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HiP T Series Instructions - Parts Manual Download Page 1

3A6823A

EN

Instructions-Parts

T-Series Intensifier 
Pump

Pneumatic pump for generating high pressure for hydrostatic tests and 
hydraulically-operated systems. 

For professional use only.

See page 3 for model information, including maximum working pressures.

Important Safety Instructions

Read all warnings and instructions in this manual 
before using the equipment. Save all instructions. 

Summary of Contents for T Series

Page 1: ...h pressure for hydrostatic tests and hydraulically operated systems For professional use only See page 3 for model information including maximum working pressures Important Safety Instructions Read all warnings and instructions in this manual before using the equipment Save all instructions ...

Page 2: ... 12 Tighten Threaded Connections 12 Storage 12 Troubleshooting 13 Repair Pump Lower 14 Disconnect the Pump Lower 14 Pump Repair 15 Reconnect the Pump Lower 16 Repair Pneumatic Motor 17 Pneumatic Valve 17 Replace Pilot Valves 19 Repair Pneumatic Motor 20 Parts 23 T Series Intensifier Pump 23 Pump Lower 24 Pneumatic Motor 26 Pneumatic Valve 28 Kits and Accessories 30 Repair Kits 30 Dimensions 33 T S...

Page 3: ...00 FKM T6025 254 FFKM 00 FFKM T6025 254 EPR 00 EPR T6016 163 NBR 00 T6016 163 1 NBR 16 250 112 0 1120 0 43 7 1 T6016 163 FKM 00 FKM T6016 163 FFKM 00 FFKM T6016 163 EPR 00 EPR T6012 125 NBR 00 T6012 125 1 NBR 12 500 86 2 862 0 56 9 2 T6012 125 FKM 00 FKM T6012 125 FFKM 00 FFKM T6012 125 EPR 00 EPR T6010 101 NBR 00 T6010 101 1 NBR 10 000 68 9 689 0 70 11 5 T6010 101 FKM 00 FKM T6010 101 FFKM 00 FFK...

Page 4: ...0 FKM T7539 397 FFKM 00 FFKM T7539 397 EPR 00 EPR T7525 255 NBR 00 T7525 255 1 NBR 25 500 175 8 1758 0 43 7 1 T7525 255 FKM 00 FKM T7525 255 FFKM 00 FFKM T7525 255 EPR 00 EPR T7519 195 NBR 00 T7519 195 1 NBR 19 500 134 4 1344 0 56 9 2 T7519 195 FKM 00 FKM T7519 195 FFKM 00 FFKM T7519 195 EPR 00 EPR T7516 158 NBR 00 T7516 158 1 NBR 15 750 108 5 1085 0 70 11 5 T7516 158 FKM 00 FKM T7516 158 FFKM 00 ...

Page 5: ...hen flammable fumes are present Use only grounded hoses Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area SKIN INJECTION HAZARD High pressure fluid from dispensing device hose leaks or ruptured components will pierce skin This may look like just a cut but it is a...

Page 6: ...enuine man ufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving ...

Page 7: ...emoves harmful dirt and moisture from compressed air supply Fluid Line Fluid filter strainer F with a 60 mesh 250 micron stainless steel element to filter particles from the fluid before it reaches the pump Supply fluid shutoff valve N shuts off supply fluid flow Shutoff bleed valve G shuts off pump fluid flow to hydraulic system Fluid pressure relief valve H use to release pressure in outlet line...

Page 8: ...available from HiP to be ordered separately Key A Main pneumatic supply line B Pneumatic line filter C Bleed type master pneumatic valve D Pump pneumatic regulator E Intensifier pump F Fluid filter strainer at the fluid supply container G Shutoff bleed valve outlet only H Fluid pressure relief valve J Fluid inlet line K Inlet port L Outlet port M Fluid outlet line to hydraulic system N Supply flui...

Page 9: ... fluid inlet line J Connect Pneumatic Supply 1 Install the pressure regulator D and gauge to con trol the inlet pressure See Models on page 3 for your model s maximum pneumatic pressure 2 Install a pneumatic line filter B to keep debris from affecting pump performance and to increase pump life 3 Connect the outlet of the master valve C to the 1 2 in female NPT port on the Intensifier pump E Connec...

Page 10: ...nt wetted parts 1 Perform the Pressure Relief Procedure 2 Connect inlet to the supply source of the flushing fluid 3 Connect outlet to a waste reservoir 4 Run the pump until the dispensed fluid is predomi nately flushing fluid 5 Perform the Pressure Relief Procedure This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as sk...

Page 11: ...the pump has transitioned from air to bubbly fluid to pure fluid Build Pressure 1 Close the fluid pressure relief valve H and open the fluid outlet valve G that is connected to the hydraulic system Bleed the hydraulic system of all air per the manufacturer s recommended practice 2 Turn off the air at the pneumatic valve C and set the pressure regulator D to 0 PSI MPa bar Seal the hydraulic system ...

Page 12: ...hat kind of maintenance is needed and then determine a regular schedule for checking your pump Tighten Threaded Connections Check that all threaded connections are tight before each use and at routine intervals Storage If the pump is going to be stored for long periods flush the pump with a light weight oil or rust inhibitor before storage to protect pump components Store the pump with protective ...

Page 13: ...17 See page 17 Pneumatic motor bounces at top of stroke Damaged bottom pilot valve 219 Replace bottom pilot valve 219 See page 19 Pneumatic motor bounces at bottom of stroke Damaged top pilot valve 219 Replace top pilot valve 219 See page 19 Icing inside motor Pneumatic motor operating at high pres sure or high cycle rate Reduce pressure cycle rate or duty cycle of motor Excessive moisture in pneu...

Page 14: ...necessary to loosen or remove either the lower bracket 111 or the locking ring 110 from the pump lower 3 5 Slide the pump lower 3 off of the pump with the lower bracket 111 and locking ring 110 still attached to the pump lower Before servicing or repairing your pump verify that pressure is relieved according to the Pressure Relief Procedure page 10 and that all fluid and pneumatic lines are proper...

Page 15: ...prings 116 and check poppets 114 Inspect for damage and wear and replace as necessary NOTE Assuming the orientation shown in FIG 3 and with the point of lower bracket 111 pointing to the front of the pump when installed the inlet port will be to the left and the outlet port to the right 6 Low and medium pressure pumps only Install the small o ring 115 onto the check poppet 114 then install the pop...

Page 16: ...hen install the outlet check housing 118 11 Medium pressure pumps only Install the spacers 119 and 121 into the outlet port of the fluid cylinder 101 then install the outlet check housing 118 12 Stack and install the seal stack as shown Use grease during installation 13 Install the packing nut 109 with a medium strength thread locking compound and torque to 5 10 ft lbs 7 14 n m The packing nut 109...

Page 17: ...otor Replace Seals or Rebuild Pneumatic Valve Inspect and replace seals and worn parts while disas sembling and reassembling the pneumatic valve on the following pages Use FIG 6 and the following table to identify the kits needed for replacements Disassemble the Pneumatic Valve 1 Perform steps 1 3 under Replace Complete Pneu matic Valve page 17 2 See FIG 6 Use a T10 star screwdriver to remove two ...

Page 18: ...Repair Pneumatic Motor 18 3A6823A FIG 6 310 307 307 309 305 312 311 303 302 308 308 301 304 310 ti16213a 321 321 313 314 1 1 1 1 1 1 1 1 1 Apply lubricant ...

Page 19: ... in place 7 Install the spring 311 Lubricate and install the pneumatic valve cup 312 see FIG 8 Align the small round magnet with the pneumatic inlet 8 Install the valve plate 305 Tighten the screws 309 to hold it in place 9 Perform steps 5 and 6 under Replace Complete Pneumatic Valve page 17 Replace Pilot Valves 1 Stop the pump and perform the Pressure Relief Procedure page 10 2 Disconnect the pne...

Page 20: ...ons and plungers are available as kits and should be replaced 9 Remove the o ring 208 from around the piston 205 10 Remove the retaining ring 204 u cup seals 203 and 233 and the o ring 209 from the bottom cover 201 Reassemble the Pneumatic Motor NOTE For easier reassembly start with the top cover 213 turned over on the workbench and assem ble the pneumatic motor upside down 1 Lubricate and install...

Page 21: ...old Torque bolts to 95 105 in lb 11 12 N m 15 Align the pneumatic valve gasket 216 on the mani fold 215 then attach the pneumatic valve 217 16 Tighten the bolts 210 halfway Work in a criss cross pattern while tightening the tie bolts Check that the shield remains in the grooves on both covers Continue tightening the bolts in pattern and torque to 25 30 ft lb 34 40 N m 17 Lubricate and install the ...

Page 22: ...racket 111 and locking ring 110 still attached to the pump lower 3 slide the pump lower onto the bottom of the pump 2 Orient the lower bracket 111 as shown in FIG 11 3 Insert the screws 5 and torque to 50 60 ft lb 68 81 N m 4 Reconnect the pneumatic and fluid hoses FIG 11 111 5 3 110 ...

Page 23: ...ilable at no cost 1 2 4 5 3 Ref Part Description Qty 1 See Air Motor Replacement pg 31 Pneumatic motor 6 0 in 1 Pneumatic motor 7 5 in 1 2 Spacer included with ref 3 3 3 See Pump Lower Replacement pg 31 Pump lower 3 4 Lock washer included with ref 3 3 5 Cap screw hex head included with ref 3 3 11 25T172 Warning label multi language 1 ...

Page 24: ...Parts 24 3A6823A Pump Lower WL D LJK 3UHVVXUH RZ 0HGLXP 3UHVVXUH RZ 3UHVVXUH 0HGLXP 3UHVVXUH RZ 3UHVVXUH 0HGLXP 3UHVVXUH 6HDO 6WDFN LJK 3UHVVXUH LJK 3UHVVXUH ...

Page 25: ...ck up ring 1 107 Packing ring 1 108 Spacer high pressure pumps only 1 109 Packing nut 1 110 Locking ring 1 111 Lower bracket 1 113 See Check Valves pg 30 O ring 2 114 Check poppet 2 115 O ring 2 116 Compression spring 2 117 Inlet check housing 1 2 npt 1 118 Outlet check housing 1 2 npt 1 119 Spacer medium pressure pump 1 120 Spacer medium pressure pump 1 121 Spacer medium pressure pump 1 122 25T00...

Page 26: ...neumatic Motor T60xx 6 0 in 152 4 mm T75xx 7 5 in 190 5 mm shown 201 210 228 209 202 204 206 205 208 212 209 213 237 243 219 229 211 214 227 216 217 218 218 219 221 215 239 239 239 233 233 239 233 233 239 240 203 222 220 ...

Page 27: ...0 6 211 Motor cylinder T6000 1 Motor cylinder T7500 1 212 B33167 Bolt cover T6000 1 B33168 Bolt cover T7500 1 213 25T085 Upper cover T6000 1 25T086 Upper cover T7500 1 214 Manifold gasket included with ref 215 2 215 24A580 Motor manifold 1 216 Pneumatic valve gasket included with ref 215 1 217 24A352 Pneumatic valve 1 218 Screw M6 included with ref 215 8 219 24A366 Pilot valve 2 220 25T105 Muffler...

Page 28: ...Parts 28 3A6823A Pneumatic Valve 310 307 307 309 305 312 311 303 302 308 308 301 304 310 321 313 314 321 ...

Page 29: ...10 Order Kit 24A359 Ref Description Qty Pneumatic Valve Repair Kit 24A538 Pneumatic Valve Seal Kit 24A536 Pneumatic Valve End Cap Kit 24A361 301 Housing 1 302 Pneumatic valve piston 2 303 Detent piston 1 304 Detent cam 1 305 Pneumatic valve plate 1 307 Cap 2 308 U cup packing 2 309 Screw M3 2 310 Snap ring 2 311 Detent Spring 1 312 Casting cup 1 313 Base cup 1 314 Casting cup gasket 1 321 O ring 1...

Page 30: ...let NBR 25T009 25T017 25T021 Material Models 0305 0507 0610 1016 1219 1625 2539 3657 5868 EPR 25T022 25T026 25T030 25T034 25T038 25T042 25T046 25T050 25T054 FFKM 25T023 25T027 25T031 25T035 25T039 25T043 25T047 25T051 25T055 FKM 25T024 25T028 25T032 25T036 25T040 25T044 25T048 25T052 25T056 NBR 25T025 25T029 25T033 25T037 25T041 25T045 25T049 25T053 25T057 Air Motor Models T6003 T6005 T6006 T6010 ...

Page 31: ...r Motor Models T6003 T6005 T6006 T6010 T6012 T6016 T6025 T6036 T6058 6 0 inch 25T087 25T088 25T089 25T090 25T091 25T092 25T093 25T094 25T095 T7505 T7507 T7510 T7516 T7519 T7525 T7539 T7557 T7568 7 5 inch 25T096 25T097 25T098 25T099 25T100 25T101 25T102 25T103 25T104 Material Models 0305 0507 0610 1016 1219 1625 2539 3657 5868 EPR 25T125 25T129 25T133 25T137 25T141 25T145 25T149 25T053 25T057 FFKM ...

Page 32: ...3A Motor Manifold 24A580 all models and sizes Motor Air Valve 24A352 all models and sizes Pilot Valve 24A366 all models and sizes Muffler Small 25T105 all models and sizes Muffler Large 25T106 includes adapter all models and sizes ...

Page 33: ...Dimensions FIG 12 T Series Pump Dimensions and Mounting Holes Size A B C D E F G H 6000 13 5 in 34 3 cm 8 75 in 22 2 cm 11 5 in 29 2 cm 5 4 in 13 7 cm 4 0 in 10 2 cm 6 5 in 16 5 cm 1 75 in 4 4 cm 5 25 in 13 3 cm 7500 10 0 in 25 4 cm 13 0 in 33 0 cm ...

Page 34: ...nal mounting holes Two M8 mounting holes Three 5 8 11 tie rod holes 5 906 in 150 mm bolt circle ti12738a ti12737a 3 38 in 86 mm 2 0 in 50 mm FIG 14 4 in 102 mm Four M8 X 1 25 optional mounting holes Three 5 8 11 tie rod holes 5 906 in 150 mm bolt circle Two M8 mounting holes ti12740a ti12739a 3 1 in 78 mm 3 1 in 78 mm ...

Page 35: ...dB Pneumatic Motor Sound Pressure 78 dB Inlet Outlet Sizes Fluid Inlet Size all models 1 2 NPT Fluid Outlet Size T6003 T6005 T6006 T7505 T7507 T7510 1 2 NPT Fluid Outlet Size T6010 T6012 T6016 T7516 T7519 T7525 HF9 Fluid Outlet Size T6025 T6036 T6058 T7539 T7557 T7568 HF4 Wetted Materials of Construction Plunger Seal NBR FKM EPR or FFKM Check Valve 17 4 316 SST Pump Body T6003 T6005 T6006 T7505 T7...

Page 36: ...ransportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTIC...

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