Sprague S-216-J Series User manual

Operation and
Maintenance Manual
MODEL S-216-J-( ) Series
AIR-DRIVEN HYDRAULIC PUMP
Sprague Products
Division of Curtiss-Wright Flow Control Corporation
10195 Brecksville Road
Brecksville, OH 44141 USA
Telephone: [phone] • Fax: [phone]
www.cwfc.com
ISSUED NOVEMBER 1994
Revised February 2005
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TABLE OF CONTENTS
Page
Section 1.0 Installation .........................................................................................................................................................4
Section 2.0 Operation ...........................................................................................................................................................4
Section 3.0 Maintenance ......................................................................................................................................................5
Section 4.0 Disassembly ......................................................................................................................................................5
Section 5.0 Inspection ..........................................................................................................................................................8
Section 6.0 Repair and Replacement ....................................................................................................................................8
Section 7.0 Reassembly .......................................................................................................................................................9
Section 8.0 Test ..................................................................................................................................................................11
Section 9.0 Illustrated Parts Breakdown (IPB) and Supplemental Data ..............................................................................12
INTRODUCTION
This Handbook provides the necessary information to install, operate service and overhaul the basic hydraulic
pump, model S-216-J-( ).
While other model pumps vary in some details of design from the basic pumps, the installation, operation,
maintenance and many of the component parts remain the same or are similar.
Many of the instructions contained in this Handbook are applicable to all hydraulic pump models with J type
air valves.
2
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The Sprague Products pump develops high output pressure by applying the principle of differential ar-
eas. The pump has a large area air piston, air-driven at low pressures. This air piston drives a small area
fluid piston that in turn pumps liquids at high pressures.
The fluid output pressure is determined by the ratio between the area of the air driven piston, the area of
the fluid driven piston, and the applied operating air pressure.
The area relationship of the air piston to the fluid piston is referred to as the pump ratio. A nominal ratio
is indicated in the dash number which follows the pump model basic number. Actual ratio may differ
from nominal ratio.
Example: S-216-J-10 pump has an approximate ratio of 10 to 1 or 10 psi liquid pressure for each 1 psi
of operating air pressure.
In operation, an S-216-J-10 pump using 100 psi of input air pressure will produce a maximum liquid
output pressure of 1000 psi; 80 psi air will produce an output pressure of 800 psi air; 60 psi air . . . 600
psi output; and 40 psi air . . . 400 psi output.
By regulating the incoming air supply at the pressure regulator, the liquid output pressure can be adjust-
ed through the pump’s pressure range.
HOW THE SPRAGUE AIR-DRIVEN PUMP WORKS
S-216-J-( ) SERIES PUMP
Air Exhaust
Port
Air Tube
Liquid Flow
Liquid Body (Stainless Steel)
Soft Seat
Check Valve
Liquid
(driven)
Piston
Air Drive Piston
(in UP position)
Air Supply
Port
J type
Air Selector Valve
(in UP position)
Liquid Flow
Liquid (driven) Piston
Soft Seat
Check Valve
Air Drive Piston
(in DOWN position)
J type
Air Selector Valve
(in DOWN position)
3
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1.0 INSTALLATION
1.1 The S-216 Series pumps require only
bolt attachment to a base plate and
plumbing connection of three lines:
a. From driving air source to pump
air inlet port.
b. From fluid source to pump fluid
inlet port.
c. From pump fluid outlet port to
working system.
To obtain effective fluid sealing at the
inlet and outlet check ports of the pump,
the NPT male threads on the two fluid
lines connecting to and from the pump
should each be sealed with two wraps of
Teflon® tape.
Note: Tape to within one or two threads
of the end of the fitting, NOT at the end.
DO NOT use pipe dope. DO NOT tape the
®Teflon is a trademark of the DuPont Company.
Figure 1-1 Basic pump dimensions and weights
Figure 1-2 Pump installed in typical circuit with recommended accessories which are available
from Sprague Products.
WARNING
Do not exceed 100 p.s.i.g. inlet air pressure.
Check Valve
Liquid Body D. Dia.
A
A
5/16″-18 UNC X 1/2″ Deep
(12.70 mm)
Mounting Holes
B
1-1/2″
(38.10 mm)
8-1/8″(206.37 mm)
9-3/4″
(247.65
mm)
7″
(177.80
mm)
C1
Liquid
Inlet
Port
C2
Liquid
Outlet
Port
8-1/4″
(209.34
mm)
2-1/8″
(53.97
mm)
2-1/8″
(53.97
mm)
1/2 NPT
Exhaust Air
Outlet Port
1/2 NPT
Inlet Port
Liquid
Pressure
Line to
Hydraulic
Circuit
Bleed Line to
Reservoir
Bleed Valve Restrictor
Valve –
Required for
Burst Testing
Strainer
Liquid Supply
Line from
Reservoir Air
Lubricator
Air Filter
Compressed Air Line
Thru Reducer into Air
Filter 3/8 NPT Port
Air Pressure
Regulator
Air Pressure Gauge
Air Shut-Off
Valve
S-216-J-( ) Air Driven
Hydraulic Pump
Muffler
Manifold
Liquid
Pressure
Gauge
Air Driven
Pump
Typical filter, regulator and lubricator assembly (FRL with air gauge installed.
c. Connect system fluid line to pump
outlet check valve.
d. A muffler may be attached to
the pump’s air exhaust port.
See Figure 1-2 for:
1. Line hook up to pump.
2. Pump installation.
3. Recommended accessories.
2.0 OPERATION
2.1 START PUMP
a. Close air shut-off valve between
pump and pressure regulator.
b. Turn on driving air supply.
c. Adjust air pressure regulator at air
control unit (FRL) to 25 psi (1.73
bar) starting pressure.
d. Open valve in hydraulic circuit to
allow free fluid flow.
e. Slowly open the air shut-off valve
to start the pump operating.
f. After pump has been primed,
close valve in hydraulic circuit.
g. Check pump and air circuit for
leaks in lines, fittings, etc.
h. With pump and circuit operating
properly, readjust air pressure
regulator until desired pump
discharge pressure is reached. The
hydraulic circuit is ready to operate.
driving air supply line thread connecting to
the pump. No special tools are required to
install the pump.
1.2 LOCATION-For maximum perfor-
mance, the pump’s fluid inlet port
should be level with or below the fluid
reservoir or fluid source.
1.3 MOUNTING-Two mounting holes are
provided on the underside of the basic
model pump’s fluid body for attach-
ment to a base plate or platform. See
Figure 1-1.
1.4 PLUMBING-All plumbing must be
rated to 1-1/2 times maximum
operating pressures.
a. Connect driving air supply line to
pump air inlet port.
b. Connect fluid supply line from
reservoir to pump inlet check valve.
4
WEIGHTS
(Approximate)
NOMINAL ACTUAL WEIGHT SHIPPING WEIGHT
RATIO LBS.-OZ. KILOGRAMS LBS.-OZ. KILOGRAMS
10:1 16-4 7.4 19 8.6
20:1, 30:1 14-8 6.6 17 7.7
35:1, 60:1,
100:1, 125:1, 12-8 5.7 15 6.8
150:1, 200:1, 300:1
Nominal A B C1 C2 D/Dia.
Ratio Inch mm Inch mm Inlet Outlet Inch mm
10:1 2-29/32 73.82 2-7/16 61.90 3/8 NPT 3/8 NPT 3.1/2 88.86
20:1 2-29/32 73.82 2-7/16 61.90 3/8 NPT 3/8 NPT 3-1/4 82.51
30:1 2-29/32 73.82 2-7/16 61.90 3/8 NPT 3/8 NPT 3-1/4 82.51
35:1 2-1/4 57.15 1-1/2 38.10 3/8 NPT 3/8 NPT 2-1/2 63.47
60:1 2-1/4 57.15 1-1/2 38.10 3/8 NPT 3/8 NPT 2-1/2 63.47
100:1 2-1/4 57.15 1-1/2 38.10 3/8 NPT 3/8 NPT 2-1/2 63.47
125:1 2-1/4 57.15 1-1/2 38.10 3/8 NPT 3/8 NPT 2-1/2 63.47
125:1 2-1/4 57.15 1-1/2 38.10 1/4 NPT 9/16-18 NBS 2-1/2 63.47
150:1 2-1/4 57.15 1-1/2 38.10 1/4 NPT 9/16-18 NBS 2-1/2 63.47
200:1 2-1/4 57.15 1-1/2 38.10 1/4 NPT 9/16-18 NBS 2-1/2 63.47
300:1 2-1/4 57.15 1-1/2 38.10 1/4 NPT 9/16-18 NBS 2-1/2 63.47
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WARNING
Before any maintenance or repair is attempted, the compressed air line
to the pump should be disconnected, and all air pressure and fluid
pressure allowed to bleed from the pump.
Chart 3-1 Schedule of inspection and maintenance.
Figure 4-2 Removing air valve cover.
Figure 4-1 Aluminum plates in vise.
When the pump is disassembled, matched
parts (i.e. fluid body and fluid piston)
should be kept together and handled care-
fully to avoid damage to lapped or honed
surfaces.
To wash metal parts, use Stoddard dry
cleaning solvent per Federal Specification
P-D-680 or MIL-F-7024, Type II or use any
quality commercial solvent that is avail-
able.
The pump disassembly and reassembly
can be done with the following standard
hand tools:
a. O-ring removal tool
b. Retainer ring pliers
c. Ratchet wrench with 7/16ʺ Dia. x 3ʺ
c. extension hex socket
d. 7/16ʺ wrench
e. 11/16ʺ wrench
f. 3/4ʺ wrench
g. 15ʺ adjustable wrench
Power equipment and special tools can be
used at user’s discretion.
4.2 Use bench vise to hold pump while
disassembling and reassembling.
Cushion vise jaws with soft aluminum
plates to prevent scratching the fluid
body. See Figure 4-1. Position pump
in vise with tube (48) to the front of
2.2 STOP PUMP
a. Close air shut-off valve. Normally
after driving air supply has been
adjusted, the pump can be on-off
controlled or reduced in pumping
rate at the air shut-off valve.
b. After stopping pump, bleed off
hydraulic pressure before discon-
necting the hydraulic circuit.
3.0 MAINTENANCE
3.1 SPECIAL TOOLS – None is required
to service pump. Use standard tools.
3.2 INSPECTION and MAINTENANCE
–Refer to Chart 3-1 as a guide to
general maintenance. Recommended
inspection periods may require ad-
justment to comply with local condi-
tions or as determined by experience.
3.3 TROUBLE-SHOOTING – Chart 3-2
aids in checking the pump and out-
lines corrective action .
To eliminate the unnecessary disas-
sembly of the pump, probable causes
of malfunction are listed in the fol-
lowing order:
a. Causes that can be corrected
without disassembly of pump.
b. Causes that can be corrected with
partial disassembly of pump.
c. Causes that require complete
disassembly of pump.
The number in parenthesis following
the part name corresponds to the item
number on the S-216-J-( ) Illustrated
Parts Breakdown (IPB), publication
no. 8239.
3.4 For disassembly, inspection, repair,
and reassembly of S-216-J-( ) pump,
refer to Sections 4.0, 5.0, 6.0 and 7.0.
3.5 For IPB, and service and overhaul in-
structions of other air-driven pumps,
refer to supplemental data sheets in
this Handbook, Section 9.0.
4.0 DISASSEMBLY
4.1 The disassembly procedure describes
the removal of the entire upper or
“air” assembly of parts from the lower
or “liquid” portion of the pump. The
number in parenthesis following the
part name corresponds to the item
number on the S-216-J-( ) Illustrated
Parts Breakdown (IPB), 8239.
5
INSPECTION REQUIRED
ITEM PERIOD MAINTENANCE
(1) Driving Air Filter (a) 10 hours Check for and drain liquid accumulated
in filter from condensation.
(b) 50 hours Check filter element and other components
for clogging. Clean as required.
(2) Driving Air Lubricator (a) 10 hours Check oil supply to fill line. Use SAE #10 or
(not required on JN equivalent good quality oil. Check oil drip
type pumps) rate (2 drops per minute normal) at
adjustment knob.
(3) Driving Air (a) Periodic Check for air leaks. Repair as required.
Pressure Regulator.
(4) Driving Air (a) 10 hours Shutoff inlet air pressure and check for
Pressure Gauge zero reading.
(b) 50 hours Calibrate against master gauge.
(5) Pump (a) 10 hours Check pump and fittings for air or fluid
leakage. Repair as required.
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4.3 Unscrew the four cap screws (3) to
remove the air valve cover (1) and its
0-ring (2). See Figure 4-2.
4.4 Remove tube assembly (48) by
removing the two fittings from the
two 90º elbows on the upper and
lower housing. See Figure 4-3. Do not
remove elbows. Apply air hose and air
pressure to lower 90º elbow to raise
air piston (14) and shuttle (4A) to up-
per position. See Figure 4-4.
4.5 Use 7/16" wrench to remove self-lock-
ing nut (44) from connecting rod (37).
See Figure 4-5.
4.6 Use 7/16 socket on ratchet wrench to
remove the twelve cap screws (45)
and nuts (46) that attach the upper
housing (19). See Figure 4-6. Lift
and remove the upper housing
assembly. Remove stop sleeve (4)
from connecting rod.
4.7 If the shuttle assembly in the upper
housing needs removal and disas-
sembly, proceed as follows:
4.7.1 Use 11/16" wrench and remove the
four sets of detent bolts (6), springs
(7), and pins (9) from the air valve
body (5A). See Figure 4-7.
4.7.2 From inside the upper housing,
push upward on shuttle stop (4F) to
remove the shuttle assembly. See
Figure 4-8.
4.7.3 Using retainer ring pliers, remove
the snap ring (4g) to release the
(4), spring (4E), and guide sleeve (4)
from the shuttle (4A). See Figure 4.9.
4.8 Remove the cylinder (13) and its o-
ring (15) from the lower housing (19).
See Figure 4-10.
4.9 Remove rod, air piston (14) and fluid
piston (16 or 27) from the fluid body
(21). See Figure 4-11.
4.10 Disassemble shifting nut (40), lock
washer (39), plain nut (38) and con-
necting rod from air piston (14). See
Figure 4-12. Unscrew air piston from
fluid piston (16). Remove the o-ring
(15) from the air piston.
Note: Disassembly is not necessary unless
one of the components is damaged.
Chart 3-2 Troubleshooting pump operation.
6
TROUBLE PROBABLE CAUSE CORRECTION
(1a) PUMP IS NOT DELIVERING (a) Reservoir fluid supply is low. Add fluid as required.
FLUID (pump running) (b) Fluid supply line to pump inlet check Remove and clean line. Check reservoir, its
(b) valve is clogged. inlet filter and outlet for accumulation of
foreign matter. Clean as required.
(c) Foreign matter is lodged in pump inlet Remove and clean check valves. Replace o-
(c) and outlet check valves (22 and 31). rings (24 and 32) on poppets (23 and 33).
(1b) PUMP IS NOT DELIVERING (d) Driving air supply is disconnected, air Reconnect line. Open valve.
FLUID (pump not running) (d) shut-off valve closed or air filter clogged. Clean air filter.
(e) Air pressure regulator not adjusted. Adjust regulator.
(f) Air shuttle valve (4A) is sticking. Remove and clean air valve and housing
assembly and its shuttle valve components.
Adjust air lubricator.
(g) Connecting rod (37) is improperly adjusted Readjust rod and nut (44). Refer to paragraph
(g) or bent (may occur after pump overhaul). 7.19 and Figure 7-14.
Straighten or replace rod.
(h) Spring (4E) in shuttle valve is broken. Replace spring.
(2) PRESSURE DROP OR (a) Leakage or blockage at inlet or outlet Remove and clean check valves. Look for
PUMP FAILS TO BUILD-UP (a) check valves (22 or 31). Damaged or foreign matter lodged in seating areas.
DISCHARGE FLOW (pressure) (a) worn o-rings. Replace damaged or worn o-rings.
(b) Fluid found in lower housing (19), Replace o-rings (17 or 29), packing
(b) damaged seals in sealing groove of retainers (18), and back-up rings
(b) fluid body. (18A or 30A).
(c) Damaged o-ring (15) in outer groove of air Replace o-ring. Inspect cylinder for scores
(c) piston (14) or scratched or scored cylinder or scratches. If marred, replace cylinder.
(c) (13). Either or both allow air pressure to escape
(c) to exhaust port.
(3) HYDRAULIC FLUID IN (a) Damaged seals in fluid body (21) or fluid Replace o-ring (17 or 29) and retainers (18
EXHAUST AIR (a) piston (16 or 28) scored. or 30). Inspect fluid piston for score marks;
polish as required. Replace pistons and fluid
body if in-service-wear allowance exceeded.
(4) AIR LEAK IN COVER OF AIR (a) Cover (1) loose. Cracked or damaged o-ring. Tighten cover bolts (3) or replace o-rings.
VALVE & HOUSING ASSY.
(5) AIR IN SYSTEM (a) Air leak in suction line from reservoir to Tighten line fittings; use Teflon® tape to
(a) pump or at pump inlet check valve. seal fittings.
(b) Reservoir fluid level below reservoir Check reservoir fluid level; refill as required.
(b) suction outlet.
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Figure 4-4 Applying air pressure to raise air piston
and rod.
Figure 4-6 Removing housing screws and nuts.
Figure 4-5 Removing self-locking nut from
connecting rod.
Figure 4-7 Removing detent bolt, spring and pin.
Figure 4-8 Pressing shuttle out of upper housing.
Figure 4-9 Removing shuttle assembly components.
Figure 4-10 Removing cylinder from lower hous-
Figure 4-11 Removing air piston and fluid
piston from fluid body and lower housing.
Figure 4-12 Disassembling air piston compo-
4.11 Using o-ring removal tool, carefully
remove the two Teflon® retainers
(18) and o-ring (17) from the seal
groove in the fluid body (21). See
Figure 4-13. Discard the old retain-
ers and o-ring.
4.12 Using adjustable wrench, remove
the inlet check valve assembly
(22-25) from the fluid body port.
See Figure 4-14. Remove o-ring
(26) or gasket (35) from port. Note
sequence of parts removal and the
position of poppet (33) relative to
the check valve body (31). Wipe
surplus fluid from inside port.
4.13 Using adjustable wrench, remove
outlet check valve assembly (22-25)
from the fluid body port. Remove
o-ring (26) or seat (36) from port.
Note sequence of parts removal and
position of poppet (33) from the
check valve body (31). Wipe surplus
fluid from port.
4.14 Check for leakage at gasket (20)
junction between the lower housing
(19) and the fluid body (21). Unless
there is evidence of leakage at gas-
ket (20), DO NOT remove the lower
housing from the fluid body.
Figure 4-3 Removing tube assembly.
7
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Figure 4-13 Removing retainers and 0-ring from
fluid body.
Figure 4-14 Removing check valves from fluid
body.
5.7 Check outside diameter (OD) of
fluid piston (16 or 27) and the inside
diameter (ID) of the fluid body (21) to
determine wear clearance between the
two parts. See Table 5-1. Remember
that the operating efficiency of the
pump depends on maintaining the
close tolerance dimension between
the piston and the body. Note: When
checking the ID of the fluid body and
the OD of the piston, check at several
points around and up and down the
bore of the body and the circum-
ference of the piston.
5.0 INSPECTION
5.1 Wash all metal parts in solvent.
Dry parts thoroughly with air or with
lint-free cloth. Remove hardened sedi-
ment with a soft bristle brush. Do not
scrape parts with a metal tool.
5.2 Under a light, and preferably under
magnification, visually inspect parts
for cracks, pitting, scoring, corrosion
or galling.
5.3 Inspect all threaded parts for chipped,
crossed or stripped threads.
5.4 Inspect and measure the free (re-
laxed) length of springs:
a. Detent springs (8), 7/8 inches
(22.23 mm);
b. Check valve springs (25), 3/4
inches (19.05 mm);
c. Check valve springs (34), 11/16
inches (17.45 mm);
d. Shuttle spring (4E), 1 5/16
inches (33.5 mm).
5.5 Roll springs over a flat surface to
check for wobble.
5.6 Check tube assembly (48) for kinks,
breaks or defective tube flares.
8
5.8 Check for smooth movement of shut-
tle assembly within air valve body.
Check contacting surfaces of shuttle
and bore of body for dirt, scratches
or galling. Check rings (4C) on shuttle
for wear, particularly at the tips. Check
o-rings (4B) under seal rings for
general condition and inspect detent
pins (9) for worn condition.
5.9 Inspect inlet and outlet check valve
seating surfaces in the fluid body (21)
for nicks, burrs or excessive wear.
Inspect valve bodies, poppets, springs
and seats for nicks, burrs, excessive
wear or rust.
6.0 REPAIR AND REPLACEMENT
6.1 Polish metal parts to remove minute
imperfections, minor scratches or
scoring. Use wet-or-dry paper grit
#600.
6.2 Check fluid piston (16 or 27) and fluid
body (21). If there is any evidence of
galling, replace both piston and body.
Carefully polish piston to remove mi-
nor scratches or nicks. Use grit #600.
Polish fluid body bore with hone to
Table 5-1 In-service wear limits, fluid piston to
fluid body.
ALLOWABLE MAX.
PUMP RATIO CLEARANCE
AND DASH NO. INCH MM
10:1 - 10 0.010 0.254
20:1 -20 0.008 0.203
30:1 -30 0.007 0.178
35:1 -35 0.005 0.127
60:1 -60 0.005 0.127
100:1 -100 0.004 0.102
125:1 -125 0.004 0.102
150:1 -150 0.003 0.076
200:1 -200 0.002 0.051
300:1 -300 0.001 0.025
remove minor imperfections. Use a
very fine polishing stone. Recheck
for wear clearances as described in
paragraph 5.7 and Table 5-1. If im-
perfections cannot be easily removed,
replace piston and body as a matched
set. Note: The replacement piston-
body set also includes the lower
housing and gasket.
6.3 Check air valve and upper housing
assembly. Polish out minor imper-
fections as described in paragraph
6.2. Keep polishing and honing to
an absolute minimum to prevent an
increase in wear clearance and result-
ing loss of air. If imperfections
cannot be easily removed, replace the
entire air valve and upper housing
assembly.
6.4 Clean all repaired parts in solvent as
described in paragraph 5.1.
6.5 Replace all metal parts that fail to
pass inspection or are damaged or
worn beyond simple repair.
6.6 Replace all o-rings, packing retainers,
gaskets, springs and detent pins at
each pump overhaul. Overhaul kits
from Sprague Products conveniently
contain all necessary parts to prop-
erly overhaul or service the pump.
See Figure 6-1.
These listed kits contain nitrile seals. Kits
can also be ordered with neoprene, viton,
and EPR seal material. Refer to catalog
SCC-0693 for kit descriptions and specific
ordering information.
Figure 6-1 Overhaul Kits.
PUMP REFERENCE OVERHAUL
MODEL NO. NO. KIT
S-216-J-10 79293-11 90680-11
S-216-J-20 77894-11 90680-21
S-216-J-30 77894-21 90680-31
S-216-J-35 77895-81 90680-41
S-216-J-60 77895-11 90680-51
S-216-J-100 77895-21 90680-61
S-216-J-125 77895-61 90680-01
S-216-J-125 77895-61001 90680-01001
S-216-J-150 77895-31001 90680-71001
S-216-J-200 77895-41001 90680-81001
S-216-J-300 77895-51001 90680-91001
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Figure 7-4 Tightening shifting nut to secure con-
necting rod into fluid piston.
Figure 7-5 Installing seals in fluid body.
7.0 REASSEMBLY
Before reassembling pump, wash metallic
parts thoroughly in solvent and dry. Lu-
bricate o-rings and threads with Vaseline,
hydraulic oil or petrolatum per Federal
Specification VV-P-236 or with lubricant
compatible with special seal compounds.
7.1 Position fluid body (21) and lower
housing (19) in vise. Note: Insert
soft aluminum plates in vise jaws to
cushion grip against fluid body. Refer
to paragraph 4-2.
Figure 7-3 Connecting rod with lock washer and
shifting nut, ready to be screwed into fluid piston.
7.2 Reassemble and install inlet and outlet
check valves into fluid body (21). See
Figure 7-1. Note order of assembly
and position of poppets (23 and 33)
by referring to Figure 7-2. Note torque
instructions in illustrations. DO NOT
over-torque valve bodies (22 or 31)
and be careful to avoid crossing
threads when installing check valve
bodies. On completion, remove from
vise.
7.3 Position fluid piston (16 or 21) in
vise. Use aluminum plates in vise
jaws. Screw air piston (14) fully onto
Figure 7-1 Installing check valves.
Figure 7-2 Inlet and outlet check valves, sequence of assembly.
9
fluid piston. Screw nut (38) firmly
with 3/4” wrench onto the threaded
end of the fluid piston. Install o-ring
(15) into groove in air piston (14).
7.4 Screw shifting nut (40) all the way up
the long length (one-inch) of threads
on the connecting rod (37) with bev-
eled end of nut toward center
of rod.
7.5 Insert lockwasher (39) under shift-
ing nut (40) and hold washer next to
under side of shifting nut (40). See
Figure 7-3. Screw connecting rod (37)
end into the threaded end of the fluid
piston (16 or 27) until the rod bot-
toms solidly. Torque shifting nut (40)
tightly against plain nut (38) to secure
connecting rod. See Figure 7-4.
7.6 Place fluid body (21) and lower hous-
ing assembly (19) in vise.
7.7 Install new seals in sealing groove in
the bore of the fluid body (21), (see
Figure 7-5) in the following sequence
relative to pump ratio:
a. 10:1, 20:1 and 30:1 pumps: packing
retainer (18)- bottom, o-ring
(17)–middle, and packing retainer
(18)–top;
b. 35:1 thru 300:1 pumps: back-up
ring (18A) on top, o-ring (17) in
middle, and packing retainer (18)
on bottom of sealing groove.
31 34 33 32 35 36 35 34 33 32 31A
21
OUTLET Check Valve Assembly INLET Check Valve Assembly
10:1 through 100:1 10:1 through 100:1
22 25 23 24 26 26 25 23 24 22
Torque check valve
bodies (22) to
120 foot pounds
OUTLET Check Valve Assembly NLET Check Valve Assembly
125:1 through 300:1 125:1 through 300:1
Torque check valve bodies
(31) to 240 foot pounds
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Figure 7-12 Installing self-locking nut on
connecting rod.
Figure 7-11 Using air pressure to raise
shuttle assembly.
Figure 7-10 Bolting upper and lower
housings together.
Figure 7-8 Inserting J type shuttle assembly into
air valve body.
Figure 7-9 Air valve and upper housing assembly
ready for attachment to lower housing assembly.
Figure 7-6 Inserting air piston and fluid piston
assembly into fluid body.
Figure 7-7 Pressing cylinder into lower housing.
10
7.8 Carefully insert assembled fluid
piston (16 or 27) and air piston (14)
assembly into bore of fluid body
to avoid scratching surfaces. See
Figure 7-6. Note: Before assembly,
lubricate bore and seals of fluid
body and fluid piston.
7.9 Press down and rotate piston (14)
until it bottoms on the top side of
the fluid body (21).
7.10 Lubricate inside wall of cylinder
(13) and o-ring (15) in groove of air
piston with Vaseline. Press cylinder
into position between air piston
and lower housing (19). Position
second o-ring (15) around outside
of cylinder and in contact with flange
of lower housing. See Figure 7-7.
7.11 Place stop sleeve over connecting
rod and screw nut (44) onto the
first several threads of the con-
necting rod.
7.12 Gripping connecting rod (37) and
the underside of nut (44), pull rod
upward so that the air piston (14)
and fluid piston (16 or 27) are in
the up position. Remove nut (44)
from rod.
7.13 Reassemble shuttle assembly and
install with “Top” up into air valve
and upper body assembly. See
Figure 7-8. Press shuttle down
evenly and slowly. Move shuttle up
and down several times to assure
smooth movement.
7.14 Install air valve and upper housing
assembly onto fluid body and lower
housing assembly. Be sure the two
elbow fittings for the tube assembly
(48) are aligned with each other for
later assembly. See Figure 7-9.
7.15 Install and loosely tighten the cap
screws (45) and nuts (46) around
the housing flanges. Tighten evenly
in clockwise opposite positions: 12,
6, 3, 9, etc. Uneven tightening will
cause binding between cylinder (13)
and air piston (14). Note: Connecting
rod should be centered in the air
valve shuttle assembly center hole if
bolts are tightened evenly.
7.16 Install the four sets of detent pins
(9), springs (8), o-ring packings (7)
and bolts (6) into the four threaded
ports in valve body (5). Detent pins
should engage in lower groove of the
shuttle (4A).
7.17 Apply air pressure to elbow fitting
(47) in the lower housings to move
the piston to the up position. See
Figure 7-11.
7.18 Install self-locking nut (44) on up-
per threaded end of connecting rod
(37). See Figure 7-12. Referring to
Figure 7-13 and paragraph 7.5, if
no lower threads of connecting rod
show above shifting nut (40), then
install self-locking nut (44) with at
least one upper thread of connecting
rod exposed beyond the self-locking
nut. Correspondingly, if one or two
lower threads of connecting rod are
exposed beyond the shifting nut,
then install self-locking nut with a
like number of connecting rod upper
threads exposed beyond the lock nut.
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INPUT OPERATING OUTPUT
PUMP MODEL AIR PRESSURE FLUID PRESSURE
DASH NO. PSI BAR PSI BAR
-10 40 2.72 400 27
100 6.80 1,000 69
-20 40 2.72 720 50
100 6.80 1,850 128
-30 40 2.72 1,240 84
100 6.80 3,100 214
-35 40 2.72 1,850 126
100 6.80 4,600 317
-60 40 2.72 2,350 160
100 6.80 6,100 420
-100* 40 2.72 3,500 238
100 6.80 8,800 607
-125 40 2.72 5,000 345
100 6.80 12,500 862
-150 40 2.72 6,200 422
100 6.80 16,000 1,103
-200 40 2.72 9,500 646
100 6.80 23,750 1,637
-300 40 2.72 14,000 953
100 6.80 33,500 2,310
7.19 Check for smooth movement up
and down of shuttle. Using shop air
(approx. 10 psi), inject air to elbow
in lower housing (19) to raise shuttle
to up position. Manually push down
on the shuttle. Repeat this up and
down movement several times to
determine smoothness of movement.
Movement should be smooth; if not,
air piston (14) is binding against cyl-
inder wall (13). Binding is caused by
uneven tightening of the 12 screws
(45) and nuts (46) at the housing
flange. Retighten screws evenly per
paragraph 7.15.
7.20 With pump movement assured,
install new o-ring (2), cover (1) and
four screws (3) to close the air valve
portion of the pump.
7.21 Reinstall tube assembly (48) to the
elbows in the upper and lower hous-
ings.
7.22 For final check of movement, inject
air pressure to air inlet port. Move-
ment of assembled shuttle, air piston
and fluid piston should be smooth
and regular.
8.0 TEST
8.1 Install pump into a typical circuit.
See Figure 1-2. Operate pump in
accordance with Section 2.0, Opera-
tion.
8.2 Conduct tests operating pump at
different driving air pressures. Close
fluid shut-off valve in pump dis-
charge line to permit pump to build
up its maximum pressure output.
At this point the pump will slow to a
stop, indicating a pressure balance
has been reached between fluid
pressure and driving air pressure.
The pump will automatically restart
when pressure imbalance occurs.
8.3 Compute ratio of fluid maximum
output pressure to driving air input
pressure. Compare pump dash
number to pump’s rated fluid output
pressure. Refer to Table 8-1.
11
For proper stroke adjustment, the number of exposed threads at B should equal the number
of exposed threads at A (one thread minimum).
Refer to Paragraphs
7.4 and 7.5
At minimum, one
thread of connecting
rod should be exposed,
Paragraph 7.18
Connecting Rod
Self-Locking Nut
Shifting Nut
B
Table 8-1 Rated air input pressures to fluid output pressures. *Except model S-216-S-100
Figure 7-14 J air valve strobe adjustment.
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8.0 IPB AND SUPPLMENTAL DATA
8239 Illustrated Parts Breakdown (IPB)
enclosed to provide additional data on the
S-216-J-() basic pump. Other pump data
may be included as required.
12
OVERHAUL KIT
The Overhaul Kit contains replacement parts
including Inlet and Outlet Check Valve O-rings and
Springs; Detent Springs, Pins and O-rings; Shuttle
Valve Rings and O-rings as well as other O-rings,
Retainers, and Connecting Self-Locking Nut and
Washer.
The kits listed below apply only to standard pumps
with elastomeric type seals. Standard kit seals are
nitrile. Optional kits with neoprene, Viton® and
EPR seals are available. In the kit numbers listed
below, the two digits after the dash indicate the
choice of optional seal materials. The first of those
digits indicates the pump ratio while the second
indicates the seal materials.
00000-X X = pump ratio
00000-X1 1 = nitrile seals
00000-X3 3 = Viton® seals
00000-X4 4 = EPR seals
Ordering Example: An Overhaul Kit with neoprene
seals is needed for an S-216-J-30. The standard
kit is 90680-31 with the 3 indicating a 30 ratio
pump and the 1 indicating nitrile seals. Change the
last digit from 1 to 2 to indicate neoprene seals.
The new number for the Overhaul Kit is 90680-32.
Pump Reference Overhaul Kit
Model Number Number Number
S-216-J-10 79293-11 90680-11
S-216-J-20 77894-11 90680-21
S-216-J-30 77894-21 90680-31
S-216-J-35 77895-81 90680-41
S-216-J-60 77895-11 90680-51
S-216-J-100 77895-21 90680-61
S-216-J-125 77895-61 90680-01
S-216-J-125 77895-61001 90680-01001
S-216-J-150 77895-31001 90680-71001
S-216-J-200 77895-41001 90680-81
S-216-J-300 77895-51001 90680-91
Exhaust air
outlet port
Driving air
inlet port
45 46
49
Nameplate
47
48
Liquid
inlet
port
Liquid
outlet
port
OUTLET Check Valve Assembly NLET Check Valve Assembly
125:1 through 300:1 125:1 through 300:1
With liquid body/piston seals for 35:1 to 300:1 ratio pumps.
31 34 33 32 35 36 35 34 33 32 31A
21
27
28
18A
17
18
OUTLET Check Valve Assembly INLET Check Valve Assembly
10:1 through 100:1 10:1 through 100:1
With liquid body/piston seals for 10:1 to 30:1 ratio pumps.
4B
2
4G 44 1
3
4A
5A
4D
98
10
5B
7
5C
13
6
14
16
17
18
19
20
21
22 25 23 24 26 26 25 23 24 22
4C
4D
4E
6
4F
37
4H
40
39
38
15
Viton is a registered trademark of DuPont Dow Elastomers.
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13
*Seal Materials: Neoprene, Viton and EPR. Teflon is a registered trademark of the DuPont Company.
Item Pump Ratio Dash Number
No Model Number Part Name -10 -20 -30 -35 -60 -100 -125 -150 -200 -300
S-216-J-10 Pump Assy., 10:1 Ratio (79293-11) •
S-216-J-20 Pump Assy., 20:1 Ratio (77894-11) •
S-216-J-30 Pump Assy., 30:1 Ratio (77894-21) •
S-216-J-35 Pump Assy., 35:1 Ratio (77895-81) •
S-216-J-60 Pump Assy., 60:1 Ratio (77895-11) •
S-216-J-100 Pump Assy., 100:1 Ratio (77895-21) •
S-216-J-125 Pump Assy., 125:1 Ratio (77895-61) •
S-216-J-125 Pump Assy., 125:1 Ratio (77895-61001) •
S-216-J-150 Pump Assy., 150:1 Ratio (77895-31001) •
S-216-J-200 Pump Assy., 200:1 Ratio (77895-41001) •
S-216-J-300 Pump Assy., 300:1 Ratio (77895-51001) •
Part No.
1 S-216-17-1 Cover air valve 1 1 1 1 1 1 1 1 1 1
2 91417-138 O-ring 1 1 1 1 1 1 1 1 1 1
3 MS90725-3 Screw cap, 1/4-20 X 1/2 long 4 4 4 4 4 4 4 4 4 4
4 90535-1 Air valve and housing assembly
— 90654-1 Shuttle Assembly (See Note 1) 1 1 1 1 1 1 1 1 1 1
4A 90522 Shuttle 1 1 1 1 1 1 1 1 1 1
4B 91417-029 O-ring 2 2 2 2 2 2 2 2 2 2
4C 90524 Ring 2 2 2 2 2 2 2 2 2 2
4D 92247 Flange 2 2 2 2 2 2 2 2 2 2
4E 90600 Spring 1 1 1 1 1 1 1 1 1 1
4F 92249 Guide sleeve 1 1 1 1 1 1 1 1 1 1
4G 90685 Snap ring 1 1 1 1 1 1 1 1 1 1
4H 92248 Stop sleeve 1 1 1 1 1 1 1 1 1 1
— 90651-1 Body and housing assembly (See Note 1) 1 1 1 1 1 1 1 1 1 1
5A 78216-1 Body (See Note 2) 1 1 1 1 1 1 1 1 1 1
5B 91417-023 Gasket (See Note 2) 1 1 1 1 1 1 1 1 1 1
5C S-216-19 Upper housing (See Note 2) 1 1 1 1 1 1 1 1 1 1
6 78238 Detent bolt 4 4 4 4 4 4 4 4 4 4
7 79552-5 Detent O-ring 4 4 4 4 4 4 4 4 4 4
8 S-216-24 Detent spring 4 4 4 4 4 4 4 4 4 4
9 82871 Detent pin 4 4 4 4 4 4 4 4 4 4
10 S-216-56 Stop 1 1 1 1 1 1 1 1 1 1
13 S-216-13 Cylinder 1 1 1 1 1 1 1 1 1 1
14 S-216-4 Air piston 1 1 1 1 1 1 1 1 1 1
15 79550-60 O-ring, 70 shore 2 2 2 2 2 2 2 2 2 2
16 S-216-61-10SS Liquid piston 1
17 79551-3-1* O-ring, 90 shore, nitrile 1
18 MS28783-3 Packing retainer, Teflon® 2
— 89801-10 Body and housing assembly (See Note 3) 1
19 89800 Lower housing 1
20 S-216-20-1 Gasket 1
21 89775 Liquid body 1
16 S-216-10-20 Liquid piston 1
17 79550-25-1* O-ring, 90 shore, nitrile 1
18 MS28782-25 Packing retainer, Teflon 2
— 89801-20 Body and housing assembly (See Note 3) 1
19 89793 Lower housing 1
20 S-216-20 Gasket 1
21 77893 Liquid body 1
16 S-216-10-30 Liquid piston 1
17 79550-20-1* O-ring, 90 shore, nitrile 1
18 MS28782-20 Packing retainer, Teflon 2
— 89801-30 Body and housing assembly (See Note 3) 1
19 89793 Lower housing 1
20 S-216-20 Gasket 1
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14
*Seal Materials: Neoprene, Viton and EPR.
Item Pump Ratio Dash Number
No Model Number Part Name -10 -20 -30 -35 -60 -100 -125 -150 -200 -300
16 S-216-10-35 Liquid piston 1
17 79550-17-1* O-ring, 90 shore, nitrile 1
18 MS28782-17 Packing retainer, Teflon 1
18A 90098-35 Back-up ring 1
— 89801-35 Body and housing assembly (See Note 3) 1
19 89793 Lower housing 1
20 S-216-20 Gasket 1
21 77888 Liquid body 1
— 89803-60-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket (See Note 4) 1
— 77890-11 Piston and body assembly 1
16 S-216-10-60 Liquid piston (See Note 4) 1
21 77888-1 Liquid body (See Note 4) 1
17 79550-14-1* O-ring, 90 shore, nitrile 1
18 MS28782-14 Packing retainer, Teflon 1
18A 90098-60 Back-up ring 1
— 89803-100-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket (See Note 4) 1
— 77890-21 Piston and body assembly 1
16 S-216-11-100 Liquid piston (See Note 4) 1
21 77888-2 Liquid body (See Note 4) 1
17 79550-12-1* O-ring, 90 shore, nitrile 1
18 MS28782-12 Packing retainer, Teflon 1
18A 90098-100 Back-up ring
— 89803-125-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket (See Note 4) 1
— 77890-61 Piston and body assembly 1
16 S-216-11-125 Liquid piston 1
21 77889-2 Liquid body 1
17 79550-11-1* O-ring, 90 shore, nitrile 1
18A 90098-125 Back-up ring 2
— 89803-150-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket (See Note 4) 1
— 77890-31 Piston and body assembly 1
16 S-216-11-150 Liquid piston 1
21 77889-3 Liquid body ) 1
17 79550-10-1* O-ring, 90 shore, nitrile 1
18A 90098-150 Back-up ring 2
— 82650-21 Valve assembly, outlet (3/8 NPT thread) 1 1 1 1 1 1
— 82651-21 Valve assembly, inlet (3/8 NPT thread) (See Note 7 1 1 1 1 1 1
22 88906 Check valve body (See Note 7) 1 1 1 1 1 1
— 79420-3 Poppet assembly (See Note 7) 1 1 1 1 1 1
23 79420-1 Poppet (See Note 7) 1 1 1 1 1 1
24 79550-8-1* Packing O-ring, 90 shore, nitrile (See Note 7) 1 1 1 1 1 1
25 S-216-23 Spring (See Note 7) 1 1 1 1 1 1
26 91417-019 O-ring, 70 shore, nitrile 1 1 1 1 1 1
— 89803-200-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket 1
— 77890-41 Piston and body assembly 1
27 S-216-11-200 Liquid piston 1
28 77889 Liquid body 1
17 79550-8-1* O-ring, 90 shore, nitrile 1
18 MS28782-8 Packing retainer, Teflon 1
18A 90098-200 Back-up
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15
1. 90654-1 shuttle assembly and 90651-1 body and housing
assembly may be purchased as an assembled set.
2. 90651-1 body and housing assembly, consisting of body
(5A), gasket (5B) and upper housing (5C), is available only
as an assembled set.
3. -10 through -35 pumps: lower housing (19), gasket (20) and
liquid body (21) are available only as an assembled set.
4. -60 through -300 pumps: liquid body (21), liquid piston (16),
O-ring (17), retainers (18), back-up rings (18A and 30A),
lower housing (19) and gasket (20) are available only as an
assembled set. O-rings, retainers and back-up rings can
be ordered separately.
Notes
5. Each liquid body and lower housing assembly (See Notes
3 and 4) is provided with an accurately located port (hole)
for tube assembly (48) and elbow (47).
6. Seal materials listed in the Parts List are nitrile. Neoprene,
Viton and EPR seals are available. Specify seal materials
when ordering.
7. Detail parts are identified in the inlet and outlet check valve
assemblies.
Item Pump Ratio Dash Number
No Model Number Part Name -10 -20 -30 -35 -60 -100 -125 -150 -200 -300
— 89803-300-1 Piston, body and housing assembly (See Note 4) 1
19 89793 Lower housing 1
20 S-216-20 Gasket 1
— 77890-51 Piston and body assembly 1
27 S-216-11-300 Liquid piston 1
28 77889-1 Liquid body 1
17 91417-011-1* O-ring, 90 shore, nitrile 1
18 MS28782-6 Packing retainer, Teflon 1
18A 90098-300 Back-up ring 1
— 82648-11 Valve assembly, outlet (9/16 NBS thread) 1 1 1 1
— 82649-11 Valve assembly, inlet (1/4 NPT thread) 1 1 1 1
31 89298-1 Outlet Check valve body (See Note 7) 1 1 1 1
31A 89298 Inlet Check valve body (See Note 7) 1 1 1 1
32 79550-5-1* Packing O-ring, 90 shore, nitrile (See Note 7) 1 1 1 1
33 89297 Poppet (See Note 7) 1 1 1 1
34 S-216-63 Spring (See Note 7) 1 1 1 1
35 S-216-28-10 Inlet check valve gasket (See Note 7) 1 1 1 1
— S-216-28-8 Outlet check valve gasket (See Note 7) 1 1 1 1
36 S-216-27-4 Outlet check valve seat only (See Note 7) 1 1 1 1
37 90523 Connecting rod 1 1 1 1 1 1 1 1 1 1
38 93776-1 Plain nut, 1/2-20 1 1 1 1 1 1 1 1 1 1
39 MS35335-33 Washer/Lock, external tooth, 1/4 1 1 1 1 1 1 1 1 1 1
40 78259 Shifting nut 1 1 1 1 1 1 1 1 1 1
44 90686 Self-locking nut, 1/4-28 1 1 1 1 1 1 1 1 1 1
45 MS90725-3 Screw cap, 1/4-20 X 1/2 long 12 12 12 12 12 12 12 12 12 12
46 MS51967-2 Plain nut, 1/4-20 12 12 12 12 12 12 12 12 12 12
47 93594 Elbow, 90º 2 2 2 2 2 2 2 2 2 2
48 88501 Tube assembly 1 1 1 1 1 1 1 1 1 1
49 80063-2 Nameplate 1 1 1 1 1 1 1 1 1 1
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© Sprague Products 2005
S216JOM 3M 205
Sprague Products
Division of Curtiss-Wright Flow Control Corporation
10195 Brecksville Road
Brecksville, OH 44141 USA
Telephone: [phone] • Fax: [phone]
www.cwfc.com
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