Ingersoll-Rand 900-082HMP User manual

Maintenance Manual
900
082HMP CHOPAND CHECK FOOT VALVE
900-082HMP Foot Valve
900
-
082HMP CHOPAND CHECK FOOT VALVE
WARNING
IMPORTANT: READ THIS MANUAL CAREFULLY BEFORE INSTALLING, OPERATING, OR
SERVICING THIS EQUIPMENT
WHEN REPAIRING THE AIR MOTOR TURN OFF THE AIR
Packing
WHEN REPAIRING THE AIR MOTOR TURN OFF THE AIR
SUPPLY AND BLEED THE MATERIAL PRESSURE FROM
THE PUMPING SYSTEM.
SERVICE KITS
Use only Ingersoll-Rand replacement parts to insure
compatibility and longest life.
x
Foot Valve Repair Kit :
900
001RK
Packing
Gland
Mounting
Flange
1 1/4 NPT
x
Foot Valve Repair Kit :
900
-
001RK
xPacking Gland Seal Kit: 300-972P3Sk
SPECIFICATIONS
Outlet Port Size 1 ¼ " NPT
Displacement = 12 Cubic inches per cycle.
Static Pressure Ratio 10 in Air Motor
65:1
Outlet
Upper
Housing
WARNING
DO NOT OPERATE AIR MOTOR AT
PRESSURES ABOVE 100PSI (6.8 BAR).
Static Pressure Ratio 10 in
.
Air Motor
65:1
Static Pressure Ratio 8 in. Air Motor 42:1
Static Pressure Ratio 6 in. Air Motor 24:1
Material Pressure Operating Range 0 PSI to 6500 PSI (442 BAR)
Lower
Housing
MAINTENANCE SCHEDULE
EVERY BARREL CHANGE:
1. Add oil to the Packing Gland.
2. Bleed air from Foot Valve.
3. Check for material Leakage: (rebuild if leaking at the threads)
4. Check for pump signal stroking.
(signal stroking is the displacement rod moving very quickly in a
Primer
Housing
OPERATION
(signal stroking is the displacement rod moving very quickly in a
direction without a pump output). If the pump is signal stroking,
bleed air from bleeder valve opposite the outlet port. If bleeding
does not correct signal stroking rebuild foot valve.
5. Depressurize when not in use. Inlet
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 1
The Pump is double acting (output in both directions).
When the Pump is going in the up direction the upper check close sand material is pumped out. The lower
checks open allowing the lower chamber to be filled. The primer checks help bring viscous material into the
chamber. In the down direction the upper check opens and the lower check closes allowing material to be
pumped out. The different diameters of the piston rod displace the material.

Maintenance Manual
900-082HMP Foot Valve
900-082HMP CHOPAND CHECK FOOT VALVE
Caution: Do not over tighten
the Housings.
M i t 200 ft Lb
CAUTION
M
ax
i
mum
t
orque
200 ft
.
Lb
s.
Foot Valve Pump
Ratio Vol. / Cycle
6 in 8 in 10 in 12.0 cubic In.
24:1
42:1
65:1
24:1
42:1
65:1
Foot Valve Wear Tolerance Limits
Displacement Rod Minimum O.D. = 1.9425.in
Upper Check Plate Maximum I.D. = 1.9460 in.
Repair Kit 900-001RK (* indicates repair kit items)
18 1 300-972P3 Packin
g
Gland Assembl
y
W/Peek Seals
Lower Check Valve Maximum I.D. = 0.8500 in.
Primer Rod Minimum O.D. = 0.8461 in.
gy
17* 1 350-411 O-Ring Viton
16* 1 360-002 O-Ring Viton
15 1 402-445HM Primer Housing for Hot Melt
14 1 300-848 Bleeder Valve 1/4 NPT, Long
13* 1 401-915 Displacement Rod
12 1 402-285 Upper Pump Housing
11* 1 401-909 Upper Check Valve
10* 1 401-907 Upper Check Plate
9* 1 360-573 O-Ring Viton
8 1 401-911DM Lower Pump Housing
7* 1 360-003 O-Ring Viton
6* 1 401-913 Lower Check Valve
5* 1 401-912 Lower Check Plate
4* 1 401-903 Primer Rod
3
1
401
902
Pi Ch k
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 2
3
1
401
-
902
P
r
i
mer
Ch
ec
k
2 1 401-900 Primer Plate
1* 1 350-022 Nylock Jam Nut 5/8-18
DET. QTY. PART No. Description

Maintenance Manual
900
082HMP FOOT VALVE
900-082HMP Foot Valve
900
-
082HMP FOOT VALVE
WARNING
WHEN REPAIRING THE AIR MOTOR TURN OFF THE AIR SUPPLY AND
BLEED THE MATERIAL PRESSURE FROM THE PUMPING SYSTEM
REMOVALAND INSTALLATION PROCEDURE
Remove the Air Motor from the Pump.
1) Remove the Air Supply hose to the Air Motor.
2) Unscrew the 400-112 Collar that is attached to
the Air Motor Piston Rod.
5) Remove the 5 or 6 Hex Screws that hold the
Primer Housing to the Follower Plate.
6) Remove the Foot Valve from the Follower
Plate by lifting it straight out.
CAUTION
THE AIR MOTOR AND FOOT VALVE ARE VERY HEAVY.
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 3
3) Remove the 3/4-10 Hex bolts that attach the
spacer rods to the Foot Valve Flange.
4) Lift the Air Motor off of the Foot Valve.
To Assemble.
1) Reverse steps 1-6.

Maintenance Manual
900
082HMP FOOT VALVE REBUILDING INSTRUCTIONS
900-082HMP Foot Valve
900
-
082HMP FOOT VALVE REBUILDING INSTRUCTIONS
DISASSEMBLY:
1) Clamp the Upper Pump Housing in a vice.
2) Remove the Primer Check.
a) Hold the Piston Rod from moving using a 1 1/8” wrench.
b) Remove the Nylock Jam Nut using a 15/16” Socket
c) Unscrew the shovel Check (counter clockwise).
d)
The Shovel Valve (primer check) can slide off the Primer Rod.
d)
The Shovel Valve (primer check) can slide off the Primer Rod.
3) Remove the Primer Housing using a Large Hex Wrench (counter clockwise).
4) Remove the Lower Check Plate from the Primer Housing.
a) Place the Primer housing so that the inlet is facing up.
b) Tap on the center of the Lower Check Plate using a soft dowel (wooden handle) until the Check plate
drops from its counter bore.
5) Remove the Lower Pump Housing from the Upper Pump Housing using a Large pipe wrench (counter
clockwise).
6)
R thU Ch kPltf thU P H i
6)
R
emove
th
e
U
pper
Ch
ec
kPl
a
t
e
f
rom
th
e
U
pper
P
ump
H
ous
i
ng.
a) Using channel pliers hold the Gusset of the Upper Check Plate and spin the check plate until it is out
of the Upper Pump Housing.
7) Remove the Upper Check Valve.
8) The Displacement Rod can be remove from the Packing Gland.
9) Remove the Packing Gland from the Upper Pump Housing using spanner wrench No. 350-652.
10) Remove the Bleeder Valve from the Upper Pump Housing 1/4 in. NPT.
11)
Remove all of the O
-
rings and discard.
11)
Remove all of the O
rings and discard.
12) Clean and Inspect all parts for damage.
ASSEMBLY:
1) Install the 350-411 O-ring into the Upper Housing packing gland bore and Lubricate.
2) Install the O-rings on the Lower Pump Housing and lubricate.
a) 360-573 O-ring goes on the Larger diameter.
b) 360-003 O-ring goes on the smaller diameter.
3) Clamp the Upper Pump Housing in a Vice and install the lubricated Packing Gland. Tighten with Spanner
W h N 350
652 t 50 Ft Lb
W
renc
hN
o.
350
-
652 t
o
50 Ft
.
Lb
s.
4) Insert the Piston Rod into the Packing Gland through the lower end of the Upper Pump Housing. The Piston
rod must be straight and spinning it helps to install it.
5) Install the Upper Check Valve (ears up) over the Piston rod.
6) Install the Upper Check Plate on the Piston rod and push it into the Upper Pump Housing. It must be fully
seated. The Upper Check Plate can go on in either direction.
7) Install the Primer Rod into the Piston Rod. The Piloted end goes into the Piston Rod. Tighten to 50 Ft. Lbs.
8)
Thread the Lower Pump Housing into the Upper Pump Housing and tighten. CAUTION DO NOT
8)
Thread the Lower Pump Housing into the Upper Pump Housing and tighten. CAUTION DO NOT
OVERTIGHTEN Maximum torque 200 Ft. Lbs.
9) Install the Lower Check Valve on the Primer Rod with the ears facing up.
10) With the Primer Housing inlet facing down install the Lower Check Plate. The Check Plate must be fully
seated. The Check Plate can go in either direction.
11) Thread the Primer Housing onto the Lower Pump Housing and tighten. CAUTION DO NOT OVERTIGHTEN
Maximum torque 200 Ft. Lbs.
12) Install the 360-002 O-ring on the Primer Housing.
13)
I t ll th P i Ch k l th P i d G d f f d
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 4
13)
I
ns
t
a
ll th
e
P
r
i
mer
Ch
ec
k
va
l
ve on
th
e
P
r
i
mer ro
d
.
G
roun
d
sur
f
ace
f
aces
d
own.
14) Thread the Primer Plate on the Primer Rod hand tight. Tapered surface faces down.
15) Thread the Nylock Jam Nut on the primer Rod and tighten to 15 Ft. Lbs.
16) Install the Bleeder Valve in the Upper Pump Housing so that the outlet hole faces down. Use Pipe sealant.
17) Install Air Motor Connector into the Piston Rod. See 900-021 drawing for proper settings

Maintenance Manual
300
972P3 1 ½ INCH PACKING GLAND
PEEK
300-972P3 Packing Gland
300
-
972P3 1 ½ INCH PACKING GLAND
-
PEEK
IMPORTANT: READ THIS MANUAL CAREFULLY BEFORE INSTALLING, OPERATING, OR
SERVICING THIS EQUIPMENT
WARNING
TO PREVENT INJURY- WHEN REPAIRING THE AIR MOTOR TURN OFF THE AIR
SUPPLY AND BLEED THE MATERIAL PRESSURE FROM THE PUMPING SYSTEM.
Seal Kit #300-972P3SK (*indicate included items)
Detail# Part# Qty. Description
5 403-259 1 Packing Retainer
4* 350-830 1 Wiper Viton
3 403-258 1 Packing Cup
2* 350-827P3 3 Peek PolySeal
1 350-810 1 Snap Ring
ASSEMBLY
1. Lubricate the seals and wiper.
2. Install the Polyseal into the end of the Packing Cup (Heal
First
)
. The use of an arbor
p
ress s
q
uarel
y
installs the
Seal
Direction
)pqy
seal.
3. Install the Snap Ring.
4. Using needle nose pliers twist the Wiper into the Packing
Retainer groove with the Lip facing UP.
5. Install the two Polyseals into the Packing Retainer Lip.
a. Push the Polyseals one at a time into the Packing
retainer with the seal lip facing down- the use of
blitllthl
DISASSEMBLY
1. Unscrew the Packing Retainer from the Packing
Cup.
2. Using needle nose pliers twist the Wiper out of its
groove
an ar
b
or press square
l
y
i
ns
t
a
ll
s
th
e sea
l
s.
6. Thread the Packing Retainer into the Packing Cup hand
tight. The Packing Retainer should bottom out to the
Packing Cup.
INSTALLATION
1. Push the Packin
g
Gland Assembl
y
over the Dis
p
ense
groove
.
3. Using needle nose pliers remove the Polyseals
from the bore of the Packing Cup. (The seals will
be destroyed).
4. Remove the Snap Ring from the end of the
Packing cup.
5. Using needle nose pliers remove the Polyseal
from the end of the Packing Cup (The seal will be
gyp
rod.
2. Thread the Packing cup into the Upper Pump Housing
and tighten.
3. Hand tighten the Packing Retainer. (Use spanner
wrench #350-652)
4. Connect the foot valve piston rod to the Air motor. (See
900-022 connector)
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 5
destroyed).
6. Clean and inspect all parts. 5. Fill the Cup With Oil (DIDP) Diisodecyl Phthalate or Wet- Sol oil #66334-B (Gallon Container)
6. Open the bleeder valve and run the pump slowly to
bleed the air from the pump.
7. Close the bleeder valve.

Maintenance Manual
900-082HMP Foot Valve
Problem Cause Solution
TROUBLE SHOOTING
Ti ht th d h i
Material leakage from
pump housing
Ti
g
ht
en
th
rea
d
s on
h
ous
i
ng
Disassemble and replace o’ring
Check for worn seat area in housings
Re
p
lace housin
g
Loose connections
Cut O’ring
Check seated crooked in housing
Cracked housing
Pump running but not
delivering material (not
creating pressure)
pg
Open bleeder valve of foot valve
(opposite of outlet)
Elevator hand valve in down position.
Increase down pressure on elevator.
Cracked housing
Air lock in foot valve.
Not enough down pressure on
material
No material available
Check material supply.
Check for foreign object or worn
parts, replace if needed.
Replace checks
Clean checks
No material available
Lower check valve not closing or
seating
Worn displacement, worn shovel
rod on O.D.
Worn checks on I.D.
Pump not delivering
material on up stroke (not
creating pressure)
Clean checks
Replace upper check (See tolerance
chart)
Replace displacement rod (See
tolerance chart)
See ele ator (do n press re)
Foreign object on upper check,
holding check open.
Worn upper check or
Worn out displacement rod
See ele
v
ator (do
w
n press
u
re)
Open bleeder valve of foot valve
(opposite of outlet)
Check elevator down pressure
Air lock in foot valve
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 6

Maintenance Manual
900-082HMP Foot Valve
Problem Cause Solution
TROUBLE SHOOTING
Pump not delivering
material on down stroke
(not creating pressure)
Clean Checks
Replace lower check (See tolerance
chart)
Replace shovel rod (See tolerance
chart)
Foreign object holding lower
checks open
Worn out lower check
Worn out shovel rod.
Check for elevator down
chart)
Check elevator down pressure
Open bleeder valve of foot valve
(opposite of outlet)
Check for elevator down
pressure
Air lock in foot valve.
Pump completely
inoperative
Turn on air
See air motor (not cycling)
See connector settings 900-022
Check elevator down
p
ressure.
Check air supply to pump
Check air motor for proper
cycling
Check for proper connection
Check for elevator down
pressure
p
Disassemble and clean
Disassemble and clean or replace.
pressure
Check for foreign objects in
pump
Check for clogged or cured
material in outlet line
INGERSOLL-RAND March 2009 ALL RIGHTS RESERVED
Doc# 900-082HMP Rev. A 7