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Step |
Action |
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1 |
Enter the Vacuum and Air Pump Test diagnostic, and wait approximately 45 seconds for the pumps to switch off and then back on. If a response is indicated on the vacuum and pressure hydro gauges, go to Step 2. If no response is indicated on the vacuum and pressure hydro gauges, check the status of LED V38 (pictured right). If LED V38 is not lit, exit and reenter the diagnostic while monitoring the LED. If LED V38 does not switch on at any time, replace the hydro controller board.
Note: LED V38 is located along the top edge of the hydro controller board (SM 31). When LED V38 is lit, both pumps should be running.
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2 |
Check for a Vacuum leak in hydro system external to pump box. Enter the Vacuum and Air Pump Test diagnostic to turn on the pumps.
Note: The pumps will switch off if the main vacuum level remains below 18"Hg for 2 minutes. If this occurs, simply exit and then reenter the diagnostic to switch the pumps back on. |
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3 |
(Pro Systems Only) Clamp off vacuum line #304 at the cap piercer drain valve to seal the vacuum system. Allow the vacuum level to stabilize and record the closed vacuum system level.
Note: The diagnostic will not display a vacuum reading if the main vacuum level is less the 18"Hg. When this occurs, use the vacuum gauge on the hydro as an indicator.
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4 |
Use the Vacuum and Air Pump Test diagnostic to switch off the pumps. |
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5 |
Remove lines #119 and #139 from the Vacuum Accumulator can. |
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6 |
Place the body of the quick connect fitting on line #119 into line #139 and tighten the clamp to form a seal.
Note: This steps isolates the pump box from the hydro while allowing the vacuum level from the pump box to be monitored on the console and vacuum gauge. Line #119 may be substituted with a pressure meter if available.
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7 |
Use the Vacuum and Air Pump Test diagnostic to switch on the pumps. |
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8 |
Allow the vacuum level to stabilize and record the pump box vacuum level using the same indicator (console or gauge) used for Step 3. |
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9 |
Subtract the closed vacuum system level obtained at Step 3 from the pump box vacuum level obtained at Step 8. If the difference is less than 1"Hg, go to Step 10 to troubleshoot the pump box. If the pump box vacuum level is 1"Hg or more greater than the closed vacuum system level, a significant vacuum leak exists beyond the pump box. Perform the following steps to isolate the vacuum leak:
- Reconnect lines #119 and #134.
Note: Leave line #304 pinched.
- Use hemostats to isolate the subsystems while observing the vacuum status in the diagnostics screen, following the path where the delta recovered to isolate the leak. Check for missing or improperly seated O-rings in the suspect canister or vacuum accumulator. Check for cracked or poorly seated fittings throughout the vacuum system.
- Once the leak has been corrected, remove the clamp from cap piercer line #304.
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10 |
Open the pump box. Refer to the Hydro Pump Removal and Replacement Procedure within this chapter for instructions on accessing the pumps as necessary.
Note: Do not switch off the instrument or pump box at this time. |
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11 |
Exit and reenter the Vacuum and Air Pump Test diagnostic, wait 45 seconds, and check if the pumps are running. If both pumps are running, go to Step 12. If one or both pumps are not running, perform the following steps to check instrument line voltage and evaluate the capacitors:
- Verify that the instrument line voltage (approximately 220VAC) is being delivered across the brown and blue wire of the pump power connectors at the relay junction box (pictured left). If the line voltage is present at each connector, go to Step 11B. If the line voltage is not present at each connector, begin power subsystem troubleshooting.
- Shutdown the console and switch off the instrument.
Caution: The instrument must be switched off at this time to prevent electrical shock.
- Measure the AC voltage drop across the starting capacitors.
Caution: Ensure that the capacitors have bled off before proceeding.
- Inspect the starting capacitor of the affected pump(s) for damage. If any abnormalities (e.g., rupture, swelling, discoloration) are observed, replace the capacitor per the Starting Capacitor Removal and Replacement Procedure .
- Disconnect the capacitor leads and measure the capacitance. Compare the measurement to the applicable specification below. If the capacitance is out of specification, replace the capacitor per the Starting Capacitor Removal and Replacement Procedure .
|
Pump |
Capacitor Rating (uF) |
Specification (uF) |
|
Pressure & Vacuum |
12.5 |
11.9 - 13.1 |
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Vacuum Only |
15 |
14.3 - 15.8 |
- If the starting capacitor measurement is OK, replace the affected pump(s).
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12 |
Check for Damaged flapper valve(s) or pump seals. Shutdown the console and switch off the instrument.
Note: Failure mode may be indicated by a loud pump. |
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13 |
Remove the 8 head screws on each pump using a large flat or T-25 Torx screw driver.
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14 |
Remove both pump heads and place them to the side. Disconnect tubing as necessary.
Note: The valve plates may stick to the head. Separate the valve plates from the head as necessary.
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15 |
Remove the valve plates from both pumps. Inspect the flapper valves on the top and bottom of each valve plate (8 total). Each flapper valve must lay flush over the hole in the valve plate. If a damaged or broken flapper (pictured right) is found, replace the flapper or rebuild the entire pump per the Pump Head Removal and Replacement Procedure . If a damanged or broken flapper is not found, go to Step 16.
Note: Ensure proper orientation of the valve plates when rebuilding the pump.
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16 |
Lift the cylinder sleeve off each piston. Inspect the cylinder sleeves and piston cups for damage or excessive wear. Rebuild the pump per the Pump Head Removal and Replacement Procedure as necessary.
Note: The piston cup may provide only slight resistance in the cylinder sleeve without adversely affecting pump capacity.
Note: Ensure proper orientation of the valve plates when rebuilding the pump.
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