MANUAL HAND PUMPMAINTENANCE AND SERVICE MANUAL

2

GA

S-H

YDR

AU

LIC

HA

ND

PU

MP

BIL

L O

F M

ATER

IAL

11

Pum

pBody

21

Pum

pHead

31

PackingGland

41

Clevis

51

PivotBar

61

Pum

pPiston

71

TopRam

81

BottomRam

91

Ram

ProtectiveCover

101

Pum

pSuctionSeat

111ValveBody

121LeftValveSleeve

131RightValveSleeve

146RingSeal

154RingSealC

ap

162ValveCap

172Stem

182StemCap

192SuctionCap

201PilotP

iston

211ReliefS

tem

221ReliefS

eat

231ReliefC

ap242ClevisPinS.S.

254AcetalBearing

261Pum

pHeadO-RingCom

p.479-70

70Duro

271Ram

O-RingC

omp.479-70

70Duro

282Ram

Wiper

90Duro

294HeadBoltH

exHeadCapScrew

S.S.

301PistonO-RingC

omp.479-70

70Duro

312PistonGuideRing

321TopRam

SpringPin

331BottomRam

SpringPin

346O-RingC

omp.479-70

70Duro

356RingSealSpring

366RingSealC

apCom

p.479-70

70Duro

372O-RingC

omp.479-70

70Duro

382StemSpringPin

392StemBoot

402StemKnob

411PilotP

istonO-RingC

omp.479-70

70Duro

421PilotP

istonGuideRing

432StemCapO-RingC

omp.479-70

70Duro

441ReliefC

apO-RingC

omp.479-70

70Duro

451ReliefS

temO-RingC

omp.479-70

70Duro

462ReliefS

temSpring

471ReliefB

allN

ylon

481ReliefS

pring

491ReliefB

oot

501ReliefK

nob

511O-RingC

omp.479-70

70Duro

524NylonBall

533Suction&DischargeSpring

544ValveBoltsHexHeadCapScrew

S.S.

552FlushPlug(STL)7/8Taper

569FlushPlug(STL)7/8Taper

576"X"W

asher

582AcetalBearing

591FlushPlug7/8TaperS

teel

602PilotP

istonBack-UpRing

611InstructionPlate

624InstructionPlateScrew

s#4Type"U"

631ClevisPinS.S.

642O-RingC

omp.479-70

70Duro

651O-RingC

omp.479-70

70Duro

661O-RingC

omp.479-70

70Duro

671O-RingC

omp.479-70

70Duro

681O-RingC

omp.479-70

70Duro

691O-RingC

omp.479-70

70Duro

721FlushPlug7/8TaperS

teel

741LockingPin

751UpperRam

SealParkerP

olyPak

RodSeal

Molythane

3

This

exp

lode

d vi

ew c

orre

spon

ds w

ith th

e ab

ove

asse

mbl

y vi

ew.

Note:Item

s70,71&73pertaintothe12cu.in.H

andPum

p

4

CEN

TRA

L H

YDR

AU

LIC

HA

ND

PU

MP

BIL

L O

F M

ATER

IAL

11

Pum

pBody

21

Pum

pHead

31

PackingGland

41

Clevis

51

PivotBar

61

Pum

pPiston

71

TopRam

81

BottomRam

91

Ram

ProtectiveCover

101

Pum

pSuctionSeat

111ValveBody

121ValveSleeve

146RingSeal

154RingSealC

ap161Pum

pPiston

172Stem

182StemCap

202PilotP

iston

211ReliefS

tem

221ReliefS

eat

231ReliefC

ap242ClevisPinS.S.

254AcetalBearing

261Pum

pHeadO-RingCom

p.479-70

70Duro

271Ram

O-RingC

omp.479-70

70Duro

282Ram

Wiper

90Duro

294HeadBoltH

exHeadCapScrew

316S.S.

301PistonO-RingC

omp.479-70

70Duro

312PistonGuideRing

321TopRam

SpringPin

331BottomRam

SpringPin

347O-RingC

omp.479-70

70Duro

357RingSealSpring

366RingSealC

apCom

p.479-70

70Duro

374O-RingC

omp.479-70

70Duro

392StemBoot

402StemKnobMPR-6

412PilotP

istonO-RingC

omp.470-70

70Duro

432StemCapO-RingC

omp.479-70

70Duro

441ReliefC

apO-RingC

omp.479-70

70Duro

451ReliefS

temO-RingC

omp.479-70

70Duro

462ReliefS

temSpring

471ReliefB

allN

ylon

481ReliefS

pring

491ReliefB

oot

501ReliefK

nobDK-49

522NylonBall

532Suction&DischargeSpring

544ValveBoltsHexHeadCapScrew

S.S.

558FlushPlug

576"X"W

asher

582AcetalBearing

591FlushPlug

612InstructionPlate

622InstructionPlateScrew

s#4Type"U"

631ClevisPinS.S.

652O-RingC

omp.479-70

70Duro

661O-RingC

omp.479-70

70Duro

671O-RingC

omp.479-70

70Duro

681O-RingC

omp.479-70

70Duro

691O-RingC

omp.479-70

70Duro

701FlushPlug

731FlushPlug

761KepnerS

huttleValve

771ShortPipeNippleS.S.

781LockingPin

792SS-400-1-2M.C.1/8Pipe1.4TubeSwagelok

802SS-400-2-2M.C.1/8Pipe1.4TubeSwagelok

811/4O.D.S

tainlessSteelTubing

861UpperRam

SealParkerP

olyPak

RodSeal

Molythane

5

This

exp

lode

d vi

ew c

orre

spon

ds w

ith th

e ab

ove

asse

mbl

y vi

ew.

Note:Item

s70,71&73pertaintothe12cu.in.H

andPum

p

6

BASIC CHECK-OUT PROCEDURES

ThefollowingthreetestsillustratetheproperworkingfunctionsoftheShaferhandpump.Failureofanyoftheseproceduresmayresultinoperatingproblemsforthevalveactuator.

TEST 1Withbothpalmbuttonsout(automat-icposition)andwiththeraminthe"UP"positionandfluidinthepumpcylinder,strokethehandpump.-Iftheringseals,valvesleevesandthemanualdischargecheckballaresealingproperly,itshouldbeimpossibletopullthepumpramdown.Theramcanbeloweredorpulleddownbyholdinginthemanualdischargereliefandpullingtheramdownatthesametime.

TEST 2Withonepalmbuttonpushedin(selectedforopenorclosedposi-tion)handpumptheactuator.Ifthepumpisspongyorwillonlydrawapartialramofoilwhilepumpingtheactuator,checkthegas/hydraulictankforcorrectoillevels.Ifthecontrolcircuitispoweredbyacentralhydraulicunit,checkthepumpreservoirtankforcorrectoillevelandinsurethatthehandvalve(ifpresent)betweenthepumpandreservoirisopen.

Ifthepumpstillwillnotdrawoildur-ingthesuctioncycle,reconditioningwillberequired.

TEST 3Thefinaltestisaccomplishedbypushinginthepalmbuttontowhat-everpositionthevalveisin,"open"or"closed".Raisethepumphandletodrawfluidintothecylinderandthenforcetheramdownward.Theramwilldischargeslowlyonrotaryvaneactuators.Workingproperly,theramshouldnotmovedownwardinaneasymanner,whenpump-ingagainstafullystroked(openorclosed)actuator.Thesameproce-durecanbeappliedtolinear"gatetype"actuators.Downwardmotionundergreatforcemayoccurifreliefsettingsareexceeded.

7

DISASSEMBLY OF PUMPAND VALVE COMPONENTSFailureoftheramto"lock-up"asshowninTest#1isageneralindicationofringsealfailure,suctioncheckvalvefailureormanualreliefcheckvalvefailure.Problemareasareusuallyduetoadefectivesuctionball,dischargereliefball,ringsealorforeignmatterimbeddedinoneorallthreeoftheabovementionedcomponents.AcutO-ringaroundtheringsea,suctioncheckseatordischargereliefseatwillproducethesamemalfunction.

NOTE:DuringanycomponentdisassemblyallO-rings,wearrings,wipersandnylonballsshouldbereplaced.

TO REMOVE THE MANUAL DISCHARGE RELIEF ASSEMBLY1) Pushthereliefknob(50)intoneutralizeanytrapped

gasoroilpressureinthesystem.2) Pullbothpalmbuttons(40)outintoautomaticposition.3) Removethedischargereliefknob(50),boot(49)and

hexheadcap(23),stem(21)andspring(46).4) Placeonehandoverthedischargereliefcavityand

jerkthepumpram(7)downto"pop"thereliefseat(22)upforremoval.

5) InspecttheO-ringonthedischargereliefseat(22),thechamferedseatandthenyloncheckball(47)forscoringordeepscratches.

TO REMOVE VALVE SLEEVE ASSEMBLY1) Pushmanualreliefvalve(50)downtoneutralizeany

trappedgasoroilpressureinthesystem.(Neglectthisifthereliefassemblyisalreadyremoved.)

2) Removethepalmvalveknob(40),boot(39)andhexheadcap(18).

3) Carefullypullthestem(17)andvalvesleeveassem-bly(12)outofthevalvebody(11).

4) Inspecttheflatsurfacesonthevalvesleeve(12)andtheO-rings(37)onthestem(17).

NOTE:Thegashydraulicpumpshavetwovalvesleeves,items(12)and(13).Thecentralhydraulicpumpshaveonlyonevalvesleeve,item(12).

5) Toremovethepilotpistons(20)insidethevalvebody(11)firstremovethepalmvalvesleeveassembly(12).Caremustbetakennottoscratchorscoretheinsideboreofthevalvebody.Replacementofthepilotpis-tonO-rings(41)shouldbemadeatthistime.

TO REMOVE THE RING SEAL ASSEMBLYNOTE:Thevalvesleeveassemblies,left(12)andright

(13)applytothegashydraulicpumps.Onevalvesleeveassembly(12)appliestocentralsystempumps.

Thevalvesleeveassembliesforallpumpsmustberemovedbeforeremovingtheringsealassemblies(14).

1) Disconnectthehydraulictubingandfittingswhichcon-

nectthecentralportstothecontrolandthedischargeportstotheactuator.Thehexheadcapretainersonthefrontfaceofthevalve(11)alsocontainringsealassemblies(14).

2) Removehexheadcapretainers(15)and(16)andsprings(35).

3) Reachinsidethevalvebody(11)throughthevalvesleeveholeandpushtheringseals(14)out.

4) Inspecttheflatfacesoftheringseals(14)forwearandtheO-rings(34)forcuts.Replacementoftheringseals(14)andO-rings(34)shouldbedoneatthistime.

DISASSEMBLY OF PUMP AND VALVE COMBINATION1) Removethefourassemblybolts(54)locatedonthe

backofthepumpbody(1).2) Carefullypullthevalvebody(11)andpumpbody(1)

aparttopreventlossofthemountingO-ringsbetweenthetwoblocks.

3) Toremovethepumpsuctionseat(10)insertedinthepumpbody(1)placeonehandovertheseatcartridge(10)andonefingertoholdthenylondischargeballonitsseatandjerkthepumpram(7)downwardtocreatepressureto"pop"thecartridge(10)outintoyourhand.

4) InspecttheseatO-rings(66)and(67),checktheball(51)andchamferedseatforscratchesandforeignmatter.

5) NOTE:Thispertainstothe12cu.in.pumpsonly.Removethedischargecheckseat(70)andinspectO-rings(71)andchamferedseatforscratchesandforeignmatter.

DISASSEMBLY OF PUMP RAM AND PISTON1) Removethesnapring(X-washers)(57)locatedout-

sideeachpin(24,63),intheclevispivotarmassembly(4)and(5).

2) Removethepins63&24),clevis(4)andpivotbar(5).3) Removethefourpumpheadbolts(29)locatedatthe

topofthepumpcylinder(1).4) Carefullypulltheram(7),andpistonassembly(6)out

ofthepumpcylinder(1).5) Inspecttheram(7),pumpcylinderbore(1),piston

O-rings(30)andpistonwearrings(31)forscoringandexcessivewear.TheO-ring(27)andPolyPaklipseal(86)andwiperrings(28)aroundeachpumpram(7&8)shouldbereplacedatthistime.OnesetO-ring(27),PolyPaklipseal(86)andwiperring(28)canbefoundinthepumphead(2).Theothersetcanbereachedbyunscrewingthehexshapedramcover(9)atthebottomofthepumpbody(1).

8

RECONDITIONINGAND ASSEMBLY

RELAPPING THE VALVE SLEEVEThevalvesleeves(12)and(13)canbeeasilyrelappedtoassurepropersealingsurfaces;assumingthescratchesinthemarenottoodeep.Noteeachvalvesleevehasfourflatsides.Onlythethreewithholesonthemneedtoberelapped.Useacircularmotionwithalappingcompoundonaflatsurfacetoremovelightscratches.

NOTE: Thecentral systempumpshaveonlyonevalvesleeve(12)tolap.

REASSEMBLY - GAS HYDRAULIC PUMPAfterrelappingthevalvesleeves(12)and(13)andre-placementoftheringseals(14),withallsixofthehexheadcapretainers(15)and(16)removed,inserttheleftvalvesleeve(12)(indicatedleftbytheletter"L"stampedonthefrontfaceofthesleeve)intothevalvebody(11).Thevalvesleeve(12)hasfourportholesdrilledthroughtheflatsurfaces.Onesetofholesarelocated90°apartfromtheother.Theothersetisadrilledthroughhole.Wheninsertingtheleftvalvesleeve(12),thetwo90°holesshouldlineupwiththetopport(15)ofthebody(11)andthefrontport(16)ofthevalvebody(1).Thefrontbeingthefacewiththedirectionplate(61).Afterinsertingthesleeve(12)asfarasitwillgo,the90°holesshouldbelinedupwiththeabovementionedports.

Afteroneofthevalvesleeves(12)isreassembled,insertthepilotpiston(20)intotheoppositesleevehole.(Thepilotpiston(20)canbeinsertedineitherdirection.)Thepilotpiston(20)shouldbepushedinwithascrewdriverorsimilarnarrowtoolonceit'sstartedintoitscavity.Thisshouldbedonecarefully topreventcuttingtheO-ring(41)orscratchingtheinsideofthevalvebody.

9

Thereassemblyoftherightvalvesleeve(13)shouldfol-lowthesameinstructionsastheleftvalvesleeve(12).Afterinsertingbothvalvesleeves(12)and(13)andtheirrespectivecaps(18),insertthesixringseals(14)throughtheportswiththelappedsurfacesoftheringseals(14)makingcontactwith theflatsidesof thevalvesleeve(12)and(13).Insertthesprings(35)andretaininghexheadcaps(15)and(16)andpulleachvalvesleeve(12)and(13)inandoutseveraltimessothesleeves(12)and(13)centerthemselvesagainsteachringseal(14).Toinsurecorrectassemblyofthesleeve(12)and(13)andringseal(14)assemblies,pushonesleeveatatimeinasfarasitwillgoandchecktoseeifthe90°portholesinthesleevelineupwiththetop(actuatorport)(15)andthefrontport(16).Ifthisalignmentiscorrect,followthesameinstructionsfortheoppositesleeve.

REASSEMBLYCENTRAL HYDRAULIC SYSTEM PUMP

Afterrelappingthevalvesleeve(12)andreplacementoftheringseals(14),withallsixofthehexheadcapretainers(15)and(16)removed,insertthevalvesleeve(12)intothevalvebody(11).Thevalvesleevehasfiveportholesperend.

NOTE: Thesleeveismarked"L"for leftand"R"forright.Thefiveportholesaredrilledthroughthefourlappedflatsurfacesofthevalvesleeve.Thefigure(below,left)indicateshowtoreinstallthevalvesleeve(12)intothevalvebodyinthecorrectposition.

NOTE: Thevalvesleevehasatotalof twelveholesdrilledinfourflatsurfaces.ThesurfacewithsixholesistheTOP.Thesurfacewiththetwoholesclosesttothetwoextremeends(leftandright)istheFRONT.Thefigureattheleftshowsthesleeveinthisposition.Thesleeveshouldbeinsertedintothevalvebodyinthispositiononly.Thefrontofthevalvebodyisthesurfacewiththeinstructionplate.Afterreinstallingthevalvesleeve(12)intothevalvebody(11),insertthepilotpistons(20)andstemcaps(18).Nextinstallthesixringseals(14)throughthepartsuntiltheymakecontactwiththelappedsurfacesofthevalvesleeve(12).Insertthesprings(35)andtheretaininghexcaps(15)and(16)andpushthevalvesleevepalmbuttonsbackandforthseveraltimestoinsuretheringseals(14)andseatthemselvesagainstthelappedfacesofthevalvesleeve(12).

10

GAS HYDRAULICSYSTEM CIRCUIT

MANUAL RELIEF VALVE

PALMBUTTON

SHAFER ACTUATOR

SPEEDCONTROL

11

CENTRAL HYDRAULICSYSTEM CIRCUIT

OILRESERVOIR

MANUAL RELIEF VALVE

CONTROL

SPEEDCONTROLS

DOUBLEHOLDING VALVE

CONTROL

SHAFER LINEAR ACTUATOR

12

MHP-01102001

Emerson Process Management Valve Automation, Inc.2500 Park Avenue West Mansfield, OH 44906Phone (419) 529-4311FAX (419) 529-3688

www.emersonprocess.com/shafer