Hydronic P825 Service manual

Hydronic Corporation
Air Driven Hydraulic Pumps and Intensifiers
P825 Installation, Use and Maintenance Manual
Contents
Introduction, Guarantee and Identification Plate
Description, tart Up 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 P825 Installation, Use and Maintenance Booklet 4-26-13
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.
Identification Plate
1Model and ratio
2Max oil pressure
3Serial number
4Max air pressure
5Year

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
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Installation Guide
Pumps should be installed in a horizontal position or optimum unctioning o
suction and delivery valves. The recommended minimum size or the suction line is
½” bore, or the pressure line is 3/8” bore and or the airline is ½” bore. It is also
recommended that pumps should be used with a hydraulic directional control
valve. The ollowing standard conditions are advised:
•Hydraulic oil having viscosity o 150 to 250 SSU
•Oil temperature 32º F to 150º F
•Air temperature 40º F to 120º F
•Room temperature 40º F to 120º 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 is strongly recommended that an air ilter/regulator/gauge unit having minimum
low capacity o 50 sc m is itted in order 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. Bear in
mind the minimum o ½” bore or the suction line.
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 and 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 valve
assembly and timing mechanism. 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.

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
Page 4
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. Qualified personnel must carry out this operation.
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 or area.
Description of the standard pump components
A Air inlet ½” NPT
B Oil outlet ¼” NPT
C Oil suction ½” NPT
D Air Exhausts

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
Page 5
tarting - Up
Oil pressure can be determined by regulation o the inlet compressed air pressure
and bearing in mind the multiplication ratio pre-selected or the pump itsel .
The models are: P825-65 RATIO 1:65
P825-120 RATIO 1:120
P825-170 RATIO 1:170
P825-265 RATIO 1:265
It should be remembered that the action o the air/oil piston assembly is powered
in both directions by the compressed air. The single air piston has two identical and
opposing oil pistons attached either side. The suction stroke o one oil piston
corresponds with output stroke o the opposing one. In this way, the suction low is
continuous and the output pressures are per ectly balanced.
Having connected the compressed air supply at a low pressure, allow the pump to
operate slowly until ully primed and a steady low o oil comes through to the
output port. Now shut o the air supply to the pump and securely connect the rest
o the hydraulic circuit to the outlet port. Switch on the air supply again and allow
the pump to run in order to bleed any air out o the hydraulic circuit. The system
pressure can then be adjusted by means o the air regulator.
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.

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
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4] Pump cycles without 4.1] Blocked suction. 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.
4.3] Low oil level 4.3] Re ill oil, check or leaks.
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 maximum damaged and leaking. parts.
oil Pressure. 5.3] Output valve seats 5.3] Replace output valve
damaged and leaking. parts.
5.4] Worn oil seal. 4.4] Replace seal.
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 local, national and ecological laws in orce.

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
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Gross weight
P825 Basic pump o any ratio 46 lbs., 20.9 kgs.
Contents of the package
The packaging will always contain the ollowing:
1 x air driven hydraulic pump
1 x installation, use and maintenance manual
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 pump 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. Pro essionally quali ied sta must install every
spare part. 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 P825 Installation, Use and Maintenance Booklet 4-26-13
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# Description Quantity * denotes contained in seal kits listed below.
1 Plug 2
2 Washer 2*
3 Spring 2
4 Centering Guide 2
5 Ball 2
6 End Cap 2
7 Screw 8
8 Washer 8
9‘O’ Ring
65 2*
120 2*
170 2*
265 2*
10 Pump Body
65 2
120 2
170 2
265 2 Seal pack #69 shown in detail. Sealing
11 Washer edge should be toward the luid side.
65 2
120 2
170 2
265 2
12 Seal
65 6*
120 6*
170 6*
265 6*
13 Guide
65 2
120 2
170 2

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
Page 9
265 2
14 Screw 12
15 Washer 12
16 Head 2
17 Ring Nut 2
18 Ring Nut
65 2
120 2
170 2
265 2
19 ‘O’ Ring 2*
20 Sealing Ring 2*
21 Sel Locking Nut 1
22 Air Piston 1
23 ‘O’ Ring 2*
24 Brackets 2
25 Cylinder Barrel 1
26 Plug 2
27 ‘O’ Rings 2*
28 Oil Piston
65 2
120 2
170 2
265 2
29 Washer 2*
30 Connector 2
31 Suction Sleeve 1
41 Screw 8
42 Washer 8
43 Cover 2
44 O-ring 2*
45 Plate 2
46 O-ring 6*
47 Floating spool 1
48 Sleeve 1
49 Screw 2
50 Pilot valve 1
51 Valve body 1
52 O-ring 2*
53 O-ring 2*
54 O-ring 1*
55 Connector 1
56 Screw 2
57 Screw 3
58 Silencer 2
59 Block 1
60 Washer 2
61 Screw 2
62 Oil Outlet Tube 1
63 Outlet Connector 2
64 Connector 2
65 Spring 2
66 Centering Guide 2
67 Ball 2
68 Ball Seat 2
69 Seal
65 2*
120 2*
170 2*
265 2*
Old Air Valve

Hydronic Air Driven Pumps P825 Installation, Use and Maintenance Booklet 4-26-13
Page 10
New Air Valve
ITEM CODE DE CRIPTION Qty
1 5.065.0052 BLOCK 1
2 * 3.051.0109 O-RING 2
3 * 3.051.0130 O-RING 8
4 3.094.0026 SCREW 3
5 4.091.0020 POWER VALVE 1
6 4.091.0028 PILOT VALVE 1
7 3.094.0061 SCREW 3
8 3.070.0096 SILENCER 1
9 3.070.0068 SILENCER 1
10 3.070.0028 PLUG 2
Seal Kits or complete overhaul:
S826-65-N-SK
S826-120-N-SK
S826-170-N-SK
S826-265-N-SK