Hydronic P820 User manual

Hydronic Corporation
Air Driven Hydraulic Pumps and Intensifiers
P820 Installation, Use and Maintenance Manual
Contents
Introduction, Guarantee and Identification Plate
Description, tartup Procedures
Description of Working Parts, torage and Disposal
Fault Finding, Maintenance and Weights
pare Parts
Hydronic Corporation, 2034 Fruit St, Algonac, MI 48001 United States o America
℡ [phone] www.hydroniccorp.com

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 2
Introduction
This handbook is intended to give the operator the basic instructions or the use and
maintenance o the pump. The air hydraulic pump operator must read this handbook
be ore putting the pump into operation. A ter correctly installing the pump, keep this
manual stored in a sa e place. I you have di iculty in understanding any part o this
handbook, contact Hydronic Corporation. Regular servicing and correct use o the
pump are undamental in obtaining optimum per ormance over its li e. When
contacting our service center, speci y the pump model and serial number; this will help
us to respond quickly and e ectively.
Guarantee
Hydronic pumps are guaranteed both or the quality o materials used and or overall
design. The warranty runs or six months o normal use at eight hours per day and ive
days per week. The warranty itsel does not cover seals or de ects arising out o
operating with unsuitable luids or at pressures above the speci ied maximum. The
guarantee cannot cover pumps that may have been tampered with. De ective goods
must be sent to Hydronic Corporation at Farmington Hills or to the distributor covering
the area, reight pre-paid in either case. Any pump returned to us must be
accompanied by a ull written description o such aults or de ects as have been
discovered. Please also ensure that the pump’s serial number is attached to the
paperwork.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 3
Identification Plate
1 Pump model and intensi ication ratio
2 Serial number pump
3 Maximum air pressure
4 Maximum working oil pressure allowed
5 Year o construction
1,2,3,4,5

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 4
Installation Guide
Pumps may be installed in a horizontal or vertical position or optimum unctioning o
suction and delivery valves. The round reservoir may be used horizontally and it is
advised that the breather and sight glass be interchanged and/or the reservoir rotated
to allow the breather to remain uppermost. The suction and return tubes inside the
reservoir may also be rotated to ensure luid is taken rom, and returned to, the bottom
o the reservoir in any given position.
The air inlet connection can be rotated at 90 º and piping o not less than 3/8” bore
should be used. 1/2” should be used i the pump is to be run at higher speeds or
greater lows.
It is advisable to use or maintain:
•Hydraulic oil having viscosity o 150 to 250 SSU
•Oil temperature 32º F to 150º F
•Air temperature 40º F to 100º F
•Room temperature 40º F to 100º F
Obstructive icing o the silencer may occur under certain temperature/humidity
conditions. This can be remedied by the addition o anti reeze oil or pneumatic
equipment to a mist lubricator.
Compressed Air ystem
It will be advisable to it an air ilter/regulator unit having minimum low capacity o 50
sc m with an air pressure gauge to ensure the pump has su icient air energy to work
correctly and provide the hydraulic per ormance you expect.
Hydraulic ystem
Valves, pipes, hoses and accessories should all correspond to maximum working
pressure o the pump used and be o a size that will ul ill low requirements.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 5
Application
Hydronic air driven hydraulic pumps are designed or operating oil hydraulic circuits
and to cover the widest range o requirements to the best advantage.
The pump itsel operates quite simply, using a known pressure intensi ication principle. A
piston with a large sur ace area is actuated by compressed air. Attached to it is a
piston with a smaller sur ace area, which is driven in a hydraulic chamber generating a
high level o hydraulic pressure. The continuous pumping action is produced by the
compressed air being switched by a special sealless spool valve. By regulating the
compressed air supply pressure rom 30 psi to 100 psi, the maximum hydraulic pressure
can be adjusted by the ratio o the pump used. As the hydraulic load o the circuit
increases and the oil pressure rises, the pump will slow down and eventually stop. In this
way, the maximum load o the circuit will be maintained without air consumption.
torage
I the pump is to be kept out o use or a long period, clean the pump in general and
drain the oil rom the tank. Cover the pump and store it in a dry, well-protected place. It
is advisable to wrap the pump in a plastic ilm. To put back into service, check all parts,
ill tank with oil and try the pump out to ensure that it working properly. This operation
must be carried out by qualified personnel.
Disposal
I the pump is to be scrapped, treat as a special type o waste. Dismantle it and divide it
into materials o the same type and dispose o them in accordance with the local laws
and regulations in your state.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 6
Description of the standard pump components
A Air valve
B Oil outlet #8 SAE
C Oil return #8 SAE
D Oil iller plug
E Oil level sight glass
A
B
C
D
E

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 7
tarting - Up
Oil pressure can be determined by regulation o the compressed air, bearing in mind
multiplication ratio pre-selected or the pump itsel .
The models are: P820 RATIO 1:5
P820 RATIO 1:10
P820 RATIO 1:20
P820 RATIO 1:30
P820 RATIO 1:40
For instance, when supplied with compressed air at 80 psi, the P820-5 will produce oil
pressure o 80 x ratio, 400 psi. It should be remembered that actual e iciency produced
by the pump is slightly less than given by the above theoretical calculation. This
di erence will not be noticed by a hydraulic gauge.
Having connected the compressed air supply at a low pressure, allow the pump to
operate slowly until primed and oil comes through to the oil output port. Now shut o
the air supply to the pump and securely connect the hydraulic circuit. Switch on the air
supply again and allow the pump to run in order to bleed any air out o the hydraulic
circuit.
Pump eatures:
•Standard mani olds and subplates are available with various con igurations o SAE
threaded ports or output and return as well as D03 inter aces.
•Optional rotation o the 1/2” NPT air inlet elbow in our positions.
•The pump itsel works automatically and operates by way o an integral valve.
•The pneumatic drive section has graphite illed seals or minimum riction, no
lubrication requirement and long li e.
•The hydraulic section comprises an alloy steel pump casing, hard chrome plated
piston rod and bronze illed seals.
•The suction side o the pump is equipped with a spring-loaded check valve. A
spring-loaded outlet ball type check valve is incorporated in the hydraulic piston.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 8
Fault Finding Chart
Fault Cause Remedy
1] Pump does not 1.1] Low pressure in 1.1] Clear any blockage or
cycle or runs slowly. compressed air line. restriction on the air line.
1.2] Formation o ice 1.2] Shut o pump or a
on the exhaust side. short time and drain o
water rom the ilter.
1.3] Accumulation 1.3] Remove silencer, clean
o waste in the silencer. and replace.
1.4] Blocked element in 1.4]Close down air-supply,
air ilter/regulator. dismantle and clean ilter.
2] Pump loses air rom 2.1] Worn valve or seal 2.1] Replace seal or valve.
silencer when stalled.
3] Excess oil leakage 3.1] Worn hydraulic seal 3.1] Replace seal.
rom air silencer.
4] Pump cycles without 4.1] Blocked oil-intake 4.1] Clean out ilter.
pumping oil. 4.2] Bad connection 4.2] Check or bad connections
on suction line. or air leaks on suction line.
5] Pump unctions but 5.1] Internal leakage 5.1] Find leak source and
only generates low in the circuit. change valve.
pressure and does not 5.2] Suction valve seats 5.2] Replace suction valve
stall at max. pressure. damaged and leaking. parts.
5.3] Output valve seats 5.3] Replace output valve
damaged and leaking. parts.
5.4] Worn oil seal. 4.4] Replace seal.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 9
Maintenance
Periodically release the condensation rom the air ilter. Replace the hydraulic oil every
1500 hours or whenever the oil is polluted.
Warning: Remember that repair work can only be made when pneumatic and
hydraulic pressure has been released and you are sure that no pressure remains in the
circuit.
Delivery of the pump
Transport
All the material shipped, including the detached parts, has been thoroughly checked
be ore being consigned to the orwarding agent. The pump is shipped in double
corrugated cardboard packaging, which assures protection o the product.
Unpacking
On receipt o the product, open the packaging and remove the pump. Take care not
to damage any part o the pump. Make an initial check on the pump or damage in
transit. In case o damage or i in doubt, do not use the pump and contact Hydronic
Corporation or your distributor. The packaging [plastic bags, expanded polystyrene,
nails, screws, wood, etc.] must not be le t within reach o children since they are
potential source o danger. Be sure to dispose o pollutant or non-biodegradable
materials in the correct way. Materials must be disposed o in accordance with the laws
in orce.
Approximate gross weight
P820 standard reservoir 33 lbs.
P828 large reservoir 44 lbs.
Contents of the package
The packaging will always contain the ollowing:
1 x air driven hydraulic pump
1 x installation, use and maintenance manual

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 10
Original spare parts
Parts orders must always be accompanied by the ollowing in ormation:
A] The pump model B] The pump serial number C] The year o construction
(all this data is given on the nameplate)
D] The part numbers E] The quantity required F] The name o the part
(All this data is given in the parts list)
A clear and correct statement o this data will allow our a ter-sales service to respond
quickly and appropriately. Every spare part must be replaced by pro essionally quali ied
sta . The manu acturer declines all responsibility or mal unctions or accidents deriving
rom any ailure o the product when unquali ied persons have made any attempt at
repair.

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 11
Pump Exploded View

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
Page 12
ITEM
SEAL
KIT PART NUMBER CODE QTY DESCRIPTION
1 S820-XX-N-18 5.068.0045 1 PNEUMATIC PISTON P820 - ø 130
2 S820-XX-N-100 3.051.0077 2 O-RING 2-247/4462
3 S820-XX-N-16 3.051.0076 2 RING
4 S820-XX-N-17 3.045.0204 1 SELF-LOCKING NUT
5 S820-5/10-N-31 5.064.0028 1 SPRING P820-5-10
5 S820-20/30/40-N-31 5.064.0029 1 SPRING P820-20-30-40
6 S820-XX-N-15 3.051.0075 2 O-RING 2-49/2500
7 S820-XX-N-20 5.084.0002 2 PLUG
8 S820-XX-N-21 3.051.0083 2 O-RING 2-10/205
9 S820-XX-N-9 5.086.0006 1 FRONT HEAD PUMP
10 S820-XX-N-105 3.072.0104 12 SPRING WASHER - ø 8
11 S820-XX-N-26 3.094.0208 6 SCREW M8x30 - UNI5739
12 S820-XX-N-47 3.070.0006 1 CONNECTOR BSP 1/4''x12
13 S820-XX-N-36 5.066.0011 1 VALVE SUCTION BOLT
14 S820-XX-N-39 5.064.0030 1 SUCTION SPRING
15 S820-XX-N-41 3.006.0006 2 SEMICONE
16 S820-XX-N-40 5.013.0008 1 SUCTION CENTERING - P820
18 S820-XX-N-19 5.018.0030 1 JACKET P820
20 S820-XX-N-108 3.094.0404 1 GRAIN M8x30 -UNI5927
21 S820-XX-N-102 3.031.0016 1 LOCK NUT
22 A820-XX-N-STF 5.042.0002 1 FLANGE
23 2-163 3.051.0078 1 O-RING 2-162/3575
24 C00500-013 3.094.0008 4 SCREW M6x16 - UNI5931
25 S820-XX-N-43 3.045.0212 1 RING NUT M40x1,5
26 - - 1 MANIFOLD WILL VARY DEPENDING ON OPTIONS
27 C02500-014 3.051.0109 2 O-RING 2-14/2050
28 C00590-088 3.094.0010 2 SCREW M8x50 - UNI5931
29 S820-XX-N-29 3.094.0207 5 SCREW M8x25 - UNI5739
30 S820-5/10-N-34 3.052.0010 1 DOWTY ø 30 P820-5-10
30 S820-20/30/40-N-34 3.052.0003 1 DOWTY 3/8'' BSP P820-20-30-40
31 S820-5/10-N-35 5.094.0303 1 SCREW VALVE SEAT P820-5-10
31 S820-20/30/40-N-35 5.094.0302 1 SCREW VALVE SEAT P820-20-30-40
32 S820-5/10-N-33 3.076.0006 1 BALL ø18,25 P820-5-10
32 S820-20/30/40-N-33 3.076.0002 1 BALL ø10 P820-20-30-40
33 S820-5/10-N-32 5.046.0007 1 CENTERING P820-5-10
33 S820-20/30/40-N-32 5.046.0006 1 CENTERING P820-20-30-40
34 S820-5/10-N-38 5.028.0032 1 SUCTION BODY VALVE P820-5-10
34 S820-20/30/40-N-38 5.028.0031 1 SUCTION BODY VALVE P820-20-30-40
35 S820-5/10-N-37 3.051.0127 1 O-RING 2-235/4312 P820-5-10
35 S820-20/30/40-N-37 3.051.0055 1 O-RING 2-223/4162 P820-20-30-40
36 S820-5-N-29 5.068.0049 1 HYDRAULIC PISTON P820-5
36 S820-10-N-29 5.068.0048 1 HYDRAULIC PISTON P820-10

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
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ITEM
SEAL
KIT PART NUMBER CODE QTY DESCRIPTION
36 S820-20-N-29 5.068.0047 1 HYDRAULIC PISTON P820-20
36 S820-30-N-29 5.068.0177 1 HYDRAULIC PISTON P820-30
36 S820-40-N-29 5.068.0046 1 HYDRAULIC PISTON P820-40
37 S820-5-N-25 5.028.0030 1 PUMP BODY P820-5
37 S820-10-N-25 5.028.0029 1 PUMP BODY P820-10
37 S820-20-N-25 5.028.0028 1 PUMP BODY P820-20
37 S820-30-N-25 5.028.0057 1 PUMP BODY P820-30
37 S820-40-N-25 5.028.0027 1 PUMP BODY P820-40
38 S820-5-N-23 3.051.0088 2 BODY SEAL P820-5
38 S820-10-N-23 3.051.0086 2 BODY SEAL P820-10
38 S820-20-N-23 3.051.0085 2 BODY SEAL P820-20
38 S820-30-N-23 3.051.0234 2 BODY SEAL P820-30
38 S820-40-N-23 3.051.0011 2 BODY SEAL P820-40
39 - 3.051.0089 2 O-RING 2-333/6250 P820-5 - INCLUDED WITH
S820-5-N-23
39 - 3.051.0087 2 O-RING 2-328/6187 P820-10 - INCLUDED WITH
S820-10-N-23
39 - 3.051.0014 2 O-RING 2-217/4118 P820-20 - INCLUDED WITH
S820-20-N-23
39 - 3.051.0057 2 O-RING 2-214/4100 P820-30 - INCLUDED WITH
S820-30-N-23
39 - 3.051.0010 2 O-RING 2-212/4087 P820-40 - INCLUDED WITH
S820-40-N-23
40 S820-5-N-30 3.051.0096 2 PISTON SEAL P820-5
40 S820-10-N-30 3.051.0094 2 PISTON SEAL P820-10
40 S820-20-N-30 3.051.0092 2 PISTON SEAL P820-20
40 S820-30-N-30 3.051.0173 2 PISTON SEAL P820-30
40 S820-40-N-30 3.051.0090 2 PISTON SEAL P820-40
41 - 3.051.0097 2 O-RING 5-703/168 P820-5 - INCLUDED WITH
S820-5-N-30
41 - 3.051.0095 2 O-RING 2-224/4175 P820-10 - INCLUDED WITH
S820-10-N-30
41 - 3.051.0093 2 O-RING 2-123/3118 P820-20 - INCLUDED WITH
S820-20-N-30
41 - 3.051.0033 2 O-RING 2-119/3093 P820-30 - INCLUDED WITH
S820-30-N-30
41 - 3.051.0091 2 O-RING 2-117/128 P820-40 - INCLUDED WITH
S820-40-N-30
42 7.078.0020-NPT 7.078.0020-
NPT 1 AIR VALVE BLOCK 1/2'' NPT
43 C02500-014 3.051.0109 2 O-RING 2-14/2050
44 C02500-008 3.051.0130 8 O-RING 2-8/2018
45 C00500-112 3.094.0026 3 SCREW M6x35 - UNI5931
46 S820-XX-N-NAV 4.091.0020 1 PNEUMATIC VALVE

Hydronic Air Driven Pumps & Intensifiers 820 Installation, Use and Maintenance Booklet 1-4-2021
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ITEM
SEAL
KIT PART NUMBER CODE QTY DESCRIPTION
47 S820-XX-N-136 4.091.0028 1 BISTABLE MEMORY
48 S901-XX-N-6103S 3.094.0061 3 SCREW M3x30 - UNI5931
49 S820-XX-N-138 3.070.0096 1 SILENCER 1/2''
50 S820-XX-N-139 3.070.0068 1 SILENCER 1/2''
51 S820-XX-N-140 3.070.0028 2 PLUG MALE 1/4''
52 A820-XX-N-50 5.090.0025 1 SUCTION PIPE
53 A820-XX-N-49 5.090.0024 1 DISCHARGE OIL PIPE
54 C02500-260 3.051.0237 1 O-RING 2-260/4650
Seal Kits
ITEM CODE CODE QTY DESCRIPTION
S820-5-N-SK 3.054.0028 1 S820-5 SEAL KIT
S820-10-N-SK 3.054.0029 1 S820-10 SEAL KIT
S820-20-N-SK 3.054.0030 1 S820-20 SEAL KIT
S820-30-N-SK 3.054.0080 1 S820-30 SEAL KIT
S820-40-N-SK 3.054.0031 1 S820-40 SEAL KIT