COM-0009

PUMPS - WIWA 85:1 & 175:1

DOCUMENT COVERING THE FOLLOWING ELMAR PARTS:

L-840880 - 85:1 GREASE PUMP

L-840750 - 175:1 GREASE PUMP

1. SYSTEM

2. AIR MOTOR

3. FLUID END

4. RELIEF VALVE

5. GENERAL MAINTENANCE

6. KITS

7. ACCESSORY

8. TROUBLE SHOOTING

9. AIR MOTOR 85:1

10. AIR MOTOR 175:1

11. FLUID SECTION DIAGRAM 85:1 & 175:1

Prepared Checked Approved Date

02 September 1999

COMPONENTS/COM-0009 © Elmar Services Ltd 1999 PAGE 1 OF 9

 1. SYSTEM

A high pressure pump, consisting of a reciprocating air drive (air motor) and a fluid
pump (fluid end) forms the heart of the system. Infinitely variable control of the air
motor and thus the displacement speed (cycle) of the fluid pump is obtained using
a pressure reducing valve (air regulator), which also controls the fluid output and
stall pressure.

The pressure ratio (pump ratio) of the high pressure pump is determined by the
area of the air motor piston versus the area of the fluid end piston rod.

The air pressure multiplied by the pump ratio gives the output fluid pressure.

Example 1: Pump ratio 85:1

Compressed air pressure

reading at air motor control 8 bar (116 psi)

Maximum fluid pressure (8 bar x 85) 680 bar (9860 psi)

Example 2: Pump ratio 175:1

Compressed air pressure

reading at air motor control 7 bar (101 psi)

Maximum fluid pressure (7 bar x 175) 1225 bar (17 760 psi)

2. AIR MOTOR

WIWA reciprocating motors are specifically designed for use with high pressure
pumps. Attention is paid to longevity of individual components using modern
technology materials, oversized air passages, low noise readings as well as system
serviceability.

3. FLUID END

WIWA pumps are of the "closed" design and feature a closed connection between
the air motor and fluid end. The piston is guided between two sets of fixed packings
constantly readjusted by a pressure spring which results in extra long packing life.
The displacement piston has been given an approximate 0.3 mm (0.012") layer of
hard chrome to protect against wear; both the upper and lower ball valves have
tungsten carbide seats. Leather and Teflon "V"-packings are installed as packing
sets. WIWA Teflon "V"-packings are graphite filled, WIWA leather packings Thiokol
impregnated.

COMPONENTS/COM-0009 PAGE 2 OF 9
 4. RELIEF VALVE

A relief valve has been fitted to the air motor. This prevents the air supply to the air
motor from exceeding 8 bar (116 psi) on the 85:1 pump, and 7 bar (101 psi) on the
175:1 pump. This determines the maximum output of these pumps.

5. GENERAL MAINTENANCE

1. Daily (or if compressed air is wet at least twice daily) drain oil and water
separator with line pressure on and blow out water.
2. Check fog oiler for correct adjustment (droplet metering) and oil level, refill if
required.

NOTE: Severe operating conditions may cause frosting of air motor. To

prevent, fill fog oiler with "Killfrost" airline lubricant or a mixture of 50:50 regular
SAE 10 Oil and Glycol.

6. KITS
85:1 AIR MOTOR:
L-661430 Air Motor Seal Kit
L-661440 Air Motor Repair Kit (includes items in above seal kit)

175:1 AIR MOTOR:

L-660770 Air Motor Seal Kit
L-660340 Air Motor Repair Kit (includes items in above seal kit)

85:1 & 175:1 FLUID SECTION:

L-660350 Fluid Section Repair Kit
L-838750 Upper Packing Mixed Assembly
L-838930 Lower Packing Mixed Assembly
L-838890 Bottom Valve Assembly

GENERAL:
L-661470 85:1 Pump Repair Kit (Kits L-661440 and L-660350 combined)
L-660360 175:1 Pump Repair Kit (Kits L-660340 and L-660350 combined)
L-837241 Engineering Adhesive for Air Motor
L-837242 Lubrication Grease for Air Motor
L-880000 "Killfrost" Airline Lubricant

7. ACCESSORY
L-690497 Test Unit for 10K Grease Pumps.
This is a workshop based unit for testing pump output of Elmar supplied grease
pumps up to 175:1 ratio.

COMPONENTS/COM-0009 PAGE 3 OF 9
 8. TROUBLE-SHOOTING

PUMP WILL NOT OPERATE

Probable cause: Remedy:
1. Air supply closed 1. Open
2. Fluid end ball valve sticking 2. Dismantle, clean
3. Air motor blocked 3. Call service

PUMP CYCLES REGULARLY, BUT WILL NOT PRIME

Probable cause: Remedy:
1. Fluid end ball valve sticking 1. Loosen, clean
2. Suction tube or hose not properly 2. Check for air leaks on hose and tube
installed ( pump pulls air ) connections on fluid supply side and
seal or tighten
3. Material too viscous 3. Reduce viscosity ( follow manufacturers
instructions )

PUMP WORKS ERRATICALLY, FLUID FLOW PULSATES

Probable cause: Remedy:
1. Pump pressure too low 1. Increase air pressure setting
2. Material too viscous 2. Reduce viscosity ( follow manufacturers
instructions )
3. Fluid end ball valves sticking 3. Loosen, clean. Immerse fluid end in
compatible cleaning agent to dissolve
and follow with flush
4. Ball valves, packings or piston worn 4. Replace

FLUID FLOW STOPS OR BECOMES SLUGGISH

Probable cause: Remedy:
1. Fluid supply empty 1. Refill
2. Foreign matter lodged in foot valve 2. Dismantle, clean
3. Packings worn 3. Replace
4. Overriding capacity of pump 4. Reduce air pressure and pump speed
5. Air motor hisses 5. Replace O-rings

AIR MOTOR FROSTS

Probable cause:
1. Pump cycling rate too high
2. Compressed air moisture content
too high
3. Unfavourable operating conditions,
high humidity, inadequate piping,
fog, temperature around freezing
point
Remedy:
1. Reduce air pressure
2. Install oil and water seperator and drain
in shorter intervals
3. Fill fog oiler with antifreeze and adjust
droplet metering

COMPONENTS/COM-0009 PAGE 4 OF 9
9. AIR MOTOR 85:1

Engineering adhesive (Elmar part L-837241)

Lubrication grease (Elmar part L-837242)

Kits: L-661430 (Wiwa #0484954) Air Motor Seal Kit

L-661440 (Wiwa #0604488) Air Motor Repair Kit
L-661470 Complete Repair Kit (Air Motor and Pump Fluid Section)

COMPONENTS/COM-0009 PAGE 5 OF 9
 AIR MOTOR 85:1
Elmar WIWA
No Qty Description Comments
Part No Part No
(1) 1 L-837002 0495441 RING SCREW ASSEMBLY (1)
2 3 L-837003 0475297 DOME NUT 2
3 3 L-838130 0460214 WASHER 3
4 1 L-837004 0474878 COVER ASSEMBLY 4
5 1 L-837005 0629922 AIR MUFFLER ASSEMBLY 5
6 1 L-837006 0474932 SPACER 6
7 2 L-837007 0497827 THREADED BOLT ASSEMBLY 7
8 2 L-838130 0460214 WASHER 8
9 4 L-837008 0310182 O-RING 9 REPAIR KIT. SEAL KIT
10 1 L-837007 0497827 THREADED BOLT ASSEMBLY 10
11 1 L-837009 0474894 SAFETY PLATE 11
12 1 L-837010 0474908 CONTROL CYLINDER 12
13 2 L-837011 0496693 CONTROL HOUSING ASSEMBLY 13
14 1 L-837012 0460192 NUT 14 REPAIR KIT
15 1 L-837013 0475319 CONTROL PISTON ASSEMBLY 15 REPAIR KIT. WEAR PART
16 1 L-837014 0474983 CONTROL AXLE 16
17 1 L-837015 0475076 ALIGNMENT, INSERT 17
18 1 L-837016 0475041 DAMPENING SPACER 18 REPAIR KIT. WEAR PART
19 2 L-837017 0494054 SPACER 19
20 1 L-837018 0480258 CARRIER ASSEMBLY 20 REPAIR KIT. WEAR PART
21 1 L-837016 0475041 DAMPENING SPACER 21 REPAIR KIT. WEAR PART
22 1 L-837019 0493961 RETAINING RING 22 REPAIR KIT
23 1 L-837020 0493953 SPACER 23
24 3 L-837021 0493414 O-RING 24 REPAIR KIT. SEAL KIT
25 4 L-837003 0475297 DOME NUT 25
26 4 L-838130 0460214 WASHER 26
(27) 1 L-837022 0601659 SAFETY RELIEF VALVE (27)
(28) 1 L-837023 0498505 REDUCING NIPPLE F. AIR REGULATOR (28)
(28) 1 0630467 UNION PIPE F. AIR MAINTENANCE (28)
29 1 L-837024 0496758 CYLINDER HEAD ASSEMBLY 29
30 1 L-837025 0475114 U-SEAL 30 REPAIR KIT. SEAL KIT. WEAR PART
31 1 L-838420 0461334 RETAINING RING 31 REPAIR KIT
32 2 L-837026 0470325 TOGGLE 32 WEAR PART
33 2 L-837027 0473081 TOGGLE BEARING 33 WEAR PART
34 2 L-837028 0411876 SPRING 34 WEAR PART
35 2 L-837029 0475122 BEARING BUSH 35
36 2 L-837030 0460362 THREADED PIN 36
37 2 L-837031 0460184 NUT 37
38 1 L-837032 0311391 O-RING 38 REPAIR KIT. SEAL KIT. WEAR PART
39 1 L-837033 0475149 PISTON PLATE 39
40 1 L-837034 0475157 GUIDE RING 40 REPAIR KIT. SEAL KIT. WEAR PART
41 1 L-837035 0477281 O-RING 41 REPAIR KIT. SEAL KIT. WEAR PART
42 1 L-837036 0475165 SPACER 42 REPAIR KIT. WEAR PART
43 1 L-837037 0475181 GUIDE AXLE ASSEMBLY 43 REPAIR KIT. WEAR PART
44 1 L-837038 0475173 MOTOR AXLE 44 WEAR PART
45 1 L-837039 0311405 O-RING 45 REPAIR KIT. SEAL KIT
46 1 L-837040 0475130 CYLINDER 46 WEAR PART
47 4 L-837041 0476056 THREADED BOLT 47
48 1 L-837042 0311405 O-RING 48 REPAIR KIT. SEAL KIT
49 1 L-837043 0475270 AIR INLET PIPE 49
50 2 L-837044 0310239 O-RING 50 REPAIR KIT. SEAL KIT
51 1 L-837045 0499749 BOTTOM ASSEMBLY 51
52 1 L-837046 0482471 BUSH ASSEMBLY 52 REPAIR KIT. SEAL KIT. WEAR PART
53 1 L-837047 0475238 SPACER 53
54 1 L-837048 0475254 RETAINING RING 54 REPAIR KIT
(55) 1 L-837049 0626045 COUPLING (55)
(56) 1 L-837050 0467367 SPLIT PIN (56)
(57) 1 L-838710 0460761 TENSION PIN (57)
58 1 L-837052 0626089 BOTTOM ASSEMBLY 58
59 4 L-837053 0460214 WASHER 59
60 4 L-837054 0460524 SCREW 60

COMPONENTS/COM-0009 PAGE 6 OF 9
10. AIR MOTOR 175:1

NOTE: See above detail. Groove in

Engineering adhesive (Elmar part L-837241)
Lubrication grease (Elmar part L-837242)
part 12 must be on the upper side.
The ideal distance between parts 11
and 12 should be approximately
2mm. Install part 34 with
countersunk section faced down.

Kits: L-660770 (Wiwa #0064599) Air Motor Seal Kit

L-660340 (Wiwa #0604496) Air Motor Repair Kit
L-660360 Complete Repair Kit (Air Motor and Pump Fluid Section)

COMPONENTS/COM-0009 PAGE 7 OF 9
 AIR MOTOR 175:1
Elmar WIWA
No Qty Description Comments
Part No Part No
(1) 1 L-838080 0461245 RING SCREW ASSEMBLY (1)
2 1 L-838090 0221538 COVER 2
3 1 L-838110 0163759 MUFFLER ASSEMBLY 3
4 1 L-830049 0629919 PERF. METAL HOUSING 4
5 4 L-838120 0461229 RETAINING NUT 5
6 4 L-838130 0460214 WASHER 6
7 1 L-838140 0220701 CAP 7
8 1 L-838150 0220639 CONTROL CYLINDER 8
9 4 L-838160 0311189 O-RING 9 REPAIR KIT. SEAL KIT
10 4 L-838170 0220728 THREADED BOLT 10
11 2 L-838180 0460648 NUT 11 REPAIR KIT
12 1 L-838190 0163775 CONTROL PISTON ASSEMBLY 12 REPAIR KIT. WEAR PART
13 1 L-838200 0220620 CONTROL HOUSING 13
14 1 L-838210 0465674 GASKET 14 REPAIR KIT. SEAL KIT. WEAR PART
15 1 L-838220 0499846 CYLINDER HEAD ASSEMBLY 15
(16) 1 L-837000 0601594 SAFETY RELIEF VALVE (16)
17 8 L-838230 -0460249 DOME NUT 17
18 8 L-838240 0461253 SPRING RING 18
19 8 L-838250 0460613 WASHER 19
20 2 L-838260 0220760 RETAINING SCREW 20
21 2 L-838270 0415154 SPRING 21 WEAR PART
22 2 L-838280 0220779 BEARING BUSH 22
23 2 L-838290 0220787 TOGGLE BEARING 23 WEAR PART
24 2 L-838300 0163813 TOGGLE 24 WEAR PART
25 1 L-838310 0461288 CYLINDRICAL PIN 25
26 1 L-838360 0220671 SINTERED BEARING 26 REPAIR KIT. WEAR PART
27 1 L-838370 0461296 RETAINING RING 27 REPAIR KIT
28 1 L-838320 0163627 COVER ASSEMBLY 28
29 2 L-838330 0460443 SCREW 29
30 2 L-838340 0463728 SCREW 30
31 2 L-838350 0460214 WASHER 31
32 1 L-838380 0221791 CONTROL AXLE 32
33 1 L-838390 0415278 DAMPENING SPACER 33 REPAIR KIT. WEAR PART
34 1 L-838400 0220752 CARRIER 34 REPAIR KIT. WEAR PART
35 1 L-838410 0466875 DAMPENING SPACER 35 REPAIR KIT. WEAR PART
36 1 L-838420 0461334 RETAINING RING 36 REPAIR KIT
37 1 L-838430 0221295 SINTERED BEARING 37 REPAIR KIT
38 2 L-838440 0311243 O-RING 38 REPAIR KIT. SEAL KIT
39 1 L-838450 0221287 PLATE 39
40 1 L-838460 0311103 U-SEAL 40 REPAIR KIT. SEAL KIT. WEAR PART
41 1 L-838420 0461334 RETAINING RING 41 REPAIR KIT
42 1 L-838470 0311421 O-RING 42 REPAIR KIT. SEAL KIT
43 1 L-838480 0311413 O-RING 43 REPAIR KIT. SEAL KIT. WEAR PART
44 1 L-838490 0221341 PISTON PLATE 44
45 1 L-838500 0477192 GUIDE RING 45 REPAIR KIT. SEAL KIT. WEAR PART
46 1 L-838510 0311235 O-RING 46 REPAIR KIT. SEAL KIT. WEAR PART
47 1 L-838520 0221368 SPACER 47 REPAIR KIT
48 1 L-838530 0221414 STOP GUIDE 48
49 1 L-838540 0415170 SPRING 49 REPAIR KIT. WEAR PART
50 1 L-838550 0163740 GUIDE AXLE ASSEMBLY 50 WEAR PART
51 1 L-838560 0221325 CYLINDER 51 WEAR PART
52 1 L-838470 0311421 O-RING 52 REPAIR KIT. SEAL KIT
53 1 L-838570 0461237 RETAINING RING 53 REPAIR KIT
54 1 L-837001 0478695 GUIDE BUSH ASSEMBLY 54 REPAIR KIT. SEAL KIT. WEAR PART
55 4 L-838610 0311243 O-RING 55 REPAIR KIT. SEAL KIT
56 2 L-838620 0221333 AIR INLET PIPE 56
57 8 L-838600 0221473 THREADED BOLT 57
58 8 L-838250 0460613 WASHER 58
59 8 L-838240 0461253 SPRING RING 59
60 8 L-838230 0460249 DOME NUT 60
61 1 L-838630 0609676 BOTTOM ASSEMBLY 61
62 1 L-838540 0415170 SPRING 62 REPAIR KIT. WEAR PART
63 1 L-838640 0221430 MOTOR AXLE 63 WEAR PART
(64) 1 L-838650 0607428 COUPLING (64) WEAR PART

COMPONENTS/COM-0009 PAGE 8 OF 9
ED 4 (A)

ELMAR SERVICES LTD NO: TI-840553-E

TITLE: PUMP WIWA 85:1 & 175:1 FLUID SECTION >

REV ECO PREPARED CHECKED APPROVED DATE

PAGE 1 OF 1
E 3940 R LARGUE 25/03/99

COMPONENTS/COM-0009 PAGE 9 OF 9