operating & service manual az-1-107-nl series
Contents
1. AIR PSI 10 20 30 40 50 60 70 80 90 100 PRESSURE Bar 0 7 1 4 2 1 2 8 3 5 4 1 4 8 ao 6 2 6 9 HYDRAULIC PSI 900 2 000 3 150 4 200 5 400 6 400 7 450 8 500 9 700 10 700 PRESSURE Bar 62 138 217 290 372 441 514 586 669 738 APPROXIMATE RATE OF DISCHARGE APPROXIMATE RATE OF DISCHARGE PRESSURE 60 PSI 4 1 Bar 80 PSI 5 5 Bar 100 PSI 6 9 Bar Ins Ltr Ins Ltr Ins Ltr PSI Bar per per per per per per min min min min min min 0 0 95 1 56 110 1 8 120 1 97 1 000 69 69 1 13 74 1 21 78 1 28 2 000 138 61 1 68 1 11 74 1 21 3 000 207 53 0 87 63 1 03 71 1 16 4 000 241 46 0 75 58 0 95 62 1 02 6 000 414 26 0 43 45 0 74 54 0 89 8 000 552 0 0 28 0 46 44 0 72 9 000 621 0 0 0 0 38 0 62 10 000 690 0 0 0 0 27 0 44 12 500 862 0 0 0 0 0 0 MATERIALS OF CONSTRUCTION Air Motor Mainly anodised aluminium with wound composite air cylinder carbon steel zinc plated tie rods Hydraulic Section Aluminium bronze cylinder unless 300 series stainless steel requested 300 series stainless steel Chrome plated piston 300 series stainless steel check valve bodies and check valve internals except balls which are 440C stainless steel Nitrile seals suitable for water oil methanol and glycol service fitted viton ethylene propylene or chemraz seal kits available INLET THREAD NPT OUTLET THREAD Y NPT AZ 1 SERIES PUMP AIR MOTOR ASSE2. OPERATING amp SERVICE MANUAL AZ 1 107 NL SERIES PUMP USA EDITION specializing in high pressure eguipment for industry specializing in the design and manufacture of high pressure eguipment for industry AN M O D REGISTERED CONTRACTOR For Sales Service Contact Hydratron Inc 1708 W Sam Houston Parkway N Houston Texas 77043 USA Tel Sales amp 832 252 1082 or Service 1866 305 9665 Fax 832 252 1083 E mail sales hydratron com Website www hydratron com Hydratron Ltd Unit 2 Blue Chip Business Park Atlantic Street Broadheath Cheshire WA14 5DD England Tel 44 0 161 928 6221 Fax 44 0 161 927 7085 E mail info hydratron co uk Website www hydratron co uk SECTION 1 AZ 1 SERIES PUMP INSTALLATION INSTRUCTIONS 1 1 1 2 1 3 1 4 1 5 MOUNTING THE PUMP 2 off 3 87 24 UNF tapped holes are located on the base of the hydraulic cylinder and supplied with 34 long mounting bolts washers and spring washers for panel mounting up to a max thickness of 1 4 6mm FLUID SUPPLY CONNECTION Make a suitable flexible or hard piped connection to the threaded fluid inlet port marked fluid in on check valve body Size of thread shown on page 8 Use PTFE tape or suitable anti seize compound to prevent galling of the threads and ensure all connections are leak free All connections to this port should be the same size or larger as smaller size fittings hoses etc can ca
3. 42 43 44 45 47 48 49 P 1 26 107 NL Qty Rh e e e N e a Part code P 1 149 P 1 150 P 1 51 P 1 10 107 P 1 28 MS28782 10 6227 10 V P 1 11 107 SF P 1 23 P 1 24 AZ 1 107 NL HYDRAULIC ASSEMBLY PARTSLIST Description PISTON NUT PISTON WASHER PISTON BUMPER HYDRAULIC PISTON GASKET BACK UP RING O RING HYDRAULIC CYLINDER OUTLET CHECK VALVE ASSEMBLY INLET CHECK VALVE ASSEMBLY ITEM 48 OUTLET CHECK VALVE ASSEMBLY P 1 23 50 D 52 23 54 55 56 E p m pn ng E P 1 20 RRT68 P 1 17 P 1 13 P 1 34 2 9 16BALL 6227 10 V BODY RETAINING RING SPRING GUIDE SPRING BALL GUIDE BALL O RING ITEM 49 INLET CHECK VALVE ASSEMBLY P 1 24 Si 58 59 60 61 62 63 Check Valve components sold separately 1f required I p MN p p kisa P 1 20 RRT68 P 1 17 P 1 13 P 1 34 2 9 16BALL 6227 10 V BODY RETAINING RING SPRING GUIDE SPRING BALL GUIDE BALL O RING 12 P 1 124 107 Item 4 5 8 10 2 14 16 18 25 20 28 30 40 41 43 44 45 51 56 58 63 P 1 124 Item 4 5 8 10 12 14 16 18 25 pi 28 30 Qty Rh e e e N e e e o o NR RR Uu Qty e e e Ne E OO AZ 1 107 NL SPARES KITS USA COMPLETE REDRESS KIT Partcode 6227 19 P 1 57 6230 9 6230 1 6230 30 28775 028 6227 56 RRT200 P 1 A 32 6227 21 P 1 16 RRT093 P 1 150 P 1 51 P 1 28 MS28782 10 6227 10 V RRT68 6227 10 V RRT68 6227 10 V Descrip
4. MBLY Lubricated with NL SUPERLUBE GREASE k Pa p 14 AZ 1 SERIES PUMP AIR MOTOR PARTSLIST Item Qty Part code Description 1 8 5 16 18x4 5 16 18NUT BOLT nut is a separate item 2 1 P 1 1 HEAD CASTING 3 1 P 1 12 PISTON BUMPER 4 2 6227 19 ORING 5 1 P 1 57 VALVE BUMPER 6 1 P 1 111 SLIDE VALVE ASSEMBLY 7 1 P 1 5 SPRING 8 1 6230 9 O RING 9 1 P 1 47 BEARING ASSY 10 1 6230 1 O RING 11 1 RRT262 SPIROLOK RING I2 2 6230 30 O RING 13 1 P 1 4 AIR CYLINDER 14 1 28775 028 O RING 15 1 P 1 48 AIR PISTON 16 1 6227 56 O RING 17 1 P 1 60 PILOT VALVE ASSEMBLY 18 1 RRT200 HEAVY DUTY CIRCLIP 19 1 P 1 7 A BOTTOM CASTING 20 1 3 16 LG SECTION ORING BUNG 21 1 1 4 20x5 16 SET SCREW GRUB SCREW ITEM 6 SLIDE VALVE ASSY P 1 111 22 4 28775 144 O RING 23 1 P 1 2 INNER SLIDE VALVE 24 1 P 1 3 SLIDE VALVE BODY ITEM 17 PILOT VALVE ASSEMBLY P 1 60 25 1 P 1 A 32 CHECK VALVE ASSEMBLY 4 1 6227 19 O RING 26 1 P 1 49 PILOT VALVE BODY 27 1 6227 21 O RING 28 1 P 1 16 SPRING 29 1 P 1 A 24 SEAT 30 1 RRTO93 SPIROLOK RING ITEM 25 CHECK VALVE ASSEMBLY P 1 A 32 al 1 8 32 NUT 32 1 P 1 39 WASHER 33 1 P 1 43 WASHER 34 1 P 1 15 SPRING 85 1 P 1 A 28 POPPET BODY 36 1 6227 9 O RING S 1 P 1 A 25 WASHER 38 1 P 1 56 CENTRE SCREW 10 AZ 1 5 NL TO 107 NL SERIES PUMP HYDRAULIC ASSEMBLY Lubricated with NL SUPERLUBE GREASE 39 40 M 43 Iniet Check Valve Outlet Check Valve 11 Item 39 40 41
5. ance Y2 NPT air supply components are required as smaller sizes will reduce the flow The pump is designed to operate on air pressure from 10 to 100 PSI unless it is a low pressure start LPS model when it will operate from 5 to 100 PSI To control the pump an air filter and regulator is required not supplied It is recommended an isolation valve not supplied is fitted between the air filter regulator unit and the pump NOTE It is not necessary to fit an air line lubricator as the pump is a NON LUBE version and internally lubricated with NL SUPERLUBE GREASE Note DO NOT EXCEED 100 PSI AIR SUPPLY MUFFLING THE EXHAUST It is recommended a muffler is fitted to the 3 NPT air out port to reduce the operating noise of the pump The muffler can be screwed directly into the 34 NPT port or piped away Do not fit a smaller muffler than 4 NPT as this can reduce the speed of the pump Use PTFE tape or suitable anti seize compound to prevent galling of the threads and ensure all connections are leak free SECTION 2 AZ 1 SERIES PUMP OPERATING INSTRUCTIONS 2 0 2 01 2 02 2 03 2 04 2 05 2 06 2 07 2 08 BEGINNING OPERATION Attach a 100 psi maximum air supply Rotate air regulator control knob anti clockwise until handle becomes free and air gauge reads 0 psi and connect an air supply 100 PSI maximum Open air supply isolation valve if fitted Rotate air regulator control knob slowly clockwise until pump begi
6. heck valve 25 refer to section 4 4 Remove retaining ring 11 and remove the bearing assembly 9 Replace O ring 8 and 10 Note The bearing assembly has a moulded rubber seat on one side if the rubber is damaged a new bearing assembly is required Do not remove slide valve sleeve 23 unless a complete new slide valve assembly 6 is being installed The valve and sleeve are precision ground and easily damaged if removed from the head casting Replace 2 x O rings 4 located inside slide valve inner sleeve 23 and the air motor casting 2 If replacing the slide valve due to wear or damage remove inner sleeve 23 outer sleeve 24 and 4 x O rings 22 If damaged replace piston bumper 3 and valve bumper 5 located in top casting note item 3 and 5 are not part of the air motor seal replacement kit When replacing a new slide valve assembly 6 locate 4 x O rings 22 ensure spring 7 is in position and carefully locate outer and inner sleeve into top casting as one unit to prevent damage Refer to section 4 5 4 4 4 41 4 42 4 43 4 44 4 45 4 46 4 5 4 51 4 52 4 53 4 54 4 55 4 6 4 61 4 61 4 62 4 63 4 64 4 7 4 71 4 72 4 73 4 74 SERVICING THE PILOT VALVE 17 AND INTEGRAL CHECK VALVE 25 Refer to section 4 31 to 4 34 Remove retaining ring 30 Unscrew seat 29 The check valve assembly 25 and spring 28 will drop out Replace O rings 4 amp 27 on pilot valve body Replace c
7. heck valve O ring 36 If check valve is damaged replace as a complete assembly 25 Refer to section 4 5 RE ASSEMBLING THE PUMP Re assembly is opposite procedure to disassembly Lubricate new O rings and bumpers with NL SUPERLUBE GREASE see spares list If reassembling the air motor ensure the air cylinder 13 is positioned correctly and tightly against the top and bottom casting BEFORE tightening the bolts Secure all bolts hand tight followed by an opposite tightening sequence to a torque of 10 12 ft Ibs Refit pump and connect pipe work in an opposite procedure to disassembly refer to section 4 1 Test air and hydraulic pipe joints for leakage SERVICING THE INLET CHECK VALVE using Inlet Check Valve Spares Kit Refer to section 4 1 Remove check valve assembly 49 from hydraulic cylinder 47 Remove retaining ring 58 and replace spring guide 59 spring 60 ball guide 61 ball 62 and O ring 63 Check body for damage and replace if necessary note not part of spares kit Refer to section 4 5 SERVICING THE OUTLET CHECK VALVE using Outlet Check Valve Spares Kit Refer to section 4 1 Remove retaining ring 51 and replace spring guide 52 spring 53 ball guide 54 ball 55 and O ring 56 Check body for damage and replace if necessary note not part of spares kit Refer to section 4 5 AZ 1 107 NL TECHNICAL SPECIFICATION HYDRAULIC PRESSURE STATIC CONDITION
8. ns to reciprocate pump should start at 10 to 15 PSI under normal conditions Rotate air regulator control knob clockwise until 25 to 30 PSI is reached on the air gauge and run pump until all air is purged out of the circuit When pressure testing bleed all air out of the item being tested before pressurising by fitting a bleed valve or vent plug at the highest point in the circuit Care should be taken to take account of any internal cavities that may trap air inside the circuit Rotate air regulator control knob anti clockwise until zero pressure is reached on air gauge Close any vent valves once all air is purged from the system Rotate air regulator control knob slowly clockwise until required hydraulic pressure is reached on the high pressure gauge Note If the object being tested is large it will take a while before the pressure builds up in the system and registers on the pressure gauge Do not set the air driving pressure too high if unattended as this may lead to the object under test being over pressurised Approximate hydraulic output pressure can be preset by air drive pressure See pump specification sheet Air drive pressure can be preset by closing an air line isolation valve fitted between the regulator and pump closing air stop valve and rotating air regulator valve clockwise until the required pressure is registered on air pressure gauge Air pressure should be set slightly below the required setting so that it can be raised to
9. the correct setting once hydraulic pressure has built up and the pump has stalled out The pump can then be started and stopped by using an air stop valve as it will go to the preset output pressure each time it is started Once set the pump will maintain the set pressure indefinitely and make up any fluid losses within the hydraulic system automatically SECTION 3 STANDARD AZ 1 SERIES PUMP FAULT FINDING e PUMP WILL NOT STROKE Possible Cause Remedy Air regulator not set correctly Check air drive pressure and re set regulator if necessary Air motor piston seal leaking See Section 4 3 Air motor pilot valve seal failure See Section 4 4 Air motor slide valve stuck See Section 4 3 Air motor slide valve seal failure See Section 4 3 Air motor check valve seal failure See Section 4 4 e LOSS OF HIGH PRESSURE Possible Cause Remedy Hydraulic check valves seal failure See Section 4 6 and 4 7 Hydraulic piston seal failure See Section 4 2 e PUMP RUNNING ERRATICALLY Possible Cause Remedy Tank fluid level low Refill tank with clean liquid SECTION 4 AZ 1 5 TO 107 SERIES PUMP SERVICING INSTRUCTIONS 4 1 4 11 4 12 4 13 4 14 4 15 4 17 4 18 4 19 4 2 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 3 4 31 4 32 4 33 4 34 4 35 4 36 4 37 4 38 4 39 REMOVING PUMP Note orientation of the air motor top casing air inlet and exhaust connections in rela
10. tion ORING VALVE BUMPER ORING O RING ORING O RING ORING HEAVY DUTY CIRCLIP CHECK VALVE ASSEMBLY O RING SPRING SPIROLOK RING PISTON WASHER PISTON BUMPER GASKET BACK UP RING O RING RETAINING RING O RING RETAINING RING O RING AIR DRIVE REDRESS KIT Partcode 6227 19 P 1 57 6230 9 6230 1 6230 30 28775 028 6227 56 RRT200 P 1 A 32 6227 21 P 1 16 RRT093 Description O RING VALVE BUMPER O RING O RING O RING O RING O RING HEAVY DUTY CIRCLIP CHECK VALVE ASSEMBLY O RING SPRING SPIROLOK RING 13 P 1 124 107 HYD END ONLY HYDRAULIC REDRESS KIT NL SUPERLUBE GREASE oz GREASE POT 14 AZ 1 107 NF SERIES PUMP Lubricated with NL SUPERLUBE GREASE ITEM 6 5 z gt ok u Eg E z5 si iz E ay do KE A TU I k MT ZA T d se ni JES n a z 15 specializing in the design and manufacture of high pressure eguipment for industry hydratron Hydratron Inc 1424 W Sam Houston Parkway N Houston Texas 77043 USA Tel Sales 832 252 1082 or 8 Service 1866 305 9665 Fax 832 252 1083 E mail sales hydratron com Website www hydratron com Hydratron Ltd Unit 2 Blue Chip Business Park Atlantic Street Broadheath Cheshire WA14 5DD England Tel 44 0 161 928 6221 Fax 44 0 161 927 7085 E mail info hydratron co uk Website www hydratron co
11. tion to hydraulic inlet and outlet check valve connections Disconnect air supply line Ensure all hydraulic pressure is released from system Disconnect air supply pipe work to pump air inlet Disconnect pipe work to inlet and outlet check valves From underneath the pump unscrew mounting screws Withdraw complete pump Refer to section 4 5 REPLACING THE HYDRAULIC PISTON SEAL using Hydraulic Seal Replacement Kit Refer to section 4 1 Loosen screw 21 located in air motor bottom casting Unscrew air motor anti clockwise from hydraulic cylinder 47 note the hydraulic piston will be removed with the air motor Replace hydraulic packing consisting of 1 off O ring 45 and 2 off PTFE back up rings 44 Lubricate O ring with clean NL SUPERLUBE GREASE see spares list Replace air motor to hydraulic cylinder gasket 43 Carefully relocate piston into hydraulic cylinder and firmly screw air motor back onto cylinder to its original orientation Tighten screw 21 Refer to section 4 5 SERVICING THE AIR MOTOR using SKAZAIR Air Motor Seal Replacement Kit Refer to section 4 1 Remove air motor retaining bolts 1 and separate top casting assembly from bottom casting Replace air piston O ring 16 14 and 2 x air cylinder O rings 12 Remove retaining ring 18 withdraw hydraulic piston 42 from air piston 15 and push pilot valve assembly 17 out through the bottom of the air piston To service the pilot valve 17 and integral c
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13. use a restricted flow supply The installation of a 100 mesh screen 140 micron fluid filter or finer is recommended located between the fluid reservoir and fluid inlet port and that the location of the fluid reservoir be above or level with the pump to ensure a flooded condition at the fluid inlet port Note Standard pumps are supplied with NITRILE hydraulic seals suitable for oil water methanol and glycol service Ensure that the fluid to be pumped is compatible with this material prior to use For other process applications Viton and Chemraz hydraulic seal kits are available PRESSURE PORT CONNECTION Make a suitably rated flexible or hard piped connection to the threaded fluid outlet port marked fluid out on check valve body Size of thread shown on page 8 Use PTFE tape or suitable anti seize compound to prevent galling of the threads and ensure all connections are leak free Connect a suitably rated gauge and a bleed valve or vent plug at the highest point in the circuit for purging air from the circuit Note hydraulic hoses or piping including adaptors or couplings must have a pressure rating equal to or more than the maximum output pressure of the pump AIR SUPPLY CONNECTION Make a suitable flexible or hard piped connection to the Y2 NPT air supply port marked air in Use PTFE tape or suitable anti seize compound to prevent galling of the threads and ensure all connections are leak free To ensure maximum perform
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