) V5,6,7 Clippard Valves (J10) Display (J9) Hinge Switch (J5) VH1 (J4) Controller Main Harness (J14) VH2 (J6) VH3 (J8) Backplane PCA (J13) Comm. Box (J11) Barometer (J12) Internal Motor (J1) Not Used...
  • Page 67 Controller Maintenance Controller Part Replacement Bottom View hbx097.eps Figure 4-6. Power Module and Tubeweld 4-15...

  • Page 68: Pump Bracket

    4322 Service Manual Pump Bracket Use the following instructions and reference Figure 4-7 to remove the pump bracket assembly (). 1. Use the instructions in “Chassis” on page 4-9 to remove the chassis. Note The control panel does not need to be separated from the chassis to complete this procedure.
  • Page 69 Controller Maintenance Controller Part Replacement White Brown White CPS Dock Blue Black Note: Red dot on motor indicates positive (+) terminal. Purple Grey Green White Fan Wire Wiring Harness hbx032.eps Figure 4-7. Piston and Pump Head Assembly Removal 4-17...

  • Page 70: Manifold

    4322 Service Manual Manifold Use the following instructions and reference Figures 4-8 and 4-9 to extract the manifold assembly from the chassis. 1. Use the instructions in “Chassis and Control Panel” on page 4-9 to remove the chassis and take off the control panel. 2.
  • Page 71 Controller Maintenance Controller Part Replacement c. Install the vent line (items  and ) that connects to the control panel atmosphere vent fitting and ensure the line from the manifold to the barometer manifold is reconnected. d. Put the Controller face down and connect the PV1 () and PV2 () electrical connectors.
  • Page 72 4322 Service Manual Bottom View hbx075.eps Figure 4-8. Pressure Line and Power Lines 4-20...
  • Page 73 Controller Maintenance Controller Part Replacement View from the CPS side View from the CPS side hbx076.eps Figure 4-9. Manifold Removal 4-21...

  • Page 74: Display

    4322 Service Manual Display Use the following instructions and reference Figure 4-10 to replace the display. 1. Use the instructions in “Chassis and Control Panel” on page 4-9 to remove the chassis. Note The control panel does not need to be separated from the chassis to complete this procedure.

  • Page 75: Keypad, Encoder, Or Encoder Wheel

    Controller Maintenance Controller Part Replacement Tilt display forward to access hinge screws hbx070.eps Figure 4-10. Display Assembly Keypad, Encoder, or Encoder Wheel Use the following instructions and reference Figure 4-11 to replace the keypad (), encoder (), or encoder wheel (): To replace the keypad (): 1.

  • Page 76: Communications Box

    4322 Service Manual 3. Lift off the wheel () from the encoder (). 4. Remove the washer and nut (not shown) that secures the encoder to the keypad (). 5. Remove the encoder () and put the new encoder on. 6.
  • Page 77 Controller Maintenance Controller Part Replacement 6. Install the anti-vibration device. 7. Slide the upper communications box () into the top of the control panel (). 8. Install the two flanges () that secure the lower communications box () to the chassis.

  • Page 78: Pressure Transducers And Barometer

    4322 Service Manual Pressure Transducers and Barometer Use the following instructions and reference Figure 4-13 to replace a pressure transducer module and/or the barometer. Warning To prevent possible personal injury, shut off the supply pressure and vent the system before removing a transducer module.
  • Page 79 Controller Maintenance Controller Part Replacement Turn off power Pressure Transducer Modules (Pressure Modules) Barometer Module gxj079.eps Figure 4-13. Pressure Transducer and Barometer Removal 4-27...

  • Page 80: Contamination Prevention System (Cps)

    4322 Service Manual Contamination Prevention System (CPS) Use the instructions in the subsequent sections to replace the CPS filters, dock, and NC isolation valve. Fine and Coarse CPS Filters (Internal) Use the following instructions and reference Figure 4-14 to replace the fine and coarse filters in the CPS.

  • Page 81: Cps Dock And Nc Isolation Valve

    Controller Maintenance Controller Part Replacement hbx078.eps Figure 4-14. Coarse and Fine Filters CPS Dock and NC Isolation Valve Use the following instructions and reference Figure 4-15 and 4-16 to replace the CPS dock assembly and/or the NC isolation valve. 1. Use the instructions in “Chassis and Control Panel” on page 4-9 to remove the chassis from the case.
  • Page 82 4322 Service Manual 4. Remove the CPS dock as follows (see Figure 4-15): a. Remove the brass tube fitting adaptor from the bottom of the CPS dock. b. Disconnect the tubeweld HM2 fitting () to the CPS dock (see Figure 4-4). c.
  • Page 83 Controller Maintenance Controller Part Replacement hbx069.eps Figure 4-15. CPS Dock Replacement 4-31...

  • Page 84: Piston Pump Head Clippard Valves

    4322 Service Manual Piston Pump Head Clippard Valves Use the following instructions and reference Figure 4-16 to replace the fine or coarse Clippard valves. 1. Remove the pump bracket assembly from the chassis. See “Pump Bracket” on page 4-16 2. Position the complete pump head assembly so that the solenoid () is upright. This is to prevent the internal items from falling out.

  • Page 85: Piston Seal

    Controller Maintenance Controller Part Replacement Piston Seal Replacement Use the following instructions to replace piston seal in the piston pump (see Figure 4-17). 1. Remove the pump bracket assembly from the chassis. See “Pump Bracket” on page 4-16. 2. Remove the piston pump head along with the Clippard valves. See Figure 4-16. The Clippard valves can stay attached to the pump head.

  • Page 86: Precision, Isolation, And Control Valves And Backplane Pca

    4322 Service Manual previously with the marking visible. 15. Install the piston pump head along with the clippard valves. See “Piston Pump Head Clippard Valves” on page 4-32. 16. Install the pump bracket assembly on the chassis. See “Pump Bracket” on page 4-16. Precision, Isolation, and Control Valves and Backplane PCA Use the following instructions to replace the precision, isolation, and control valves and backplane PCA.
  • Page 87 Controller Maintenance Controller Part Replacement View of valves installed on the manifold Manifold shown fully assembled hbx035.eps Figure 4-18. System Manifold Exploded View 4-35...

  • Page 88: Nc Isolation Valve

    4322 Service Manual NC Isolation Valve Use the following instructions and reference Figure 4-19 to replace the NC isolation valve (). 1. With a soft grip pair of channel locks, turn the NC isolation valve () counterclockwise to remove. 2. Remove the four screws () that attach base of the NC isolation valve to the manifold assembly.

  • Page 89: Access The Electronics Box

    Controller Maintenance Controller Part Replacement Access the Electronics Box Use the following instructions and reference Figure 4-20 to gain access to the electronics box. 1. Remove the mains power cord from the power entry module. 2. Use the instructions in “Chassis and Control Panel” on page 4-9 to remove the chassis.

  • Page 90: Main Pca And P-Vlv Pca

    4322 Service Manual Main PCA and P-VLV PCA Use the following instructions and reference Figure 4-20 to replace the main pca () or the p-vlv pca (). 1. Use the instructions in “Access the Electronics Box” to open the electronics box. 2.

  • Page 91: Amplifier Pca

    Controller Maintenance Controller Part Replacement Amplifier PCA Use the following instructions and reference Figure 4-20 to replace the amplifier pca assemblies (). Note The amplifier pca assemblies () are located behind the p-vlv pca (). If just the amplifier pca assemblies () need replaced, the electronics box does not need to be opened and replacement can be accomplished from the rear of the electronics box as described by the instructions in this procedure.
  • Page 92 4322 Service Manual View of the Electronics Box Wiring Connections Keypad (J16) Display Backlight (J7) V5,6,7 Clippard Valves (J10) Display (J9) Hinge Switch (J5) VH1 (J4) Controller Main Harness (J14) VH2 (J6) VH3 (J8) Backplane PCA (J13) Comm. Box (J11) Barometer (J12) Internal Motor (J1) Not Used...

  • Page 93: Quick Connect Fittings (Qc) And Filter

    Controller Maintenance Controller Part Replacement Quick Connect Fittings (QC) and Filter Use the instructions below and Figure 4-21 to replace the QC fitting (). 1. Use the instructions in “Chassis and Control Panel” on page 4-9 to remove the chassis. 2.
  • Page 94 4322 Service Manual 4-42...

  • Page 95: Intensifier Maintenance

    Chapter 5 Intensifier Maintenance Title Page Introduction ......................5-3 Safety ......................... 5-3 Standard Torque Look-Up Table ............... 5-4 Intensifier Hour Meter ..................5-5 Maintenance Procedures ..................5-7 Front-Panel and Case Cleaning ..............5-7 Pressure Generation and Leak Test ............... 5-7 Electronic Pressure Sensor Alignment ............

  • Page 97: Introduction

    Intensifier Maintenance Introduction Introduction This chapter supplies maintenance procedures and part replacement procedures for the Intensifier. Table 5-1 lists the maintenance tasks for the Intensifier and the recommended time interval between maintenance. Warning To prevent injury to personnel or damage to the Product, Intensifier maintenance is to only to be completed by maintenance personnel who have been properly trained on how to complete the maintenance procedures.

  • Page 98: Standard Torque Look-Up Table

    4322 Service Manual Standard Torque Look-Up Table Torque value for standard hardware is listed in Table 5-2. If a nonstandard torque value is required, the torque value is listed in the procedure next to the hardware. For example: “Install the low profile screw () that secures the planet gear () to the lower cam mount plate ().

  • Page 99: Intensifier Hour Meter

    Intensifier Maintenance Intensifier Hour Meter Intensifier Hour Meter The Intensifier has two built-in electronic hour meters that assist with maintenance: • The maintenance hour meter displays how many hours the motor was used since the last reset. Service personnel can choose when to reset the maintenance hour meter to support their organizations maintenance practices and procedures.

  • Page 100: Hour Meter Conversion Table

    4322 Service Manual Table 5-3. Hour Meter Conversion Table Flashing LED Maintenance Hours Total Hours 0 - 199 0 - 1,999  200 - 299 2,000 - 2,999  300 - 399 3,000 - 3,999  400 - 499 4,000 - 4,999 ...

  • Page 101: Maintenance Procedures

    Intensifier Maintenance Maintenance Procedures Maintenance Procedures This section supplies maintenance information for the Intensifier. Front-Panel and Case Cleaning To clean the Calibrator, wipe it with a cloth that is lightly dampened with water or mild detergent. Do not use aromatic hydrocarbons, chlorinated solvents, or methanol based fluids.

  • Page 102: Electronic Pressure Sensor Alignment

    4322 Service Manual Electronic Pressure Sensor Alignment The electronic pressure sensor must be field aligned if the pressure generation amount is off by more than 10 %. If a new electronic pressure sensor is installed, the new sensor must have a field alignment performed followed by a factory alignment to store the new coefficients.

  • Page 103: Seal Replacements

    Intensifier Maintenance Maintenance Procedures Seal Replacements It is recommended that the pressure port, shaft seals, piston seals, and backup rings be replaced within the time interval listed in Table 5-1 to ensure performance to the specifications. Seals may need to be replaced sooner if a leak occurs that requires maintenance action.
  • Page 104 4322 Service Manual Controller Fuse Holder Intensifier gxj081.eps Figure 5-1. Fuse Replacement 5-10...

  • Page 105: Intensifier Part Replacement

    Intensifier Maintenance Intensifier Part Replacement Intensifier Part Replacement This section supplies instructions on how to replace specific parts within the Intensifier. Note The replacement procedures in this chapter only contain specific instructions on how to replace a part and do not list part numbers. For a full list of part numbers, see Chapter 7 “List of Replaceable Parts”.
  • Page 106 4322 Service Manual hbx008.eps Figure 5-2. Intensifier Case Removal 5-12...
  • Page 107 Intensifier Maintenance Intensifier Part Replacement Use the following instructions and Figure 5-3 to separate the control panel assembly from the booster pump assembly. The following steps are best performed with the intensifier placed upside down on the work bench resting on the control panel assembly () handles: Remove the four screws () and the four lock washers () that secures the upper pressure line () to the control panel assembly ().

  • Page 108: Pump Cam

    4322 Service Manual Use the following instructions and Figure 5-3 to reconnect the control panel assembly to the booster pump assembly: Put the booster pump assembly () on a flat work surface. Connect the control panel assembly () to the booster pump assembly () as follows: Install the motor cable retaining clamp (not shown) on the bottom of the booster pump assembly ().
  • Page 109 Intensifier Maintenance Intensifier Part Replacement Plastic Spacers hbx103.eps Figure 5-4. Pump Motor with Plastic Spacers 7. Lift the pump housing off from the cam assembly. 8. Remove the shaft wave spring and shaft bearing. Note The bearing might be retained in the sun gear hub. Be careful not to lose it as it has a loose fit and may fall out.
  • Page 110 4322 Service Manual Place the sheet metal cover plate over the top and install the eight outer screws () and lock washers () securing both the sheet metal cover and the upper shaft mount plate to the pump assembly housing. Add Loctite to Hardware when Tightened hbx012.eps...

  • Page 111: Pump Cam Disassembly

    Intensifier Maintenance Intensifier Part Replacement Pump Cam Disassembly Use the following instructions and Figure 5-6 to disassemble the pump cam assembly: Note This procedure supplies instructions on how to completely disassemble the entire pump cam assembly. Many procedures only requires the pump cam assembly to be partially disassembled.

  • Page 112: Pump Cam Reassembly

    4322 Service Manual Pump Cam Reassembly Use the following instructions and Figure 5-6 to reassemble the pump cam assembly: 1. Position the piston guide rail spacers () on the lower piston guide plate () and secure them from the underside with 16 (two per spacer) socket head screws (19) and lock washers ().
  • Page 113 Intensifier Maintenance Intensifier Part Replacement Add Loctite to Hardware when Tightened Add Teflon Grease when Installed hbx017.eps Figure 5-6. Cam Assembly Replacement 5-19...

  • Page 114: Motor Controller

    4322 Service Manual Motor Controller Use the following instructions and Figure 5-7 to replace the motor controller (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Note Depending on the previous level of disassembly the control panel assembly screws may not be fully removed as the spacers help captivate the screws.
  • Page 115 Intensifier Maintenance Intensifier Part Replacement hbx016.eps Figure 5-7. Motor Controller Replacement 5-21...

  • Page 116: Planetary Gears And Gear Bearings

    4322 Service Manual Planetary Gears and Gear Bearings Use the following instructions and Figure 5-8 to replace a planetary gear () or bearing (items  and ). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Remove pump cam assembly from the booster pump assembly housing. See “Pump Cam”...
  • Page 117 Intensifier Maintenance Intensifier Part Replacement Bearing Installation Depth in Planet Gears Bearing Pin Bearings 0.70 mm Planet Gear 1.70 mm Larger Chamfer on Clip Side hbx020.eps Figure 5-8. Planetary Gear Replacement 5-23...

  • Page 118: Pressure Port Shaft And Seals

    4322 Service Manual Pressure Port Shaft and Seals Use the following instructions and Figure 5-9 to replace the pressure port shaft () and seals ( and ). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Remove pump cam assembly from the booster pump assembly housing. See “Pump Cam”...

  • Page 119: Icm

    Intensifier Maintenance Intensifier Part Replacement Use the following instructions and Figures 5-6 and 5-9 to replace an ICM assembly (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Remove pump cam assembly from the booster pump assembly housing. See “Pump Cam”...
  • Page 120 4322 Service Manual clevis can be removed when the low stroke of the cam is positioned in front of a clevis. See “Pump Cam Disassembly” on page 5-17. To replace the piston seals (, , and ): a. Remove the entire piston clevis assembly from the ICM assembly. b.
  • Page 121 Intensifier Maintenance Intensifier Part Replacement a. Position the piston insertion tool on the end of the ICM as shown in step 1 in Figure 5-11. Note that the clevis assembly needs to be removed for this procedure. b. Apply a small film of Krytox silicon lubricant to the o-ring (), seal (), and centering ring () As in Figure 5-10.
  • Page 122 4322 Service Manual hbx094.eps Figure 5-11. Piston Insertion 6. To replace the roller (), refer to Figure 5-12: a. Remove the c-clip () that retains the bearing (). b. Push the roller shaft () through the roller block (). Use of a bench-top press is recommended.
  • Page 123 Intensifier Maintenance Intensifier Part Replacement d. Push the roller shaft () into the roller block (). Use of a bench-top press is recommended. e. Install the c-clip () that retains the bearing (). Reassemble the pump cam assembly. Use the pump cam reassembly procedure on page 5-18.

  • Page 124: Pressure Gauge

    4322 Service Manual Pressure Gauge Use the following instructions and Figures 5-7 and 5-13 to replace the pressure gauge (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Note Depending on the previous level of disassembly the control panel assembly screws may not be fully removed as the spacers help captivate the screws.

  • Page 125: Vent Or Isolation Valve

    Intensifier Maintenance Intensifier Part Replacement Vent or Isolation Valve Use the following instructions and Figure 5-14 to replace the vent () or isolation valve (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Put the control panel () on a flat work surface upside down, using support blocks to keep it raised above the surface.

  • Page 126: Electronic Pressure Sensor

    4322 Service Manual Electronic Pressure Sensor Use the following instructions and Figure 5-15 to replace the electronic pressure sensor (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Put the control panel () on a flat work surface upside down, using support blocks to keep it raised above the surface.

  • Page 127: Overpressure Relief Valve

    Intensifier Maintenance Intensifier Part Replacement Overpressure Relief Valve Use the following instructions and Figure 5-15 to replace the overpressure relief valve (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Put the control panel () on a flat work surface upside down, using support blocks to keep it raised above the surface.

  • Page 128: Power Supply Pca And Intensifier Pca

    4322 Service Manual hbx024.eps Figure 5-16. Power Entry Module and Power Supply PCA Replacement Power Supply PCA and Intensifier PCA Use the following instructions and Figure 5-16 to replace the power supply pca (). Remove the chassis and separate the chassis. See “Chassis” on page 5-11. Put the control panel () on a flat work surface upside down, using support blocks to keep it raised above the surface.

  • Page 129: Quick Connect Fittings (Qc) And Filter

    Intensifier Maintenance Intensifier Part Replacement 11. Put the chassis together and put into the case. See “Chassis” on page 5-11. Quick Connect Fittings (QC) and Filter Use the following instructions and Figure 5-17 to replace both of the QC fittings (). Remove the chassis and separate the chassis.
  • Page 130 4322 Service Manual Intensifier front panel shown. Procedure the same for the Controller. hbx030.eps Figure 5-17. Quick Connect Fitting Removal 5-36...

  • Page 131: Nitrogen Cylinder Maintenance

    Chapter 6 Nitrogen Cylinder Maintenance Title Page Introduction ......................6-3 Safety ......................... 6-3 Visual Inspection ....................6-4 External Cylinder Cleaning Procedure .............. 6-4 Internal Cylinder Cleaning Procedure ............... 6-4 Nitrogen Recharge Procedure ................6-5...
  • Page 132 4322 Service Manual...

  • Page 133: Introduction

    Nitrogen Cylinder Maintenance Introduction Introduction This chapter supplies maintenance instructions and procedures for the Nitrogen Cylinder. Warning Cylinder maintenance is to only to be completed by maintenance personnel who have been formally trained on how to complete the maintenance procedures. The Nitrogen Cylinder (the Cylinder) is used to supply very high pressure gas and should be handled with care, especially when it is filled.

  • Page 134: Visual Inspection

    4322 Service Manual Visual Inspection The visual inspection makes sure the Cylinder is in good operating condition before it is used. Never use the Cylinder if it shows signs of corrosion, gouges, indents, bulges, heat damage or if it has been dropped or otherwise damaged. Visually inspect the Cylinder before use as follows: 1.

  • Page 135: Nitrogen Recharge Procedure

    Nitrogen Cylinder Maintenance Nitrogen Recharge Procedure 4. Rinse cylinder completely with warm tap water (or soft water if the tap water is hard). 5. Steam clean and dry the cylinder with clean compressed air. Caution To prevent damage to the product, make sure the cylinder is completely dry before installing the regulator.
  • Page 136 4322 Service Manual 7. Open the bleed valve to vent the nitrogen from the fill regulator. 8. Disconnect the filling regulator and the fill adapter. 9. Reconnect the Nitrogen Cylinder Regulator. Nitrogen Cylinder Regulator (supplied) Cylinder Main Shutoff Nitrogen Cylinder Fill Adapter (supplied) Example Fill Regulator (not supplied)

  • Page 137: List Of Replaceable Parts

    Chapter 7 List of Replaceable Parts Title Page Introduction ......................7-3 How to Order Replacement Parts ..............7-3 Calibrator Final Assembly ................. 7-4 Controller Final Assembly ................. 7-9 Intensifier Final Assembly ................. 7-21...
  • Page 138 4322 Service Manual...

  • Page 139: Introduction

    Electronic components can be ordered directly from the Fluke Corporation and its authorized representatives with the Fluke part number. Parts price information is available from the Fluke Corporation or its representatives. To contact Fluke Calibration, call one of the following telephone numbers: • Technical Support USA: 1-877-355-3225 •...

  • Page 140: Calibrator Final Assembly

    4322 Service Manual Calibrator Final Assembly Table 7-1. Calibrator Final Assembly Description Part Number 4322 CONTROLLER 4237630 4322 INTENSIFIER 4237653 4322 NITROGEN CYLINDER 4221336 HANDHELD CONTROL 4113229 4322 ACCESSORY KIT 4208134 4322,ACCESSORY DOCUMENATION KIT 4362344 Shown Pressure Intensifier Pressure Controller “the Intensifier”...
  • Page 141 MANUAL, SERVICE, MANUAL, PORTABLE 4133214 AUTOMATED PRESSURE CALIBRATOR FOR 4322- SHOWN SYS-NAVAIR MANUAL, OPERATORS, MANUAL, PORTABLE 4133206 AUTOMATED PRESSURE CALIBRATOR FOR 4322- SHOWN SYS-NAVAIR 4362733 DVD, TRAINING VIDEO FOR 4322-SYS-NAVAIR SHOWN Note: [1] – Handheld Control and test leads sold separately.

  • Page 142: Accessory Kit Assembly

    4322 Service Manual Top Case Bottom Case hbx060.eps Figure 7-2. Accessory Kit Assembly...

  • Page 143: Adapter Kit Assembly

    List of Replaceable Parts Calibrator Final Assembly Table 7-3. Adapter Kit Assembly Item Description Part Number Quantity Notes FITTING, HM4 EQUIVALENT 4150810 FITTING, HF4 EQUIVALENT 4150822 FITTING, 1/8 MALE PIPE THREAD (NPT) 4150831 FITTING, 1/4 MALE PIPE THREAD (NPT) 4150846 FITTING, 1/2 MALE PIPE THREAD (NPT) 4150854 FITTING, 1/8 FEMALE PIPE THREAD (NPT)

  • Page 144: Spares Kit Assembly (Not Shown)

    4322 Service Manual Table 7-4. Spares Kit Assembly (not shown) Description Part Number Quantity Notes O-RING, URETHANE, 14 MM ID X 1 MM C/S, PU90 DURO 4398685 YELLOW, COMPOUND # U9001Y O-RING, URETHANE, 12 MM ID X 1 MM C/S, PU90 DURO 4398697 YELLOW, COMPOUND # U9001Y O-RING, URETHANE, 8 MM ID X 1 MM C/S, PU90 DURO...

  • Page 145: Controller Final Assembly

    List of Replaceable Parts Controller Final Assembly Controller Final Assembly Table 7-5 lists and Figure 7-4 shows the orderable assemblies inside the Controller. Some of the assemblies have internal parts that can be separately ordered and are listed in the subsequent sections.

  • Page 146: Controller Top-Level Assembly

    4322 Service Manual Removable Modules Pressure Transducers Barometer A10 (PCAs, electronics box, and chassis walls) hbx090.eps Figure 7-4. Controller Top-Level Assembly 7-10...
  • Page 147 List of Replaceable Parts Controller Final Assembly Table 7-6. A1 Control Panel Assembly Ref. Description Part Number Quantity Notes DISPLAY ASSEMBLY 4227342 MANIFOLD MOUNT QC W/DUST CAP AND CHAIN 4408161 DOCK ASSEMBLY, 4322 CONTROLLER, TESTED 4483357 NC ISOLATION VALVE (VH3) 4244728 POWER ENTRY MODULE 3136592...

  • Page 148: A1 Control Panel Assembly

    4322 Service Manual H5/H6 (CPS DOCK O-RING NOT SHOWN) CPS Dock H32/H8 hbx091.eps Figure 7-5. A1 Control Panel Assembly 7-12...

  • Page 149: A8 System Manifold Assembly

    List of Replaceable Parts Controller Final Assembly Table 7-7. A8 System Manifold Assembly Ref. Description Part Number Quantity Notes VH1 NC ISOLATION VALVE 4244762 V5 2-WAY VALVE (HI-P) 3466665 V6 2-WAY VALVE (HI-P) V7 3-WAY VALVE 3139019 PV1 PRECISION CONTROL VALVE TESTED 4483384 PV2 PRECISION CONTROL VALVE TESTED 4483378...
  • Page 150 4322 Service Manual H12/H3 H12/H3 (Lower Port) hbx092.eps Figure 7-6. System Manifold Assembly 7-14...
  • Page 151 List of Replaceable Parts Controller Final Assembly Table 7-8. A9 Pump Bracket Assembly Ref. Description Part Number Quantity Notes VALVE KIT, CS-4193, SOLENOID ASSY, COIL AND 4399748 SPIDER, 6 V VALVE KIT, CS-4193-10, SOLENOID ASSY, COIL AND 4399753 SPIDER,12 V 4322-PUMP,REBUILD KIT FOR 4322 PISTON PUMP 4237107 FAN CABLE WITH FAN...

  • Page 152: A9 Pump Bracket Assembly

    4322 Service Manual Complete Assembly: A1 hbx093.eps Figure 7-7. A9 Pump Bracket Assembly 7-16...
  • Page 153 List of Replaceable Parts Controller Final Assembly Table 7-9. A10 Electronics Box Assembly Ref. Description Part Number Quantity Notes P-VLV PCA 4213295 MAIN BOARD PCA, TESTED 4561120 BRAIN BOARD PCA, TESTED 4561112 POWER SUPPLY, 12 V 4369964 POWER SUPPLY, 5 V 4369958 M4 X 10 SHCS 3153272...

  • Page 154: A10 Electronics Box Assembly

    4322 Service Manual H1/H3 H1/H3 H11/H7 H20/H21/H22 H11/H7 H11/H7 H11/H7 H28/H29 H11/H7 H11/H7 H39/H7 H1/H3 H11/H7 H11/H7 hbx099.eps Figure 7-8. A10 Electronics Box Assembly 7-18...
  • Page 155 List of Replaceable Parts Controller Final Assembly Table 7-10. A15 CPS Assembly Ref. Description Part Number Quantity Notes SURGE NIPPLE 4255160 BALL 3474441 SURGE VALVE CUP 4255149 FINE FILTER COALESCING FILTER PACK - 30 MM 4358838 AND 20 MM LONG FILTERS DUT TUBE 4155835 M1.6 X 5 SHCS...

  • Page 156: A15 Cps Assembly

    4322 Service Manual (30 mm) H4 (20 mm) hbx101.eps Figure 7-9. A15 CPS Assembly 7-20...

  • Page 157: Intensifier Final Assembly

    List of Replaceable Parts Intensifier Final Assembly Intensifier Final Assembly Table 7-11. A1 Intensifier Assembly Item Description Part Number Quantity Notes CONTROL PANEL ASSEMBLY BOOSTER PUMP ASSEMBLY CASE, INTENSIFIER 4227172 TUBEWELD ASSEMBLY 4280424 UNION 4087953 10-32 FITTING 3148322 BOOSTER SUPPLY TUBE 4243427 M6 HEX NUT 2536890...
  • Page 158 4322 Service Manual (4X) hbx042.eps Figure 7-10. Intensifier Final Assembly 7-22...

  • Page 159: A1 Control Panel Assembly (Page 1)

    List of Replaceable Parts Intensifier Final Assembly Table 7-12. A1 Control Panel Assembly (Page 1) Item Description Part Number Quantity Notes ASSY, 10K PSI SENSOR 4235320 VALVE,PRESSURE RELIEF,MINIATURE,SS,1/4 NPTM 4483325 INLET, TESTED GAUGE W/CLAMP 4243475 MANIFOLD QUICK CONNECT ASSEMBLY 4345866 HF2 VALVE 3328687 TUBE - GAUGE TO MANIFOLD 4322-5675...
  • Page 160 4322 Service Manual hbx049.eps Figure 7-11. Control Panel Assembly (Page 1) 7-24...
  • Page 161 List of Replaceable Parts Intensifier Final Assembly Table 7-13. A1 Control Panel Assembly (Page 2) Item Description Part Number Quantity Notes INTENSIFIER PCA 4142630 POWER SUPPLY PCA 4369947 MOTOR CONTROLLER 4212180 POWER ENTRY MODULE 4341311 M3 X 6 SHCS 3154248 M3 LWASH 3153752 M3 X 30 STANDOFF...
  • Page 162 4322 Service Manual hbx100.eps Figure 7-12. Control Panel Assembly (Page 2) 7-26...
  • Page 163 List of Replaceable Parts Intensifier Final Assembly Table 7-14. A2 Booster Pump Assembly Item Description Part Number Quantity Notes ENCODER PCA 4213347 PUMP CAM ASSEMBLY CAM PLATE & PLANET GEARS ASSEMBLY M4 X 12 SHCS 3153285 M4 LOCK WASHER 3153914 UPPER SHAFT MOUNT PLATE 4139956 C-CLIP...

  • Page 164: A2 Booster Pump Assembly

    4322 Service Manual hbx043.eps Figure 7-13. A2 Booster Pump Assembly 7-28...
  • Page 165 List of Replaceable Parts Intensifier Final Assembly Table 7-15. A2/A2 Pump Cam Assembly Item Description Part Number Quantity Notes ICM & SHAFT ASSEMBLY A2/A3 CAM PLATE & PLANET GEARS ASSEMBLY M3 X 10 SHCS 3153224 M3 LOCK WASHER 3153752 M4 X 12 SHCS 3153285 M3 X 8 FLAT HEAD 4212956...

  • Page 166: A2/A2 Pump Cam Assembly

    4322 Service Manual hbx045.eps Figure 7-14. A2/A2 Pump Cam Assembly 7-30...

  • Page 167: A2/A3 Cam Plate And Planetary Gears Assembly

    List of Replaceable Parts Intensifier Final Assembly Table 7-16. A2/A3 Cam Plate and Planetary Gears Assembly Item Description Part Number Quantity Notes LOW PROFILE SCREW 4212460 BEARING PIN 4140031 WAVE SPRING 4212650 BEARING 4212505 INTERNAL RETAINING RING 4216922 C-CLIP 4219005 CAM MOUNT PLATE 4136182 PLANET GEAR...

  • Page 168: Icm And Shaft Assembly

    4322 Service Manual Table 7-17. ICM and Shaft Assembly Item Description Part Number Quantity Note ICM ASSEMBLY 4217558 PISTON & CLEVIS ASSEMBLY 4217564 O-RING 2527053 PRESSURE PORT SHAFT 4136175 CYLINDER RETAINING NUT 4181212 CYLINDER HOUSING 4136244 O-RING,URETHANE, 3.5 MM ID X 1 MM C/S, PU90 4398715 DURO YELLOW, COMPOUND # U9001Y O-RING,URETHANE, 14 MM ID X 1 MM C/S, PU90...

  • Page 169: Piston And Clevis Assembly

    List of Replaceable Parts Intensifier Final Assembly Table 7-18. Piston and Clevis Assembly Item Description Part Number Quantity Note C-CLIP 3330240 BEARING 4212497 SHIM 4140101 4139995 CAM FOLLOWER 4342531 PISTON 4328000 SEAL ASSEMBLY, HIGH PRESSURE 4338494 SEAL RETAINER 4139988 SCREW, SHOULDER, EXTRA LOW HEAD, M4 X 5 MM 4216637 L , 4 MM F, 303 SS 4322-5902, CLEVIS, GROOVED CAM, INTENSIFIER...
  • Page 170 4322 Service Manual 7-34...

  • Page 171: Troubleshooting

    Chapter 8 Troubleshooting Title Page Introduction ......................8-3 Controller Troubleshooting ................8-3 Controller Fault Codes .................. 8-3 Electrical Problems ..................8-5 Pressure Generation and Indication Problems ..........8-5 CPS and Quick-Connect Problems ..............8-6 Intensifier Troubleshooting ................8-6 Electrical Problems ..................8-6 Pressure Selection and LED Indications ............
  • Page 172 4322 Service Manual...

  • Page 173: Introduction

    Troubleshooting Introduction Introduction This chapter supplies troubleshooting and fault isolation information for the Controller and the Intensifier. Use the troubleshooting charts to isolate problems. Controller Troubleshooting Use the information in the subsequent sections to troubleshoot the Controller. Controller Fault Codes Code Description Action...
  • Page 174 4322 Service Manual Code Description Action Number [###] pressure transducer Fault codes 41 through 53 indicates problems with the module not responding pressure transducer modules, the barometer modules, or the associated pca assemblies. To clear the fault: [###]pressure transducer 1. Make sure the module is in the correct slot. communication error 2.

  • Page 175: Electrical Problems

    Troubleshooting Controller Troubleshooting Electrical Problems Problem Probable Cause Action The Controller does not turn on. Not plugged in. Make sure the unit is plugged in and power is available. If the Power not available. unit is plugged in, use the Fuse blown.

  • Page 176: Cps And Quick-Connect Problems

    4322 Service Manual CPS and Quick-Connect Problems Problem Probable Cause Action Cannot remove the CPS from System is pressurized. Vent pressure. Once the CPS is the Controller. removed, clean or repair the Dock interlock not working interlock. correctly. Cannot connect the hose to the Wrong fitting.

  • Page 177: Pressure Selection And Led Indications

    Troubleshooting Intensifier Troubleshooting Pressure Selection and LED Indications Problem Probable Cause Action STOP key LED flashing slow. Supply pressure is below 500 Increase supply pressure to psi. 500 psi or more. Push  to clear the error. When pressure selection is Target pressure key pushed with Increase supply pressure to made, green LED illuminates...

  • Page 178: Pressure Generation And Indication Problems

    4322 Service Manual Pressure Generation and Indication Problems Problem Probable Cause Action Pressure generation is slow but Possible worn piston seals. If generation takes more than does build to pressure selection. 4 minutes to reach set pressure or if pressure generation is erratic (above and below set pressure) then replace seals.

  • Page 179: Wiring Schematics

    Chapter 9 Wiring Schematics Title Page Introduction ......................9-3 Controller Wiring Schematics ................9-3 Intensifier Wiring Schematics ................9-6...
  • Page 180 4322 Service Manual...

  • Page 181: Introduction

    Wiring Schematics Introduction Introduction This chapter supplies wire and connector schematics for the Controller and Intensifier. Controller Wiring Schematics Figure 9-1 shows the part numbers of wiring harnesses in the Controller. Figures 9-2, 9-3, and 9-4 show each harness along with wire colors and connector pins. 4244645 4244689 SAFETY SWITCH...
  • Page 182 4322 Service Manual 4244781 SW 1 BLACK BLACK GREEN 4244796 4244835 POWER BROWN ENTRY WHITE MODULE BLUE BLACK PWR SUPPLY GREEN/YELLOW ORANGE YELLOW WHITE GREEN/YELLOW GREEN BLACK PWR SUPPLY WHITE 4319911 BLACK 4329387 4244692 PINK VAISALA GRAY GREEN GREEN BAROMETER GREEN WHITE WHITE...
  • Page 183 Wiring Schematics Controller Wiring Schematics 4244689 SW 1 BLACK 4244645 BLACK BROWN ORANGE YELLOW KEYPAD 4244737 4251018 BLACK BLACK 4244755 BLACK BLACK BLACK 4244762 WHITE WHITE 4244762 4244728 WHITE WHITE 4244728 4157718 WHITE WHITE BLACK DOCK TARGET TARGET hbx083.eps Figure 9-3. Wiring Harness Schematics (Sheet 2)

  • Page 184: Intensifier Wiring Schematics

    4322 Service Manual 4244812 4241708 COMM 4244770 BROWN BLACK ORANGE GREEN SENSOR YELLOW WHITE GREEN WHITE MOTOR + GRAY BLACK MOTOR - VIOLET WHITE WHITE BLACK BLACK BLACK BLUE BLUE BROWN BROWN ORANGE WHITE YELLOW WHITE hbx084.eps Figure 9-4. Wiring Harness Schematics (Sheet 3) Intensifier Wiring Schematics Figure 9-5 shows the internal wiring and connector pins for the Intensifier.
  • Page 185 Wiring Schematics Intensifier Wiring Schematics hbx065.eps Figure 9-5. Intensifier Wiring Diagram...
  • Page 186 4322 Service Manual...

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