Heritage 1022 User manual

SERVICE MANUAL
1 0 2 2
AIR OPERATED PUMP, 60:1
INSTALLATION, OPERATION
and MAINTENANCE
Consisting of the following:
Part Number 18500: Air Motor, 8-1/2”
Part Number 12600:Fluid End, 2.6

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CUSTOMER:
PURCHASE ORDER NO.:
SALES ORDER NO.:
INVOICE NO.:
SERIAL NO(s).:

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GENERAL INFORMATION
WARRANTY
The standard Heritage PumpsTM Warranty provides protection against
defective workmanship and materials for one year after shipment and does
not include certain expendable parts such as gaskets, O-rings, and other soft
goods and rubber parts which will deteriorate with normal wear or improper
storage. The standard warranty does not cover damage to any parts that is
the result of failure to maintain and operate the equipment in accordance to
the recommended practices for operation and maintenance.
Heritage PumpsTM reserves the right to, in the normal course of business,
make product improvements in materials, production methods, or
engineering design changes which may not be reflected in this publication
without incurring any liability or obligation beyond that stipulated in the
purchase contract.
All claims for warranty must include the appropriate serial number of the unit
and include a Heritage PumpsTM Return Material Authorization No. (RMA
No.).
This manual is intended as a guide for normal operation of the Heritage
PumpsTM product for which this manual pertains. Many factors affect the
proper function or malfunction of this equipment. Complete knowledge of all
factors affecting the operation of the equipment and all detailed facets to be
encountered is not possible. If a situation is encountered not covered in this
manual, contact the manufacturer.

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WARNING! WARNING!
The Heritage PumpsTM air operated pumps are mechanical devices with moving
parts that are used to move fluid and create high pressure flows. Use extreme
caution and exercise all safety practices when performing maintenance or
operating these pumps. Do NOT ignore the warnings and cautions in this
publication. It is important to follow all instructions in this manual using only
approved methods, tools, and parts/materials. Do NOT permit the operation of any
questionable equipment or safety practices as this creates dangerous conditions to
personnel. Accidents are caused by careless unsafe acts and operating conditions.
SAFETY IS A CHIOCE AND IT IS YOUR RESPONSIBILITY! YOU MUST CHOOSE TO
PRACTICE SAFETY TO PROTECT YOURSELF AND OTHERS.
WARNING! WARNING!
BEFORE PERFORMING ANY MAINTENANCE OPERATIONS, THERE ARE IMPORTANT
SAFETY PRECAUTIONS TO PERFORM.
1. Disengage the power source to the pump. This should include using the
appropriate lockouts on air supply valves and electric supply to compressors
providing air to the pump.
2. Shut off the supply of fluid to the suction inlet of the pump.
3. Shut down any accessory equipment.
4. Bleed off all pressure in the discharge line of the pump.
FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS IN THIS MANUAL COULD
RESULT IN DAMAGE TO PROPERTY, EQUIPMENT, AND SERIOUS BODILY INJURY OR
EVEN DEATH. MAINTENANCE AND REPAIR WORK SHOULD BE PERFORMED BY
COMPETENTLY TRAINED AND QUALIFIED PERSONNEL AND CONFORMS TO ANY
RELEVANT LOCAL REGULATIONS.

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ATEX WARNING STATEMENTS
Pumps and Pump Packages
1. When installing a pump or pump package in a potentially explosive
environment, confirm that these conditions were specified at the time of
purchase and that the supplied equipment conforms to all requirements and
displays the appropriate ATEX nameplate or is supplied with a certificate of
conformity. Any questions as to the conformity of the equipment should be
directed to Heritage Pumps, LLC before installation and commissioning.
2. All fluids being processed should be maintained within specified safe
temperature limits. Failure to control fluid temperature could cause the
pump and/or system components to become a possible source of ignition due
to temperature rise. In cases where the fluid temperature is 70o C, the surface
temperature of the equipment will not exceed 80o C, provided the pump and
related system is installed, maintained, and operated as specified in this
manual.
3. All maintenance and repair work should be performed only by properly
trained competent personnel adhering to any and all local regulations.
4. All pneumatic equipment, controls, and safety devices must be suitably rated
for the environment and system pressure in which it is installed.
5. When the equipment is installed in an environment where the accumulation
of dust or gases is a risk, be sure that all equipment is properly grounded and
that only non-sparking tools are used for installation and maintenance.
6. Control/safety devices should be installed into the system to minimize the risk
of sparking as the result of mechanical overload. The power supply to the Air
Motor and auxiliary equipment should have an isolator switch or control valve
installed to disconnect and lockout in the off position. A check valve and relief

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valve/safety head should be installed near the discharge port of the pump
fluid end. All system safety and control devices should be installed,
maintained, and operated in accordance to the respective manufacturer’s
instructions. Always check to be sure that all valves are in the open position
when starting the pumps to prevent rapid over pressurization of the system
and causing a possible failure.
7. Proper maintenance and operation of the pump and related auxiliary
equipment in accordance to the specific manufacturer’s instructions is
required to prevent premature failure of components which could create
potentially dangerous conditions and equipment failure. The regular routine
inspection and replacement of worn components is required to maintain the
safety and integrity of the system and related components.
8. In accordance to certain guidelines covered by legislation, the pump and its
components have been designed and tested to ensure safe operation when
properly installed, operated, and maintained. Heritage PumpsTM declares this
machinery safe to use for the duty specified as defined by the Declaration of
Incorporation of Conformity that is issued with this instruction manual.
9. The use of this equipment as classified higher than Category I as defined in
Article 9 of 97/23/EC is prohibited. For calculation purposes, the volume of
chambers is less than 1L.
AT THIS TIME THE HERITAGE PUMPS ARE NOT ATEX CERTIFIED; HOWEVER, THEY
DO CONFORM TO ATEX STANDARDS. HERITAGE PUMPS, LLC IS IN THE PROCESS
OF OBTAINING ATEX CERTIFICATION.

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TABLE OF CONTENTS
1.0 System Design and Layout ...................................................................7
1.1 General Considerations......................................................................... 9
1.2 Lifting .............................................................................................. 9
1.3 Mounting Pump ................................................................................... 9
1.4 Suction Line Design and Specifications ............................................... 10
1.5 Discharge Line Design and Specifications ........................................... 10
1.6 Air Inlet Line Design and Specifications ............................................. 11
2.0 Installation, Start-up and Operation .................................................... 12
2.1 Installation and Start-up ..................................................................... 12
2.2 Recommended Service Procedure ..................................................... 12
2.3 Recommended Air Motor Maintenance ............................................ 13
3.0 Air Motor Disassembly & Reassembly Procedure................................. 15
3.1 Air Motor Trouble Shooting ............................................................... 15
3.2 Exploded View .......................................................................... 16
3.3Disassembly ....................................................................................... 17
3.4Reassembly ........................................................................................ 19
4.0 Pump Fluid End Disassembly & Reassembly Procedure........................ 22
4.1 Pump Fluid End Trouble Shooting ..................................................... 22
4.2 Exploded View .......................................................................... 23
4.3Disassembly ....................................................................................... 24
4.4Reassembly ........................................................................................ 24

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1.0 SYSTEM DESIGN AND LAYOUT
1.1 GENERAL CONSIDERATIONS
A properly designed layout will save time and minimize expense
during installation, operation and maintenance. It is important to
select the proper location for the pump to insure adequate positive
suction head to the pump inlet, which contributes to overall pump
efficiency. Piping design and layout is an even more important
design consideration. All suction lines should be as short and direct
as possible. There should be minimal bends and utilize full opening
valves and fittings to eliminate any flow restrictions. Optimal pump
operation and ease of maintenance should include other basic
considerations outlined below.
1.2 LIFTING-WARNING!
The pumps discussed in this manual can be safely lifted manually
by an individual; however, care should be taken to avoid accidental
bodily injury or damage to the pump from accidental dropping. Do
not lift the pumps by the air lines!
1.3 MOUNTING PUMP
1. When determining the location of the pump. Consider the
proximity to associated equipment, fluid supply, ease of
maintenance access, and any elements of environmental
contamination.
2. The pump mounting bracket should provide support under the
Cylinder Base, preferably securing the pump by the Stanchion
Rods. (See Heritage PumpsTM Mounting Bracket Assembly Part No.
17360).
3. The pump should be mounted level and perpendicular with the Foot
Valve and pump inlet connect at the bottom. An angular mounted

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pump that is not perpendicular may have erratic operation and
difficulty priming.
4. The mounting method must provide adequate support to avoid any
flexing of the equipment or the system.
1.4 SUCTION LINE DESIGN AND SPECIFICATIONS
1. The suction line must be equal to or one size larger than the inlet
connection on the Foot Valve. The line should be as short and
straight as possible from the fluid reservoir.
2. A full opening ball or gate valve (no reduced port valves) should
be installed on the suction line at the fluid reservoir to permit
draining of the line or removal of any debris. The use of a Y-type
strainer in the suction line is recommended to prevent debris
from accidentally entering the Foot Valve of the pump.
3. Do not install flow meters or other instrumentation which would
restrict flow in the suction line.
4. Insure there is not any rise in the suction line which can collect
air of other fluid vapor.
5. If it is necessary to install a charge pump into the suction line, it
should have an output greater than the peak volume required to
fill the suction need of the pump on the suction stroke plus at
least 50%. A good rule of thumb is to use a charge pump with
double the output of the pump being supplied.
6. The suction line needs to be solidly and independently
supported without putting the pump in a strain to prevent
vibration from having any direct influence on the pump.
1.5 DISCHARGE LINE DESIGN AND SPECIFICATIONS
1. The discharge line should be equal to or larger than the
discharge port of the pump and sufficiently capable of handling
the maximum pump discharge pressure in the system.

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2. Avoid using a bend in the discharge line immediately after the
discharge port. Bends in the discharge line should be made
utilizing 45o long radius elbows, avoiding 90o elbows whenever
possible.
3. A properly sized check valve and relief valve/safety head should
be installed near the discharge port. The relief valve/safety head
should be set to relieve pressure at 15-25% above the maximum
pressure of the operating system.
4. The discharge line needs to be solidly and independently
supported without putting the pump in a strain to prevent
vibration from having any direct influence on the pump.
1.6 AIR INLET LINE DESIGN AND SPECIFICATIONS
1. A properly sized air filter/moisture separator should be installed
as these pumps require moisture free air.
2. After the air filter/moisture separator, install a properly sized air
pressure regulator set at 120 PSIG (8.27 bars) maximum.
3. After the air pressure regulator and as near to the pump as
possible, install a properly sized automatic air lubricator. (See
Section 2.3 RECOMMENDED AIR MOTOR MAINTENANCE,
found earlier in this manual for detailed instructions on
lubrication flow rates and applications.)
WARNING! WARNING!
AIR SUPPLY PRESSURES SET ABOVE THE STATED MAXIMUMS CAN RESULT
IN PROPERTY DAMAGE, PERSONAL BODILY INJURY, OR DEATH.

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2.0 INSTALLATION, START-UP AND OPERATION
2.1 INSTALLATION AND START-UP
1. Visually inspect the unit for any signs of damage during shipping.
2. Connect the air supply line to the inlet connection on the pump,
connect the suction line to the fluid inlet of the pump, and
connect the discharge line to the pump.
3. Open the valve on the suction line to supply fluid to the pump
fluid inlet.
4. Open any valves in the pump discharge line.
5. Slowly open the valve in the air inlet line to start the pump
operation at slow speed until the pump Fluid End and the
discharge lines are completely primed.
6. Slowly open the air inlet valve until fully open.
7. Observe pump operation checking the following:
i. Check the Fluid End and all fluid connections for leaks.
ii. Check the top side of the pump block for any packing
leakage.
iii. Check to see that the “up” and “down” strokes are of equal
speed.
iv. Repeat this procedure any time the pump has been out of
service for an extended time period. The upper packing set
can dry out and loose its seal if the pump is not used
regularly.
8. WARNING! DO NOT INSERT FINGERS OR TOOLS INTO THE
AREA WHERE THE PISTON ROD AND PLUNGER ROD ARE
COUPLED TOGETHER AND MOVING UP AND DOWN. FINGERS
CAN BE SEVERELY PINCHED OR EVEN CRUSHED.

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2.2 RECOMMENDED SERVICE PROCEDURE
Under normal operating conditions, a routine maintenance and
service inspection is required at 800-1500 hours, based on the
service and operating environment of the Air Operated Pump. At
this service interval, it is recommended that a Seal Kit (Part No.
18597) be installed. For uninterrupted service, it is highly
recommended that (1) one Major Repair Kit (Part no. 18599) or
Minor Repair Kit (Part No. 18598) be kept on hand for routine
maintenance or emergency repairs. (Both the Major Repair Kit and
the Minor Repair Kit include the Seal Kit.)
2.3 RECOMMENDED AIR MOTOR MAINTENANCE
The Heritage PumpsTM Air Motors need to be supplied moisture
free air by providing an adequately sized air filter/moisture
separator to insure optimal operation of the Air Motor. In very cold
and humid operating conditions combined with high cycle rates
and high discharge pressures, it is strongly recommended that a
properly sized air filter/moisture separator and an automatic air
lubricator be included in the air inlet line. The Air Motor does
require lubrication using a 10W30 nondetergent motor oil. This
should be provided by an automatic air lubricator installed just
ahead of the air inlet port to the Air Motor. Check the automatic
air lubricator frequently to insure there is an adequate level of
10W30 nondetergent motor oil in the reservoir. Check the flow
rate through the clear sight dome. The proper flow rate is (1) one
drop per minute or every 50-60 cycles. In cold weather when icing
can be a problem, increase the flow rate to (2) two drops every 50-
60 cycles. Very high cycle rates, above 60 cycles per minute, 90-
120 cycles per minute, will require higher injection rates. After
each refilling of the automatic lubricator, it is important to check

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the injection rate and readjust as required. The use of detergent
type lubricants will create serious problems for the air motor and
VOID THE WARRANTY.

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3.0 AIR MOTOR DISASSEMBLY & REASSEMBLY PROCEDURE
3.1 AIR MOTOR TROUBLE SHOOTING
PROBLEM
CAUSE
CORRECTION
Air motor stalls at
the top or bottom
of the stroke –no
air blows from
exhaust ports.
Piston rod is loose
where it connects to the
fluid end plunger rod.
Trip Springs or Trip Rod
Valve Spring is broken
Air Motor is frozen due
to icing or lack of
lubrication.
Muffler has become
fouled or clogged with
contaminates.
Tighten connection.
Inspect and replace as needed.
Install air filter / moisture
separator. Check lubricator and
fill with lubricant.
Replace muffler and check air
supply line. Inspect the air
filter and lubricator.
Air motor stalls –
air blows from
exhaust ports
See CAUSES above
Air valve is in the dead
stall position.
O-Rings are worn, cut or
otherwise damaged.
See CORRECTIONS above
Remove one of the trip spring
retainers, trip spring and ball.
Carefully push the air valve up
or down. Lubricate the air
valve and reassemble.
Install seal kit for the respective
air motor. If dust, dirt or other
contaminants are found in the
air motor, check the air supply
system.

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3.2 EXPLODED VIEW

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3.3 DISASSEMBLY
In the next two sections there will be numerous references to
specific parts by name found in the provided exploded views. Each
part will have a number in ( ) parenthesis. That number refers to a
number connected to an arrow that designates an item number in
the attached parts list. The parts list will contain the specific Part
Number for that item.
WARNING! WARNING! WARNING!
1. Close the air inlet valve and disconnect the air line from the air
inlet on the Air Motor Cylinder Head (1).
2. Close the suction line valve and disconnect the suction line from
the Foot Valve (See Section 4.2 item 17) of the pump.
3. Bleed off all pressure in the discharge line and disconnect the
discharge line from the Pump Block (See Section 4.2 item 6).
NOTE: FAILURE TO FOLLOW STEPS 1-3 CAN RESULT IN PROPERTY
DAMAGE, SERIOUS BODILY INJURY OR DEATH.
4. Unthread the Fluid End Coupling Nut (See Section 4.2 item 2)
from the Air Motor Piston Rod (32). Use a 1” open end wrench
as a back up to hold the Piston Rod (32) and use a 1-3/8” open
end wrench to loosen the Coupling Nut.
5. Remove the Nuts (See Section 4.2 item 8) and Washers (Section
4.2 item 3) from the Stanchion Rods (Section 4.2 item 4).
6. Remove the Fluid End Assembly from the Stanchion Rods (See
Section 4.2 item 4) and lay to the side. (Removal of the
Stanchion Rods is not required, but it will make servicing the Air
Motor less awkward.)
7. Remove mufflers (13) to make servicing easier. If the Air Motor
is equipped with aluminum mufflers, these can be soaked in
kerosene to remove residue build up.

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8. Remove the Nuts (2) and Bolts (9), Trip Spring Retainers (5),
Springs (7), and Balls (4) from both sides of the Cylinder Head
(1).
9. Disconnect the Air Line (11) from the Adapter (10) at the
Cylinder Head (1) and the Cylinder Base (34).
10. Remove the six Cylinder Tie Nuts (35) and Cylinder Tie Bolts (3)
using a 9/16” box end wrench and socket with a ratchet.
11. Slide the Cylinder Base (34) off the Piston Rod (32).
12. With the Piston (29) in the up-stroke position slide the Cylinder
(26) off the Piston (29) and from the Cylinder Head (1). Take care
to not scratch the inside diameter of the Cylinder (26) as it is
being removed.
13. Position the Cylinder Head (1) so that the Retainer Ring (23) can
be removed from the bottom side of the Cylinder Head (1) and
remove the Cylinder Head (1) from the Piston Assembly. The
Valve Sleeve (14) may come out of the Cylinder Head (1). If it
remains, it can be left in place, unless the O-Rings are to be
replaced. To remove the Valve Sleeve (14) use the Valve Sleeve
Removal Tool (Part No. 17389).NOTE: Do NOT damage the
inside bore surface of the Cylinder Head (1) while removing the
Valve Sleeve (14).
14. Remove the Stop Nut (16) and the Upper Valve Keeper (17). Use
an adjustable wrench on the flat found on the Trip Rod Assembly
(27) to hold the assembly. DO NOT USE A VISE OR ANY TOOL
THAT WOULD SCRATCH THE TRIP ROD SURFACE.
15. Slide the Air Valve (18) off the Trip Rod Assembly (27) and
remove the Lower Valve Keeper (20) and Bushing (21).
16. If the Piston Rod (32) is to be replaced, place the Piston (29) in a
vise holding it on the flat sides (DO NOT HOLD ON THE OUTSIDE

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DIAMETER AS THIS WILL DAMAGE THE PISTON) and remove the
Piston Rod (32).
17. Remove the Piston Nut (24) and the Piston Nut Washer (28)
while the Piston (29) is still secured in the vise.
18. Remove the Trip Rod Assembly (27) and the Trip Rod Collar (31).
19. Remove all used O-Rings and Gaskets and discard.
3.4 REASSEMBLY
All parts to be reused should be cleaned with kerosene or other
environmentally safe cleaning fluid. As parts are being
reassembled, be sure to lubricate all parts and seals with a silicone
based non-water soluble lubricant. Be sure to use genuine
Heritage PumpsTM repair parts. If this is a routine maintenance,
use Seal Kit 18597. If this is a major overhaul use Minor Repair Kit
18598 or Major Repair Kit 18599.
Note: During the reassembly process, it is important to exercise
care when installing O-Rings or inserting parts with O-Rings for
seals. Avoid cutting O-Rings to insure proper sealing. Ensure all
seals and O-Rings are adequately lubricated with the appropriate
lubricant.
1. Install the new O-ring (33) into the Cylinder Base (34).
2. Install the new O-Ring (30) onto the Piston (29).
3. Install the new O-Rings (15) and (22) in the Bushing (21).
4. Thread the Piston Rod (32) into the Piston (29). Use of a
temporary thread locker is acceptable. Be sure to hold the
Piston (29) by the flat sides in a vise and do not damage the O-
Ring groove.

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5. Insert the new Valve Trip Collar (31) into the Piston Rod (32) and
then insert the Trip Rod Assembly (27).
6. While holding the Piston (29) in a vise, screw the Piston Nut (24)
and Piston Nut Washer (28) into the Piston Rod (29).
7. Install the Cylinder Gasket (25) into the Cylinder Head (1) and
the Cylinder Base (34).
8. Carefully insert the Piston (29) and Piston Rod (32) assembly into
the Cylinder Base (34). It is recommended to place a wrap of
tape around the threads of the Piston Rod to prevent cutting the
O-Ring (33) in the Cylinder Base (34).
9. Install new O-Rings (19) on the Air Valve (18).
10. Install the Lower Valve Keeper (20) with the small diameter up
and be sure it seats the small counterbore on the shoulder of
the Trip Rod (27).
11. Insert the Trip Rod Assembly (27) through the Air Valve (18)
and seat the small end onto the Lower Valve Keeper (20).
Next, thread the Upper Valve Keeper (17) onto the Trip Rod
Assembly (27). While holding the Trip Rod with an adjustable
wrench, thread the Upper Valve Keeper (17) down to the Air
Valve (18) until finger tight, then back off ¼ turn max, so that
the Air Valve (18) moves slightly. Then thread the Stop Nut
(16) down to the Upper Valve Keeper (17) and lock the two
together. Be sure the position of the Upper Valve Keeper (17)
does not change position.
12. Apply grease to the Piston O-Ring (30) and to the Inside of the
Cylinder (26). Carefully work the Cylinder over the Piston O-
Ring avoiding damage to the O-Ring.
13. Install new O-Rings (15) onto the Valve Sleeve (14) and grease
the assembled valve sleeve and the inside bore of the Cylinder
Head (1). Carefully insert the Valve Sleeve (14) into the