morse 96MK1939-P User manual

The Specialist In Drum Handling Equipment
MODEL 96MK1939-P
Star Hydraulic Pump
Operator’s Manual
for Star Hydraulic Pump
Model 96MK1939-P
Serial Number 0604 to ____ (MMYY)
Copyright 2021 - Morse Mfg. Co., Inc. Form PL96MK1939 (0604-____) (Updated 16 Nov, 2021) 1
ITEM # QTY. PART # DESCRIPTION
1 1 96MK1939-20 REPAIR KIT (Includes Items Marked *)
2 1 96MK1728-4 PUMP PISTON
3 1 96MK1728-2 PUMP BARREL
4 *1 96MK1728-7 PUMP PISTON WIPER
6 *1 96MK1728-5&6 PUMP PACKING AND BACK UP
7 1 1035-P COLLAR, 1/2”, RELEASE VALVE
8 1 1040-P 1/4 - 20 X 2-1/2 SHCS STL
9 *1 96P1-20 PUMP BARREL “O” RING
10 1 96CP13-10RP PISTON PIN (INCLUDES RINGS)
11 2 96CP13-10RP LINK PIN (INCLUDES RINGS)
12 *1 96P1-12RP PUMP VALVE (COMPLETE)
13 1 96CP13-13RP OVERLOAD VALVE (COMPLETE)
14 1 96MK1939-3RP RELEASE VALVE (COMPLETE)
15 1 96CP13-23 LEVER HANDLE
16 1 96P1-16 BREATHER SCREW
17 1 96CP13-9 PUMP SOCKET
18 1 96CP13-12 PUMP LINK
19 1 96MK1939-P PUMP, HYD, HAND, STAR
* Included in item # 1, Repair Kit, 96MK1939-20
[email protected] 103 Kuhn Rd.
Syracuse, NY, 13208 USA
morsedrum.com [phone]
Contents
Page
Parts Lists and Diagrams. . . . . . . . . . . . . . . . . . 1
Installation / Assembly Instructions. . . . . . . . . . 2
Service Instructions. . . . . . . . . . . . . . . . . . . . 2 - 4

The Specialist In Drum Handling Equipment
MODEL 96MK1939-P
Star Hydraulic Pump
Operator’s Manual for Star Single Piston Hydraulic Pump as installed on:
400 Series Serial # 0604 to ____ (MMYY) 82 Series Serial # 0604 to ____ (MMYY)
405 Series Serial # 0604 to ____ (MMYY)
morsedrum.com
Copyright 2021 - Morse Mfg. Co., Inc. Form PL96MK1939 (0604-____) (Updated 16 Nov, 2021) 2
MAINTENANCE
In servicing hydraulic units, cleanliness is of
the utmost importance. A clean work place
and proper tools are necessary to insure
e󰀩cient and e󰀨ective repair. Special tools
can be furnished on request.
AIR BLEEDING
Air accumulation in a hydraulic system will
cause erratic action. This may appear as
pump failure to the inexperienced user.
For this reason, it is advisable to air bleed
each pump before attempting to operate.
To remove air from the pump, open release
valve with pump in an upright position.
Operate the pump slowly through the full
piston stroke about a dozen times. Close
the release valve. Pump should be ready
for use.
OIL
If the pump fails to operate, check the oil level before attempting any repairs. The maximum ll level is 1.5” below the inside of the
reservoir cover. The reservoir has an 80 cubic inch capacity. CAUTION: Use only Hydraulic Oil when relling. NEVER USE BRAKE
FLUID. Approved Sources: Morse part # 3983-P 1 Quart Hydraulic Oil.
Mobile DTE 11M - Product # 603100-0
Lubriplate “Special low pour hydraulic oil” # 76762 (pour -750F)
Emergency Sources: SAE 5W Motor Oil - (Viscossity 60 S.U.S.)
Automatic transmission uid such as Dexron, MOBIL ATF D/M
NOTE: Specify pump model number when ordering parts.
- - IMPORTANT - -
Installation / Assembly Instructions
Machine is shipped with hydraulic uid.
BEFORE operation, REMOVE the RED shipping
plug from the hydraulic reservoir. REPLACE with
supplied BLACK breather.
Insert pump handle into pump socket.

The Specialist In Drum Handling Equipment
MODEL 96MK1939-P
Star Hydraulic Pump
Operator’s Manual for Star Single Piston Hydraulic Pump as installed on:
400 Series Serial # 0604 to ____ (MMYY) 82 Series Serial # 0604 to ____ (MMYY)
405 Series Serial # 0604 to ____ (MMYY)
morsedrum.com
Copyright 2021 - Morse Mfg. Co., Inc. Form PL96MK1939 (0604-____) (Updated 16 Nov, 2021) 3
TROUBLE
Pump will not hold pressure
Pump fails to supply pressure
Pump piston does not draw a full
charge. (This is evident by a cushion
e󰀨ect at the top of the pump stroke.)
Pump piston raises by itself under
pressure
Pump functions properly but will
generate only a given pressure below
its normal maximum pressure
POSSIBLE CAUSES
1. Release valve ball not seating properly
2. Ball valves not seating properly
3. Overload valve ball not seating properly
1. Lack of oil
2. Air bound pump
3. Release valve ball not seating properly
4. Small ball in ball valve circuit not seating
properly
5. Overload valve ball not seating properly
1. Air bound system
2. Lack of oil
Large ball in ball valve circuit not seating
properly
Overload valve not set properly
CORRECTIVE REPAIR
INSTRUCTIONS
Refer to RELEASE VALVE
Refer to PUMP VALVE
Refer to OVERLOAD VALVE
Refer to OIL
Refer to AIR BLEEDING
Refer to RELEASE VALVE
Refer to PUMP VALVE
Refer to OVERLOAD VALVE
Refer to AIR BLEEDING
Refer to OIL
Refer to PUMP VALVE
Refer to OVERLOAD VALVE
PUMP VALVE
If the pump fails to supply pressure or if the piston is under pressure at all times, the pump
valve may need a cleaning. Stand pump in upright position while removing valve plug and
valve seal. Tilt pump to remove valve springs and balls. Allow oil to drain from the reservoir
through these valve holes to wash foreign matter from hole. Lay pump on its side to clean
and inspect valve chamber. Be careful not to mar or nick ball valve seats. Clean valve
balls and spring in solvent. Replace rusted or corroded balls. Do not stretch ball springs.
To reassemble, insert, in sequence, small ball, small spring, large ball and large spring in
cleaned chamber. Finally, screw in valve seal plug (96CP13-151RP).
If the valve fails to operate properly after cleaning it may be necessary to re-seat the valve
balls. Remove the springs and tap each ball lightly in its respective seat using the 1/4” ball
seating tool (96CP13-42) for the small ball and the 3/8” ball seating tool (96CP13-43) for
the large ball. Remove balls to make sure they are not stuck to the seats. Reassemble
pump valve as before. See “Air Bleeding” instructions before attempting to operate the
pump.
RELEASE VALVE - SCREW TYPE
If the pump fails to lift or hold a load, the release valve may be dirty. Remove release
screw, release valve seal and 9/32” release valve ball. Clean and inspect valve seat and
screw. A slight depression in the end of the screw is not harmful. Screws with excessive
deformation should be replaced. Re-seat the release ball using the 1/4” ball seating tool
(96CP13-42). Insert the release valve packing using the valve packing inserting tool
(96P1A-40). Reinstall release screw. See “Air Bleeding” instructions before attempting to
operate the pump.

The Specialist In Drum Handling Equipment
MODEL 96MK1939-P
Star Hydraulic Pump
Operator’s Manual for Star Single Piston Hydraulic Pump as installed on:
400 Series Serial # 0604 to ____ (MMYY) 82 Series Serial # 0604 to ____ (MMYY)
405 Series Serial # 0604 to ____ (MMYY)
morsedrum.com
Copyright 2021 - Morse Mfg. Co., Inc. Form PL96MK1939 (0604-____) (Updated 16 Nov, 2021) 4
OVERLOAD VALVE
If the pump fails to lift or hold a load after the release valve and pump
valves have been checked, the overload valve may be dirty. To clean
valve, remove valve plug and valve plug seal. Using a screwdriver, remove
overload valve screw. Tip pump forward to remove valve spring, valve
plunger and steel ball. Clean and inspect valve hole. If the ball seat is
marred, re-seat same by lightly tapping ball on seat using tool (96CP13-
45). Remove ball to prevent sticking. Reassemble ball, plunger, spring
and valve screw. Connect a pressure gauge to the pressure outlet. Stroke
pump to obtain maximum desired pressure. Turn valve screw clockwise
to increase pressure reading and counterclockwise to reduce maximum
reading. After valve is set properly, replace valve seal plug (96CP13-
151RP). See “Air Bleeding” instructions before attempting to operate the
pump.
PUMP PISTON
Leakage of oil around the pump piston indicates worn or damaged piston packing.
To replace packing:
Remove piston activating linkage.1.
Remove piston. (see piston drawing.)2.
Remove all packings. (see piston drawing.)3.
Clean all parts and dry with compressed air.4.
Install new packings, wipers and static seals, being sure, packing sealing5.
lips, face down toward the pressure. (Dip each part into clean hydraulic oil
before assembly.)
Open the release valve (to allow air to bleed from piston barrel back to6.
reservoir) and insert the piston.
Replace piston linkage.7.
NOTE: With release valve open, stroke pump about a dozen times to bleed8.
air completely from pump.