SPX SPX Corporation S885 Ilth Street Rockford, IL-61109-3699 USA Fax: (800) 765-8326 Fax; (800) 288-7031 Internet Address ‘itpishew powerteam.com POWER TEAN’ Tech. Services: (800) 477-8326 Onier Entry: (800) 541-1418 Form No. 1000140 Operating Instructions and Parts List for: C€ Pressure Pump Mk 7 Series AIR OPERATED - MK7 RANGE PRESSURE PUMP Pump Design Parameters ‘The air driven pump works on the principle of the differential piston. The air piston being larger in diameter and area than the hydraulic piston to which itis connected. This means the hydraulic pressure generated is equal to the air inlet pressure X the ratio of air piston to hydraulic piston. As the pressure ratio increases the flow rate decreases. This is because the air piston is a constant size and the hydraulic piston decreases in diameter to achieve a higher pressure. Consequently the volume in the hydraulic cylinder decreases. ‘The volume displaced with these pumps depends on the hydraulic piston volume X the stroke rate. ‘The MK.7 pump strokes at about 300 strokes/minute. It should be noted however that as the outlet, pressure increases the pumping rate will slow down. © 2005 SPX Corporation Introduction ‘The principle of operation is very simple and relies on the four main components which are: Air Cylinder This is a cast aluminum housing into which the air piston is fitted (the diameter ofthe air cylinder is the same for all models in the respective ranges). Air Changeover Valve ‘The valve is fitted on the top of the air cylinder and passes the incoming air into the air cylinder. Hydraulic Cylinder This cylinder contains the hydraulic piston and seals. The diameter of this piston determines the ratio of the pump and the hydraulic pressure that can be achieved. Check Valve ‘There are two check valves fitted, one to the suction and one to the discharge of the hydraulic cylinder. Mode of Operation ‘The compressed air is fed into the changeover valve where it is then directed into the air cylinder. This forces down the air piston. The air piston is secured directly to the hydraulic piston which compresses the liquid in the chamber forcing it ‘out of the outlet non-return valve. The spool in the changeover valve has now moved to the end of its stroke ‘causing the incoming air to be directed to the underside of the air piston. This forces the air piston to lift and return to the top position, at the same time liquid is drawn into the hydraulic chamber through the inlet non-return valve. The driving air is exhausted as the air piston returns to the top of its stroke, Sheet No. 1 of 10 Rev Date: 30 Aug 2005Operating Instructions and Parts List, Form No. 1000140, Back sheet 1 of 10 IMPORTANT SAFETY INFORMATION A This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this |symbol to avoid possible injury or death [Denotes an imminently hazardous situation which, if Inot avoided, will result in death or serious injury. A warning Denotes a potentially hazardous situation which, if not javoided, could result in death or serious injury. A caution Denotes a potentially hazardous situation which, if not javoided, may result in minor or moderate injury. CAUTION ICaution used without the safety alert symbol indicates la potentially hazardous situation which, if not avoided, Imay result in property damage. IMPORTANT Denotes an operating or service procedure or condition |considered essential for expedient and efficient loperation and service, A warnine Itis the operators responsibility to read and understand the following safety statements, * Only qualified operators should install, operate, adjust, maintain, clean, or repair this air pump. * Inspect pump before use. Replace any worn or damaged parts, Failure to observe these warning ‘can result in severe injury or death, + Never use any equipment BA WARNING Srethea tons pump ated below the maximum pressure ofthe pump. AA WARNING To help provent personal injury, ‘+ Always wear hearing protection as required Always wear eye protection whenever operating hydraulic equipment, + Operation, repair, or maintenance of hydraulic! pneumatic equipment should be performed by a qualified person who understands the proper function of the equipment per local directives and standards. + Hydraulic/pneumatic equipment must be assembled correctly and then checked for proper function before use. Use components of the same hydraulic pressure ratings. Never use your hands or other body parts 2 to check for a possible leak. High pressure fluid can be injected under your skin causing serious injury andior infection Never place your hands or other body parts near a hydraulic fluid leak. + Ifimproperly used, pressurized equipment can be potentially hazardous. Therefore: Hydraulic connections must be securely fastened before building pressure in the system. Release all system pressure before loosening any hydraulic connection in the system. * Do not exceed the pressure rating noted on the pump data plate. Creating pressure beyond the rated pressure can result in personal injury. + Gauges and accessories may not be included with the pump. However, use the proper gauges and equipment when trouble-shooting, IMPORTANT + Property dispose of all fluids, components, and assemblies at the end of their useful life. * Hydraulic fluid should be compatible with all hydraulic components. + For chemical compatibility ratings see "Seal Material Compatibility Table” on sheet 10 of 10.Operating Instructions and Parts List, Form No. 1000140 OPERATING INSTRUCTIONS MK7 PRESSURE PUMP Installation ‘The pump is designed to work in a vertical position and only three connections are required. Pump operating temperature range 25° F - 150° F (-4° C - 65°C) 1. Connect a suitable filtered air supply not exceeding 100 psi (7 bar) to the pump via an air regulating valve. This valve will control the alr pressure to the pump between 0-100 psi. (0-7 bar). Suggested filter / breather 10 microns. AX WARNING 00 NOT USE AIR PRESSURE TO THE PUMP IN EXCESS OF 100 PSI (7 bar) All air piping should be checked for cleanliness before being connected to the pump. Its recommended that an air shut-off valve be installed to isolate the pump for maintenance purposes. 2. Connect a suitable filtered low pressure fluid supply to the inlet valve (Item 44). A positive head of fluid is recommended for maximum performance. 3. Connect suitable high pressure tubing or fitings to the outlet valve (item 45) as required. A hydraulic gauge with a scale of at least 50% higher than maximum working pressure of the system should be connected in the pipeline from the pump outlet valve. tis also recommended that a shut off valve be installed in the line to shut off the air pressure when the pump is to cease delivery for short periods. 4, On units with bleed plugs (PMAS20", PMA770", PMA980", PMA1740", PMA2410°) bleed system before use. When the above connections are made the pump is ready for use. To Operate 1. Gently turn handle of regulating valve (available on request) counter-clockwise, unti itis free. 2. Turn on hydraulic supply, oil or water. 8. Open shut off valve in airline and turn handle of regulating valve, clockwise until pump starts to reciprocate. ‘Adjust to suit test pressure. Clockwise movement of valve handle increases hydraulic pressure and counter- clockwise reduces it, When handle is screwed 'Home' air will pass through to the pump at the same pressure it enters the valve. If a set hydraulic pressure is required, leave regulating valve set to give desired pressure and control pump by using either the air or the hydraulic shut-off valve. DO NOT EXCEED 100 PSI (7 BAR) AIR PRESSURE. Maintenance AX WARNING To help prevent personal injury, ‘* Disconnect the pump from the supply system before performing maintenance or repair procedures. ‘© Repairs and maintenance are to be performed by a qualified technician. With proper attention to installation detail, the pressure pump requires minimum maintenance and should provide trouble-free service. The air cylinder 'O' Ring, ram, packing and all air seals in the cylinder are made of synthetic rubber. There are no metal to metal moving parts, consequently wear is negligible providing dust or grit does not settle on interior parts. All packings are lubricated when assembled and should not require further lubrication. If the airs filtered and dry, a lubricator should be fitted. Indication of dry cylinder 'O' rings is ‘Jerky’ travel or shuddering of the piston, ‘The ram seals for ratios 1:4 - 1:36 inclusive are attached to the ram and are bi-directional and are assembled with a slight longitudinal movement between the ram shoulder (item 38) and the washer (item 41) The ram seals for ratios 1:54.5 - 1:368 inclusive are contained within the hydraulic cylinder (tem 36) and kept in place with a gland plug (item 37). When this gland plug is screwed home the Sheet No. 2 of 10 correct longitudinal clearance is achieved. Rev Date: 30 Aug 2005Operating Instructions and Parts List, Form No. 1000140, Back sheet 2 of 10 TO CHANGE HYDRAULIC SEAL a) Switch off air and fluid to the pump and disconnect the air line b) Remove screw (item 8) and carefully withdraw from the hydraulic cylinder, the air piston and ram, air cylinder and the air change-over mechanism. The pull is being exerted from the top of the piston rod (item 11) where it locates in the shutile (tem 13) and excessive force should not be used. If difficulty is experienced, unscrew the locknut (item 17) and remove air cylinder and changeover mechanism. This will leave the air spool assembly connected to the piston rod (item 11) and ram (item 38) . One can then remove the ram by gripping the air piston (item 2), turing it and pulling it out. ©) Atter removing the rams the seals can be changed: i) For ratios 1:4-1:36 incl. unscrew cap head screw (item 42) remove washer (item 41) then replace seal. ii) For ratios 1:54.5 - 1:368 incl. remove packing nut Item 37). Itis also advisable to replace the anti-extrusion ring (item 40) when replacing the seal. Before re-assembly in the reverse order, check the air piston ‘O' ring and replace if necessary. Air Changeover Mechanism This consists of 2 shuttles. The primary or 3 way shuttle (item 13) is operated mechanically via the piston rod (item 11) which in turn receives its movement from the main air piston (item 2). The main or 4 way shuttle (item 22) is operated via an air signal from the primary shuttle (item 13) and in turn admits air to one side of the air piston (item 2) while directing the other side to exhaust. I a constant noticeable air leak is detected from the silencer hole when the pump is in the stall condition, examination of the primary and main shuttles (item 13 and 22) should reveal damaged seal rings which must be replaced as required, To check the main shuttle (item 22) for faulty seal rings, remove the four screws in each of the end covers (item 20) and push main shuttle (item 22) out of either end of the main body (item 1). For checking ‘0’ rings on the primary shuttle (tem 13) one has to remove the air cylinder body (item 1). Unscrew the six retaining bolts (item 8) and withdraw the air piston (item 2) the ram (item 38) the piston rod (item 11) the air cylinder body (item 1) and the changeover mechanism complete. Remove circlp (item 6) and pull down piston rod (item 11) and withdraw the primary shuttle (item 13) and the bushing (tem 18). Re-assemble in the reverse order. Inlet and Outlet Valves ‘These are basically the ‘in-line! type and contain either a ball or poppet with a spring. This causes the ball or poppet to seat on an'O' ring. Access is gained by unscrewing the two halves of the valves. Ensure air and low pressure hydraulic supply lines are adequately fitered.Keep pump clean IMPORTANT ‘When ordering spares quote the item number and description from the assembly drawing and state ratio and serial number of pump. Pump seals are only available in kits. Seal Kits Pneumatic Kit All Ratios Part No. cmis24 Hydraulic Kits Ratios Part No. Ratios Part No. 14 M1591 154.5 M1598 19 cote 176.5 cM 1604 1:13.6 cM1536 1113 M1530 1:19 cm15s2 12145 cM1544 1:28 M1567 1:286 M1558 1:98 cois78 1:968 cM 1584Operating Instructions and Parts ist Form No. 1000140 PARTS LIST counter 45, 47 36745 GENERAL ARRRANGEMENT RATIOS 154.6 TO 1:145 NOTE ITEMS 47 ‘ARE NOW SEATED WITHIN BODY OF HYDRAULIC CYLINDER. DOCOUOooo = TI poonnnnan _, ] —P arms ouner wer | - 45 47 36 46 44 GENERAL ARRANGEMENT RATIOS 1:19 TO 1:96 NOTE ITEMS 46 & 47 ‘ARE NOW SEATED WITHIN BODY OF HYDRAULIC CYLINDER. HYDRAULIC tat eaiteetis 5 ti - 4736 46 44 FPA Ta [aoe] 9 [oo | Co Fe Te tor [eras | Pee fa A Tk ——_—_ —__|— (GENERAL ARRANGEMENT RATIOS 1.256 ee apa ee [a 181:988 SHOWN ABOVE ‘Sheet No. Sof 10 Rev Date: 30 Aug 2005Operating Instructions and Parts List, Form No. 1000140, Back sheet 3 of 10 PARTS LIST 5 15. 16 13 34 12 NoTE 1, LOCTITE 542 TO BE APPLIED ON WASHER SPINDLE NUT (ITEM 26) AND PISTON ROD (ITEM 11) 2. PARTS LIST MAY VARY FROM THAT OF THE DRAWING. 52 E oumLer 45 | a7 y \ \ 36 \ 46 44 SECTION VIEW Y-Y NOTE ARRANGEMENT SHOWS ITEMS 46 & 47 OUTSIDE HYDRAULIC CYLINDER RATIOS 1:4 TO 1:13.6 =o. | =~ q SECTION VIEW X-X ‘ASSY No. [RATIO | NAVINUET (THREAD) [NAV OUTLET (THREAD) Magy |_4:i_| __VP-0007 1" NPT) VP.0010 (a/4" NPT) PMABOU. @:1_| _VP-0007 (7 NPT) \VP-0010 (94° NPT) PMAgou | 1861 | vP-0007 (1" NPT) ‘VP-0010 (a/4" NPT) PMAI300_| 19:1 | VP-0009 (ai@" NPT) ‘VP-0004 (172° NPT) PMAieoU | 28:1 | _vP-0000 (aa" NPT) ‘VP-0004 (1/2" NPT) PMAZ«OU_| 36:1 | _VP-0000 (a/4" NPT) ‘VP-0004 (1/2" NPT) PMABTOU | S51 | VP-0008 (1/2" NPT) \VP.0004 (1/2" NPT) PMASeOU | _7e1 | — VP-0008 (1/2" NPT) ‘VP-0004 (12° NPT) PMATTOU__| 1181 |— VP-0006 (1/2" NPT) ‘VP-0004 (12° NPT) PMAgEOU | F45:1_| —VP-0008 (1/2" NPT) 1VP-0008 (1/2" NPT) PMATTSOU_[~256:1 | VP-0011 (172°NPT) _ | VOSBAt (HP AUTOCLAVE) PMAZEIOU [9681 | VP-00T1 (12° NPT) | VOSBAY (HP AUTOCLAVE) ASSYNo_ | RATIO_[ NAV INCET (THREAD) | NAV OUTLET (THREAD) Pare | 41 \VOSBAT (f" BSP) ‘Va0BB1 (84° BSP) PMAOB [ot VOsBAT (BSP) ‘Va0861 (34° BSP) PMAQOB [1361 VosBAT (TBSP) Va0eB1 (9/4" BSP) PMAtso8 | 191 |vaoeei (a" ese) | voraat (12" BSP) PMAISOB [281 | va0BBH (a/4" BSP) Vo%BAt (1/28 BSP) PMazso8 | 96:1 | VS08B1 (a/4" BSP) VOIBAt (1/2" BSP) PMAg7OB [545.1 | _VoIBAN 1/2" BSP) \VOIBAT (1/2" BSP) PMAS208 | _76:1_| _VOIBAT (1/2" BSP) VOIBAt (172° BSP) PMA770B_| 113:1_| VOIBAT (1/2" BSP) VOIBAT (12° BSP) PMASGO | 145:1 | VOTBAT (2 BSP) VOIBAT (12° BSP) PMAI7408 | 256: | VO7BAT(1/2"BSP) | VOSBAI (HP AUTOCLAVE) PMA26108 | 968:1 | _VO7BAT (1/2" BSP) _|_Vo5BAI (HP AUTOCLAVE)Operating Instructions and Parts List Form No. 1000140 PARTS LIST - PMA370B & PMA370U (Ratio 54.5:1) item Pat No, No. No. Read Description 7 168509 1 Aluminum Ai Cynder BodyiGov 2 468508 1 Piston 2 331392 1 “4 333036 2 [Prre fing ior 7] 3 31276 1 Orne tre 7 168506 1 —— 8 335056 6 wa ew Mk 10 335058 1 ——— " 168508 1 Mic Piston Rod “2 330558 1 13 168509 1 METS Way Spo Aluminum “14 336480 2 46 33574 4 16 4168510 1 - 7 335649 1 Flemthane 1” BSP Nut 18 68511 1 Bushing 9 168512 1 Aluminum End Cover 20 4168519 1 ‘Aluminum End Cover 21 169749 1 4 Port SLV (Siow Op) 2 ‘69082 1 4 Port Shute Aluminum “24 335062 5 25 seo118 1 nd Cap Pose 26 335071 1 Lock Nut MB Mic 28 168601 1 Pug (MK? Air Cylinder 23 335085 8 “20 08-380 4 Gonm OD Gh¢ Ring Seat “31 168514 1 End Cover Gasket 82 468560 1 End Cover Gasket 33 168558 1 Piug (00 Not Rw 34 arais i Madan - PowerTeam Label 36 160628 1 Hycrauic Cynder 154.5 38 4168520 1 3 Hycrauie Ram 1-4 439 392220 1 Seal AS12605 MK 140 168691 1 Ant Ring +49 335068 1 Fubber Ring Mk 44 vvp-0003 i NPT Nan REIT VAVETHTt (or PMA 370U) 45 voreat 2 BSP NAV Init & Outlet (or PMA 3708) vps 2° NPT Nan Baim Valve Out fr PMA 970U) 147 168589 1 48 a3sta1 1 — 1 3a0ae0 1 32 269123 1 Exhaust Label For 53 819.001 2 Hamm 54 395602 1 55 320-008 1 STencer (V2 BSP) + Included in CM1524 Pneumatie Kit + Included in CM1598 Hydraulic Kit Sheet No. 7 of 10 Rev Date: 30 Aug 2005Operating Instructions and Parts List Form No. 1000140 Seal Material Compatibility Table E = Excellent ‘Seal Seal Materi Fluid Material Fluid Viton | EPDM (Nitrile [Viton [EPDM NR E NR] Acetaldehyde NR) F NA | Furtural F E F Acetic Acid E F E | Gasoline ND F NR | Acetic Acid anhycride |} G E E | Glycerine NR E NA | Acetone E NR E Heptane F NR NR | Acetonitile E NR E Hoxane NR ND NR | Acetophenone E ND E Isobutane ND NO G Allyl alcohol E a E Light Machine oi ND ND 6 Allyl chloride E NR E Linseed oil 6 F F ‘Ammonia E E E Mercury NR 6 E Aniline 6 NR E Methanol 6 E E Beer NR NR | Meth! chloride E NR E Benzene NR ND | Methylene chloride NR NR G Bromobenzene a E E Milk NR NR NA | Butyl acetate NR F E Nitrobenzene E G E r-Butric acid E NR E | n-Octane ND NR 6 Butric acid E G E | olhydrautic F NR E Cabon Tetrachloride E a E | Oiveoil E E E Castor of E NR E Parafin ol NR NR E Chiorobenzene E ND E Pentane NR F E Chloroform NR NR E Phenol E e E Cottonseed oil E F E Propane F F E m-Cresol 6 NR E Rape oll E F E Cruide oi! 6 E E | Seawater 6 NR E Cyclohexane E NR E | Soyabean oil ND G F Diethylamine F E E | Toluene E 6 E Diathylene glyco! F F E | Trichiorethylene E E G Ethanol E F E | turpentine F NR NR | Ether (aiethy-) 6 G E Urea NR G NR | Ethyl acetate E E E | Water E E 6 Ethyl alcoho! NR F G Ethylene chloride E E E Ethylene gylco! NR F F Ethylene oxide S E E Formaldehyde F G F Formic acid NOTE: ‘These chemical compatibility ratings are provided as a general guide for use at your own discretion and risk. Variations in temperature, pressure, or concentration may effect the chemical resistance of a material. We recommend testing under specific conditions to determine the suitability for your application No guarantee of chemical compatibility is given or inferred. Sheet No. 10 of 10 Rev Date: 30 Aug 2005,Operating Instructions and Parts List, Form No. 1000140, Back sheet 10 of 10 TECHNICAL SPECIFICATIONS Ratio 1 4 _|s fie |1i9_ [284 |s6 [545 |re5 |113° [145 [ase |s68 IRam/Dia (mm) 7e2 |508 |413 (350 |285 254 |206 |175 [143 f27 |95 |so IRam/Dia (in) 3 fa |1.625 1.975 | 1.125 |1 813 |.688 |.s63 |so0 |.375 |.313 loutput per cycle (litres) 16 |.07 |.05 |.034 |.023 J.018 |.012 |.008 |.006 |.004 |.0025 |.0017 loutput per cycle (ind) 72 |432 fees j204 | 137 |108 |.71 |s1 [94 jar [1s |.t04 IMaximum flow litres/min 370 |230 |1is0 (110 |73 |s8 |s8 jes j18 fs |e4 |.s8 lat zero pressure IMaximum flow in3ymin 2260 |1400 |o1s 670 | 455 |a54 |230 |170 |110 |o1 |s1_— |a5 lat zero pressure IMax. Output pressure (bar)| 27 60 a0 |130 | 190 [240 |370 |s20 |770 Jas0 |1740 |2410 lwith air supply of 7 bar IMax. Output pressure (psi) | 390 870 |1300 |1880 | 2750 |s480 |s360 |7540 |11160 |14210 [25230 |35000 jwith air supply of 100 psi