Home

Hydropumps - pnrdynamic co.,ltd.

1. PTT000 144 D10687 000 135 X X B O RING P11003 137 X 9 O RINC P11000 2531 1 TO PILOT VALVE ASSEMBLY 11 6027 000 1 NP 5 epe PRING 11 5005M002 12 PISTON APA D10817 13 RETAINING RING P10263 195 14 7 11000 028 X 2 15 mE D10263 m T6 BEA 11 5047NO0 1 T2 R2625000 X X x 11000 225 11 6025A000 nerro 1 11 6002A000 MEN 10230 10250 28 WASHER FLAT PT0214 038 16 29 WASHER LOCK 10212 038 8 L 90 NUT 12 37CNFH12 8 _______ HEAD ASSEMBLY 06 DRYLUBE 10516 S 2 7 ZZ 724 DS APR RSS INS OAN A Wy AS UN NNUS 1 SP 2 gt 2 SENS NS a HEAD ASSEMBLY 06 DRY LUBE 10516 PACKING REPAIR ITEM DESCRIPTION PART NUMBER QTY SET R10105 1 1160922000 1 j 7 72 BUMPER 15052800 1 DC Nu S me 7 74 BUMPER 11 5057PO00 piene 24000444 mm MES RENE 7 P11000135 Xx ann eee 10 SPRING m o ae oe an 12 ERR MM 12 RETAINING RING P10203493 1 x 43 stEEvE a
2. 13 3 _ 3 a P 16 18 20 Scal Teohnolodisn Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Tawnship Line Road Utrechthaven 11e 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 500 5180 Singapore 347740 aor Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 9 OF 10 TABLE 1 BMX MOTOR ASSEMBLY PARTS LIST ITEM NUMBER NUMBER REQUIRED 19 20 21 22 23 24 25 26 27 28 29 1 00 00 ENO 5 1 PART NUMBER DESCRIPTION 8 9 2 PI00 2 2 02 ORig 2 PI019 ____ 020 Pilot Valve Assembly Head Spring 8 ORig 2029 ORig 2 INCLUDED IN FLUID END OVERHAUL KIT World Headquarters Expansion Seal Technologies 2701 Township Line Road Hatfield PA 19440 1770 USA Tel 1 215 721 1100 Fax 1 215 721 1101 Toll Free 1 800 355 7044 Expansion Seal Technologies Europe Utrechthaven 11e 3433 PN Nieuwegein The Netherlands Tel 31 30 600 6180 Fax 31 30 600 6188
3. 2404 HL Alphen aan den 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY AN 180 8001 REGISTERED COMPANY Copyright 2003 Expansion Seal Technologies
4. 4 Connect high pressure hose to high pressure outlet pump See Figure 2 5 Open high pressure bleed valve by rotating handle counter clockwise Bleed air from pump by opening air valve slightly and running until pump cycles for approximately five seconds 6 Turn air off and close high pressure bleed valve completely WARNING NEVER LOOSEN ANY CONNECTION UNTIL YOU ARE ABSOLUTELY CERTAIN ALL PRESSURE HAS BEEN RELIEVED FROM THE SYSTEM METHOD OF HYDROTEST NOTE When testing small vessels desired pressure will be attained quickly 1 Make appropriate connections to item being tested 2 Turn air pressure regulator knob fully counter clockwise 3 Open air valve In back of Pump turn air pressure regulator knob clockwise slightly until pump begins to cycle and then stalls 4 Gradually increase air pressure by rotating air pressure regulator clockwise until pump stalls at desired test pressure 5 Torelease pressure open the high pressure bleed valve by rotating counter clockwise QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 721 1101 e mail info expansionseal com In Europe tel 31 30 600 6180 fax 31 30 600 6188 e mail info expansionseal nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia singnet com sg On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group
5. 564954 103 71 _ 10000 10000 689 5 34 2 58 1004 150 254 9 100 69 Total required SCFM to produce rated flow at maximum pump pressure This is relevant only when the system is used for continuous injection at the maximum rated pressure Normal testing requires much less SCFM to begin with and falls to O at stall test pressure OTHER PRESSURES AND VOLUMES AVAILABLE UPON REQUEST CONTACT FACTORY FOR DETAILS SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE WEIGHT DIMENSIONS APPROX HEIGHT SHIPPING NOT INCLUDING HANDLE WEIGHT in mm Ibs Kg 14 355 6 16 406 36 9144 150 68 0 FRONT PANEL REAR PANEL PRESSURE AIR IN WATER IN OUT Q 1 2 NPT PRESSURE REGULATOR PRESSURE RELIEF VALVE WATER OFF AIR OFF NOTE REAR PANEL CONNECTIONS MAY BE LOCATED ON SIDES OF PUMPS World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 81 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2706 10 04 REV
6. Adjust to about one drop of oil every 20 strokes of the pump ii water being pumped may be leaking past the packing in the hydraulic cylinder into the Air Motor See paragraph 3 for correction procedure Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd E 2701 Township Line Road Utrechthaven 11e 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 30 500 5180 Singapore 347740 ao Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IM TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 8 OF 10 FIGURE 3 BMX Il AIR MOTOR ASSEMBLY 2 1 ay 15 JO AIR INLET AIR EXHAUST ae 20 Dop J 9 8 6 al 14 d Po 6 12
7. Expansion Seal Technologies Asia Pte Ltd 35 Tannery 11 10 Tannery Block Ruby Industrial Complex Singapore 347740 Tel 65 6745 8560 Fax 65 6742 8700 150 9001 REGISTERED COMPANY SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 10 OF 10 FIGURE 4 BMX II HYDRAULIC CYLINDER DRAWING 34 33 35 ITEM QTY 3600 6000 10000 DESCRIPTION _ PI3023 PI2025 PI3025 15025 PI2026 PI3026 15026 PI2050 PI3050 15050 Overhaul Kit INCLUDED IN OVERHAUL KIT World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd E 2701 Township Line Road Utrechthaven 11e 35 Tannery 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 600 6180 Singapore 347740 GROUP Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2706 10 04 REV 1 05 05 PAGE 1 OF 3 OPERATING INSTRUCTIONS BLUE MAX 3 HYDROSTATIC TEST PUMP EFFICIENT EASY OPERATION e Air operated pump e Wide range of pressures volumes e Easy to operate controls e Output pressure regulation control e High pressure syst
8. 000501 Adl 1 NIGYS d 1001 15702 FIND _______ on SE ME LI _ uonduseed woa sz 5210009 uvous eoe 90009150 MIS ON ea 500 amp os 121 4 lt 5506 139 0 02 0009 8 SSNH 199 09s 89H 70059 Zt ij 1 0009109 ot 00910 s RHedsNNn Ft 2926207805 2420 2 2 6 PZE ores 07 86 6 121 0009 Coron anc st 0018 6 69000 808 Bone oo 4 0009 wr 83 09 00282 95040009 EA t z 210009 OE ML VEEN AMO TIE PUMP ASSEMBLY 10 60004030 TAKE IUD eu AIP ASSEMBLY 11 6094 AGt RETAINING RING 12 R2005000 HYDRAULIC ASSEMBLY 11 6010030 1 501000 1 6010 080 11 60108100 MOUNTING DIMENSIONS INT MANUF GP amp AU TI d MM 1 1100 4 INCLUDED 11 601IWXXX PISTON amp CYLINUER ASSEMBLY REPRESENTS PUMP ASSEMBLY RATIO NUMBER XAMPLE 11 6089N030 HYDRAULIC 3 INC
9. 1 05 05 PAGE 3 OF 3 OPERATING INSTRUCTIONS CAUTION READ INSTRUCTIONS BEFORE OPERATING THIS PUMP TO SET UP PUMP SEE FRONT AND REAR PANEL LAYOUTS ON PAGE 2 1 Close the Air and Water Valves by turning to the OFF position Close the Pressure Relief Valve by turning clockwise Front panel 2 Set Regulator to 0 by pulling up and fully turning counter clockwise Front panel 3 Connect input air supply 120 psi maximum and input water supply to inlet connections on pump Rear panel 4 Connect the high pressure hose to the pressure out connection on pump leak tight Rear panel 5 Make appropriate leak tight connections to item being tested 6 Turn Water valve to ON position By turning counter clockwise open the Pressure Relief Valve to bleed air from pump for approximately ten seconds Front panel 7 Close Pressure Relief Valve completely by turning clockwise Front panel WARNING NEVER LOOSEN ANY CONNECTION UNTIL YOU ARE ABSOLUTELY CERTAIN ALL PRESSURE HAS BEEN RELIEVED FROM THE SYSTEM METHOD OF HYDROTEST NOTE When testing small vessels desired pressure will be attained quickly 1 Confirm Regulator is set at 0 by pulling up and fully turning counter clockwise 2 Turn Air Valve to ON position Turning the Regulator clockwise will start the pump The pressure can be regulated by adjusting the Regulator clockwise to increase and counter clockwise to decrease pressure Front panel 3 When
10. Road Hoorn 312a 2404 HL Alphen aan den Rijn 35 Tannery 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IM TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EST Hydrostatic Test Pumps P Series Test Pump Jit Blue Max II Test Pump TUV MANAGEMENT SERVICE P Series Hydrostatic Test Pump 150 9001 Blue Max II Portable Hydrostatic Test Pump Accurate Convenient Efficient P Series Hydrostatic Test Pump Max ll Portable Hydrostatic Test Pump A self contained pump used for testing tubes pipes or various pressure vessels A portable test pump used for testing tubes pipes or All stainless steel high pressure side various pressure vessels Easy to read 4 diameter pressure gauge Efficient easy operation BMX2 has air operated pump wide ranges of pressures and volumes easy to operate Self contained in tool box Provides storage for hose controls and output pressure regulation controls fittings amp plugs Portable Lightweight design one man operation low Mating quick connect couplings Available for air inlet center of gravity for stability semi pneumatic tires water inlet and high pressure outlet Low maintenanc
11. are properly in place and that no O Rings have been damaged in reassembly IMPORTANT When reassembling the Air Motor ensure that the Air Cylinder Part 1006 is in proper position against the flanges on the Pump Head and the Air Cylinder End before tightening the bolts that clamp the Air Motor together Use a soft hammer to position the flanges tightly against the Air Cylinder Ends BEFORE tightening the bolts Failure to do so may result in over tightening the bolts initially and when the bolts on the opposite side are drawn up this may result in the bolt lugs being broken or twisted off when the assembly is drawn down into position Bolts should be secured lightly at first then drawn up in sequence until uniform torque has been applied to all of the bolts around the perimeter of the pump World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Utrechthaven 11 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 500 5180 Singapore 347740 aor Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 7 OF 10 TROUBLESHOOTING GUIDE 8 PUM
12. is in proper alignment before screwing the Air Motor into position 4 The Hydraulic Piston has a Rubber Bumper 34 in the head If replacement is required remove the Retainer Item 33 with a spanner wrench and install new Rubber Bumper and Washer Item 32 Apply thread sealant to the Retainer threads when replacing and tighten securely but not to exceed 4 ft lbs of torque 5 REPAIRING OR REPLACING THE HYDRAULIC CHECK VALVES These valves should not give any trouble unless foreign matter such as dirt or grit is present in the fluid supply If a leak develops remove the check valves from the Hydraulic Cylinder Remove the O Ring and replace with a new one Inspect the ball seat in the Valve while the O Ring is removed If it shows any indication of wear or damage the entire Valve Assembly should be replaced Refer to Parts List for part numbers and cross section of the Valves 6 When operations described in Paragraphs 1 to 5 inclusive have been completed the entire unit will have been dismantled and all parts inspected for wear and damage It is especially important that all parts that operate in O Rings or Packing be free from pits scoring or any other defects that may cause excessively rapid wear of O Rings and Packing As leaks will develop almost immediately under these conditions and satisfactory performance will not result 7 REASSEMBLING THE PUMP Reverse the procedure used for dismantling ensuring that all Retaining Rings
13. provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Utrechthaven 11e 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 500 5180 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IM TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES FIGURE 2 FRONT PANEL DISCHARGE PRESSURE d au AIR PRESSURE AIR PRESSURE REGULATOR BLEED VALVE HIGH PRESSURE WATER IN OUT DC2705 REV 4 12 03 PAGE 4 OF 10 FIGURE 1 REAR PANEL AIR IN AIR VALVE AIR LUBRICATOR _ Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST p
14. the Retaining Ring Item 14 from the Head Assembly Remove the Bearing Assembly Item 7 by lifting or prying it out with a hammer handle or similar tool The Air Piston Actuating Valve part of Item 1 Valve Assembly may also be removed at this time The Bearing Assembly has a molded rubber seat and should be replaced if worn or damaged The O Ring 8 in the Bearing Assembly the O Ring Item 11 in the upper part of the Air Piston Actuating Valve and the O Ring on the Pilot Valve Assembly head should be replaced as a routine matter while the pump is disassembled as they are especially important for maximum performance D The Head has a Rubber Bumper Item 15 inserted in the upper portion of the body This acts as an air seal and also a cushion for the Air Piston Actuating Valve If worn or damaged it should be replaced NOTE When worn or damaged the Air Piston Actuating Valve and the Sleeve in which it operates are supplied as a Valve Assembly Part 1001 See Parts List The Sleeve may be removed from the Head Casting by means of an internal puller engaging the slots in the Sleeve Install a new set of O Rings Part 10021 4 required and included with Valve Assembly when ordering as a replacement part Be sure to coat the O Rings and the Sleeve O D with an O Ring lubricant to avoid possibility of damage to the O Rings when installing the new sleeve CAUTION DO NOT REMOVE THE SLEEVE FROM THE HEAD CASTING UNLESS REPLACEMEN
15. the test reaches the desired pressure turn the Air Valve to the OFF position and push Regulator down Front panel 4 Upon completion of the test release the system pressure by opening the Pressure Relief Valve counter clockwise Front panel 5 the Water Valve to the OFF position and leave the Air Valve in the OFF position Do not attempt to disconnect until all the water has been bleed out of pump 6 Pull up on the Regulator and return the Air Gauge to the 0 position by turning counter clockwise Front panel QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 721 1101 e mail info expansionseal com In Europe tel 31 172 418841 fax 31 172 418849 e mail info estgrp nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia singnet com sg On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line
16. time Replace if necessary HYDRAULIC CYLINDER PACKING REPLACEMENT EXCEPT BMX2 1000 Refer to Figure 4 and Table 2 It is not necessary to dismantle the Air Motor Proceed as follows Remove the Motor Pump Assembly and loosen the Set Screw in the Air Cylinder End Item 31 Unscrew the Air Motor from the Hydraulic Cylinder The Hydraulic Piston will be removed with the Air Motor permitting convenient replacement of the packing in the Hydraulic Cylinder Replace World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Tawnship Line Road Litrechthaven 11e 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 600 6180 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IM TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 6 OF 10 the Backup Rings and the O Rings When installing the new packing be sure that the Backup Rings and the O Rings are properly in place If they are damaged or not installed correctly the O Rings will malfunction with resultant loss of pressure and packing failure When replacing the Air Motor install a new Gasket Item 30 and ensure that the Hydraulic Piston
17. 5 O RING eee 15 1 P1t000 113 O RING ____________________________ 15 1 100 172 E 16 1 1160098030 HYDRAULIC CYLINDER __________ 16 1 11 60098050 HYDRAULIC CYLINDER 16 1 11 6009B080 HYDRAULIC CYLINDER _ 16 1 11 60098100 HYDRAULIC CYLINDER _ a eee 17 1 11 50208000 SEAT OUTLET Page 1 of 1 SOUTHERN CALIFORNIA HYDRAULIC ENGINEERING CORPORATION Desgner and Manufacturers of Hydrauhe amp Pneumatic 1130 COLUMBIA STREET BREA CALIFORNIA 92821 WWW SCHYDRAULIC COM AIR MOTOR ASSEMBLY D6 DRY LUBE 10515 Sheet 1 of 2 r Ll EN L d GG T 596 gt 555 EN m mf pi 1 22 Lg 2 4 yi OMG Li J pa SS TN 47377 7 SOUTHERN ENGINEERING CORPORATION Designer and Manufacturers of Hydraulic 4 Poeumatie Equipment 1130 COLUMBIA STREET BREA CALIFORNIA 92821 WWW SCHYDRAULIC COM AIR MOTOR ASSEMBLY D6 DRY LUBE C10515 Sheet 2 of 2 rev o1auco2 p macu AIR MOTOR ASSEMBLY C10515 D6 DRY LUBRICATION ITEM DESCRIPTION PART QTY PACKING SET REPAIR KIT NUMBER R10105 R10104 2 BUMPER eae 11 5012NO000 P11000 214 Sis MAUI a
18. APA 01023 1 pu 14 BEARING ASSEMBLY 11 5047 000 4 15 RETAINING RING _ 12482625000 1 X 2110002614 1 x _ 17 Pio0023 1 X AIR CHECK ASSEMBLY 11 6032X403 AIR CHECK ASSEMBLY 11 6032X403 DESCRIPTION 12 21044408 1 _ 1150395000 4 WASHER 1150432N00 1 145177041 41 _ 11 5015400 1 _ 1100 4 1 11 5025N403 1 __1 11 5056 000 SOUTHERN CALIFORNIA HYDRAULIC ENGINEERING CORPORATION Designer and Manufacturers of Hydraulic amp Pneumatic Equipment 1130 COLUMBIA STREET BREA CALIFORNIA 92821 WWW SCHYDRAULIC COM PILOT VALVE ASSEMBLY 11 6027A000 Sheet 1 of 1 16 02 Ci 2 2 5 94 PILOT VALVE ASSEMBLY 11 6027A000 QTY PACKING SET REPAIR KIT 810105 810104 1 6023A000 X 74 SPRING 75 CHECK ASSY 76 SEAT 11 5024A403 1 77 RETAINING RING 12 RO93S000 7 NOTE AIR MOTOR PACKING SET R10105 ALSO INCLUDES AN O RING P11000 111 USED ON AIR CHECK ASSEMBLY 11 6032X403 Mex E m memean EXPANSION SEAL TECHNOLOGIES DC720 02 92 PAGE 1 OF 2 OPERATING INSTRUCTIONS FOR P SERIES HYDROSTATIC TEST PUMP INTRODUCTION The P Series Hydrostatic Test Pump is designed to supply high pressure water
19. E e Mounted regulator lubricator e Glycerin filled test gauge e Water inlet filter ENCLOSED CABINET e Safer operation e Quiet design e Protection against component abuse and damage Convenient control location World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Utrechthaven 11e 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 600 6180 Singapore 347740 aor Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 2 OF 10 FEATURES Air powered pump in selection of pressures and volumes Air input regulator and lubricator Air pressure gauge Test pressure gauge glycerin filled Water filter High pressure system bleed valve High pressure test hose Heavy duty enclosure with handle Semi pneumatic tires Operation instructions printed on pump PERFORMANCE DATA MAXIMUM PRESSURE VOLUME PRESSURE MODELNO psi 100CPM RATIO REQUIRED REQUIRED BMX2 1000 1000 69 86GPM 56 CFM 100 PSI BMX2 3600 3600 2 6 GPM 56 CFM 100 PSI BMX2 10000 10000 1 GPM 56 CFM 100 PSI Total required CFM to produce rated flow at maxi
20. EXPANSION SEAL TECHNOLOGIES DC2707 10 04 SERVICE MANUAL FOR BLUE MAX 3 HYDROSTATIC TEST PUMP EST Group s Blue Max 3 pump is equipped with a SC Southern California Hydraulic Engineering Corporation s pump This pump may be accessed by removing the rear panel on the Blue Max 3 unit See the following pages for service guides and technical information regarding the pump QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 513 4333 e mail info expansionseal com In Europe tel 31 172 418841 fax 31 172 418849 e mail info estgrp nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia singnet com sg On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters l Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den 35 Tannery 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Comp
21. G AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC720 02 92 PAGE 2 OF 2 7 After testing is complete turn the Water Inlet Control Valve to the closed position and bleed all system pressure by turning the H P Relief Valve to the H P RELIEF position Water will drain from the back of the pump 8 regulator fully counterclockwise to adjust pressure setting of pump to zero 9 Disconnect the unit and connect the next unit to be tested to the high pressure hose 10 Repeat steps 1 through 9 until all assemblies have been tested NOTE For rapid testing using the same test pressure on each part leave the regulator adjusted to the desired test pressure When the Pump Control Valve is then turned to the PUMP position the pump will then pressure the system to the last setting QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 721 1101 e mail info expansionseal com In Europe tel 31 172 418841 fax 31 172 418849 e mail info estqrp nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia gsingnet com sg On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products a
22. LUDED IN HYDRAULIC REPAIR KIT FOR 10 6000W030 PLIMP 2 INCLUDED IN 11 50235000 OUTLET CHECK VALVE ASSEMBLY INCLUDED IN 11 30245000 INLET CHECK VALVE ASSEMBLY BILL OF MATERIALS FILE 10 550 010 XLS 11 6010 REVISION 07 12 01 HEEB ITEM NO PART NO DRAWING NUMBER amp DESCRIPTION 11 6010W030 THRU W100 HYDRAULIC ASSEMBLY DESCRIPTION C 1 2 10202 068 RETAININGRING _ ____ ______ N EXE E ee MARRON eje 3 2 P100 112 O RNG __________________ 4 2 1204405562 2222 ae __ 4 1150195000 SEATINLET E 6 2 11 50345002 BALLGUDE 5 0 0 000000000 7 2 11 50178000 SPRNGGUDE ee eje 8 1 11 5028 000 GASKET E 9 2 PH227212 ______ T cj 9 2 P11227 115 BACKUP _ EE m 9 2 11227 13 BACK UP 9 21 11227 112 BACKUP n 11 5051P000 PISTON BUMPER BE 1 11 12 1 12 2573758 452 HEAD CAP SCREW gt 13 1 1250010407 HELICAL SPRING LOCK WASHER 2 a ME 11 60088030 HYDRAULIC PISTON 00000 14 1 11 60085050 HYDRAULIC PISTON 14 1 11 60085080 HYDRAULIC PISTON LL i 14 1 11 60085100 HYDRAULIC PISTON 0 LL LLL 15 1 P11000212 E H 15 1 P11000 11
23. P NOT RUNNING PROPERLY If for any reason the pump does not run properly look for one of the following causes A If the pump appears to be short stroking and running too fast without pumping properly it usually indicates that the Air Check Assembly is not working properly See Paragraph 2 for correct procedure Loss of pressure may be caused by one of two reasons the Hydraulic Check Valves have developed a leaky condition or the fluid is bleeding past the Packing in the Hydraulic Cylinder See Paragraphs 3 4 and 5 for repair instructions Also check air pressure at pump inlet if hydraulic pressures fluctuate Should the pump commence to run erratically and in a jerky manner after a period of time it usually is an indication that a seizing action is taking place in the Hydraulic Piston and Cylinder Assembly See Paragraphs 1 and 3 for disassembly instructions This is usually caused by foreign matter such as alkali dirt or grit being present in the fluid supply If the Hydraulic Piston and Cylinder have not been damaged a thorough cleaning will normally place the pump in operation again For maximum flow volume ensure that a sufficient flow of air is supplied to the pump Hooking the pump up to a long run of relatively small pipe supplying air may cause slow operation If an excessive amount of oil or water is coming through the pump air exhaust check the following i Lubricating unit in the air supply is delivering too much oil
24. S 1 TO DISASSEMBLE THE AIR MOTOR Refer to Air Motor Assembly C10515 for Part Numbers and cross section of the Pump a Remove the eight 3 8 bolts Item 27 that clamp the Air Cylinder Item 23 between the Head Item 1 and the Air Cylinder End Item 24 Remove the Air Head by tapping on a fitting screwed into either the AIR IN or AIR OUT ports with a soft hammer NOTE Inspect all parts for wear or damage and replace as necessary It is especially important that all parts that operate in the O Rings or Packing be free from pits scoring or any other defects that may cause excessively rapid wear of O Ring and Packing since leaks will develop almost immediately under these conditions and satisfactory performance will not result When removing Retaining Rings care must be taken not to damage the groove in which it seats Damaged to the groove can decrease the holding effectiveness and may allow the Retaining Ring to become disengaged during operation Careless removal of the Retaining Rings can damage the groove creating BURRS These BURRS can migrate throughout the Air Motor Assembly causing major damage to all internal components b Remove the Retaining Ring Item 22 from the bottom of the Air Piston Item 20 and remove the Hydraulic Piston The Pilot Valve Assembly Item 10 may then be pushed out through the bottom of the Air Piston c Remove the Retaining Ring Item 17 from the Head Assembly Remov
25. T IS TO BE MADE THE VALVE ASSEMBLY IS PRECISION GROUND AND HONED TO VERY CLOSE TOLERANCES AND THE SLEEVE MAY BE DAMAGED WHEN REMOVED FROM THE HEAD CASTING 2 3 REPAIRING THE PILOT VALVE ASSEMBLY The Pilot Valve Assembly Item 20 has an Air Check Assembly Part 1025 located on the lower end Remove the Retaining Ring Part 1024 which locks the Valve Seat Part 1027 in place and remove the Valve Seat with a spanner wrench The Air Check Assembly and the Spring Part 4 P1026 will then drop out and may be inspected for wear and damage Replace the springs and worn parts as required If adjustment is required in the Air Check Assembly the assembly should be screwed together until the component parts are drawn up just snugly with no travel in the bolt assembly and then the nut should be backed off ONE COMPLETE TURN When the assembly adjustment has been done correctly the valve will open approximately 1 32 inch when the bolt assembly is depressed to open the valve Deform the threads on the end on the Bolt after completion of assembly to ensure the Self Locking Nut being in proper position NOTE Both the O D and 1 0 of the stem of the Air Piston Item 4 must be free from wear scoring or other damage as they must form a leak tight seal with the contacting O Ring Satisfactory performance will not be obtained where air leakage may occur between the Piston stem and the O Rings The O Ring Item 12 may also inspected at this
26. WATER SHOULD BE USED AS THE TEST MEDIUM PRIOR TO USE Ensure the reservoir is filled with either water oil Ensure a suitable high pressure hose is connected to the outlet connection labeled FLUID OUT on the backside of the pump Ensure the PRESSURE RELEASE valve is closed turn clockwise 1 Remove the handle from the storage rings and place on the LOW PRESSURE pump 2 With the PRESSURE RELEASE closed pump the LOW PRESSURE pump to remove any residual air in the system 3 Connect the outlet hose to the test object ensuring all connections are leak tight 4 After all appropriate connections have been made proceed with pumping the LOW PRESSURE pump until either the gauge reads 1 000 PSI or until there is high resistance in the handle If a higher test pressure is required move the handle from the LOW PRESSURE pump to the HIGH PRESSURE pump 56 Continue to pump until the gauge reads the desired test pressure or 10 000 PSI max 6 Upon completion of testing release the pressure by slowly opening the PRESSURE RELEASE valve turn counter clockwise until the gauge reads 0 PSI QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 721 1101 e mail info expansionseal com In Europe tel 31 30 600 6180 fax 31 30 600 6188 e mail info expansionseal nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia singnet com s
27. air or replacement as required REPAIRING OR REPLACING THE HYDRAULIC CHECK VALVES These Valves should not give any trouble unless foreign matter such as dirt or grit are present the fluid supply leak develops remove the Check Valves from the Hydraulic Cylinder Remove the O Ring and replace with a new one Inspect the ball seat in the Valve while the O Ring is removed If it shows any indication of wear or damage the entire Valve Assembly should be replaced Refer to Parts List for Part Numbers and cross sections of the Valves NOTE There are several different model pumps When ordering parts give the Part Number the Pump Model Number and Serial Number When Operations described in Paragraphs 1 to 5 inclusive have been completed the entire unit will have been dismantled and all parts inspected for wear and damage It is especially important that all parts that operate in the O Rings or Packing be free from pits scoring or any other defects that may cause excessively rapid wear of O Rings and Packing Since leaks will develop almost immediately under these conditions and satisfactory performance will not result REASSEMBLING THE PUMP Reverse the procedure used for dismantling making sure that all Retaining Rings are properly in place and that no O Rings have been damaged in reassembly Before installing the Retaining Rings inspect the groove for damage and the presence of foreign matter Damage to the g
28. air supply and unit to be tested are completed as described in Hydro Pump Set Up 3 Open the Water Inlet Valve introducing water to the system 4 Bleed vent all air and or gases from the system by opening fittings located at the highest points in the test set up where air can become trapped Allow water to continue to flow from these fittings until it is free from air re tighten all fittings WARNING COMPRESSED AIR IS VERY DANGEROUS UNDER HIGH PRESSURE TAKE ALL PRECAUTIONS TO THOROUGHLY BLEED ALL THE AIR FROM THE SYSTEM BEFORE PRESSURE IS INTRODUCED 5 Turn the Pump Control Valve to the PUMP position and slowly adjust the regulator clockwise until the desired test pressure is reached on the pressure gauge WARNING STAND AT SAFE DISTANCE FROM ANY VESSEL BEING TESTED 6 Turn Pump Control Valve to the TEST position when the desired test pressure has been reached Observe the pressure gauge for a drop in pressure which would indicate a leak World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den Rijn 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVIN
29. e Mounted regulator lubricator glycerin filled test gauge water inlet suction strainer maintain pressure or shut off to determine pressure drop Enclosed cabinet Safer operation quiet design protection against component abuse and damage convenient control location Operating range Air supply 25 125 psi 1 72 8 58 bar Temperature 30 170 F World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den 35 Tannery 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 180 8001 REGISTERED COMPANY DC 8064 Rev 2 2 03 Web Address www expansionseal com E Mail info expansionseal com Hydrostatic Test Pumps P Series Test Pump Model Number Maximum Outlet Pressure Open Flow Rate Flow Rate At 85 Rated Output PSI BAR GPM GPM PSR 2300 2300 158 1 43 65 PSR 7800 7800 535 39 22 Part Number Description Features Self lubricating air over water PSR 0001 Inlet control valve assembly intensifier 5 0002 Pump rebuild kit PSR 0003 High flow option Lockable aluminum tool box PSR 0004 1 2 diameter
30. e base When the bolts are replaced be sure that the air cylinder is in proper position against the flanges on the pump head and the air cylinder end before tightening the bolts that clamp the air motor together Use a soft hammer to position the flanges tightly against the air cylinder ends BEFORE tightening the bolts Failure to do this can result in over tightening the bolts initially and when bolts on the opposite side are drawn up this may result in the bolt lugs being broken or twisted off when the assembly is drawn down into position Bolts should be secured lightly at first and then drawn up in sequence until uniform torque has been applied to all of the bolts around the perimeter of the pump 19 19 ft lbs 2 CONNECTION TO AIR SUPPLY LINE HII A filter regulator lubricator assembly located as close to the pump as possible is required in the air supply line The air input to pump is a 1 2 npt port and is marked AIR IN The assembly should be connected to it in the order named with the lubricator adjacent to the pump The pump will deliver at its maximum rated capacity at 100 psi amp 56 scfm of free air with a 1 2 inside diameter supply line Use of a smaller size supply line will not allow the pump to operate at full capacity 3 LUBRICATION A good grade of petroleum based lubricating oil should be used such as Castrol Braco Micronic 783 or any good grade of oil with equivalent properties Automat
31. e the Bearing Assembly Item 16 by lifting or prying it out with a hammer handle or similar tool The APA Piston Item 12 may also be removed at this time The Bearing Assembly has a molded rubber seat and should be replaced if worn or damaged The O Ring Item 19 in the Bearing Assembly the O Ring Item 3 in the upper part of the APA Piston and the O Ring on the Pilot Valve Assembly head should be replaced as a routine matter while the Pump is disassembled as they are especially important for maximum performance This O Ring is Part P11000 216 12 6227N021 see Pilot Valve Assembly 11 6027A000 d The Head Assembly has a Rubber Bumper Item 4 inserted in the upper portion of the body This acts as an air seal and also a cushion for the Air Piston Actuating Valve If worn or damaged it should be replaced e When the Dry Seal Item 6 and the O Rings Item 8 are worn or damaged they need to be replaced Remove the Retaining Ring Item 13 by using a small screwdriver Slide the Dry Seal off of the APA Piston Item 12 The O Ring Item 7 inside the Dry Seal should also be replaced When installing the Dry Seal Item 6 and the O Rings Items 7 amp 8 a small coat of silicone grease or other suitable lubricant should be applied CAUTION DO NOT remove the Sleeve from the Head Casting unless replacement is to be made 2 REPAIRING THE PILOT VALVE ASSEMBLY Refer to Pilot Valve Assembly 11 6027A000 for t
32. em bleed valve e High pressure test hose PORTABLE e Lightweight design e One person operation e Low center of gravity for stability Semi pneumatic tires LOW MAINTENANCE e Mounted regulator lubricator e Test pressure gauge glycerin filled pressure gauge Water inlet filter ENCLOSED CABINET e Safer operation e Quiet design e Protection against component abuse and damage e Convenient control location e Heavy duty enclosure with handle World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den Rijn 35 Tannery Rd 11 10 Tannery Block Hatfield 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IM TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2706 10 04 REV 1 05 05 PAGE 2 OF 3 PERFORMANCE DATA AIR MAXIMUM CAPACITY MAXIMUM PRESSURE PRESSURE MODEL NUMBER PRESSURE AT 100 CPM SCFM SCMH RATIO REQUIRED psi bar GPM LPS REQUIRED 1000 1000 68 9 8 60 65 10 4 56954 100 6 9 _ 3600 3600 248 2 _2 60 20 364 564954 100 69 10000 10000 689 5 1 00 08 974
33. for hydrostatic testing utilizing 25 125 psi compressed air to drive the pump The pump is supplied with a quick connect terminating with male 3 8 NPT for connecting to the compressed air supply a valve assembly terminating with a female 3 8 NPT for connecting with the unit under test HYDRO PUMP SET UP NOTE To avoid contamination of internal pump components a water strainer and air filter should be installed in line with the water and air supply hoses 1 Connect the Water Inlet Valve to the water supply hose Make sure the valve is in the OFF position valve handle perpendicular to line Turn on the water supply 2 Connect the air supply to the air inlet quick connect coupling 3 Connect the unit to be pressure tested to the high pressure hose assembly using the male 3 8 NPT fitting Make sure all connections are rated for the pressure being applied 4 Make sure the Pump Control Valve is in the TEST position and the regulator is turned fully counterclockwise 5 Using the quick connect fittings supplied connect the Water Inlet Valve to the water inlet marked WATER the air inlet coupling to the air inlet marked AIR and the high pressure hose to the high pressure outlet marked H P OUT on the hydro pump panel PUMP OPERATING INSTRUCTIONS 1 Pump Control Valve and Relief Valve to the TEST position and turn the regulator fully counterclockwise 2 Verify that the connections for water supply
34. g On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd c 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 172 418841 Singapore 347740 GROUP Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 8001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 1 OF 10 OPERATING INSTRUCTIONS amp SERVICE MANUAL BLUE MAX HYDROSTATIC TEST PUMP EFFICIENT EASY OPERATION operated pump e Wide range of pressures and volumes e Easy to operate controls e Output pressure regulation control PORTABLE e Lightweight design One person operation Low center of gravity for stability e Semi pneumatic tires LOW MAINTENANC
35. he pumps inlet port 2 Providing a pressurized fluid supply This pressure is not to exceed 150 psi CAUTION THIS PUMP IS DESIGNED FOR EITHER PETROLEUM BASED HYDRAULIC OIL OR PLAIN WATER AS SPECIFIED WHEN ORDERING AND IS NOT GAURANTEED TO PUMP FLUIDS OTHER THAN SPECIFIED HEREIN OR FLUIDS THAT HAVE CORROSIVE QUALITIES WHICH WILL DETERIORATE THE PACKING OR METAL PARTS OF THE PUMP CONTACT THE FACTORY OR THE CLOSEST SC DISTRIBUTOR FOR INFORMATION ON PUMPS FOR SPECIAL FLUIDS 6 CONNECTION TO FLUID OUTLET OR PRESSURE SIDE Pana 1 The size and type of port is shown on the pump assembly drawing and is marked FLUID OUT on the pump The same care should be taken in making connections to this port as is necessary for all high pressure connections Only fittings sufficiently rated for the pumps maximum output pressure should be used 7 STARTING THE PUMP a Fill the lubricator unit in the air supply line with oil as recommended in item 3 b Screw down the pressure regulator to 0 psi before turning on air into the pump c Release pressure side of pump to reservoir or atmosphere so the pump can prime itself CAUTION BE SURE THAT THE FLUID SUPPLY REACHES THE PUMP PROMPTLY UPON STARTING RUNNING THE PUMP DRY MAY DAMAGE HYDRAULIC COMPONENTS d Screw down the pressure regulator slowly until the pump starts Pump should start on 10 to 15 psi of air under normal conditions Continue to increase air pressure to 40 psi and let the
36. high pressure hose 10 ft Water supply connection Regulator to control inlet ai r Length Width Height Approximate Shipping supply Weight High pressure bleed valve Abe High pressure outlet Blue Max Test Pump Model Number Maximum Pressure Volume 100 Pressure Ratio Maximum CFM Maximum Air PSI BAR Required Required BMX2 1000 1000 69 8 6 gpm 10 1 56 CFM 100 psi BMX2 3600 3600 247 2 6 36 1 56 CFM 100 psi 686 BMX2 10000 10000 1 gpm 97 1 56 CFM 100 psi Total required CFM to produce rated flow at maximum pump pressure This is relevant only when the system is used for continuous injection at the maximum rated pressure Normal testing applications require much less CFM to begin with and fall to 0 at stall test pressure Weight Dimensions Features Powered pump in selection of pressures and Weight Width Height Approx Shipping Weight volumes Airinput regulator and lubricator 19 21 44 85 Ibs 4 Air pressure gauge Test pressure gauge glycerin filled Water suction strainer with crow s foot connector Other pressures and volumes available upon request Contact factory for details High pressure system bleed valve High pressure test hose 15 feet w swivel Heavy duty enclosure with handle World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a
37. his process The Pilot Valve Assembly 11 6027A000 has an Air Check Assembly 11 6032X403 located in the lower end Remove the Retaining Ring Item 7 12 R093S000 which locks the Valve Seat Item 6 11 5024 403 in place and remove the Valve Seat with a spanner wrench The Air Check Assembly Item 5 11 6032X403 and the Spring Item 4 11 5016M001 will then drop out and may be inspected for wear or damage Replace the springs and worn parts as required Do not disassemble Air Check Item 5 The Air Check will only be assembled and properly adjusted at the factory 3 TO REPLACE THE PACKING IN THE HYDRAULIC CYLINDER It is not necessary to dismantle the Air Motor Proceed as follows Disconnect the air supply line remove the muffler if necessary and loosen the Set Screw Item 26 in the Air Cylinder End Item 24 Unscrew the Air Motor from the Hydraulic Cylinder The Hydraulic Piston will be removed with the Air Motor permitting convenient replacement of the packing in the Hydraulic Cylinder The Parts List for the Hydraulic Assembly will give the size and kind of packing required and when installing new packing be sure that the Backup Rings are properly in place If they are damaged or not installed correctly the Ring will malfunction with resultant loss of pressure and packing failure When replacing the Air Motor install a new Gasket part 1 1 5028N000 and see that the Hydraulic Piston is in proper alignment before sc
38. ic Transmission Fluid Type A will also be satisfactory when recommended lubricants are not available For good lubrication one drop for every 20 strokes of the pump is ample If an excessive amount of oil appears to be flowing through the pump during operation lubrication may be somewhat reduced to avoid excessive waste 4 AIR EXHAUST The air exhaust from the pump is a 1 npt port and is marked AIR OUT A muffler is desirable for quietness of operation If no muffler is available and noise is objectionable exhaust may be piped away to a remote location Pipe or hose can be used for this purpose and should have a 1 inside diameter or larger so that the efficiency of the pump will not be impaired 5 CONNECTION TO FLUID SUPPLY LINE The size and type of port is shown on the pump assembly drawing and is marked FLUID IN on the pump Clean fluid is very important Grit or foreign matter in the fluid supply will damage hydraulic components resulting in improper functioning of the pump A free flow type of filter 100 mesh with ports no smaller than the inlet port of the pump should be used to obtain maximum performance and avoid the possibility of cavitation To ensure proper priming of the pump maximum performance and to avoid the possibility of cavitation a fluid supply with a positive head is recommended This positive head can be accomplished in one of two ways 1 Positioning the fluid level of the reservoir above the level of t
39. lex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 OU Toll Free 1 800 355 7044 Fax 431 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY AN 150 9001 REGISTERED COMPANY AUD TV MELIA LU ENGINEERING CORPORATION Desyener and Manufacturers of Hydraule amp Pneumatic Lgupment 1130 COLUMBIA STREET BREA CALIFORNIA 92821 714 257 4800 FAX 714 257 4810 www schydraulic com INSTALLATION amp OPERATING INSTRUCTIONS FOR SC AIR OPERATED HYDRAULIC PUMP 10 6 SERIES PLEASE READ CAREFULLY 1 MOUNTING THE PUMP There are drilled and tapped holes in the base of the pump for this purpose The size quantity and spacing of these holes are shown on the parts list furnished with each pump Mounting of the pump may be in any position vertical preferred When mounting is in inverted position a drain hole should be provided to drain off any liquid that might accumulate in the pilot valve air chamber Contact the factory or the closest SC distributor for information on the inverted modification IMPORTANT The pump is designed so that the air motor head may be rotated in increments of 45 degrees to facilitate connection to air and hydraulic lines This may be done by removing the eight bolts that clamp the air motor together The head may then be rotated to any desired position that will also allow proper alignment of the bolts in the head and th
40. mum pump pressure This is relevant only when the system is used for continuous injection at the maximum rated pressure Normal testing requires much less CFM to begin with and falls to O at stall test pressure WEIGHT DIMENSIONS Approx Shipping Length 9 Weight 19 OTHER PRESSURES VOLUMES AVAILABLE UPON REQUEST CONTACT FACTORY FOR DETAILS SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE World Headquarters Expansion Seal Technologies Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Utrechthaven 11 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 30 500 5180 Singapore 347740 aor Toll Free 1 800 355 7044 Fax 31 30 600 6188 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 REV 4 12 03 PAGE 3 OF 10 OPERATING INSTRUCTIONS CAUTION READ INSTRUCTIONS BEFORE OPERATING THIS PUMP TO SET UP PUMP 1 Before use verify adequate oil exists in Air Lubricator Reservoir on back of pump If necessary fill with clean hydraulic oil ASTM Grade 215 ISO Grade 46 or equivalent 2 Close air valve Rear of Pump See Figure 1 3 Connect input air supply 120 psi maximum and input water supply to inlet connections on pump
41. nd services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen den Rijn 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 Tel 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2702 01 94 PAGE 1 OF 2 OPERATING INSTRUCTIONS HIGH FLOW OPTION FOR THE PORTABLE HYDROSTATIC TEST PUMP DESCRIPTION The High Flow Option Assembly for the P Series Hydrostatic Test Pump is used to speed the vessel filling process when a large volume of water is required for testing The pump and a standard water supply can run concurrently or just the water supply to fill the vessel EQUIPMENT REQUIRED P Series Hydrostatic Test Pump High Flow Option Assembly PSR 0003 Standard water supply approximately 50 psi with a male 3 4 NPT connection r BALL VALVE 1 2 NPT HIGH FLOW OPTION ASSEMBLY ASSEMBLY INSTRUCTIONS 1 Attach a Quick Connect to HP port on High Flow option 3 8 npt Assemble on
42. nds Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2702 01 94 PAGE 2 OF 2 VESSEL FILLING AND TESTING INSTRUCTIONS 1 Turn the regulator fully counterclockwise 2 Turn valve on pump to test position Turn the HP relief valve to the closed position 3 Connect compressed air supply to the quick connect fitting on pump panel marked AIR 4 Fill the vessel to be tested with water by opening the Ball valve on the High Flow option Air must be bled from the system at this time by opening pressure fitting s at the highest point s in the set up and allow water to drain from the fittings until all air is excluded Re tighten all fittings after air is thoroughly bled CAUTION MAKE SURE ALL AIR HAS BEEN BLED FROM THE SYSTEM BEFORE APPLYING TEST PRESSURE 5 Begin hydrostatic testing by turning the valve on the pump to PUMP and slowly adjust the pressure regulator clockwise to achieve the desired test pressure CAUTION MAKE SURE ALL GASES HAVE BEEN BLED FROM THE SYSTEM BEFORE TESTING DO NOT STAND NEAR VESSEL WHILE UNDER PRESSURE 6 Turn the valve on the pump to the TEST position when the test pressure has been reached Observe the pressure gage for a dro
43. p in pressure which would indicate a leak 7 After testing is complete turn Ball Valve on the High flow option to the closed position Release pressure turning the HP relief valve H P RELIEF position Water will drain from the back of the pump 8 Turn regulator fully counterclockwise to adjust pressure setting of pump to zero 9 Disconnect the unit which has been tested and connect the next unit to be tested to the High Pressure Hose 10 Repeat steps 1 through 9 until all assemblies have been tested World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen aan den Rijn 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherlands Ruby Industrial Complex Tel 1 215 721 1100 Fax 1 215 721 1101 31 172 418841 Singapore 347740 Toll Free 1 800 355 7044 Fax 31 172 418849 Tel 65 6745 8560 Fax 65 6742 8700 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2703 08 07 PAGE 1 OF 1 HIGH PRESSURE HAND PUMP OPERATING INSTRUCTIONS WARNING PRESSURE TESTING IS INHERENTLY DANGEROUS STRICT ADHERENCE TO THESE OPERATING INSTRUCTIONS AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL ALL PERSONNEL MUST BE CLEAR OF TEST AREA WHEN PRESSURE TESTING FOR SAFETY AN INCOMPRESSIBLE LIQUID SUCH AS
44. pump run until all air has been purged from the system e Check the lubricator unit to see that the proper amount of oil is being supplied to the pump as recommended in item 3 f After steps a through e have been completed air pressure to the pump may be regulated until the desired hydraulic pressure is attained in the system NOTE All models of the pump are designed to operate in the range of 10 to 100 psi air pressure Higher air pressure may be applied on intermittent duty but not to exceed 150 psi and is not recommended for continuous operation The 10 6 series 201 and 301 models should not be operated except on intermittent duty at hydraulic pressures above 30 000 psi as the life expectancy of the packing in the hydraulic assembly will be relatively short when operating continuously at pressures above 30 000 psi The 10 6 Series 402 model should not be operated except on intermittent duty at hydraulic pressures above 40 000 psi 8 TROUBLE SHOOTING GUIDE The pump has been thoroughly tested at the factory and found to be in perfect working condition If for some reason the pump does not function properly do not attempt to repair it but contact the factory or the closest SC distributor for instructions When calling have the pump model number serial number and a brief description of the problem readily available Before doing this the items should be checked E all connections to the pump correct Ve
45. rewing the Air Motor down into position Tighten the Air Motor securely and also the Set Screw Item 26 in the Air Cylinder End Item 24 TO REPLACE THE PACKING IN 10 6000W151 THROUGH 10 60005402 Refer to Hydraulic Assembly Drawings 11 6165W151 through 11 61655301 and 11 61695000 Using a Pin Wrench remove Retainer Part 4211 6158 11 6162 or 11 6176 remove Bearing Part 411 6163 11 6177 Back up Part 010653 Seal Rod Part P11202 Install new Seal Rod and Back Up replace Bearing Upper and Retainer Torque Retainer to 10 12 Ft Lb Page 1 of2 na m ina NOTE Models with Isolator Attachment or V Ring packing in the Hydraulic Cylinder will require removal of the Isolator or the Adapter on V Ring packed Cylinders to replace the packing THE HYDRAULIC PISTON has a Rubber Bumper Part 11 5051P000 in the head If replacement is required remove Cap Screw part 12 25F37SBC45Z and install new Rubber Bumper and Washer part 12 5001C407 Apply LOCTITE sealant to the Cap Screw threads when replacing and tighten securely but not to exceed four foot pounds of torque NOTE The Piston stem is chrome plated and honed and lapped to a very close tolerance with the Hydraulic Cylinder Should it show indications of wear or being scored usually due to foreign matter being present in the hydraulic fluid the entire Hydraulic Piston and Cylinder Assembly Part 11 6011X XXX should be returned to the factory for rep
46. rify that the air supply line is connected to the port marked AIR IN and the fluid supply i is connected to the port marked FLUID IN If either of these connections are incorrect the pump will not function properly b Is there an adequate and unrestricted air supply Verify that sufficient air pressure and flow are available to produce the desired pump output An insufficient air supply can hinder the published performance data of the pump 15 there an adequate and unrestricted fluid supply Verify that the reservoir is full and or the fluid supply does reach the pump if not the pump will not prime properly d 15 the pressure side of the pump unloaded Verify that the pressure side of the pump is unloaded If not the pump will not prime properly Upon verifying all of the above begin item 7 again If the pump still does not function properly contact the factory or the closest SC distributor for instructions TYPICAL CIRCUIT FOR INSTALLATION 1 AIR SHUT OFF VALVE 2 ASSEMBLY Ca 3 AIR PRESSURE GAUGE me 4 SCPUMP aS ae 5 EXHAUST MUFFLER E ORC 6 HYDRAULIC PRESSURE GAUGE 7 FLUID BLEED VALVE 8 HYDRAULIC FILTER Pana 2 SUD MV ENGINEERING CORPORATION Desyener and Manufacturers of Hydraulic 4 kguipment 1130 COLUMBIA STREET BREA CALIFORNIA 92821 714 257 4800 FAX 714 257 4810 SERVICING INSTRUCTIONS FOR SC AIR OPERATED HYDRAULIC PUMP D6 SERIE
47. roove can decrease the holding effectiveness of the Ring while foreign matter can cause contamination of the pump leading to failure IMPORTANT When reassembling the Air Motor be sure that the Air Cylinder Part 11 6151P000 is in proper position against the flanges on the Pump Head and the Air Cylinder End before tightening the bolts that clamp the Air Motor together Use a soft hammer to position the flanges tightly against the Air Cylinder Ends BEFORE tightening the bolts Failure to do this can result in over tightening the bolts initially _ and when the bolts on the opposite side are drawn up this may result in the bolt lugs being broken or twisted off when the assembly is drawn down into position Bolts should be secured lightly at first then drawn up in sequence until uniform torque has been applied to all of the bolts around the perimeter of the Pump 15 17 ft lb PUMP NOT RUNNING PROPERLY If for any reason the Pump does not run properly look for one of the following causes a If the Pump appears to be short stroking and running too fast without pumping properly it usually indicates that the Air Check Assembly is not working as it should be See paragraph 2 for correction procedure b Loss of pressure may be caused by one of two reasons the Hydraulic Check Valves have developed a leaky condition or the hydraulic fluid is bleeding past the Packing in the Hydraulic Cylinder See paragraphs 3 4 and 5 for repair instruction
48. rovides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies 2701 Township Line Road Hatfield PA 19440 1770 USA Expansion Seal Technologies Europe Expansion Seal Technologies Asia Pte Ltd 35 Tannery Rd 11 10 Tannery Block 3433 PN Nieuwegein The Netherlands Ruby Industrial Complex Tel 31 30 600 6180 Fax 31 30 600 6188 Tel 1 215 721 1100 Fax 1 215 721 1101 GROUP Toll Free 1 800 355 7044 SPECIALISTS IN TUBE TESTING SLEEVING AND PLUGGING TECHNOLOGY Singapore 347740 Tel 65 6745 8560 Fax 65 6742 8700 150 9001 REGISTERED COMPANY EXPANSION SEAL TECHNOLOGIES DC2705 1 REV 4 12 03 PAGE 5 OF 10 SERVICING INSTRUCTIONS TO DISASSEMBLE THE AIR MOTOR Refer to Table 1 for Parts List and Part Numbers and cross section of the pump shown in Figure 3 A Remove the 8 3 8 bolts Items 16 amp 17 that clamp the Air Cylinder 6 between the Head Casting Item 22 and the Air Cylinder End Item 3 Remove the Head by tapping on a fitting screwed into either the Air In or Air Out ports with a soft hammer B Remove the Retaining Ring 13 from the bottom of the Air Piston Item 4 and remove the Hydraulic Piston The Pilot Valve Assembly Item 20 may then be pushed out through the bottom of the Air Piston C Remove
49. s c Should the Pump commence to run erratically and in a jerky manner after a period of time it is usually an indication that a seizing action is taking place in the Hydraulic Piston amp Cylinder Assembly See paragraphs 1 and 3 for disassembly instructions Foreign matter such as alkali dirt grit or chemicals that do not have sufficient lubrication qualities being present in the fluid supply usually causes this If the Hydraulic Piston and Cylinder have not been damaged a thorough cleaning will normally place the Pump in operation again d For maximum volume of flow make sure that a sufficient flow of air is supplied to the Pump Hooking the Pump up to a smaller pipe size than the AIR IN port on the Pump will not allow it to run at its full rated capacity Long runs of relatively small pipe supplying air to the Pump will have the same effect e It is important to remember that this pump requires no lubrication in the air supply f If an excessive amount of oil or water is coming through the Pump air exhaust check the following 1 filtering unit in the air supply is not functioning properly The bowl should be cleaned periodically to assure delivery of the clean air to the Pump 2 The hydraulic fluid being pumped oil or water may be leaking past the packing in the Hydraulic Cylinder into the Air Motor See paragraph 3 for correction procedure Page 2 of 2 REV ISI SL8Vd ASSY 511495 0009
50. to pump at HP out 2 Connect water supply to Ball valve on High flow option 3 4 npt The valve should be closed 3 Connect the hose attached to the LP port on High Flow option to the water inlet on the pump 4 Connect the hose supplied with the pump to the HP port on High Flow option 1 2 npt Adapter 1 2m 3 8f is required Connect to vessel to be tested NOTE INSURE ALL CONNECTIONS ARE LEAK TIGHT QUESTIONS Contact EST Customer Service at any of the following locations with questions In USA and Canada tel 800 355 7044 fax 215 721 1101 e mail info expansionseal com In Europe tel 31 172 418841 fax 31 172 418849 e mail info estgrp nl In Asia tel 65 6745 8560 fax 65 6742 8700 e mail estasia singnet com sg On the Internet www expansionseal com Expansion Seal Technologies is part of the EST Group of companies EST Group provides a complete range of repair products services and replacement parts covering the life cycle of tubular heat exchangers and condensers additionally EST provides products and services to facilitate pressure testing pipe piping systems pressure vessels and their components Visit EST Group on the internet at www estgrp com World Headquarters Expansion Seal Technologies Expansion Seal Technologies EMEA Expansion Seal Technologies Asia Pte Ltd 2701 Township Line Road Hoorn 312a 2404 HL Alphen den Rijn 35 Tannery Rd 11 10 Tannery Block Hatfield PA 19440 1770 USA The Netherla

Hydropumps - pnrdynamic co.,ltd.

Contents

Download Pdf Manuals

Related Search

Related Contents