Transcript
DynaMc EP Oil Cooler Retrofit Kit
A1272501 and A1272502
OVERVIEW Use kit A1272501 to retrofit a hydraulic oil cooler (w/ 230V fan) to DynaMc EP HPU part number 1272702 or 1272703. Use kit A1272502 to retrofit a hydraulic oil cooler (w/ 115V fan) to DynaMc EP HPU part number 1272701, 1272704 or 1272705. CONTENTS OF KIT A1272501 (230V FAN) ITEM PART NO. QTY DESCRIPTION 1 MAB00134 4 ¼-20NC X5/8” LG. HHCS PL 2 MAR00051 4 M6 X 1.0 X 16 HHCS PL 3 MBA00005 4 ¼-20MC HEX NUT STL PL 4 MBE00005 8 ¼” REGULAR SPLIT LK WASHER 5 MFQ00140 1 6MPT/4MSL ELBOW 6 MFQ00141 2 4MSL/8MSAE ELBOW 7 MJQ00502 1 OIL COOLER W/230V IP55 FAN 8 MLE00098 3FT #18/3 SJO ELEC CABLE 9 MLK00059 1 CORD STRAIN RELIEF 10 MLM00002 2 2/16-2/22 CLOSED END SPLICE 11 MLM00266 2 18-22x0.11 INS FEMALE DISCONNECT 12 MLN00113 4 5.5” X .095” CABLE TIE 13 SLABBBB023 1 HOSE ASSY OAL 23” 14 SLABBCB019 1 HOSE ASSY OAL 19” 15 1272501 1 DYNAMC EP OIL COOLER BRACKET 16 127250101 1 INSTRUCTION SHEET 17 MLM00275 2 18-22 X #8 RING TERMINAL 18 MAR00013 1 M4-.7MM X 12MM LG CHSMS SS CONTENTS OF KIT A1272502 (115V FAN) ITEM PART NO. QTY DESCRIPTION 1 MAB00134 4 ¼-20NC X ¾” LG. HHCS PL 2 MAR00051 4 M6 X 1.0 X 16 HHCS PL 3 MBA00005 4 ¼-20MC HEX NUT STL PL 4 MBE00005 8 ¼” REGULAR SPLIT LK WASHER 5 MFQ00140 1 6MPT/4MSL ELBOW 6 MFQ00141 2 4MSL/8MSAE ELBOW 7 MJQ00503 1 OIL COOLER W/115V IP55 FAN 8 MLE00098 3FT #18/3 SJO ELEC CABLE 9 MLK00059 1 CORD STRAIN RELIEF 10 MQF00395 1 5-POS LEVER NUT TERMINAL 11 MLM00266 2 18-22x0.11 INS FEMALE DISCONNECT 12 MLN00113 4 5.5” X .095” CABLE TIE 13 SLABBBB023 1 HOSE ASSY OAL 23” 14 SLABBCB019 1 HOSE ASSY OAL 19” 15 1272501 1 DYNAMC EP OIL COOLER BRACKET 16 127250101 1 INSTRUCTION SHEET 17 MLL00104 0.5FT #12 ELEC WIRE WHITE 18 MLM00275 2 18-22 X #8 RING TERMINAL 19 MLM00261 1 18-22 x #6 RING TERMINAL 20 MAR00013 1 M4-.7MM X 12MM LG CHSMS SS
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PROCEDURE MECHANICAL REWORK 1. Disconnect the hose assembly from the adapter in the fusion manifold “T1” port.
2. Disconnect the hose assembly from the “T” port on the HPU manifold.
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3. Remove the two mounting bolts in the top of the return filter and remove the filter along with the two hose assemblies that are attached to the filter.
4. Remove and discard the hose assembly that was threaded directly into the back side of the filter head that was previously disconnected from the fusion manifold and replace it with item 5 elbow. Orient item 6 so that it is pointing toward the opposite wall of the EP frame. Be careful not to over tighten this adapter or possible damage (cracking) of the filter port will result. 5. Attach and tighten item 14 hose assembly with the 45⁰ hose end fitting connected to item 5 elbow. This hose is easier to tighten now as access is limited after the oil cooler and mounting bracket are attached to the unit. Reattach the return filter using the fasteners that were previously removed.
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6. Reattach the hose assembly that was previously disconnected from the “T” port of the HPU manifold.
7. Attach item 13 hose assembly to the elbow in port “T1” of the fusion manifold and feed the other end between the return filter and wall of the EP frame. The other end will be connected to the top of the oil cooler later.
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8. Drill four 9/32” diameter mounting holes for the oil cooler bracket per the drawing below. The oil cooler bracket can be used as a template for drilling the final holes after the first hole is located and drilled. Note: Earlier versions of the oil cooler mounting bracket have three mounting holes and later versions have 4 mounting holes. Drill the appropriate number of mounting holes for the bracket that is supplied in the kit.
9. Install the lower two bolts in the oil cooler bracket using items 1, 3 and 4. Lean the oil cooler bracket out to accept the oil cooler. The bracket must be installed so that the leg of the bracket is located on the inside of the frame as shown with the arrow below. The head of this mounting bolt must be located on the inside of the bracket in order for the mounting hardware to clear the fan housing (washer and nut on the outside). The other side/leg of the bracket will fit-up outside of the frame. Note: The oil cooler cannot be installed if all of the mounting hardware is installed in the bracket first.
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10. Install item 6 elbows in both ports of the oil cooler.
11. Lay the oil cooler in the bracket and rotate the mounting bracket upward. Install the last bracket mounting bolt(s). It may be necessary to loosen the two accumulator bracket mounting bolts to position the accumulator so that there is not interference between the upper corner of the fan housing and the accumulator mounting strap.
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12. Fasten the oil cooler to the mounting bracket using items 2 and 4.
13. Connect the other end of item 13 hose assembly to the elbow on the left side of the oil cooler.
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14. Connect the other end of item 14 hose assembly (routed to the hydraulic oil filter) to the elbow on the right side of the oil cooler.
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ELECTRICAL REWORK 120 VOLT INSTRUCTIONS 1. Remove lid from electrical box. 2. Drill 5/8” hole 2.5” from top of box and centered below the existing strain relief as shown in the pictorial at the end of this section. It depicts the back view of the MLK00059 strain relief installed in the hole. 3. Strip 1” of the jacket from one end of the MLE00098 cable. Strip 9/32” of insulation from the black, white, and green leads. Crimp one MLM00266 to the black lead, one MLM00266 to the white lead, and one MLM00275 to the green lead. Attach disconnects to the power tabs on the cooling fan and screw the ring terminal to the fan’s frame with MAR00013. 4. Support the cable to the fan using an MLM00113 cable tie. 5. Support the rest of the cable by attaching it to existing hydraulic lines with cable ties. 6. Feed the MLK00059 Strain Relief threaded end into the 5/8” drilled hole from the rear of the Electrical box and secure with locknut inside the box. Feed other end of the MLE00098 cable through strain relief and into electrical box. 7. Locate the white wire that runs from the (N) terminal of the control board to the 5-position, lever-nut terminal block and remove it from the terminal block. Connect the removed end of the white wire to one of the terminals of the new 5-position terminal block included in the kit (MQF00395). 8. Strip 3/8” from one end of the short length of #12 white wire (MLL00104) and terminate it in a second position of the new lever-nut terminal block. Strip 3/8” from the other end of the white wire and connect this to the position left vacant in the original 5-position, lever-nut terminal block from step 7. 9. Cut and strip enough of the MLE00098 cable routed inside the box in step 6, so that the black lead will reach the switch terminal shown in the schematic at the end of this section. 10. Strip 9/32” of insulation from the black lead and crimp the supplied MLM00261 ring terminal to this wire. Attach ring terminal to switch lead as shown on schematic. 11. Strip 3/8” from the white lead of the MLE00098 cable and terminate to a third position of the lever-nut terminal block added in step 7. You should be left with 2 unused terminals when finished. 12. Strip 9/32” of insulation from the green wire of cable MLE00098 and crimp the supplied ring terminal MLM00275 to the green wire. Attach ring terminal MLM00275 to the inside-shoulder of the electrical box as shown in the picture at the end of this section. Reinstall the electrical box lid.
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120 Volt Schematic
120 Volt Electrical Box
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240 VOLT INSTRUCTIONS; 1. Remove lid from electrical box. 2. Drill 5/8” hole 2.5” from top of box and centered below the existing strain relief as shown in the pictorial at the end of this section. It depicts the back view of the MLK00059 strain relief installed in the hole. 3. Strip 1” of jacket from one end of the MLE00098 cable. Strip 9/32” from the black, white, and green wires. Crimp one MLM00266 to the black wire and one MLM00266 to the white wire. Crimp one MLM00275 to the green wire. Connect the black and white wire to the fan’s power tabs and the green wire to the fan’s frame using 8-32 screw, MAR00013. 4. Support the cable to the fan with an MLM00113 cable tie. 5. Support the rest of the cable by attaching to existing hydraulic lines with cable ties. 6. Feed the MLK00059 strain relief threaded end into the 5/8” hole from the rear of the box and secure with locknut from inside the box. Feed other end of cable MLE00098 through strain relief and into the electrical box. 7. Refer to the schematic at the end of these instructions and locate the two closed-end splices; each contains three wires on the load sides of fuses F1 and F2. Remove the splices. Cut and strip enough of the MLE00098 cable jacket inside the box so that the black and white wires will reach the tie points we removed the splices from. 8. Strip the ends of the black and white wires about 3/4”. Connect the black wire to the fuse F1 tie point by twisting the stripped part around the 3 existing wires. Cap these 4 wires with one of the MLM00002 closed-end splices and crimp tightly. 9. Connect the white wire to the fuse F2 tie point by twisting the stripped part around the existing 3 wires. Cap these 4 wires with an MLM00002 closed-end splice and crimp tightly. 10. Strip the end of the green wire 9/32”. Crip one MLM00275 tightly to the green wire of cable MLM00098. Using the ring terminal, connect the green wire to the internal shoulder of the electrical box as shown in the picture at the end of this section. Reinstall the electrical box lid.
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240 Volt Schematic
240 Volt Electrical Box
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DRAWING REVISION HISTORY LISTING PART NO: 127250101 DESCRIPTION: DYNAMC EP OIL COOLER RETROFIT KIT INSTRUCTION SHEET APPR. REV DATE JRN A 10/8/12
BY LTD
DESCRIPTION OF REVISION A1272501 CHANGED ITEM 1 FROM MAB00003 (3) TO MAB00134 (4) CHANGED ITEM 3 MBA00005 FROM (3) TO (4) CHANGED ITEM 4 MBE00005 FROM (7) TO (8) CHANGED ITEM 7 FROM MJQ00495 TO MJQ00502 CHANGED ITEM 8 FROM MLE00049 TO MLE00098 CHANGED ITEM 10 FROM MLM00010 (2) TO MLM00002 (2) ADDED ITEM 17 MLM00275 (2) ADDED ITEM 18 MAR00013 (1) A1272502 CHANGED ITEM 1 FROM MAB00003 (3) TO MAB00134 (4) CHANGED ITEM 3 MBA00005 FROM (3) TO (4) CHANGED ITEM 4 MBE00005 FROM (7) TO (8) CHANGED ITEM 7 FROM MJQ00496 TO MJQ00503 CHANGED ITEM 8 FROM MLE00049 TO MLE00098 ADDED ITEM 18 MLM00275 (2) ADDED ITEM 19 MLM00261 (1) ADDED ITEM 20 MAR00013 (1) UPDATED INSTRUCTIONS FOR THE INSTALLATION OF NEW IP55 FAN AND THREE WIRE CABLE.
