Fluke 700HPPK User manual

PN 4847685
February 2017
© 2017 Fluke Corporation. All rights reserved. Specifications are subject to change without notice.
All product names are trademarks of their respective companies.
700HPPK
High Pressure Pneumatic Pump
Service Information

i
Table of Contents
Title Page
Introduction .................................................................................................................... 1
Contact Fluke Calibration............................................................................................... 1
Kit Contents.................................................................................................................... 2
Safety Information .......................................................................................................... 4
Tools Required............................................................................................................... 5
Manifold Service (SK-700HPM-FS) Instructions ............................................................ 6
Strainer Washer Replacement/Service...................................................................... 6
Plunger Seal Replacement........................................................................................ 7
Replacement ............................................................................................................. 9
Pump Quick Service....................................................................................................... 10
Pump Quick Service (SK-700HPP-QS) Instructions.................................................. 10
Lubricate the Product ................................................................................................ 10
Piston O-Ring Replacement ...................................................................................... 12
Pump Full Service (SK-700HPP-FS) Instructions .......................................................... 13
Piston O-Ring Replacement ...................................................................................... 13
Inner Pump Shaft O-Ring Replacement .................................................................... 14
Micron Filter and Non-return Valve Replacement (for SK-700HPP-FS only)............. 15
Safe Operation............................................................................................................... 16

700HPPK
Service Information
ii

1
Introduction
The 700HPPK High Pressure Pneumatic Pump and
Manifold Service Kits (the Kit) comes with the necessary
items to service the 700HPPK High Pressure Pneumatic
Test Pump (the Product). For Product usage,
specifications, and basic maintenance information, see
the 700HPPK Instruction Sheet. This document applies to
these Service Kits:
•Pump Quick Service, SK-700HPP-QS
•Pump Full Service, SK-700HPP-FS
•Manifold Service, SK-700HPM-FS
Regular lubrication (typically every 30-days) is the most
important maintenance and ensures trouble-free
operation, and delays having to do Quick-Service and/or
Full-Service. See Lubricate the Product. If pump
operation becomes more difficult or the pump shaft does
not have a thin film of grease on it, this should be done.
Remove the manifold from the pump before you begin
any of these instructions.
Contact Fluke Calibration
To contact Fluke Calibration, call one of the following
telephone numbers:
•Technical Support USA: 1-877-355-3225
•Calibration/Repair USA: 1-877-355-3225
•Canada: 1-800-36-FLUKE (1-800-363-5853)
•Europe: [phone]
•Japan: [phone]
•Singapore: [phone]
•China: [phone]
•Brazil: [phone]
•Anywhere in the world: [phone]
To see product information or download manuals and the
latest manual supplements, visit Fluke Calibration’s
website at www.flukecal.com.
To register your product, visit http://flukecal.com/register-
product.

700HPPK
Service Information
2
Kit Contents
The three kits are described below:
The SK-700HPM-FS contains:
•Strainer Washer
•Filter retainer O-ring
•Plunger Seal
The SK-700HPP-Quick-Service Kit contains these
items:
•Silicone grease, NLGI 2, 15 g tube
•Desiccant pack
•700HPP Pump Quick-Service Seal Kit, see Figure 1.
oPiston O-Ring (qty. 3)
oPiston rod O-Ring (qty. 1)
oAir exchange valve O-Ring (qty. 1)
oBall bearing, qty. 2 (not shown)
The SK-700HPP-FS contains:
•Silicone grease, NLGI 2, 15 g tube
•Desiccant pack
See Figure 1 for these items.
•Non-return valve with O-ring (and , qty. 1
each)
•Spring (, qty. 1)
•Micron filter (, qty. 1)
•Brass end cap lower O-ring (, qty.1)
•Handle connector upper O-ring (, qty.1)
•Air-exchange valve O-ring (, qty. 1)
•Handle connector lower O-ring (, qty.1)
•Non-return valve housing O-ring (, qty.1)
•Retainer nut O-ring (, qty.1)
•Piston rod O-ring, (,qty. 1)
•Piston O-ring (, qty. 1)

High Pressure Pneumatic Pump
Kit Contents
3
1
3
4
257
8
6
9
11
12
10
idg011.eps
Figure 1. Full-Service Seal Kit Contents

700HPPK
Service Information
4
Safety Information
A Warning identifies conditions and procedures that are
dangerous to the user. A Caution identifies conditions
and procedures that can cause damage to the Product or
the equipment under test.
WARNING
To prevent personal injury:
•Read all safety information before you
use the Product.
•Use the Product only as specified, or the
protection supplied by the Product can
be compromised.
•Carefully read all instructions.
•Do not use the Product if it operates
incorrectly.
•Do not use the Product if it is altered or
damaged.
•Disable the Product if it is damaged.
•Do not attempt to operate the Product
above its rated pressure.
•Avoid tipping the Product so that it will
fall over.
•Use care when working with this
Product. Do not drop the Product or
strike it with sharp objects.
•Carefully follow the cleaning and
decontamination instructions in the
manual. Do not use unapproved solvents
or cleaners on the product.
•To prevent eye damage or personal
injury, use approved eye protection.
Caution
To prevent damage to the 700HPP not
covered by the warranty, use only parts and
silicone grease specified in the Kit Contents
section. Do not use petroleum, oil, aerosol-
based lubricants, or other parts for these
procedures.

High Pressure Pneumatic Pump
Tools Required
5
Tools Required
Tools required for the procedures in this document are:
(All tools are metric, equivalent SAE shown where
possible.)
•2.5 mm hex wrench
•4 mm hex wrench
•17 mm wrench
•20 mm (13/16 in) slim jaw wrench
•24 mm (15/16 in) wrench
•25 mm (1 in) slim jaw wrench
•30 mm (1-3/16 in) wrench
Or use an adjustable wrench and adjustable wrench (slim
jaw)

700HPPK
Service Information
6
Manifold Service (SK-700HPM-FS)
Instructions
Strainer Washer Replacement/Service
To avoid build-up of particulate contamination from units
under test, regularly inspect the strainer washer. See
Table 1.
1. Disconnect the test hose () by unscrewing it from
the coupling fitted to the filter retainer.
2. Unscrew the filter retainer () and remove the
strainer washer ().
3. Clean or replace the strainer washer.
4. Inspect the O-ring () on the filter retainer. Replace
if necessary.
5. Lubricate O-ring with small amount of grease.
6. Refit the strainer washer to the main body.
7. Refit the filter retainer and tighten just beyond hand
tight with a wrench.
8. Reconnect the test hose.
Table 1. Manifold Service
1
2
3
4
idg004.eps
Number Description
Test hose connection
Filter retainer
Filter retainer O-ring (PN 4809741)
Strainer washer (PN 4809533)

High Pressure Pneumatic Pump
Manifold Service (SK-700HPM-FS) Instructions
7
Plunger Seal Replacement
To remove the plunger seal, see Figure 2:
1. Remove the set screws () from the knob ().
2. Slide the knob from the plunger assembly.
3. Remove the cap screws ().
4. Withdraw the plunger (), plunger nut (), and
bonnet () as an assembly from the main body.
5. If the plunger seal () remains on the plunger, slide
it off.
6. If the plunger seal is in the main body, carefully insert
the end of the plunger into the seal, approximately
4.5 mm (3/16 in) and gently tilt to pull seal out.

700HPPK
Service Information
8
5
6
4
3
1
2
7
idg008.eps
Figure 2. Plunger Seal Replacement

High Pressure Pneumatic Pump
Manifold Service (SK-700HPM-FS) Instructions
9
Replacement
Carefully inspect the plunger seal for damage to its outer
edges on the open face of both the inner and the outer
diameters. Any damage to these surfaces results in a
leak when reassembled. See Figure 3.
idg005.eps
Figure 3. Plunger and Plunger Seal
1. Carefully put the plunger into the back, flat-side of
the plunger seal, and then gently slide them together.
Note
The plunger seal has an embedded O-ring that
must face towards the main body to make the
seal when assembled.
2. See Figure 4. Carefully insert the plunger assembly
into the main body so that the bonnet () is evenly
supporting the plunger seal (), and the seal is
aligned with the tapered hole in the body.
1 2
idg006.eps
Figure 4. Plunger and Main Body
3. Use the bonnet to gently push the seal into the body.
4. Ensure there is grease on the plunger threads, apply
if necessary.
5. Use a 4 mm hex wrench to secure the plunger
assembly with the cap screws and tighten to 5.5 N·m
(50 lbf·in).
6. Refit the knob, and use a 2.5 mm hex wrench to
secure it with the set screws to 1 N·m (10 lbf·in).

700HPPK
Service Information
10
Pump Quick Service
For quick service of the Product, do steps 1 through 5
from Lubricate the Product.
Pump Quick Service (SK-700HPP-QS)
Instructions
To replace the desiccant, see Figure 5:
1. Unscrew and open the black lid () of the clear
desiccant tube () at the base of the pump.
2. Remove the old desiccant material from the tube.
3. Tear open one of the provided desiccant packs and
pour the desiccant material into the clear desiccant
tube.
4. Screw the lid back on.
Repeat this process every 3 to 4 months or as necessary
to keep moisture out of the desiccant.
1
2
idg003.eps
Figure 5. Desiccant Access
Lubricate the Product
Note
For this section, it is not necessary to replace
the desiccant first.
To lubricate the Product:
1. Pull up the handle of the pump approximately 15 cm
(6 in).
2. Hold the exposed metal body of the pump with one
hand and unscrew the handle to remove the handle
from the unit. The bolt comes off with the handle as
one piece.

High Pressure Pneumatic Pump
Pump Quick Service
11
Note
A 20 mm wrench may be necessary to hold the
handle connector/pump body in place when the
pump handle is rotated counterclockwise.
3. By hand, unscrew the hose fitting at the bottom of
the pump to remove the hose.
4. By hand, unscrew the large plastic nut located at
the top of the pump.
Note
To make step 5 easier, remove the outer body
round end cap by unscrewing it by hand (under
the top manifold bracket). The manifold
mounting bracket can then be removed, which
gives more access to the desiccant assembly.
5. By hand, unscrew the outer body/desiccant tube
assembly from the pump base. The entire assembly
should come off of the pump base.
6. Set the assembly aside. The metal pump body is
now exposed.
Note
If the black pump outer body unscrews from the
clear desiccant tube, the desiccant will spill into
the pump. A strap wrench might be required at
the bottom of the desiccant tube to remove the
entire assembly.
7. Pull up and fully extend the metal pump body.
8. Apply a thin coating of the provided silicone grease
to the exposed pump shaft below the top metal
pump body.
9. To reassemble the pump, reverse these steps.
Follow the Safe Operation procedure to ensure that the
pump is in good condition.

700HPPK
Service Information
12
Piston O-Ring Replacement
To replace the piston O-ring, do steps 1 through 6 from
Lubricate the Product. See Figure 6:
1. Use a 20 mm wrench to unscrew the handle
connector from the pump body.
2. Lift the handle connector to expose the O-ring.
3. Remove the O-ring to expose the pin on the bottom
of the handle connector.
4. Push the pin from one side and then pull the pin out
of the handle connector.
Note
When you reassemble the pump, make sure that
this O-ring is secured in its groove.
20 mm
idg013.eps
Figure 6. Piston O-Ring Replacement (A)
5. Use a 30 mm wrench to unscrew the pump body end
cap and slide off the metal pump body. See Figure 7.
30 mm
idg014.eps
Figure 7. Piston O-Ring Replacement (B)
Hold the lower nut (air exchange valve) with a 24 mm
wrench and then with a 17 mm wrench, unscrew the
exposed ball/O-ring retainer nut. See Figure 8.

High Pressure Pneumatic Pump
Pump Full Service (SK-700HPP-FS) Instructions
13
1
24 mm
17 mm
2
3
idg015.eps
Figure 8. Piston O-Ring Replacement (C)
6. Pull the piston up and out of the pump. Note that the
piston is held in place by the O-ring. Do not lose the
two balls located in the top of the pump.
7. On the air exchange valve, there is a large black O-
ring (). If the O-ring is worn, replace the O-ring.
When you reassemble the pump, add a small
amount of silicone grease to this O-ring.
8. The piston shaft O-ring () is on the bottom of the
ball/O-ring retainer nut. If the O-ring is worn, replace
the O-ring.
9. On the bottom of the piston, there is a small green
O-ring (). Carefully remove this O-ring and apply
a small amount of silicone grease to the
replacement when you reassemble the pump.
10. Reassemble the pump in the reverse order.
Pump Full Service (SK-700HPP-FS)
Instructions
Follow the directions for the desiccant replacement and
lubrication from the pump quick service instructions
above.
Piston O-Ring Replacement
To replace the piston O-ring, do steps 1 through 10 from
Piston O-Ring Replacement and then insert the piston
back in the pump and screw the ball/O-ring retainer nut
back on and move on to the next procedure.

700HPPK
Service Information
14
Inner Pump Shaft O-Ring Replacement
1. Unscrew the air exchange (Figure 9, ) valve with a
24 mm wrench (without unscrewing the ball/O-ring
retainer nut) while ensuring the ball bearings do not
fall off from their pockets.
1
idg019.eps
Figure 9. Air Exchange Valve
2. Once completely unscrewed, remove the pump shaft
assembly and the brass end cap from the bottom of
the pump to expose the non-return valve at the base
(Figure 10, ).
3. Remove the brass end cap from the pump shaft.
2
1
idg017.eps
Figure 10. Pump Shaft O-ring Replacement
4. There are two O-rings in the brass end cap, see
Figure 10:
•An upper thin O-ring which seals against the
bottom of the pump body (no need to replace).
•A thicker O-ring () which sits inside a machined
slot at the bottom of the end cap and seals
against the pump shaft.
Carefully remove the thicker O-ring.
5. Apply silicone grease before installing the new O-ring.

High Pressure Pneumatic Pump
Pump Full Service (SK-700HPP-FS) Instructions
15
Micron Filter and Non-return Valve Replacement
(for SK-700HPP-FS only)
1. Unscrew and completely remove the non-return valve
housing at the base on the pump using a 25 mm
wrench, see Figure 10.
2. See Figure 11. Use long-nose pliers to pull out the
micron filter () from the bottom of the housing.
3
5
4
2
1
idg018.eps
Figure 11. Micron Filter and Non-return Valve
Replacement
3. Use a flat-head screwdriver to unscrew the brass
screw () and pull out the spring () and the non-
return valve with O-ring ().
4. Replace the spring and the non-return valve (with O-
ring) with new ones provided in the Kit.
5. Remove and replace the O-ring () on the outside of
the non-return valve housing.
Note
Do not apply grease to any of these items during
or after replacement. These items must be
completely dry.
6. If necessary, clean the base of the manifold.
7. Reassemble the pump in the reverse order; replace
the O-ring on the top of the ball/O-ring retainer nut
(Figure 8), the O-ring on the handle connector that
covers the retention pin (O-ring in Figure 6), and the
O-ring at the top of the handle connector (Figure 6, O-
ring not shown).

700HPPK
Service Information
16
Safe Operation
To verify safe operation of the Product after maintenance
or repair:
 WARNING
To prevent eye damage or personal injury,
use approved eye protection.
1. Attach a pressure gauge to the hose or the
accessory fitting on the calibration manifold
(700HPPK only). Use any approved (properly-rated)
adapter as required.
2. Close the upper vent valve (700HPPK) and slowly
pressurize the pump/gauge system to 21 MPa
(3000 psi, 210 bar).
3. Maintain pressure for 60 seconds, and check for
excessive leaks.
4. Use the upper vent valve on the calibration manifold
(700HPPK only) to slowly release the pressure.
Pressure can also be vented using the vent valve at
the base of the pump.
If the Product fails this verification, contact Fluke
Calibration for service information. See Contact Fluke
Calibration.
See the 700HPPK Instruction Sheet at www.Flukecal.com
for full specifications and usage instructions.