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Shafer Hand Pump Owner's manual

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MANUAL HAND PUMP
MAINTENANCE AND SERVICE MANUAL
2
GAS-HYDRAULIC
HAND PUMP
BILL OF MATERIAL
1 1 PumpBody
2 1 PumpHead
3 1 PackingGland
4 1 Clevis
5 1 PivotBar
6 1 PumpPiston
7 1 TopRam
8 1 BottomRam
9 1 RamProtectiveCover
10 1 PumpSuctionSeat
11 1 ValveBody
12 1 LeftValveSleeve
13 1 RightValveSleeve
14 6 RingSeal
15 4 RingSealCap
16 2 ValveCap
17 2 Stem
18 2 StemCap
19 2 SuctionCap
20 1 PilotPiston
21 1 ReliefStem
22 1 ReliefSeat
23 1 ReliefCap
24 2 ClevisPinS.S.
25 4 AcetalBearing
26 1 PumpHeadO-RingComp.479-70 70Duro
27 1 RamO-RingComp.479-70 70Duro
28 2 RamWiper 90Duro
29 4 HeadBoltHexHeadCapScrewS.S.
30 1 PistonO-RingComp.479-70 70Duro
31 2 PistonGuideRing
32 1 TopRamSpringPin
33 1 BottomRamSpringPin
34 6 O-RingComp.479-70 70Duro
35 6 RingSealSpring
36 6 RingSealCapComp.479-70 70Duro
37 2 O-RingComp.479-70 70Duro
38 2 StemSpringPin
39 2 StemBoot
40 2 StemKnob
41 1 PilotPistonO-RingComp.479-70 70Duro
42 1 PilotPistonGuideRing
43 2 StemCapO-RingComp.479-70 70Duro
44 1 ReliefCapO-RingComp.479-70 70Duro
45 1 ReliefStemO-RingComp.479-70 70Duro
46 2 ReliefStemSpring
47 1 ReliefBallNylon
48 1 ReliefSpring
49 1 ReliefBoot
50 1 ReliefKnob
51 1 O-RingComp.479-70 70Duro
52 4 NylonBall
53 3 Suction&DischargeSpring
54 4 ValveBoltsHexHeadCapScrewS.S.
55 2 FlushPlug(STL)7/8Taper
56 9 FlushPlug(STL)7/8Taper
57 6 "X"Washer
58 2 AcetalBearing
59 1 FlushPlug7/8TaperSteel
60 2 PilotPistonBack-UpRing
61 1 InstructionPlate
62 4 InstructionPlateScrews#4Type"U"
63 1 ClevisPinS.S.
64 2 O-RingComp.479-70 70Duro
65 1 O-RingComp.479-70 70Duro
66 1 O-RingComp.479-70 70Duro
67 1 O-RingComp.479-70 70Duro
68 1 O-RingComp.479-70 70Duro
69 1 O-RingComp.479-70 70Duro
72 1 FlushPlug7/8TaperSteel
74 1 LockingPin
75 1 UpperRamSealParkerPolyPak
RodSeal Molythane
3
This exploded view corresponds with the above assembly view.
Note:Items70,71&73pertaintothe12cu.in.HandPump
4
CENTRAL HYDRAULIC
HAND PUMP
BILL OF MATERIAL
1 1 PumpBody
2 1 PumpHead
3 1 PackingGland
4 1 Clevis
5 1 PivotBar
6 1 PumpPiston
7 1 TopRam
8 1 BottomRam
9 1 RamProtectiveCover
10 1 PumpSuctionSeat
11 1 ValveBody
12 1 ValveSleeve
14 6 RingSeal
15 4 RingSealCap
16 1 PumpPiston
17 2 Stem
18 2 StemCap
20 2 PilotPiston
21 1 ReliefStem
22 1 ReliefSeat
23 1 ReliefCap
24 2 ClevisPinS.S.
25 4 AcetalBearing
26 1 PumpHeadO-RingComp.479-70 70Duro
27 1 RamO-RingComp.479-70 70Duro
28 2 RamWiper 90Duro
29 4 HeadBoltHexHeadCapScrew316S.S.
30 1 PistonO-RingComp.479-70 70Duro
31 2 PistonGuideRing
32 1 TopRamSpringPin
33 1 BottomRamSpringPin
34 7 O-RingComp.479-70 70Duro
35 7 RingSealSpring
36 6 RingSealCapComp.479-70 70Duro
37 4 O-RingComp.479-70 70Duro
39 2 StemBoot
40 2 StemKnobMPR-6
41 2 PilotPistonO-RingComp.470-70 70Duro
43 2 StemCapO-RingComp.479-70 70Duro
44 1 ReliefCapO-RingComp.479-70 70Duro
45 1 ReliefStemO-RingComp.479-70 70Duro
46 2 ReliefStemSpring
47 1 ReliefBallNylon
48 1 ReliefSpring
49 1 ReliefBoot
50 1 ReliefKnobDK-49
52 2 NylonBall
53 2 Suction&DischargeSpring
54 4 ValveBoltsHexHeadCapScrewS.S.
55 8 FlushPlug
57 6 "X"Washer
58 2 AcetalBearing
59 1 FlushPlug
61 2 InstructionPlate
62 2 InstructionPlateScrews#4Type"U"
63 1 ClevisPinS.S.
65 2 O-RingComp.479-70 70Duro
66 1 O-RingComp.479-70 70Duro
67 1 O-RingComp.479-70 70Duro
68 1 O-RingComp.479-70 70Duro
69 1 O-RingComp.479-70 70Duro
70 1 FlushPlug
73 1 FlushPlug
76 1 KepnerShuttleValve
77 1 ShortPipeNippleS.S.
78 1 LockingPin
79 2 SS-400-1-2M.C.1/8Pipe1.4Tube Swagelok
80 2 SS-400-2-2M.C.1/8Pipe1.4Tube Swagelok
81 1/4O.D.StainlessSteelTubing
86 1 UpperRamSealParkerPolyPak
RodSeal Molythane
5
This exploded view corresponds with the above assembly view.
Note:Items70,71&73pertaintothe12cu.in.HandPump
6
BASIC
CHECK-OUT PROCEDURES
ThefollowingthreetestsillustratetheproperworkingfunctionsoftheShaferhandpump.Failureof
anyoftheseproceduresmayresultinoperatingproblemsforthevalveactuator.
TEST 1
Withbothpalmbuttonsout(automat-
icposition)andwiththeraminthe
"UP"positionanduidinthepump
cylinder,strokethehandpump.-If
theringseals,valvesleevesand
themanualdischargecheckball
aresealingproperly,itshouldbe
impossibletopullthepumpram
down.Theramcanbeloweredor
pulleddownbyholdinginthemanual
dischargereliefandpullingtheram
downatthesametime.
TEST 2
Withonepalmbuttonpushedin
(selectedforopenorclosedposi-
tion)handpumptheactuator.If
thepumpisspongyorwillonly
drawapartialramofoilwhile
pumpingtheactuator,checkthe
gas/hydraulictankforcorrect
oillevels.Ifthecontrolcircuitis
poweredbyacentralhydraulicunit,
checkthepumpreservoirtankfor
correctoillevelandinsurethatthe
handvalve(ifpresent)betweenthe
pumpandreservoirisopen.
Ifthepumpstillwillnotdrawoildur-
ingthesuctioncycle,reconditioning
willberequired.
TEST 3
Thenaltestisaccomplishedby
pushinginthepalmbuttontowhat-
everpositionthevalveisin,"open"
or"closed".Raisethepumphandle
todrawuidintothecylinderand
thenforcetheramdownward.The
ramwilldischargeslowlyonrotary
vaneactuators.Workingproperly,
theramshouldnotmovedownward
inaneasymanner,whenpump-
ingagainstafullystroked(openor
closed)actuator.Thesameproce-
durecanbeappliedtolinear"gate
type"actuators.Downwardmotion
undergreatforcemayoccurifrelief
settingsareexceeded.
7
DISASSEMBLY OF PUMP
AND VALVE COMPONENTS
Failureoftheramto"lock-up"asshowninTest#1isageneral
indicationofringsealfailure,suctioncheckvalvefailureor
manualreliefcheckvalvefailure.Problemareasareusually
duetoadefectivesuctionball,dischargereliefball,ringseal
orforeignmatterimbeddedinoneorallthreeoftheabove
mentionedcomponents.AcutO-ringaroundtheringsea,
suctioncheckseatordischargereliefseatwillproducethe
samemalfunction.
NOTE:DuringanycomponentdisassemblyallO-rings,wear
rings,wipersandnylonballsshouldbereplaced.
TO REMOVE THE MANUAL
DISCHARGE RELIEF ASSEMBLY
1) Pushthereliefknob(50)intoneutralizeanytrapped
gasoroilpressureinthesystem.
2) Pullbothpalmbuttons(40)outintoautomaticposition.
3) Removethedischargereliefknob(50),boot(49)and
hexheadcap(23),stem(21)andspring(46).
4) Placeonehandoverthedischargereliefcavityand
jerkthepumpram(7)downto"pop"thereliefseat
(22)upforremoval.
5) InspecttheO-ringonthedischargereliefseat(22),
thechamferedseatandthenyloncheckball(47)for
scoringordeepscratches.
TO REMOVE VALVE SLEEVE ASSEMBLY
1) Pushmanualreliefvalve(50)downtoneutralizeany
trappedgasoroilpressureinthesystem.(Neglect
thisifthereliefassemblyisalreadyremoved.)
2) Removethepalmvalveknob(40),boot(39)andhex
headcap(18).
3) Carefullypullthestem(17)andvalvesleeveassem-
bly(12)outofthevalvebody(11).
4) Inspecttheatsurfacesonthevalvesleeve(12)and
theO-rings(37)onthestem(17).
NOTE:Thegashydraulicpumpshavetwovalve
sleeves,items(12)and(13).Thecentralhydraulic
pumpshaveonlyonevalvesleeve,item(12).
5) Toremovethepilotpistons(20)insidethevalvebody
(11)rstremovethepalmvalvesleeveassembly(12).
Caremustbetakennottoscratchorscoretheinside
boreofthevalvebody.Replacementofthepilotpis-
tonO-rings(41)shouldbemadeatthistime.
TO REMOVE THE RING SEAL ASSEMBLY
NOTE:Thevalvesleeveassemblies,left(12)andright
(13)applytothegashydraulicpumps.Onevalve
sleeveassembly(12)appliestocentralsystem
pumps.
Thevalvesleeveassembliesforallpumpsmustbe
removedbeforeremovingtheringsealassemblies
(14).
1) Disconnectthehydraulictubingandttingswhichcon-
nectthecentralportstothecontrolandthedischarge
portstotheactuator.Thehexheadcapretainerson
thefrontfaceofthevalve(11)alsocontainringseal
assemblies(14).
2) Removehexheadcapretainers(15)and(16)and
springs(35).
3) Reachinsidethevalvebody(11)throughthevalve
sleeveholeandpushtheringseals(14)out.
4) Inspecttheatfacesoftheringseals(14)forwear
andtheO-rings(34)forcuts.Replacementofthering
seals(14)andO-rings(34)shouldbedoneatthis
time.
DISASSEMBLY OF PUMP AND VALVE COMBINATION
1) Removethefourassemblybolts(54)locatedonthe
backofthepumpbody(1).
2) Carefullypullthevalvebody(11)andpumpbody(1)
aparttopreventlossofthemountingO-ringsbetween
thetwoblocks.
3) Toremovethepumpsuctionseat(10)insertedinthe
pumpbody(1)placeonehandovertheseatcartridge
(10)andonengertoholdthenylondischargeballon
itsseatandjerkthepumpram(7)downwardtocreate
pressureto"pop"thecartridge(10)outintoyourhand.
4) InspecttheseatO-rings(66)and(67),checktheball
(51)andchamferedseatforscratchesandforeign
matter.
5) NOTE:Thispertainstothe12cu.in.pumpsonly.
Removethedischargecheckseat(70)andinspect
O-rings(71)andchamferedseatforscratchesand
foreignmatter.
DISASSEMBLY OF PUMP RAM AND PISTON
1) Removethesnapring(X-washers)(57)locatedout-
sideeachpin(24,63),intheclevispivotarmassembly
(4)and(5).
2) Removethepins63&24),clevis(4)andpivotbar(5).
3) Removethefourpumpheadbolts(29)locatedatthe
topofthepumpcylinder(1).
4) Carefullypulltheram(7),andpistonassembly(6)out
ofthepumpcylinder(1).
5) Inspecttheram(7),pumpcylinderbore(1),piston
O-rings(30)andpistonwearrings(31)forscoringand
excessivewear.TheO-ring(27)andPolyPaklipseal
(86)andwiperrings(28)aroundeachpumpram(7
&8)shouldbereplacedatthistime.OnesetO-ring
(27),PolyPaklipseal(86)andwiperring(28)can
befoundinthepumphead(2).Theothersetcanbe
reachedbyunscrewingthehexshapedramcover(9)
atthebottomofthepumpbody(1).
8
RECONDITIONING
AND ASSEMBLY
RELAPPING THE VALVE SLEEVE
Thevalvesleeves(12)and(13)canbeeasilyrelappedto
assurepropersealingsurfaces;assumingthescratchesin
themarenottoodeep.Noteeachvalvesleevehasfour
atsides.Onlythethreewithholesonthemneedtobe
relapped.Useacircularmotionwithalappingcompound
onaatsurfacetoremovelightscratches.
NOTE: Thecentralsystempumpshaveonlyonevalve
sleeve(12)tolap.
REASSEMBLY - GAS HYDRAULIC PUMP
Afterrelappingthevalvesleeves(12)and(13)andre-
placementoftheringseals(14),withallsixofthehex
headcapretainers(15)and(16)removed,inserttheleft
valvesleeve(12)(indicatedleftbytheletter"L"stamped
onthefrontfaceofthesleeve)intothevalvebody(11).
Thevalvesleeve(12)hasfourportholesdrilledthrough
theatsurfaces.Onesetofholesarelocated90°
apart
fromtheother.Theothersetisadrilledthroughhole.
Wheninsertingtheleftvalvesleeve(12),thetwo90°holes
shouldlineupwiththetopport(15)ofthebody(11)and
thefrontport(16)ofthevalvebody(1).Thefrontbeing
thefacewiththedirectionplate(61).Afterinsertingthe
sleeve(12)asfarasitwillgo,the90°holesshouldbe
linedupwiththeabovementionedports.
Afteroneofthevalvesleeves(12)isreassembled,insert
thepilotpiston(20)intotheoppositesleevehole.(The
pilotpiston(20)canbeinsertedineitherdirection.)The
pilotpiston(20)shouldbepushedinwithascrewdriver
orsimilarnarrowtoolonceit'sstartedintoitscavity.This
shouldbe donecarefully toprevent cuttingthe O-ring
(41)orscratchingtheinsideofthevalvebody.
9
Thereassemblyoftherightvalvesleeve(13)shouldfol-
lowthesameinstructionsastheleftvalvesleeve(12).
Afterinsertingbothvalvesleeves(12)and(13)andtheir
respectivecaps(18),insertthesixringseals(14)through
theportswiththelappedsurfacesoftheringseals(14)
making contactwiththeatsidesofthevalvesleeve
(12)and(13).Insertthesprings(35)andretaininghex
headcaps(15)and(16)andpulleachvalvesleeve(12)
and(13)inandoutseveraltimessothesleeves(12)and
(13)centerthemselvesagainsteachringseal(14).To
insurecorrectassemblyofthesleeve(12)and(13)and
ringseal(14)assemblies,pushonesleeveatatimein
asfarasitwillgoandchecktoseeifthe90°
portholes
inthesleevelineupwiththetop(actuatorport)(15)and
thefrontport(16).Ifthisalignmentiscorrect,followthe
sameinstructionsfortheoppositesleeve.
REASSEMBLY
CENTRAL HYDRAULIC SYSTEM PUMP
Afterrelappingthevalvesleeve(12)andreplacement
oftheringseals(14),withallsixofthehexheadcap
retainers(15)and(16)removed,insertthevalvesleeve
(12)intothevalvebody(11).Thevalvesleevehasve
portholesperend.
NOTE: Thesleeveismarked"L"forleftand"R"for
right.Theveportholesaredrilledthroughthe
fourlappedatsurfacesofthevalvesleeve.
Thegure(below,left)indicateshowtoreinstall
thevalvesleeve(12)intothevalvebodyinthe
correctposition.
NOTE: Thevalvesleevehasatotaloftwelveholes
drilledinfouratsurfaces.Thesurfacewith
sixholesistheTOP.Thesurfacewiththetwo
holesclosesttothetwoextremeends(leftand
right)istheFRONT.Thegureattheleftshows
thesleeveinthisposition.Thesleeveshould
beinsertedintothevalvebodyinthisposition
only.Thefrontofthevalvebodyisthesurface
withtheinstructionplate.Afterreinstallingthe
valvesleeve(12)intothevalvebody(11),insert
thepilotpistons(20)andstemcaps(18).Next
installthesixringseals(14)throughtheparts
untiltheymakecontactwiththelappedsurfaces
ofthevalvesleeve(12).Insertthesprings(35)
andtheretaininghexcaps(15)and(16)and
pushthevalvesleevepalmbuttonsbackand
forthseveraltimestoinsuretheringseals(14)
andseatthemselvesagainstthelappedfaces
ofthevalvesleeve(12).
10
GAS HYDRAULIC
SYSTEM CIRCUIT
MANUAL RELIEF VALVE
PALM
BUTTON
SHAFER ACTUATOR
SPEED
CONTROL
11
CENTRAL HYDRAULIC
SYSTEM CIRCUIT
OIL
RESERVOIR
MANUAL RELIEF VALVE
CONTROL
SPEED
CONTROLS
DOUBLE
HOLDING VALVE
CONTROL
SHAFER
LINEAR ACTUATOR
12
MHP-01102001
Emerson Process Management Valve Automation, Inc.
2500 Park Avenue West
Manseld, OH 44906
Phone (419) 529-4311
FAX (419) 529-3688
www.emersonprocess.com/shafer
/