S-216-J Manual
Contents
1. 45 46 47 Liquid Liquid outlet inlet port port OVERHAUL KIT The Overhaul Kit contains replacement parts including Inlet and Outlet Check Valve O rings and oprings Detent Springs Pins and O rings Shuttle Valve Rings and O rings as well as other O rings Retainers and Connecting Self Locking Nut and Washer The kits listed below apply only to standard pumps with elastomeric type seals Standard kit seals are nitrile Optional kits with neoprene Viton and EPR seals are available In the kit numbers listed below the two digits after the dash indicate the choice of optional seal materials The first of those digits indicates the pump ratio while the second indicates the seal materials 00000 X X pump ratio 00000 X1 1 nitrile seals 00000 X3 3 Viton seals 00000 X4 4 EPR seals Ordering Example An Overhaul Kit with neoprene seals is needed for an S 216 J 30 The standard kit is 90680 31 with the 3 indicating a 30 ratio pump and the 1 indicating nitrile seals Change the Nameplate NS WO ll a E o Lj ees C 24 22 AN Ob tt Z G OUTLET Check Valve Assembly INLET Check Valve Assembly Ratio 10 101 NPT NS LA UL Ei Z 31 o s H 34 33 32 35 36 last digit from 1 to 2 to indicate neoprene seals The new number for the Overhaul Kit ie 90680 32 OUTLET Check Valve Assembly INLET Check Val2. B Liquid Flow D gt MYT s SoftSeat d B Check Valve cra Ne eek pa Check Valve Liquid Ee Stainless Steel Liquid driven Piston 9 216 J SERIES PUMP The Sprague Products pump develops high output pressure by applying the principle of differential ar eas The pump has a large area air piston air driven at low pressures This air piston drives a small area fluid piston that in turn pumps liquids at high pressures The fluid output pressure is determined by the ratio between the area of the air driven piston the area of the fluid driven piston and the applied operating air pressure The area relationship of the air piston to the fluid piston is referred to as the pump ratio A nominal ratio is indicated in the dash number which follows the pump model basic number Actual ratio may differ from nominal ratio Example 216 J 10 pump has an approximate ratio of 10 to 1 or 10 25 psi liquid pressure for each 1 psi of operating air pressure In operation an S 216 J 10 pump using 100 psi of input air pressure will produce a maximum liquid output pressure of 1025 psi 80 psi air will produce an output pressure of 820 psi air 60 psi air 615 psi output and 40 psi air 410 psi output By regulating the incoming air supply at the pressure regulator the liquid output pressure can be adjust ed through the pump s pressure range 1 2 NPT Exhaust Air Outlet Port lt 1 2 NPT Inlet Port
3. ZX 5 16 18 UNC X 1 2 Deep 12 70 mm Mounting Holes Figure 1 1 Basic pump dimensions and weights 1 0 INSTALLATION 1 1 The S 216 Series pumps require only bolt attachment to a base plate and plumbing connection of three lines a From driving air source to pump air inlet port b From fluid source to pump fluid inlet port c From pump fluid outlet port to working system To obtain effective fluid sealing at the inlet and outlet check ports of the pump the NPT male threads on the two fluid lines connecting to and from the pump should each be sealed with two wraps of Teflon tape Note Tape to within one or two threads of the end of the fitting NOT at the end DO NOT use pipe dope DO NOT tape the 216 J Air Driven Muffler Hydraulic Pump oS Ld s OC Q W I Manifold EN Liquid Pressure Gauge Liquid Pressure Line to L Hydraulic T aC Circuit d Bleed Valve Bleed Line to Reservoir Valve Lo P Y S Restrictor M Inch A2 Inch Nominal Ratio mm mm E D Dia fe mm B C1 mm Inlet C2 Outlet ESE 2 29 32 bs 82 2 ES 73 82 3 Si 86 2 7 16 61 90 2 oan m 85 2 DP 69 85 3 m mea 51 3 8NPT 3 8 NPT 4 2 3 8 6033 2 3 8 60 33 1 1 2 38 10 2 1 2 63 47 1 4NPT 1 4 HPCT 2 5 16 58 74 2 23 64 59 75 WEIGHTS NOMINAL Approximate 100 1 101 1 125 1 150 1 200 1 300 1 driving air supply line thre
4. Seal Materials Neoprene Viton and EPR Pump Assy 10 1 Ratio 79293 11 Pump Assy 20 1 Ratio 77894 11 Pump Assy 30 1 Ratio 77894 21 Pump Assy 35 1 Ratio 77895 81 Pump Assy 60 1 Ratio 77895 11 Pump Assy 100 1 Ratio 77895 21 Pump Assy 125 1 Ratio 77895 61 NPT Pump Assy 125 1 Ratio 77895 61001 Pump Assy 150 1 Ratio 77895 31001 Pump Assy 200 1 Ratio 77895 41001 Pump Assy 300 1 Ratio 77895 51001 Cover air valve 1 1 1 O ring screw cap 1 4 20 X 1 2 long Air valve and housing assembly shuttle Assembly shuttle O ring Ring Flange opring Guide sleeve Snap ring otop sleeve sch AD N N S BR Ss i AD AO N ch i KR SS 1 1 4 1 1 1 2 2 2 1 1 1 1 1 sch AD N N S KR SS ch i i AD AO N i i KR SS sch a PN NO PO HS HS S BR Se sch sch i M MO PO HS HS BR st tO c AO AO PO HSH SS S BR h ost ch sch A NS PO HS SS S KR a Body and housing assembly Detent bolt Detent O ring Detent spring Detent pin Stop Cylinder Air piston O ring Liquid piston Seal nitrile Packing retainer Teflon Body and housing assembly Liquid piston O ring nitrile Packing retainer Teflon Body and housing assembly Liquid piston O ring nitrile Packing retainer Teflon Body and housing assembly 4 4 4 4 4 4 4
5. Sprague Operation and Maintenance Manual MODEL S 216 J Series AIR DRIVEN HYDRAULIC PUMP Revised October 2014 CURTISS WRIGH T TABLE OF CONTENTS Section T0 TS LESE LO REED RETE Section 2 0 Operation Section 3 0 Maintenance Section 4 0 Disassembly RRRONROOROOE m Sechon 5 0 INSPEC iii eona aa ere Section 6 0 Repair and Replacement eene nnns Section 7 0 Reassembly ccc ccc cecccesesceseeeeccseeseecceeseseeeueeeseeueesecseueesesueeeseseeeseesueesesnueeeeesaesy dg C ee Section 9 0 Illustrated Parts Breakdown IPB and Supplemental Data INTRODUCTION This Handbook provides the necessary information to install operate service and overhaul the basic hydraulic pump model S 216 J While other model pumps vary in some details of design from the basic pumps the installation operation maintenance and many of the component parts remain the same or are similar Many of the instructions contained in this Handbook are applicable to all hydraulic pump models with J type air valves HOW THE SPRAGUE AIR DRIVEN PUMP WORKS J type J type Air Selector Valve Air Selector Valve in UP position E 1 Air Exhaust in DOWN position Air Supply Port Air Drive Piston Wil Y EU Air Drive Piston a I in UP position LES in DOWN position fr Liquid 1 driven Piston
6. 22 or 31 and be careful to avoid crossing threads when installing check valve bodies On completion remove from vise 7 3 Position fluid piston 16 or 21 in vise Use aluminum plates in vise jaws Screw air piston 14 fully onto Figure 7 5 Installing seals in fluid body fluid piston Screw nut 38 firmly with 3 4 wrench onto the threaded end of the fluid piston Install o ring 15 into groove in air piston 14 7 4 Screw shifting nut 40 all the way up the long length one inch of threads on the connecting rod 37 with bev eled end of nut toward center of rod 7 5 Insert lockwasher 39 under shift ing nut 40 and hold washer next to under side of shifting nut 40 See Figure 7 3 Screw connecting rod 37 end into the threaded end of the fluid piston 16 or 27 until the rod bot toms solidly Torque shifting nut 40 tightly against plain nut 38 to secure connecting rod See Figure 7 4 7 6 Place fluid body 21 and lower hous ing assembly 19 in vise 7 nstall new seals in sealing groove in the bore of the fluid body 21 see Figure 7 5 in the following sequence relative to pump ratio a 10 1 20 1 and 30 1 pumps packing retainer 18 bottom o ring 17 middle and packing retainer 18 top b 35 1 thru 300 1 pumps back up ring 18A on top o ring 17 in middle and packing retainer 18 on bottom of sealing groove For o ring replacement of JB models see page 15 7 8 Carefu
7. 4 4 4 4 4 4 4 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 2 1 Teflon is a registered trademark of the DuPont Company 13 Model Number 5 216 10 35 9550 17 1 MS28782 17 90098 35 89801 35 89803 60 1 89793 5 216 20 71890 11 S 216 10 60 71888 1 9550 14 1 MS28782 14 90098 60 89803 100 1 89793 5 216 20 77890 21 5 216 11 100 1888 2 9550 12 1 MS28782 12 90098 100 89803 125N 1 89803 125 1 89793 5 216 20 71890 71 71890 61 5 216 11 125 77888 5 1889 2 9550 11 1 90098 125 89803 150 1 89793 5 216 20 77890 31 5 216 11 150 77889 3 9550 10 1 90098 150 89803 200 1 89793 5 216 20 77890 41 5 216 11 200 77889 79550 8 1 MS28782 8 90098 200 89803 300 1 89793 5 216 20 1890 51 5 216 11 300 77889 1 91417 011 1 MS28782 6 90098 300 Liquid piston O ring nitrile Packing retainer Teflon Back up ring Body and housing assembly Piston body and housing assembly Lower housing Gasket Piston and body assembly Liquid piston Liquid body O ring nitrile Packing retainer Teflon Back up ring Piston body and housing assembly Lower housing Gasket Piston and body assembly Liquid piston Liquid body O ring nitrile Packing retainer Teflon Back up ring Piston body and housing assembly Piston body and housing assembly Lower housing Gasket Piston and body assembly Piston and body assembly Liquid piston Liquid Body Liquid body O ring nitrile
8. 7 16 wrench to remove self lock ing nut 44 from connecting rod 37 oee Figure 4 5 4 6 Use 7 16 socket on ratchet wrench to remove the twelve cap screws 45 and nuts 46 that attach the upper b Reservoir fluid level below reservoir suction outlet pump or at pump inlet check valve housing 19 See Figure 4 6 Lift and remove the upper housing assembly Remove stop sleeve 4 from connecting rod 4 Ifthe shuttle assembly in the upper housing needs removal and disas sembly proceed as follows 4 7 1 Use 11 16 wrench and remove the four sets of detent bolts 6 springs 7 and pins 9 from the air valve body 5A See Figure 4 7 4 7 2 From inside the upper housing push upward on shuttle stop 4F to remove the shuttle assembly See Figure 4 8 4 73 Using retainer ring pliers remove the snap ring 4G to release the flanges seal fittings Check reservoir fluid level refill as required 4 spring 4E and guide sleeve 4 from the shuttle 4A See Figure 4 9 4 8 Remove the cylinder 13 and its o ring 15 from the lower housing 19 See Figure 4 10 4 9 Remove rod air piston 14 and fluid piston 16 or 27 from the fluid body 21 See Figure 4 11 410 Disassemble shifting nut 40 lock washer 39 plain nut 38 and con necting rod from air piston 14 See Figure 4 12 Unscrew air piston from fluid piston 16 Remove the o ring 15 from the air piston Note Disassemb
9. Back up ring Piston body and housing assembly Lower housing Gasket Piston and body assembly Liquid piston Liquid body O ring nitrile Back up ring Piston body and housing assembly Lower housing Gasket Piston and body assembly Liquid piston Liquid body O ring nitrile Packing retainer Teflon Back up Piston body and housing assembly Lower housing Gasket Piston and body assembly Liquid piston Liquid body O ring nitrile Packing retainer Teflon Back up ring Seal Materials Neoprene Viton and EPR Pump Ratio Dash Number NPT HPCT Part Name 125 125 po eck ech eck ech c sch EEGEN 14 Pump Ratio Dash Number NPT HPCT 125 125 1 d Model Number Part Name 82650 21 Valve Assy outlet 3 8NPT thread 88906 Check valve body 79420 3 Poppet assembly 79420 1 Poppet 79550 8 1 Packing O ring nitrile 5 216 23 opring 91417 019 1 O ring nitrile 02651 21 Valve Assy inlet 3 8 NPT thread 88906 Check valve body 79420 3 Poppet assembly 79420 1 Poppet 79550 8 1 Packing O ring nitrile 5 216 23 opring 91417 019 1 O ring nitrile 02648 11 Valve Assy outlet 1 4 HPCT thread 89298 1 Outlet Check valve body 79550 5 1 Packing O ring nitrile 89297 Poppet S 216 63 Spring S 216 28 8 Outlet check valve gasket S 216 27 4 Outlet check valve seat only 82649 11 Valve Assy inlet 1 4 NPT thread 89298 Inlet Check valve body 79550 5 1 Packing O ring nitrile 89297 Poppet S
10. 15 Install and loosely tighten the cap screws 45 and nuts 46 around the housing flanges Tighten evenly 7 14 in clockwise opposite positions 12 6 3 9 etc Uneven tightening will cause binding between cylinder 13 and air piston 14 Note Connect ing rod should be centered in the air valve shuttle assembly center hole if bolts are tightened evenly 7 16 Install the four sets of detent pins 9 springs 8 o ring packings 7 and bolts 6 into the four threaded ports in valve body 5 Detent pins Should engage in lower groove of the Shuttle 4A 7 17 Apply air pressure to elbow fitting 47 in the lower housings to move the piston to the up position See Figure 7 11 Figure 7 8 Inserting J type shuttle assembly into air valve body Figure 7 9 Air valve and upper housing assembly ready for attachment to lower housing assembly 10 7 18 Install self locking nut 44 on up per threaded end of connecting rod 37 See Figure 7 12 Referring to Figure 7 13 and paragraph 7 5 if no lower threads of connecting rod show above shifting nut 40 then install self locking nut 44 with at least one upper thread of connecting rod exposed beyond the self locking nut Correspondingly if one or two lower threads of connecting rod are exposed beyond the shifting nut then install self locking nut with a like number of connecting rod upper threads exposed beyond the lock nut Figure 7 10 Bolting upp
11. 216 63 Spring 5 216 28 10 Inlet Check valve gasket 90523 Connecting rod 93776 1 Plain nut 1 2 20 M S35335 33 Washer Lock external tooth 1 4 78259 Shifting nut 90686 Self locking nut 1 4 28 M S90725 3 Screw cap 1 4 20 X 1 2 long M S51967 2 Plain nut 1 4 20 93594 Elbow 90 88501 Tube assembly 80063 2 Nameplate ch zech EN panni cevimes sch ee zech sesch sch sesch sesch sesch zech zech sesch sesch zech zech zech sesch esch zech ch zech esch zech i n2 RO A h Ga 216 JB ASSEMBLY Retaining Ring Retainer Body amp D m Q Housing Retaining ER ons RER lt i Back Up Ring o Piston S 216 JB 150 94195 150 94193 125 94158 150 94157 150 90098 150 94172 112 S 216 11 150 S 216 JB 200 94195 200 94193 125 94158 200 94157 200 90098 200 94172 110 S 216 11 200 S 216 JB 300 94195 300 94193 125 94158 300 94157 300 90098 300 94172 011 S 216 11 300 Disassembly 1 Remove retaining ring 2 Lift out retainer bushing and seals S 216 JB 101 94192 101 94193 125 94158 100 S 216 JB 125 94195 125 94193 125 94158 125 94157 125 90098 125 94172 113 S 216 11 125 Assembly is reverse of disassembly 15 CURTISS WRIGHT 10195 Brecksville Road e Brecksville OH 44141 USA e Telephone 440 838 7528 e Fax 440 838 7639 Dar
12. ID of the fluid body and the OD of the piston check at several points around and up and down the bore of the body and the circum ference of the piston ALLOWABLE MAX CLEARANCE INCH MM 0 010 0 254 0 008 0 203 0 007 0 178 0 005 0 127 0 005 0 127 0 004 0 102 0 004 0 102 0 004 0 102 0 004 0 102 0 003 0 076 PUMP RATIO AND DASH NO 35 60 0 002 0 051 0 001 0 025 Table 5 1 In service wear limits fluid piston to fluid body 5 8 Check for smooth movement of shut tle assembly within air valve body Check contacting surfaces of shuttle and bore of body for dirt scratches or galling Check rings 4C on shuttle for wear particularly at the tips Check o rings 4B under seal rings for general condition and inspect detent pins 9 for worn condition 5 9 Inspect inlet and outlet check valve seating surfaces in the fluid body 21 for nicks burrs or excessive wear Inspect valve bodies poppets springs and seats for nicks burrs excessive wear or rust 6 0 REPAIR AND REPLACEMENT 6 1 Polish metal parts to remove minute imperfections minor scratches or scoring Use wet or dry paper grit 600 6 2 Check fluid piston 16 or 27 and fluid body 21 If there is any evidence of galling replace both piston and body 8 Carefully polish piston to remove minor scratches or nicks Use grit 600 Polish fluid body bore with hone to remove minor imperfec tions Use a very fine polishing stone Recheck fo
13. ad connecting to the pump No special tools are required to install the pump 1 2 LOCATION For maximum perfor mance the pump s fluid inlet port should be level with or below the fluid reservoir or fluid source MOUNTING Two mounting holes are provided on the underside of the basic model pump s fluid body for attach ment to a base plate or platform See Figure 1 1 PLUMBING AII plumbing must be rated to 1 1 2 times maximum operating pressures a Connect driving air supply line to pump air inlet port b Connect fluid supply line from reservoir to pump inlet check valve 1 3 1 4 Air Shut Off Valve CQ Air Pressure Regulator ex Air Pressure Gauge a en Compressed Air Line Thru Reducer into Air Filter 3 8 NPT Port Air Driven Pump ai Liquid Supply Line from Reservoir Air Filter Air Lubricator Required for Burst Testing Strainer Typical filter regulator and lubricator assembly FRL with air gauge installed Figure 1 2 Pump installed in typical circuit with recommended accessories which are available from Sprague Products 4 ACTUAL WEIGHT LBS 0Z SHIPPING WEIGHT KILOGRAMS LBS 0Z KILOGRAMS c Connect system fluid line to pump outlet check valve d A muffler may be attached to the pump s air exhaust port See Figure 1 2 for 1 Line hook up to pump 2 Pump installation 3 Recommended accessories 2 0 OPERATION 2 1 START PUMP a Cl
14. d with neoprene viton and EPR seal material 10 through 101 SS SS NS SN B AS me R OUTLET Check Valve Assembly NPT 00 48 a INLET Check Valve Assembly NPT Torque check valve bodies 22 to 120 foot pounds 125 through Sei rien il RY TIME MAR LIE ee 9 I x E mmm mmm OUTLET Check Valve Assembly HPCT 31 34 33 32 35 36 s 34 33 32 31A INLET Check Valve Assembly NPT Torque check valve bodies 31 to Ratio 125 150 240 ft Ibs Ratio 200 300 340 ft Ibs Figure 7 2 Inlet and outlet check valves sequence of assembly Figure 7 1 Installing check valves E R M uU D G A E Figure 7 3 Connecting rod with lock washer and shifting nut ready to be screwed into fluid piston 7 0 REASSEMBLY Before reassembling pump wash metallic parts thoroughly in solvent and dry Lubri cate o rings and threads with Vaseline or hydraulic oil 7 1 Position fluid body 21 and lower housing 19 in vise Note nsert soft aluminum plates in vise jaws to cushion grip against fluid body Refer to paragraph 4 2 Figure 4 Tightening shifting nut to secure con necting rod into fluid piston 7 2 Reassemble and install inlet and outlet check valves into fluid body 21 See Figure 7 1 Note order of assembly and position of poppets 23 and 33 by referring to Figure 7 2 Note torque instructions in illustrations DO NOT over torque valve bodies
15. ed from the pump TROUBLE PROBABLE CAUSE a Reservoir fluid supply is low b Fluid supply line to pump inlet check 1a PUMP IS NOT DELIVERING FLUID pump running valve is clogged c Foreign matter is lodged in pump inlet and outlet check valves 22 and 31 d Driving air supply is disconnected air Shut off valve closed or air filter clogged e Air pressure regulator not adjusted f Air shuttle valve 4A is sticking 1b PUMP IS NOT DELIVERING FLUID pump not running g Connecting rod 37 is improperly adjusted or bent may occur after pump overhaul h Spring 4E in shuttle valve is broken a Leakage or blockage at inlet or outlet 2 PRESSURE DROP OR PUMP FAILS TO BUILD UP DISCHARGE FLOW pressure check valves 22 or 31 Damaged or worn o rings b Fluid found in lower housing 19 damaged seals in sealing groove of fluid body c Damaged o ring 15 in outer groove of air piston 14 or scratched or scored cylinder 13 Either or both allow air pressure to escape to exhaust port a Damaged seals in fluid body 21 or fluid 3 HYDRAULIC FLUID IN EXHAUST AIR 4 AIR LEAK IN COVER OF AIR VALVE amp HOUSING ASSY piston 16 or 28 scored a Cover 1 loose Cracked or damaged o ring a Air leak in suction line from reservoir to CORRECTION Add fluid as required Remove and clean line Check reservoir its inlet filter and outlet for accu
16. er and lower housings together Figure 11 Using air pressure to raise shuttle assembly Figure 7 12 Installing self locking nut on connecting rod 7 19 Check for smooth movement up 7 20 2 ch 2 KN and down of shuttle Using shop air approx 10 psi inject air to elbow in lower housing 19 to raise shuttle to up position Manually push down on the shuttle Repeat this up and down movement several times to determine smoothness of movement Movement should be smooth if not air piston 14 is binding against cyl inder wall 13 Binding is caused by uneven tightening of the 12 screws 45 and nuts 46 at the housing flange Retighten screws evenly per paragraph 7 15 With pump movement assured install new o ring 2 cover 1 and four screws 3 to close the air valve portion of the pump Reinstall tube assembly 48 to the elbows in the upper and lower hous ings For final check of movement inject air pressure to air inlet port Move ment of assembled shuttle air piston and fluid piston should be smooth and regular 0 TEST 8 0 8 1 8 2 8 3 Install pump into a typical circuit See Figure 1 2 Operate pump in accordance with Section 2 0 Opera tion Conduct tests operating pump at different driving air pressures Close fluid shut off valve in pump dis charge line to permit pump to build up its maximum pressure output At this point the pump will slow to a Stop indica
17. ket 20 DO NOT remove the lower housing from the fluid body Ww Ts zy el 2 me P Figure 4 12 Disassembling air piston components Figure 4 13 Removing retainers and O ring from fluid body E Er 3 5 y Figure 4 14 Removing check valves from fluid body 5 0 INSPECTION 5 1 Wash all metal parts in solvent Dry parts thoroughly with air or with lint free cloth Remove hardened sedi ment with a soft bristle brush Do not scrape parts with a metal tool 5 2 Under a light and preferably under magnification visually inspect parts for cracks pitting scoring corrosion or galling 5 3 Inspect all threaded parts for chipped crossed or stripped threads 9 4 Inspect and measure the free re laxed length of springs a Detent springs 8 7 8 inches 22 29 MM b Check valve springs 25 3 4 inches 19 05 mm c Check valve springs 34 11 16 inches 17 45 mm d Shuttle spring 4E 1 5 16 inches 33 5 mm 5 9 Roll springs over a flat surface to check for wobble 5 6 Check tube assembly 48 for kinks breaks or defective tube flares 5 Check outside diameter OD of fluid piston 16 or 27 and the inside diameter ID of the fluid body 21 to determine wear clearance between the two parts See Table 5 1 Remember that the operating efficiency of the pump depends on maintaining the close tolerance dimension between the piston and the body Note When checking the
18. lly insert assembled fluid piston 16 or 27 and air piston 14 assembly into bore of fluid body to avoid scratching surfaces See Figure 7 6 Note Before assembly lubricate bore and seals of fluid body and fluid piston 7 9 Press down and rotate piston 14 until it bottoms on the top side of the fluid body 21 7 10 Lubricate inside wall of cylinder 13 and o ring 15 in groove of air piston with Vaseline Press cylinder into position between air piston and lower housing 19 Position second o ring 15 around outside of cylinder and in contact with flange of lower housing See Figure 7 7 Place stop sleeve over connecting rod and screw nut 44 onto the first several threads of the con necting rod 7 12 Gripping connecting rod 37 and the underside of nut 44 pull rod upward so that the air piston 14 and fluid piston 16 or 27 are in the up position Remove nut 44 from rod 7 13 Reassemble shuttle assembly and install with Top up into air valve 7 11 Wu e Figure 6 Inserting air piston and fluid piston assembly into fluid body and upper body assembly See Figure 7 8 Press shuttle down evenly and slowly Move shuttle up and down several times to assure smooth movement Install air valve and upper housing assembly onto fluid body and lower housing assembly Be sure the two elbow fittings for the tube assembly 48 are aligned with each other for later assembly See Figure 7 9 7
19. ly is not necessary unless one of the components is damaged 4 11 4 12 NN mem p Figure 4 3 Removing tube assembly 4 13 4 14 e St Ee EG war Xv vn ME CETT ai Ao a APT Figure 4 8 Pressing shuttle out of upper housing Figure 4 4 Applying air pressure to raise air piston and rod E P AS Me 2 Figure 4 5 Removing self locking nut from connecting rod Figure 4 9 Removing shuttle assembly components nets MEE Figure 4 10 Removing cylinder from lower housing Figure 4 6 Removing housing screws and nuts D Figure 4 11 Removing air piston and fluid piston from fluid body and lower housing Using o ring removal tool carefully remove the two Teflon retainers 18 and o ring 17 from the seal groove in the fluid body 21 See Figure 4 13 Discard the old retain ers and o ring For o ring removal of JB models see page 15 Using adjustable wrench remove the inlet check valve assembly from the fluid body port See Figure 4 14 Note the sequence of parts removal and the position of poppet See Figure 7 2 Wipe surplus fluid from the inside port Using adjustable wrench remove outlet check valve assembly from the fluid body port Note the Sequence of parts removal and posi tion of poppet Wipe surplus fluid from port Check for leakage at gasket 20 junction between the lower housing 19 and the fluid body 21 Unless there is evidence of leakage at gas
20. mulation of foreign matter Clean as required Remove and clean check valves Replace O rings 24 and 32 on poppets 23 and 33 Reconnect line Open valve Clean air filter Adjust regulator Remove and clean air valve and housing assembly and its shuttle valve components Adjust air lubricator Readjust rod and nut 44 Refer to paragraph 7 19 and Figure 7 13 straighten or replace rod Replace spring Remove and clean check valves Look for foreign matter lodged in seating areas Replace damaged or worn o rings Replace o rings 17 or 29 packing retainers 18 and back up rings 18A or 30A Replace o ring Inspect cylinder for scores or scratches If marred replace cylinder Replace o ring 17 or 29 and retainers 18 or 30 Inspect fluid piston for score marks pol ish as required Replace pistons and fluid body If in service wear allowance exceeded Tighten cover bolts 3 or replace o rings Tighten line fittings use Teflon tape to 5 AIR IN SYSTEM Chart 3 2 Troubleshooting pump operation 4 3 Unscrew the four cap screws 3 to remove the air valve cover 1 and its O ring 2 See Figure 4 2 4 4 Remove tube assembly 48 by removing the two fittings from the two 90 elbows on the upper and lower housing See Figure 4 3 Do not remove elbows Apply air hose and air pressure to lower 90 elbow to raise air piston 14 and shuttle 4A to up per position See Figure 4 4 4 5 Use
21. nnecessary disas sembly of the pump probable causes of malfunction are listed in the fol lowing order a Causes that can be corrected without disassembly of pump b Causes that can be corrected with partial disassembly of pump c Causes that require complete disassembly of pump The number in parenthesis following the part name corresponds to the item number on the S 216 J Illustrated Parts Breakdown IPB pages 12 15 3 4 For disassembly inspection repair and reassembly of 216 J pump refer to Sections 4 0 5 0 6 0 and 7 0 3 9 For IPB and service and overhaul in structions of other air driven pumps refer to supplemental data sheets in this Handbook Section 9 0 4 0 DISASSEMBLY 4 1 The disassembly procedure describes the removal of the entire upper or air assembly of parts from the lower or liquid portion of the pump The number in parenthesis following the part name corresponds to the item number on the S 216 J Illustrated Parts Breakdown IPB pages 12 15 When the pump is disassembled matched parts i e fluid body and fluid piston should be kept together and handled care fully to avoid damage to lapped or honed surfaces To wash metal parts use any quality com mercial solvent that is available The pump disassembly and reassembly can be done with the following standard hand tools a O ring removal tool b Retainer ring pliers c Ratchet wrench with 7 16 Dia
22. ose air shut off valve between pump and pressure regulator b Turn on driving air supply c Adjust air pressure regulator at air control unit FRL to 25 psi 1 73 bar starting pressure d Open valve in hydraulic circuit to allow free fluid flow e Slowly open the air shut off valve to start the pump operating f After pump has been primed close valve in hydraulic circuit g Check pump and air circuit for leaks in lines fittings etc h With pump and circuit operating properly readjust air pressure regulator until desired pump discharge pressure is reached The hydraulic circuit is ready to operate A WARNING Do not exceed 100 p s i g inlet air pressure Teflon is a trademark of the DuPont Company 2 2 STOP PUMP a Close air shut off valve Normally after driving air supply has been adjusted the pump can be on off controlled or reduced in pumping rate at the air shut off valve b After stopping pump bleed off hydraulic pressure before discon necting the hydraulic circuit 3 0 MAINTENANCE 3 1 SPECIAL TOOLS None is required to service pump Use standard tools 3 2 INSPECTION and MAINTENANCE Refer to Chart 3 1 as a guide to general maintenance Recommended inspection periods may require ad justment to comply with local condi tions or as determined by experience 3 3 TROUBLE SHOOTING Chart 3 2 aids in checking the pump and out lines corrective action To eliminate the u
23. r wear clearances as described in paragraph 5 7 and Table 5 1 If imperfections cannot be easily removed replace piston and body as a matched set Note he replacement piston body set also includes the lower housing and gasket 6 3 Check air valve and upper housing assembly Polish out minor imper fections as described in paragraph 6 2 Keep polishing and honing to an absolute minimum to prevent an increase in wear clearance and result ing loss of air If imperfections cannot be easily removed replace the entire air valve and upper housing assembly Clean all repaired parts in solvent as described in paragraph 5 1 Replace all metal parts that fail to pass inspection or are damaged or worn beyond simple repair 6 6 Replace all o rings packing retainers gaskets springs and detent pins at each pump overhaul Overhaul kits from Sprague Products conveniently contain all necessary parts to prop erly overhaul or service the pump See Table 6 1 e P o gt C1 PUMP REFERENCE OVERHAUL MODEL NO NO KIT S 216 J 10 90680 11 S 216 J 20 90680 21 S 216 J 30 90680 31 S 216 J 35 90680 41 S 216 J 60 90680 51 90680 61 90680 01 90680 01001 90680 71001 90680 81 90680 91 5 216 J 100 S 216 J 125N 77895 61001 5 216 J 125 77895 61001 5 216 J 150 77895 31001 5 216 J 200 77895 41001 5 216 J 300 77895 51001 Table 6 1 Overhaul Kits These listed kits contain nitrile seals Kits can also be ordere
24. ting a pressure balance has been reached between fluid pressure and driving air pressure The pump will automatically restart when pressure imbalance occurs Compute ratio of fluid maximum output pressure to driving air input pressure Compare pump dash number to pump s rated fluid output pressure Refer to Table 8 1 Connecting Rod self Locking Nut At minimum one thread of connecting rod should be exposed Paragraph 7 18 _ Refer to Paragraphs 7 4 and 7 5 For proper stroke adjustment the number of exposed threads at B should equal the number of exposed threads at A Top nut can be adjusted at later time if needed Figure 7 13 J air valve stroke adjustment PUMP MODEL DASH NO EN INPUT OPERATING AIR PRESSURE BAR 2 12 6 80 2 12 6 80 2 17 6 80 A2 6 80 2 12 6 80 2 12 6 80 2 12 6 80 2 12 6 80 2 12 6 80 2 12 6 80 2 12 6 80 Table 8 1 Rated air input pressures to fluid output pressures 11 OUTPUT FLUID PRESSURE PSI BAR 1 025 71 1 910 132 3 200 22 4 160 328 2 945 176 6 330 437 9 100 628 4 000 2 6 10 000 689 12 500 862 6 530 90 16 200 1 117 10 160 701 24 900 1 717 14 650 1010 36 500 2 917 9 0 IPB AND SUPPLMENTAL DATA Illustrated Parts Breakdown IPB en closed to provide additional data on the S 216 J basic pump Other pump data may be included as required R Exhaust air outlet port N A y CD y 48 A Driving air W I i inlet E
25. ve Assembly Ratio 125 300 HPCT Pump Reference Overhaul Kit Pump Reference Overhaul Kit Model Number Number Number Model Number Number Number S 216 JB 35 94186 035 01 94186 035 01 K S 216 J 10 79293 11 90680 11 S 216 JB 60 94186 060 01 94186 060 01 K S 216 J 20 77894 11 90680 21 S 216 JB 100 94186 100 01 94186 100 01 K S 216 J 30 71894 21 90680 31 S 216 JB 101 NPT 94186 101 01 94186 101 01 K S 216 JB 125 NPT 94186 125 01 94186 125 01 K ae Merl dad S 216 J 100 77895 21 90680 61 S 216 JB 125 HPCT 94186 125 11 94186 125 11 K j S 216 JB 150 94186 150 11 94186 150 11 K S 216 J 125 NPT 77895 61 90680 01 5 216 JB 200 94186 200 10 94186 200 11 K S 216 J 125 HPCT 77895 61001 90680 01001 S 216 JB 300 94186 300 11 94186 300 11 K S 216 J 150 77895 31001 90680 71001 S 216 J 200 77895 41001 90680 81 S 216 J 300 77895 51001 90680 91 Viton is a registered trademark of DuPont Dow Elastomers 12 Pump Ratio Dash Number 125 125 Model Number Part Name NPT HPCT 5 216 J 10 5 216 J 20 5 216 J 30 5 216 J 35 5 216 J 60 5 216 J 100 5 216 J 125N 5 216 J 125 5 216 J 150 5 216 J 200 5 216 J 300 5 216 17 1 91417 138 MS90725 3 90535 1 90654 1 90522 91417 029 90524 92247 90600 92249 90685 92248 90651 1 78238 79552 5 9 216 24 82871 5 216 56 5 216 13 5 216 4 9550 60 5 216 61 105 8 94204 225 MS28783 3 89801 10 5 216 10 20 9550 25 1 MS28782 25 89801 20 5 216 10 30 9550 20 1 MS28782 20 89801 30
26. win Road Willowbrook Industrial Estate Corby NN17 5XZ U K Telephone 44 1536 425980 e Fax 44 1536 425981 http sprague cwfc com Sprague Products 1014 S216JOM 5M 1014
27. x 3 extension hex socket d 16 wrench e 11 16 wrench f 3 4 wrench g 15 adjustable wrench Power equipment and special tools can be used at user s discretion 4 2 Use bench vise to hold pump while disassembling and reassembling Cushion vise jaws with soft aluminum plates to prevent scratching the fluid body See Figure 4 1 Position pump in vise with tube 48 to the front of the pump Figure 4 2 Removing air valve cover REQUIRED MAINTENANCE Check for and drain liquid accumulated in filter from condensation Check filter element and other components for clogging Clean as required Check oil supply to fill line Use SAE 10 or equivalent good quality oil Check oil drip rate 2 drops per minute normal at adjustment knob 3 Driving Air a Periodic Check for air leaks Repair as required Pressure Regulator 4 Driving Air a 10 hours Shutoff inlet air pressure and check for Pressure Gauge Zero reading b 50 hours Calibrate against master gauge a 10 hours Check pump and fittings for air or fluid leakage Repair as required Chart 3 1 Schedule of inspection and maintenance PERIOD a 10 hours bcd 1 Driving Air Filter b 50 hours 2 Driving Air Lubricator not required on JN type pumps a 10 hours AA WARNING Before any maintenance or repair is attempted the compressed air line to the pump should be disconnected and all air pressure and fluid pressure allowed to ble
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