powr-pro service parts - Muncie Power Products
Contents
1. SEAL NOTE Lip seals Items 5 softlip and 7 hardlip must be assembled back to back as shown WEAR PLATE POSITION OUTLET HIGH PRESSURE wie Q ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 14 1 1 PM1 1001 O B Snap Ring Body Mach Inlet PM1 1002D Spacer PM1 1125 27 FIWM 27 GPM PM1 1003M Seal Retainer PM1 1125 31 FIWM 31 GPM PM1 1004 Retainer O Ring 2 7x0 103 PM1 1125 35 FJCM 35 GPM PM1 1005M Inside Shaft Seal PM1 1125 40 FJCM 40 GPM PM1 1107 CLXXX__ Front Cover SAE C 4 Bolt PM1 1005 Outside Shaft Seal Reversed HABP 62 Test Port Plug 6 SAE PM1 1008 Ring Seal PM1 1024 Dowel Pin PM1 1013 Bearings PM1 1017 Key PM1 1009M Pressure Balance Seal PE1 1230 Washer 5 8 PM1 1014M Wear Plates 2AOOMWNOORWD PO BR BP a a Pp HS a _ h hk Capscrew Gear sets PL1 1028 14 Capscrew 27GPM 5 8 11UNC X 5 1 4 PM1 1016 K07 27 2 1 1 4in Round Shaft 27GPM PL1 1028 16 Capscrew 31GPM 5 8 11UNC X 5 1 2 PM1 1016 K07 31 2 1 1 4in Round Shaft 31GPM PL1 1028 19 Capscrew 35GPM 5 8 11UNC X 5 3 4 PM1 1016 K07 35 2 1 1 4in Round Shaft 35GPM PL1 1028 23 Capscrew 40GPM 5 8 11UNC X 6 PM1 1016 K07 40 2 1 1 4in Round Shaft 40GPM 20 PM1 1126 SER Rear Cover with test ports Str Thd PM1 1016 S05 2 1 1 4in 14T Splined Shaft 27GPM 24 PS1 1010 Check Assembly 2 2 NO PM1 1016 S05 3 1 1 4in 14T Splined Shaft 31GPM PM1 1016 S05 35 2 1 1 4in 14T Sp2. SL WITH VP10 FLOW CONTROL VALVE Hose must be routed to return line at reservoir on VP15 flow control P PUMP F RETURN LINE FILTER PMV POWER MISER VALVE V DIRECTIONAL CONTROL VALVE FC FLOW CONTROL VALVE C CYLINDER BV BLEED OFF VALVE R RESERVOIR SL SUCTION LINE PL PRESSURE LINE PG TAKE PRESSURE READINGS HERE VG TAKE VACUUM READINGS HERE It is recommended that hose between pump outlet and Bleed Off Valve be 3 8 9 5 mm ID SAE 100R2 minimum Maximum recommended vacuum at the inlet of this pump is 5 In Hg 17 Bar MUNCIE POWER PRODUCTS INC KIT NO 48M81252 ELECTRIC AIR SHIFT POWR PRO INSTALLATION KITS POWR PRO ELECTRIC AIR SHIFT SYSTEM PARTS LIST AND DESCRIPTION 1 1 44MB2164 31M15759 44MB6844 44MB6842 44MB6942 44MB2252 30M12020 33136299 34M30006 34M18009 37M18000 45M44430 34M18187 31M18164 44M30137 34M18002 3 3 3 4 3 3 3 3 2 2 2 1 2 1 2 3 NOTE Solenoid should be mounted in a place that is protected from harsh weather exposure Include only when EOS 110 is sold with pump POWR PRO MANUAL AIR SHIFT SYSTEM BATTERY 35M15002C SOY Nipple Pressure Protection Valve Tube Fitting Tube Fitting Tube Fitting elbow Street Tee Switch amp Light Assy Solenoid Valve Fuse Holder Terminal Clip Ring Terminal Electrical Wire Air Tubing 30 9 14 m Female Spade Connector Pressure Switch Breather Butt Spli
3. POWR PRO and POWER MISER LAM SERIES PUMP SYSTEMS DESIGN NO 1 POVVER MISER POWR PRO PARTS LIST AND SERVICE MANUAL PUMPS COME IN EIGHT POPULAR SIZES FROM 14 TO 40 GPM 53 151 LPM STD REPLACEMENT GPM LPM MAX MAX MAX MAX OFF MODE PUMP MODELS 1000RPM RPM PSI BAR VACUUM PSI BAR PML14 1CFSL 3000 3000 207 PML19 1CFSL 3000 3000 207 5 IN HG PML23 7CFSL 3000 2900 172 5 IN HG 207 5 IN HG 207 172 PML25 1CFSL 2500 2500 172 5 IN HG 207 207 172 17BAR 17BAR 17BAR 17BAR PMM27 7 CFSL 3000 3000 207 5 IN HG 17BAR PMM31 7CFSL 3000 3000 207 5 IN HG PMM35 7CFSL 2500 2500 172 5 IN HG PMM40 7CFSL 40 151 2500 2500 172 5 IN HG Note Contact Muncie for specific part number construction or performance data Not available for use with Powr Pro System Off mode RPM 2500RPM on mode except PML 25 and PMM 40 which is 2300RPM The 3D diamond like design appearing on Muncie s hydraulic pumps is a trademark of Muncie Power Products Inc Muncie Indiana USA registered in the United States and various foreign countries 17BAR 17BAR 17BAR MUNCIE POWER PRODUCTS INC M SERIES PUMP SERVICE Service Kits Part No e Included in Seal Kit GSK PM1 PMV e x Included in Rebuild Kit RBK PM1 PMV Ring seal slot points toward bearings SEAL DETAIL A V AN KX wer EZA A S VEZ A p L
4. 25135516 N A N A 49135501 N A 26135514 27136238 28136236 12135304 49136237 26135594 19135595 12136877 N A N A 2 1 1 1 1 1 1 1 2 1 2 2 Valve Body 2 inch 50 8 mm 1 1 2 inch 88 1 mm Plug Spool 2 inch 50 8 mm 1 1 2 inch 88 1 mm Insert Bushing Locking Collar Dowel Pin Short Spring Air Cup O Ring Piston Piston Dowel Pin Long Screw Air Cup O Ring Air Cup O Ring Spool O Ring Insert ASSEMBLY AND DISASSEMBLY NOTES 1 Removal of the Insert Bushings is not recommended 2 A light coating of grease should be applied to the Valve Spool before pushing thru O Rings 3 The Spool and Lockcollar surfaces must be completely degreased before pressing together Upon assembly the total spool end play should be between 002 005 inches 05 127 mm 4 The Throttle Plate should be installed from the front side 19135518 22135519 28135294 28135287 12136867 12136868 49T36066 49136067 N A GSK PPV 32 GSK PPV 24 AK PPV Screw Locknut Race 2 inch 50 8 mm 1 1 2 inch 88 1 mm O Ring Flange 2 inch 50 8 mm 1 1 2 inch 88 1 mm Throttle Plate 2 inch 50 8 mm 1 1 2 inch 38 1 mm Dowel Pin Throttle Plate Stop Seal Kit 2 inch 50 8 mm 1 1 2 inch 38 1 mm Includes Items 9 13 19 Air Cap Kit Includes Items 7 8 9 10 11 13 Muncie name is cast into this side in such a way that when rotated to the closed position the edge mak
5. READINGS HERE B Bypass LDL LUBE DRAIN LINE Not used with VP15 Flow Control F RETURN LINE FILTER Hose runs directly to tank It is recommended that hose between pump outlet POWR PRO valve and back to tank be 3 8 9 5 mm ID SAE 100R2 minimum Maximum recommended vacuum at the inlet of this pump is 5 in Hg 17 Bar POWR PRO eee INSTALLATION P Port o ah aid A 3 3 8 9 5 mm NOTE 4g Re kba Crossover Lube Line POWR PRO Pump System must have lube line in stalled and routed back to ES B e a the reservoir with its own eee 9 5 mm hig l 4 pressure port for lube line for proper operation Do J line hookup only Not to be not use a bleed valve with POWR PRO T Port gt Se used for auxiliary systems this system Must have 3 8 9 5 mm hose Sy routed directly back to the reservoir Do not hook into any other lines 6 MUNCIE POWER PRODUCTS INC POWER MISER BLEED OFF VALVE The Bleed Off Valve is required with POWER MISER and is installed at the top of the reservoir and routed from the pump outlet to prevent accidental pump operation during the Off Mode Pump pressurization in excess of 20 PSI 1 4 Bar in the Off Mode will result in pump damage This item must be purchased separately 3 8 NPSF Pipe Thread FFC 3 2 Pressure compensated fixed flow regulator POWER MISER PLUMBING DIAGRAMS Te H PL AO A R l SL E E BV f G R WITHOUT FLOW CONTROL VALVE FC Va
6. 30 F 221 C Minimum Ref Pour Point ASTM D 97 57 15 F 10 C Maximum Foam Resistance ASTM D 892 Test Seq Il Viscosity at Startup 7500 SSU 1620 CS Maximum Rust Resistance ASTM D 665 60 No Rust Corrosion Resistance ASTM D 130 65 Class 1 Oxidation Stability ASTM D 943 1500 Hours Min Aniline Point ASTM D 611 64 180 220 F 82 104 C Anti Wear Additive 06 Zinc Minimum NOTE Cold weather operation requires special oil considerations Viscosity should not exceed 7500 SSU 1620 CS at lowest startup temperature Continuous operation should range between 60 1000 SSU 10 5 216 CS for all temperature ranges Never use Diesel fuel or kerosene to thin the oil TROUBLE SHOOTING GUIDE FOR HYDRAULICS Hydraulic analysis and proper repair require the use of a vacuum gauge and pressure gauge for testing Ports are provided in rear cover for testing Pump unusually noisy ON Pump unusually noisy OFF Il Pump fails to respond Ill Oil heating up ON Oil heating up OFF A Low supply of oil B Heavy oil C Dirty oil filter D Suction line too small E Restriction in suction line F Air leak in suction line G Oil temperature extremely high causing vapor to form in the oil H Pump sucking air through the shaft oil seal when pump is idling Excessive pressure build up in the Off Mode A Low oil supply B Insufficient relief valve press
7. 4 MUNCIE POWER PRODUCTS INC 2 3 4 5 6 l 8 10 11 PUMP DISASSEMBLY Place pump into a vise with drive shaft down Clamp onto front cover Using a dark marker or punch mark all three sections on one side for reference during reassembly Figure 1 Remove the 8 cap screws 4 in L Series Lift off rear cover If necessary pry loose but be careful not to damage machined surfaces Figure 2 Remove center section with same procedure as above Remove both the drive and driven gear Remove wear plates and seals from both the front and rear covers Figure 3 Inspect bearings and if necessary remove with a bearing puller Figure 4 Remove ring seals from the drive gear side front and rear covers These should be replaced any time unit is rebuilt to prevent shaft seal leaks or blowing out Rotate front cover in the vise so it faces up remove snap rings Remove spacer or outboard bearings with bearing puller Figure 5 Tap out shaft seals and discard O Rings clean seal retainer with solvent and smooth surface with emery paper Replace if gouged or nicked at seal area E x O EN atin repaga Ao nS UREE MUNCIE POWER PRODUCTS INC 11 PARTS INSPECTION THE FOLLOWING IS A GUIDE IN EVALUATING PARTS TO SEE IF REPLACEMENT IS NEEDED GEAR HOUSINGS Wear in excess of 005 127 mm cut out necessitates replacement of the gear housing Place a straight edge across bore If you can sl
8. ECOMMENDED FLOW VELOCITIES HOSE CHART HOSE CHART METRIC BASED ON FORMULA BASED ON FORMULA ___ GPM x 0 3208 LPM x 0 1666 VELOCITY FT SEC AREA SQ IN AREA SQ CM VELOCITY M SEC MAXIMUM MAXIMUM RECOMMENDED RECOMMENDED VELOCITY FOR 2g VELOCITY FOR INTAKE LINES l INTAKE LINES a i Loo oo MAXIMUM sv l MAXIMUM RECOMMENDED 39 RECOMMENDED VELOCITY FOR VELOCITY FOR RETURN LINES RETURN LINES m MAXIMUM RECOMMENDED VELOCITY FOR PRESSURE LINES MAXIMUM RECOMMENDED VELOCITY FOR PRESSURE LINES ACTUAL INSIDE DIAMETER OF PIPE ACTUAL INSIDE DIAMETER OF PIPE TUBE AND HOSE CM FLOW GALLONS MINUTE NOMINAL STANDARD PIPE SIZES TUBE AND HOSE INCHES PIPE TUBE amp HOSE VELOCITY FT SEC FLOW LITERS MINUTE NOMINAL STANDARD PIPE SIZES VELOCITY M SEC SQ IN PIPE TUBE AREA OF AREA OF amp HOSE SQ CM 14 MUNCIE POWER PRODUCTS INC OIL RECOMMENDATIONS Muncie does not promote specific manufacturers brands of oil Specifications below are guidelines and the oil manufacturer should be consulted for your exact application needs Viscosity ASTM D 88 56 100 F 40 C 1 73 187 SSU 37 CS Ref 210 F 100 C Approx 45 SSU 5 9 CS Minimum Viscosity Index ASTM D 567 53 100 F 82 C Optimum Gravity API ASTM D 287 64 29 F 2 C Minimum Flash Point ASTM D 92 57 400 F 204 C Minimum Fire Point ASTM D 92 57 4
9. M 170 3 LPM 56 7 LPM 10 3 3 3 3 3 3 3 3 3 3 3 3 3 Example MODEL VP10 VP10 28 33 40 etc VP10 00 VP00 28 VP00 33 VP00 36 VP00 40 VP00 52 VPO00 55 VP00 63 VP 1001 VP 1002 VP 1003 VP 1004 VP10 GSK NOTE Refer to pump brochures for actual pump performance curves MODEL VP15 VP 15001 VP 15002 VP 15003 VP 15004 VP 15005 VP 15006 VP 15007 VP 15008 VP 15009 VP 15010 VP 15011 VP 15012 NA VP 15014 VP15 GSK Flow Required Maximum Flow of Pump Bypass Flow 15 GPM Assembly with Appropriate Flow Control Orifice Manifold Assembly less Orifice Flow control orifice 359 in 09 12 mm Dia Code Q 397 in 10 08 mm Dia Code R 415 in 10 54 mm Dia Code P 438 in 12 19 mm Dia Code J 500 in 12 70 mm Dia Code U 516 in 13 11 mm Dia Code T 562 in 13 21 mm Dia Code V By pass Hose Assembly By pass Hose Fittings Manifold O Ring Cartridge Assembly Seal Kit Cartridge Only Flow Rate Out Of Valve GPM LPM 20 30 40 50 60 70 80 90 76 113 151 182 227 265 303 341 Flow Rate Into Valve GPM LPM Adjustment Assembly O Ring O Ring Backup Ring O Ring Backup Ring O Ring Backup Ring O Ring Lock Wire Spring Assembly Cap Bypass Assembly O Ring Manifold 10 Seal Kit NOTE Piston is not available Incl Items as an individual service part 2 3 4 5 6 7 8 9 14 due to being a matched set with pressed in sleeve 1
10. al Rear Cover Gear sets PL1 1016 K01 14 2 1 in rnd 14 GPM PL1 1016 K01 19 2 1 in rnd 19 GPM PL1 1016 K01 25 2 1 in rnd 25 GPM PL1 1016 K01 23TV 2 1 in rnd 23 GPM Tandem 1 1 O P KR NNN AA Aa aaa a PL1 1016 K07 23 2 1 4 in rnd 23 GPM 24 PL1 1016 K07 25 2 1 4 in rnd 25 GPM PL1 1016 K07 14TV 2 1 1 4 in rnd 14 GPM Tandem 29 PL1 1016 K07 19TV 2 1 1 4 in rnd 19 GPM Tandem PL1 1126 SCR PL1 1126 XX PL1 1126 TVH PL 1028 14 PL 1028 19 PL 1026 23 PL 1028 25 PL1 1028 016S PL1 1028 014S PE1 1230 BOR 6 PS1 1009EK Pocket Seals 12 Pieces PL1 1125 25 FIWM Body 25GPM 1 5 SF x 1 25 SF Rear Cover W 6SAE Test Ports Rear Cover No Ports Rear Cover Tandem Versatile Flange Capscrew Capscrew 14 GPM Capscrew 19 GPM Capscrew 23 GPM Capscrew 25 GPM Stud 5 8 11UNC x 12 1 4 tandem 5 8 11UNC x 11 3 4 tandem Washer 5 8 O Ring 0 47x0 079 PS1 1017 Key 1 4 X 3 8 X 1 1 4 NOTE 1 Torque assemblybolts to 200 ft lbs 270Nm PM1 1017 Key 5 16 X 15 32 X 1 1 2 2 Maximum vacuum is 5 in Hg 17 Bar MUNCIE POWER PRODUCTS INC 3 Air Cap Components Items 7 8 10 amp 11 on units built prior to Oct 94 cannot be re placed individually and should be replaced with complete Kit No AK PPV 1 Fated POWR PRO SERVICE PARTS Part numbers shown are for units built AFTER Oct 94 Older units are not serviceable except for air components N A N A
11. ce a OPTIONAL WIRE PATH IF EOS 110 iS NOT USED I GROUND TO FRAME BATTERY YO O ti Optional a TRUCK AIR SUPPLY TANK i EX supeey Ex Lat LJOLJ 5 3 f A B rigar OF ON 4 Sii a KIT NO 48M61256 MANUAL AIR SHIFT PARTS LIST AND DESCRIPTION 44MB2164 31M15759 44MB6844 44MB6942 45M44430 44MB2252 30137954 5 OY 34736941 7 LL 8 7 6 35137955 O o E T 32M12001 he 33736299 34M18002 a TN Nipple Pressure Protection Valve Tube Fitting Tube Fitting 1 4 in Air Tubing 30 ft Street Tee Pressure Switch Harness Pigtail Air Valve Light Assembly Fuse Assembly Butt Splice Ring Terminal 18GA Wire 12 ft Dash Bracket Bolt Kit Face Plate 34M18009 37M18000 36MA1004 36MK1007 36M01453 7 FP oe PORT LEGEND R NOT USED HW TRUCK AIR Y SUPPLY TANK s 1 AIR IN 2 POWR PRO OFF AIN PORT 2 3 EXHAUST 4 POWR PRO ON PORT4 J PUSH OFF MUNCIE POWER PRODUCTS INC PULL ON 1 CONOoaBRWDND 4 i 2 2 2 i 2 POWER MISER INSTALLATION KITS KIT NO 48M81251 ELECTRIC AIR SHIFT PARTS LIST AND DESCRIPTION 35M2X749 30M12020 44MB2164 31M15759 44MB6844 44MB6842 44MB2254 33136299 34M18250 45M44430 34M18009 31M1749C 44MB6942 34M18187 37M18000 44M30137 44MB2242 Solenoid Valve N 0 Switch amp Light Assembly Nipple Pressure Prote
12. ction Valve Tube Fitting Tube Fitting Street Tee Fuse Assembly Terminal Clip Air Tubing 30 9 14 m Ring Terminal Pressure Switch Tube Fitting elbow Female Spade Connector for overspeed light Electrical Wire 3 64 m Breather Adapter owe 5 Optional Wire kir er ri hes Ke a att oa Red cole ft J ee a o Path if EOS 110 is not used POWER MISER ELECTRIC AIR SHIFT SYSTEM EOS 110 to Frame Include only when EOS 110 is sold with pump NOTE Solenoid should be mounted in a place that is protected from harsh weather exposure KIT NO 48M61255 MANUAL AIR SHIFT POWER MISER MANUAL AIR SHIFT SYSTEM PARTS LIST AND DESCRIPTION 1 1 44MB2164 31M15759 44MB6844 44MB6842 45M44430 44MB6942 33136299 34M18002 44MB2252 34M18250 34M18009 32M12001 35M18653 36MA1004 37M18000 31M1749C 44MB2242 36M01005 36MK1007 MUNCIE POWER PRODUCTS INC Nipple Pressure Protection Valve Tube Fitting Tube Fitting Air Tubing 30 9 14m Tube Fitting elbow Fuse Assembly Butt Splice Street Tee Terminal Clip Ring Terminal Light 12 Volt Air Valve Dash Bracket Electrical Wire 3 64m Pressure Switch N C Adaptor Face Plate Bolt Kit Truck Air Supply Tank FLOW CONTROL VALVES NOTE Flow control and orifices should be sized such that they bypass no higher than 50 of the desired control flow 30 GPM 113 5 LPM 45 GP
13. e center wear plates where the gears mesh Erosion here indicates oil contamination Pitted thrust plates indicate cavitation or oil aeration Discolored wear plates indicate over heating probably insufficient oil SEALS AND GASKETS Replace all rubber polymer seals and shaft ring seals whenever disassembling pump Include all O rings pocket seals behind wear plates shaft seal and gasket seals BEARINGS If gears are replaced bearings must be replaced Bearings should fit into bore with a light press fit A neat hand fit is allowable If bearings can fall out bore may be oversize DOWEL PINS If either the dowel pin or dowel hole is damaged the pin or machined casting or both must be replaced If more than reasonable force is required to seat dowels the cause may be poorly deburred or dirty parts cocking of the dowel in the hole or improper pin to hole fit CHECK VALVES Examine small check valves in shaft end cover to make sure they are intact and functioning If there are no check valves here make sure the high pressure side of the shaft end cover is plugged MUNCIE POWER PRODUCTS INC A 11 12 13 14 SSN oS PUMP REASSEMBLY BASED ON NEEDED PARTS HAVING BEEN REPLACED AND ALL OTHER PARTS THOROUGHLY CLEANED Place front cover face down in vise Stone off outer edge to remove any burrs produced from disassembly Re clean Figure 1 Insert new ring seal with NOTCH visible Re install bearing
14. e seal retainer O rings first into the pump Drop in spacer or outboard bearing and install snap ring we FIGURE 1_ FIGURE2 FIGURE 3 FIGURE 4 FIGURE 5 MUNCIE POWER PRODUCTS INC 13 REBUILT PUMP CONDITIONING WARNING On initial pump startup be sure the Powr Pro or Power Miser valve is in the On Mode for proper pump lubrication requirements Failure to do so could lead to possible pump damage Before installing a new or rebuilt pump or motor back off the main relief valve until the spring tension on the adjusting screw is relieved This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recommended operating pressure Before connecting any lines to the pump or motor fill all ports with clean oil to provide initial lubrication This is particularly important where the unit is located above the oil reservoir After connecting the lines and mounting the replacement unit operate the pump or motor at least two minutes at zero pressure at lowest possible rom During this break in period the unit should run free and not develop an excessive amount of heat If the unit operates properly speed and pressure can then be increased to normal operating settings Reset the main relief valve to its proper setting while the pump is running at maximum operating engine motor speed for the vehicle FLOW CAPACITIES FOR PIPE TUBE AND HOSE AT R
15. equires a smaller thickness Air Cylinder O Ring For service parts purposes identify by the following Requires new style Air Cylinder O Ring Thickness 103 in 2 62 mm 070 in 1 77 mm Style Casting No Prefix Air Cyl O Ring No Old A50X x PV 103 New B52 2 12135281 This change occurred August 1989 MUNCIE POWER PRODUCTS INC 5 POW PR PRO VALVE 3 8 9 5 mm Crossover Hose Into P Port The POWR PRO valve principal is to Abe te allow the Hydraulic System to be turned OFF to a low horsepower O i Air Piston g Cross Drilled Hole consumption Standby mode While Moves In Out Opens Closes OFF the crossover lube line directs oil Ja a wi back into a valve chamber to run back to the reservoir Now when i turned on full pump flow is available konut ded to operate the system but the lube line passage is now blocked to pre Pump On Port f vent any loss of oil Lube line pres 4 3 8 9 5 mm Hose Out Of T sure when the pump is OFF must not Port And To The Reservoir exceed 20 PSI 1 4 Bar Note POWR PRO must be shifted with a 2 position 4 way valve WITHOUT FLOW CONTROL VALVE WITH VP10 FLOW CONTROL VALVE Hose must be routed to return line at reservoir on VP15 flow control P PUMP V DIRECTIONAL CONTROL VALVE PPV POWR PRO VALVE C CYLINDER FC FLOW CONTROL VALVE R RESERVOIR CL CROSSOVER LINE PL PRESSURE LINE SL SUCTION LINE VG TAKE VACUUM READINGS HERE PG TAKE PRESSURE
16. es contact with the Dowel Pin Also be sure that the crossdrilled hole in the Spool lines up with the P Port upon final assem bly Lightly tap the Throttle Plate to allow unit to center it self Torque Nuts and Screws to 18 in lbs 2 kg meters The Air Cylinder should be positioned so that a slight preload of Throttle Plate in the closed position is seen Torque screws to 105 in lbs 1 21 kg meters MUNCIE POWER PRODUCTS INC POWER MISER VALVE SERVICE PARTS PV 101 PV 101V 27135283 12136880 070 1 77 19135279 19135275 21120519 21135276 29135282 01135271 01135285 01135292 PV 102 PV 103 1 103 2 62 PV 104 1 PV 104 2 PV 105 1 PY 105 2 PV 106 PV 107 1 PV 107 2 PVe10 3 Air Cylinder Air Cylinder Viton Spring O Ring Mtg Bolts 20 Mtg Bolts 24 amp 32 Lockwasher 20 Lockwasher 24 amp 32 Pipe Plug Body 20 Body 24 Body 32 12136869 12136868 12136867 28135273 28135287 28135294 49135272 49135286 49135293 26135277 1 1 4 31 75 1 1 2 38 10 2 50 80 PV 108 1 PV 108 2 PV 108 3 PV 109 1 PV 109 2 PV 109 3 PV 110 1 PV 110 2 PV 110 3 PV 111 O Ring 20 O Ring 24 O Ring 32 Race 20 Race 24 Race 32 Plunger 20 Plunger 24 Plunger 32 Cotter Pin Power Miser Valve Assembly Power Miser Valve Assembly Power Miser Valve Assembly NOTES A design change has been made on the Power Miser valve which r
17. in POWR PRO valve POWR PRO throttle plate misadjusted and won t close MUNCIE POWER PRODUCTS INC 15 NOTES ISO 9001 Muncie Muncie Power Products Inc Member of the Interpump Hydraulics Group Power General Offices and Distribution Center P O Box 548 e Muncie IN 47308 0548 E 765 284 7721 FAX 765 284 6991 E mail info munciepower com tea t ANT Products Web site http www munciepower com ZFS See SP11 01 Rev 4 11 Printed in the U S A Drive Products Exclusive Agents for Canada SO Certified by an Accredited Registrar Muncie Power Products Inc 2011
18. ip a 005 127 mm feeler gauge under the straightedge in the cut out area replace the gear hous ing Pressure pushes the gears against the housing on the low pressure side As the hubs and bearings wear the cut out becomes more pronounced Excessive cut out in a short period of time indicates excessive pressure or oil contamina tion If the relief valve settings are within prescribed limits check for shock pres sures or tampering Withdraw oil sample and check it and tank for dirt GEARS Replace if there is any wear detectable by touch in the seal areas or at the drive coupling 002 05 mm wear is the maximum allowable Wear in the shaft seal areas indicate oil contamination and shaft replacement is required Wear or damage to splines keys or keyways necessitates replacement Any wear on the hubs detectable by touch or in excess of 002 05 mm necessitates replace ment Nicking grooving fretting of teeth surfaces or head discoloration also ne cessitates replacement Scoring grooving or burring of outside diameter of teeth generally means replacement is necessary unless damage is light and can be stoned off Maximum shaft runout is 001 025 mm WEAR PLATES The wear plates seal the gear section at the sides of the gears Wear here will allow internal slippage that is oil will bypass within the pump 002 05 mm maximum wear is allowable Replace wear plates if they are scored eroded pit ted or discolored Check th
19. lined Shaft 35GPM 22 2 BOR6 Rng ATADOS PM1 1016 S05 4 1 1 4in 14T Splined Shaft 40GPM NOTE Torque assembly bolts to 200 ft lbs 270Nm PM1 1015 Body Seal Maximum vacuum is 5 in Hg 17 Bar 1 0 7 1 5 0 2 MUNCIE POWER PRODUCTS INC L SERIES PUMP SERVICE Service Kits Part No e Included in Seal Kit GSK PM1 PMV e Included in Rebuild Kit RBK PM1 PMV Ring seal slot points toward bearings PPV option is not available for 14GPM models SEAL DETAIL SEAL NOTE Lip seals Items 5 softlip and 4 hardlip must be assembled back to back as shown WEAR PLATE POSITION OUTLET HIGH PRESSURE ee eee i NG NAW INLET LOW PRESSURE ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 1 17 4 PL1 1001 O B Snap Ring PL1 1024 Dowel Pin PL1 1003M Seal Retainer 18 1 Body Mach Inlet Sas Bra A P MR d PL1 1125 11 XX Body 11GPM No Ports utside onalt seal Reverse PL1 1125 14 FIPM Body 14GPM 1 25 SF x 1 0 SF PL1 1005M Inside Shaft Seal PL1 1125 19 FIWM Body 19GPM 1 5 SF x 1 25 SF PL1 1107 CLXXX Front Cover SAE C 4 Bolt i PL1 1107 DLPAB Front Cover SAE B 2 4 Bolt Ope ea or ee PL1 1008M Ring Seal HHBP 6BZ Test Port Plug 6 SAE PS1 1010 Check Valve Assembly PL1 1012 Body Seal Front Cover PL1 1013 Bearings PL1 1014MM Wear Plates PL1 1015 Body Se
20. ure C Pump worn or damaged D POWR PRO or POWER MISER valve not shifting A Foreign matter lodged between re lief valve plunger and relief valve seat B Using very light oil in hot climate C Dirty oil D Oil level too low E Insufficient relief valve pressure F Relief valve pressure too high G Pump worn slippage H Excessive pressure build up in the Off Mode A Fill to proper level B Change to proper oil C Clean and replace filter D Increase size of suction line E Remove F Check for loose connection G Check entire circuit H Check by squirting oil around the seal Replace if faulty Install Bleed Off Valve POWER MISER Replace damaged Bleed Off Valve POWER MISER Check hose routing damage Blockage in POWR PRO valve POWR PRO throttle plate misadjusted and won t close A Fill to proper level B Reset to correct pressure setting using gauge C Inspect repair or replace D Inspect air cylinder amp air activation system A Inspect and remove foreign matter B Drain and refill with proper oil C Drain flush and refill with clean oil D Fill to proper level E Set to correct pressure F Same as E G Replace or repair H Install Bleed Off Valve RPOWER MISER Replace damaged Bleed Off Valve POWER MISER Check hose routing damage Blockage
21. using arbor press until it bottoms Install wearplates and seals onto bearings Note that pocket seals L Series need to have center seals installed first Hold in place with grease Outer seals can be slid into position and cut to length with wearplates in stalled Figure 2 Install the gears until they bottom against the wearplates Grease the body O rings and install into the groove in the center section Install the same way as removed by aligning the marks NOTE Any burrs should have been stoned off prior to reassembly Figure 3 Remove any burrs from the rear cover and clean Insert ring seal and bearings as described in step 2 Install wearplates as described in step 3 Figure 4 Install rear cover onto pump housing by aligning the marks Lightly tap into place Figure 5 Install the 8 cap screws Snug up the bolts using a criss cross pattern Rotate the drive shaft with a 6 wrench to make sure there is no binding Now torque the bolts M Series is 200 Ft Lbs 27 6 kg meters L Series is 225 Ft Lbs 31 1 kg meters using the criss cross pattern again Rotate pump onto work bench face up Install the new shaft seals into the seal retainer Reference service parts page for proper position using Permatex aviation form a gasket sealer on the outside seal casing Grease O rings and install onto retainer Using a greased seal guide L Series Part No A 1254 5 M Series Part No A 1254 6 on the drive shaft install th
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