How to Replace Old Style Control Manifold with New Style Manifold on AS-Series Pumps

Written By: Arion Vandergon (and one other contributor)
  • Comments: 1
  • Favorites: 2
  • Completions: 1

Difficulty

Moderate

Steps

14

Time Required

00:15:00 - 00:30:00

Sections

1

Flags

0

  1. Turn power OFF to AccuStream pump and at main breaker supplying pump.

    • Turn power OFF to AccuStream pump and at main breaker supplying pump.

    • All lockout/tagout procedures must be followed. Failure to do so could result in serious injury or death.

  2. Remove hydraulic pressure gauge. Remove control knobs from front of manifold. Label control knots "Cut" and "Pierce", respectively, to identify for re-installation.

    • Remove hydraulic pressure gauge.

    • Remove control knobs from front of manifold.

    • Label control knots "Cut" and "Pierce", respectively, to identify for re-installation.

  3. Disconnect hoses and fittings from bottom of old control manifold. Remove DIN connectors from solenoids on back of old control manifold.

    • Disconnect hoses and fittings from bottom of old control manifold.

    • Remove DIN connectors from solenoids on back of old control manifold.

    • Label DIN connectors "Cut" and "Pierce", respectively, for re-installation.

  4. Remove both 24VDC coils from solenoids on back of old control manifold. Remove both 24VDC coils from solenoids on back of old control manifold. Remove both 24VDC coils from solenoids on back of old control manifold.

    • Remove both 24VDC coils from solenoids on back of old control manifold.

  5. Remove old control manifold from pump frame. Install plug (6MBP) into port stamped BD on top of new manifold. Install plug (6MBP) into port stamped BD on top of new manifold.

    • Remove old control manifold from pump frame.

    • Install plug (6MBP) into port stamped BD on top of new manifold.

  6. Install 90° fitting (6MJ-6MB90) into port stamped CP on top of new manifold. Be sure to have fitting facing towards pressure gauge port as shown in picture.

    • Install 90° fitting (6MJ-6MB90) into port stamped CP on top of new manifold.

    • Be sure to have fitting facing towards pressure gauge port as shown in picture.

  7. Install straight fittings (removed from old manifold) into ports, labeled T and PP, on bottom of new manifold. Install large 24VDC coil (removed from old manifold) onto large solenoid stem of control manifold. Install large 24VDC coil (removed from old manifold) onto large solenoid stem of control manifold.

    • Install straight fittings (removed from old manifold) into ports, labeled T and PP, on bottom of new manifold.

    • Install large 24VDC coil (removed from old manifold) onto large solenoid stem of control manifold.

  8. Install new manifold onto pump frame. Use medium strength thread lock on fasteners.

    • Install new manifold onto pump frame.

    • Use medium strength thread lock on fasteners.

  9. Install large 24VDC coil (removed from old manifold) onto large solenoid stem of control manifold. Install small 24VDC Coil (12586) onto small solenoid stem above large stem and beside bullet accumulator. Solenoid directly below oil accumulator (black bulb) is not used in this application.

    • Install large 24VDC coil (removed from old manifold) onto large solenoid stem of control manifold.

    • Install small 24VDC Coil (12586) onto small solenoid stem above large stem and beside bullet accumulator.

    • Solenoid directly below oil accumulator (black bulb) is not used in this application.

  10. Reinstall DIN connectors to respective coils as shown in pictures. Tighten DIN connectors to coils. Tighten DIN connectors to coils.

    • Reinstall DIN connectors to respective coils as shown in pictures.

    • Tighten DIN connectors to coils.

  11. Connect short hydraulic line from "T" fitting near tank to port labeled T on bottom of new manifold. Connect hydraulic line from "T" fitting on hydraulic pump to port labeled PP on bottom of new manifold. Connect hydraulic line from "T" fitting on hydraulic pump to port labeled PP on bottom of new manifold.

    • Connect short hydraulic line from "T" fitting near tank to port labeled T on bottom of new manifold.

    • Connect hydraulic line from "T" fitting on hydraulic pump to port labeled PP on bottom of new manifold.

  12. Connect hydraulic line from compensator on pump to port labeled CP on top of new manifold. Install pressure gauge in new manifold. Use pipe tape and dope on gauge threads to prevent leaks.

    • Connect hydraulic line from compensator on pump to port labeled CP on top of new manifold.

    • Install pressure gauge in new manifold.

    • Use pipe tape and dope on gauge threads to prevent leaks.

  13. Install control knobs "Cut" and "Pierce" into respective ports on front of manifold. Install control knobs "Cut" and "Pierce" into respective ports on front of manifold. Install control knobs "Cut" and "Pierce" into respective ports on front of manifold.

    • Install control knobs "Cut" and "Pierce" into respective ports on front of manifold.

  14. Turn pump on in cooling mode (Cooling On) to allow oil to cycle and re-fill hydraulic lines and manifold. Turn pump on in run mode (Pump On) and verify that "Cut" and "Pierce" control knobs function correctly.

    • Turn pump on in cooling mode (Cooling On) to allow oil to cycle and re-fill hydraulic lines and manifold.

    • Turn pump on in run mode (Pump On) and verify that "Cut" and "Pierce" control knobs function correctly.

    • Pump is now ready to continue cutting process.

Finish Line

One other person completed this guide.

Author

with 1 other contributor

Arion Vandergon

Member since: 08/08/2012

4 Guides authored

One Comment

Great guide, Thanks.

bjadams688 - Reply

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