Diagrams & spare parts

FW 992 XL.NXT - FW 993 XXL.NXT

FW 2000M.NXT-2500M.NXT
Diagrams can be found at the end of the manual
Flexo Wash ApS North America:

Langs Skoven 38 Flexo Wash LLC

8541 Skødstrup 2010 Plantside Drive
Denmark Louisville, KY 40299
Tel: 0045 86 99 36 31 USA
Fax: 0045 86 99 13 43 Tel: 001 888 493 5396
Fax: 001 888 543 5396
Liquids and filters:
E-mail: [email protected] Spare parts:
[email protected]
Spare parts:
E-mail: [email protected]

When ordering spare parts, please inform us about:

Machine model and Serial number:

Set CE label here

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 1
11 Pic 1.1 10 Pic 1.2
8

12

4
14
5

6
7
3

13

1 2
4 Picture 1.1 Picture 1.2
Backside

2 1+2

1 3 5
Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT
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 Picture 1.3

1 3 4
6

2
5

Picture 1.4

1
2
3
4

Picture 1.5

1 2 3

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 2.0 - Spray arm
FW 992/FW 993 XL/XXL.NXT

6 8

5
4

2 1

Picture 2.1 - Spray arm

FW 2000 / 2500.NXT

5 6
4

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 3.0 - Traction station
FW 992.NXT

5
3 8
7
2

Picture 3.1 - Traction station

FW 2000-2500M.NXT

6.1

6.2

5.1
5.2

3 7
8
2
1
4

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 3.2 - Traction station
FW 993.NXT
3

2
5

1
6

Picture 3.3 - FW 993 NXT

Option - Gear cover

6 3

4
7

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 3.4 - FW 993.NXT
Option - Heavy duty traction station
3

Picture 4.0 – FW 2000-2500M.NXT

Option - Stationary sleeve holders

Pic 4.1

7
6

2
4 5

10
1 3

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 4.1 – FW 2000-2500M.NXT
Option - Stationary sleeve holders
3

1 2

4
5

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 3
Picture 5

5
4

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 6
1 3
18 2 12

4
13

5
17

16
15

14

6
20 7
8
9
10
11
19

Picture 6.1
Option - HP reduction
3

1 2

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 7
7

3 2

Picture 7.1
Option - Semi Automatic filling system
1

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 8
4

3
Picture 9
8 6 9

7 9 3 2 4 5 1

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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 Picture 10
UL Version
1 2 3

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Usual wear and spare parts

• The below mentioned parts must be considered as wear parts.

• Stand time varies and depends on usage, maintenance, etc. The estimated lifetimes are
based on maximum 500 operation hours pr. year.
• Our philosophy is that on a service visit we come prepared to replace these parts.
• We make no un-necessary replacement, but we will rather replace too early than too late.
• Unforeseen down time cost more than an extra part exchanged.

Gear Wheels in traction stations

Visual inspection will detect wear.
Recommended change: Every 2 years
Customer should keep a spare set of gear wheels in stock.

High pressure hose

Wears out and begins to leak. Especially internal hoses are exposed to wear and tear from
movement of travers and chemicals.
Leakage means lower pressure for rinsing and poor performance of machine.
Recommended change: Every 1-2 years
Customer should keep a spare in stock.

High pressure nozzles

The high velocity of the water wears on the nozzle. Spray pattern and dynamic impact will
decrease and result in poor performance. Can also be partly plugged by particles from the
water.
Recommended change: Every 1-2 years
Customer should keep a spare in stock.

Lid hose and hose to moving nozzles

The hose is worn out from exposure to chemical and operation, of lid.
The result is often a “hard bend” which restrict the liquid flow or a leakage.
Visual inspection will detect wear. Also check steel band.
Recommended change: Every 1-2 years
Customer should keep spare hose and steel band in stock.

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Water inlet filter for High pressure pump
When partly plugged the high-pressure pump cannot get sufficient water flow and will be
destroyed.
Recommended change (or check): Every 3 months
Customer should keep a spare in stock.

PVDF (Teflon) seals (Clamp sealing)

The stainless-steel pipes are assembled with “clamp seals” for easy dismantling. The disk seals
become hard and after dismantling there is risk of leakage.
Recommended change: At each dismantling.
Customer should keep in stock.

V-rings / shaft seals

Wears out, gets hard and begins to leak. Even small leak can have fatal impact if control
system etc. becomes exposed to liquid.
Recommended change: Every 1-2 years
Customer should keep a spare in stock.

Air cylinder for lid

Recommended change: minimum every 3 rd year.

Coupling
The coupling absorbs vibrations, misalignments and is designed as the weakest link in the
drive system. If the track station or traverse slide is blocked/jammed, the coupling brakes
immediately. This prevents further damage to the machine. Even without overload it can break
because of “metal weakness”.
Visual inspection can sometime detect wear.
Recommended change: minimum every 3 rd year.
Customer should keep a spare in stock.

Diaphragm Pump
Wear parts in the pump: diaphragms, balls, and valve seats.
Lack of service results in, excessive wear on internal change-over-valve because of leaking
membranes and low pump pressure.
Recommended change: Every 2nd year. For ATEX machines every 1 year.
Customer should keep in stock a spare part set or a replacement pump for quick exchange.

Filter for cleaning liquid

Replace regularly to maintain prolong liquid stand time.
Replace at every service.
Customer should keep a spare in stock (buy more with discount).

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Picture Position Description Part Number Remarks
1.0 1 Push button, black + backpl + nut 400-01763

1.0 2 Main switch 40A 3p 15 kW 400-01243

1.0 3 Standard control panel blue foil 2023 130-104283

1.0 4 Display and I/O board, programmed 300-00643 With I/O board
1.0 5 Emergency stop, complete 400-01904

1.0 6 Start button for Panel foil 400-00554

1.0 7 Stop ring OD16 liquid dose 300-00006

1.0 8 V-ring seal, 20/35x10 400-00185 Wear part

1.0 9 Manometer, Air, panel mounted ø61 400-01363

1.0 10.1 HP hose S/A L=1350 130-104084 For XL (2000)

1.0 10.2 HP hose S/A L=1560 130-104080 For XXL (2500)
1.0 10.3 Energy chain, pr meter 400-00090

1.0 10.4 Energy chain bracket set 400-00784 Ends f. e-chain

1.0 11.1 Square rod, 992 XL, 993XL,FW2000 130-104547 For XL (2000)
1.0 11.2 Square rod, 993XXL, FW2500 130-105137 For XXL (2500)
1.0 12.1 Base with lid for operation light 400-02305

1.0 12.1 Light element, green C33 400-02306

1.0 12.1 Base 80 mm +25 operation light 400-02225

1.0 12.1 Light bulb for process lamp 400-01640

1.0 13 Shaft for rotation 130-103155

1.0 14 Hose 19mm, grey 400-00219 L=22 cm

Picture Position Description Part Number Remarks

1.1 1.1 Sensor rod, spring mounted, XXL 130-108993 For XXL only
1.1 1.2 Sensor rod, spring mounted XL 130-108994 For XL only
1.1 2 Stop ring SS 20mm 400-00757

1.1 3 Spring for trolley lock 400-01785

1.1 4 Back for adjustable spray arm sensor bracket 130-109752

1.1 5 Side plate for adjustable spray arm sensor 130-109753

bracket

Picture Position Description Part Number Remarks

1.2 1 Inductive sensor M18 NC 8 mm 400-04037 Wear part
1.2 2 Cable f/sensor, straight 3 m 400-01282

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Picture Position Description Part Number Remarks
1.3 1.1 Traverse shaft M12 L = 1950 130-104552 For XL (2000)
1.3 1.2 Traverse shaft M12 L = 2450 130-105140 For XXL (2500)
1.3 2 Bearing plate for traverse 130-103928

1.3 3 Flange bearing for traverse 400-00562

1.3 4 Stop ring SS 20mm 400-00757

1.3 5 V-ring seal, 20/35x10 400-00185

1.3 6 Spindle adaptor Stainless ø12 300-00136

1.3 7 Coupling elastic rotation 400-00047

1.3 8 Motor 24V, traverse drive 400-00050

Picture Position Description Part Number Remarks

1.4 1 Bearing plate for traverse 130-103928

1.4 2 Flange bearing for traverse 400-00562

1.4 3 Washer nylon M12 Ø13X24X2,5 400-02465

1.4 4 Stop ring SS 12 mm 400-00756

Picture Position Description Part Number Remarks

1.5 1 Block sensor support traverse, POM 400-00659

1.5 2.1 Ø5x1000mm w. threaded ends 130-108999 For XXL only

1.5 2.2 Ø5x750mm w. threaded ends 130-109000 For XL only
1.5 3 Block traverse spindle, POM 400-00565

Picture Position Description Part Number Remarks

2.0 1 Wheel, pom. nozzle arm 400-00658

2.0 2 HP Jet nozzle 4,5 l/min at 100 bars 400-00146

2.0 3 Air nozzle, FW 400-00148

2.0 4.1 Lower spray arm 992/993 XL 130-103919 For XL only

2.0 4.2 Lower spray arm 992/993 XXL 130-107084 For XXL only
2.0 5 Upper spray arm 992/993.NXT 130-105941

2.0 6 Ø10 clips 130-104136

2.0 8 Angle 45 degr. m/n 1/8" 400-00764

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Picture Position Description Part Number Remarks
2.1 1 Wheel, pom. nozzle arm 400-00658

2.1 2 HP Jet nozzle 4,5 l/min at 100 bars 400-00146

2.1 3 Air nozzle, FW 400-00148 Wear part

2.1 4 Air nozzle, FW 400-00148 Wear part
2.1 5 Pipe plug 1/4" 400-00803

2.1 6 Sprayarm, upper for FW2000/2500.NXT 130-105947

2.1 7.1 Lower spray arm FW2000M.NXT 130-107644 For FW2000 only
2.1 7.2 Lower spray arm FW2500M.NXT 130-107182 For FW2500 only
2.1 8 Ø10 clips 130-104136

Picture Position Description Part Number Remarks

3.0 1 Stainless eccentric lock 400-03506

3.0 2 Double flange glider POM 130-104096

3.0 3 Single Flange glider POM 130-104246

3.0 4 Lower Fastener for POM-glider 130-104093

3.0 5 Finger protection 1, gear 130-103072

3.0 6 Finger protection 2, gear 130-103073

3.0 7 Shaft for wheel - narrow standard 130-103741

3.0 8 Gear set FW 992 XL Narrow - one side 300-00556 Wear part

Picture Position Description Part Number Remarks

3.1 1 Stainless eccentric lock 400-03506

3.1 2 Double flange glider POM 130-104096

3.1 3 Single Flange glider POM 130-104246

3.1 4 Lower Fastener for POM-glider 130-104093

3.1 5.1 Shaft Protector Tr.st. FW_M L. 130-104327

3.1 5.2 Shaft Protector Tr.st. FW_M R. 130-104437

3.1 6.1 Gear protector. Right 130-106599

3.1 6.2 Gear protector. Left 130-106598

3.1 7 Shaft for gear wheel. FW NXT 130-104225

3.1 8 Gear set, FW1500M-2500M NXT. One side 300-00746 Wear part

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Picture Position Description Part Number Remarks
3.2 1 Gear set FW 993 Narrow - one side 300-00510

3.2 2 Gear for Shaft 300-00010

3.2 3 Gear roll, narrow 130-103810

3.2 4 POM Gear M:2 Z:21 pitch diameter 42 mm 130-103745

3.2 5 Finger protection 130-103993

3.2 6 Stainless eccentric lock 400-03506

3.2 7 Double flange glider POM 130-104096

3.2 8 Lower Fastener for POM-glider 130-104093

3.2 9 Single Flange glider POM 130-104246

Picture Position Description Part Number Remarks

3.3 1 Top for 993 gear cover 152,5 mm wide 130-103966

3.3 2 Sealing for gear cover ends - 3 mm 130-103992

3.3 3 Sealing for gear cover - 3 mm 130-103630

3.3 4 Bottom for 993 gear cover 130 mm wide 130-103967

3.3 5 Single Flange glider POM 130-104246

3.3 6 Double flange glider POM 130-104096

3.3 7 Left traction station 993 130-104244

Picture Position Description Part Number Remarks

3.4 1 Gear set FW 993 Heavy duty - one side 300-00861

3.4 2 Gear for Shaft 300-00010

3.4 3 Heavy duty narrow gear, complete 130-110153

3.4 4 POM Gear M:2 Z:21 pitch diameter 42 mm 130-103745

3.4 5 Finger protection 130-103993

Picture Position Description Part Number Remarks

4.0 1 Double flange glider POM 130-104096

4.0 2 Single Flange glider POM 130-104246

4.0 3 Lower front fastener, POM 130-106752

4.0 4 Flange Glider Single, POM 130-107057

4.0 5 Cylinder 25x100x1/8" 400-01389

4.0 6 Brush shaft seal ø20mm 400-00731

4.0 7 Ball bearing ID15 15x32x9 400-01392

4.0 8 Igus bushing 20,5/23-21 400-01726

4.0 9 Shaft bracket POM 130-106753

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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4.0 10 Sleeve bearing ID10 400-01428

Picture Position Description Part Number Remarks

4.1 Gearset stationary sleeve holder, FW15- 300-00747 Complete set
2500M.NXT
4.1 1 Gear, Shaft , FW 1500-3000 300-00011

4.1 2 Gear M:2 Z:30 pitch diameter 60 mm POM 130-103740

4.1 3 Gear for fixed sleeve 300-00154

4.1 4 Shaft for wheel - narrow standard 130-103741

4.1 5 Axle for sleeve holder SL2200 130-104499

4.1 6 Flange bearing Igus 400-01391

Picture Position Description Part Number Remarks

5.0 1 Cylinder for lid ø50-500 400-00642

5.0 2 Safety magnet switch f/lid 5 meter 400-01336

5.0 3 Axis for lid cylinder 130-104620

5.0 4.1 Bushing for cylinder holder 130-104573

5.0 4.2 Axle for cylinder holder - tub 130-104619

5.0 5 One-way flow control valve 400-04157

5.0 6 Machine Feet PK 130-220 M16 400-00240

Picture Position Description Part Number Remarks

6.0 1 Clamp sealing Teflon 1 ½" with lip 400-00256 Wear part
6.0 2 Seal kit for BF-valve Ø38mm EPDM 400-04590 Wear part
6.0 3 Tank level indicator set - non-ATEX 300-00417

6.0 4 Solenoid valve 1/4" FW/ Mi.08- including coil 400-00568

6.0 5 Rubber plug 26/32x30mm, 11 mm hole 400-01689

6.0 6 Hose 1/2" (12,7mm) grey 400-00858

6.0 7.1 Filter house, FW 400-00253

6.0 7.2 Filter 50my, FW, PW, PK after rinse 550-00001 Wear part
6.0 7.3 Filter key, FW Machines 400-00254

6.0 8 Heating element 1x400V 3kW L=295 1,5" 400-00026 400V

6.0 8 Heating element 1x480V 3kW L=295 1,5" 400-01361 480V
6.0 8 Heating element 2x480V 3 kW L=280 1,5" UL 400-03264 UL version
6.0 9 Cam clutch 316 male, F ½" 400-02492

6.0 10 3-way ball valve 1/2" T bore 400-01502

6.0 11 Ball valve 1/4" N/N 400-01504

6.0 12 Act pneumatic air/spring ATEX for BF-valve 1"- 400-04583

2"

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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6.0 13 Inductive sensor M12 NO 4 mm 400-04827

6.0 14.1 Filter house, HP Water inlet 400-00599

6.0 14.2 Filter insert for P.P. house 400-00600 Wear part
6.0 15 Manometer for HP pump, water 250 bar 400-00173

6.0 16 HP regulator valve FW 400-00159

6.0 17 HP hose S/A L=450 130-104110

6.0 18 Hose connect angle 1 1/2x38mm 400-00783

6.0 19.1 HP pump 230V/400V 50Hz 13l/min 170 bar 400-03987 230/400V 50Hz-60HZ
5,5kW
6.0 19.2 HP pump 208-240V/440-480V 60Hz 13l/min 170 400-01929 480V - 60Hz
bar 4kW
6.0 19.3 HP pump 230V/400V 50Hz 21l/min 150 bar 400-03829 For 993 ONLY (EU)
5,5kW
6.0 19.4 HP pump large FW993 + SL 6 60 Hz, 200 bar 400-00042 For 993 ONLY (US)
6.0 20 Solenoid valve for water inlet 24 vdc 400-00122

Picture Position Description Part Number Remarks

6.1 1 Connection Plug with Light 24V 30mm 400-01310 Option. HP Reduction
6.1 2 Pressure reduction valve 400-00744 Option. HP Reduction
6.1 3 HP hose S/A L=430 mm 130-105350 Option. HP Reduction

Picture Position Description Part Number Remarks

7.0 1.1 Level Float Switch 400-01482 Wear part
7.0 1.2 Cable f/sensor, straight 3 m 400-01282

7.0 2.1 Pump DL 15 PM 2ET 400-00092

7.0 2.2 Diaphragm for DL 15 EPDM E4 400-04666 Wear part

7.0 2.3 Balls & Seat DL 15 PG TTT 400-00094 Wear part
7.0 3 Throttle valve 400-01187

7.0 4.1 Pump DL 25 1", Plastic 400-00605

7.0 4.2 Diaphragm for DL/DH 25 EPDM E4 400-04670 Wear part

7.0 4.3 Balls & seats, Teflon, set of 4x4 DL/DH 25 400-04505 Wear part
7.0 5 Hose 19mm, grey 400-00219

7.0 6 Air regulator 1/2" 400-00065

7.0 7 Solenoid air valve ½", air dry 400-00657

Picture Position Description Part Number Remarks

7.1 1 Exchange valve G1/8 FL ATEX 400-01423 Option. Semi automatic
filling
7.1 2 Throttle valve manuel 1/4" 400-01035 Option. Semi automatic
filling
7.1 3 3 way valve w. actuator 400-02295 Option. Semi automatic
filling

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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Picture Position Description Part Number Remarks
8.0 1 Cooling fan 80 x 80 x 25, 24V, 490mW 400-03907

8.0 2 Filter for cooling fan 80 x 80 x 25 400-03908 Wear part

8.0 3 Gearmotor 24V FW Mi/PK 08- 400-00571

8.0 4 Coupling elastic, traverse 400-00048

8.0 5 Motor 24V, traverse drive 400-00050

Picture Position Description Part Number Remarks

9.0 1 Contactor 3P - 5,5kW 12A 400-03804

9.0 2 Safety relay unit - Bernstein 400-02221

9.0 3 Safety relay unit - Omron 400-01337

9.0 4 Motor circuit breaker 9-14A 400-01242

9.0 4.1 Motor circuit breaker 6,3-10A. ONLY 3x440- 400-02012 FW992+FW2000-2500M.
480V US ONLY
9.0 5 Contactor 3P - 7,5kW 18A 400-01859

9.0 6 Fuse automatic 3P 3A 400-03610

9.0 7 Power supply 24V 3P 10A/240W 400-04797 For EU and US

9.0 8 Display and I/O board, programmed 300-00643 With display
9.0 9 Fuse automatic 2P 10A 400-02760

9.0 9 Gateway 4G 400-05341 Not included in models

shipped to AE and BR

Picture Position Description Part Number Remarks

10.0 1 Fuse automatic 3P 4A UL489 400-03219 UL Version
10.0 2 Fuse automatic 2P 10A UL489 400-03206 UL Version
10.0 3 Fuse automatic 1P 10A UL 24V 400-03218 UL Version

Diagrams & spare parts: FW 992 XL-933XXL.NXT and 2000-2500M.NXT

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FW992 + FW2000-2500M:
400-03987
FW993:
400-03829
24VDC 24VDC

DO-28+

DO-28-

0VDC 0VDC
 DI05

SIM

2G M1 NB

MOBILE

GPS

TRB255

24VDC 24VDC
0VDC 0VDC
EARTH EARTH
Heat contactor Heat contactor
weld weld
Tank 1 Tank 2
DI05
Heat safety contactor