STAINLESS STEEL CHOP CHECK PUMP FLUID SECTION MANUAL REPAIR AND MAINTENANCE – CCPLS-1000-SS MAGNUM VENUS PLASTECH Stainless Steel Chop Check Pump – Repair and Maintenance CCPLS-1000-SS 03/29/2007 TABLE OF CONTENTS: STAINLESS STEEL CHOP CHECK PUMP FLUID SECTION MANUAL – REPAIR AND MAINTENANCE: CHAPTER 1 – SS FLUID SECTION DISASSEMBLY CHAPTER 2 – SS FLUID SECTION ASSEMBLY CHAPTER 3 – DRAWINGS CHAPTER 1 STAINLESS STEEL CHOP CHECK PUMP FLUID SECTION DISASSEMBLY WARNING: When removing Pump Fluid Section, Hoses and Resin Surge Chamber, be sure to bleed off fluid pressure from the system before disconnecting. Release Surge Chamber charge before removing Surge Chamber. System may be under pressure and cause injury. Note: The Fluid Section can be rebuilt in place or easily removed and taken to a workbench. Flushing the fluid section with suitable cleaning agent can make the rebuild process much easier. TO REMOVE THE FLUID SECTION FROM THE PUMP ASSEMBLY: 1. 2. Put the pump into the lowest position of the down stroke. Disconnect the resin hose from the side of the Pump fluid section. Warning: Be sure to remove fluid pressure from the system before disconnecting resin hose, tie rods or surge chamber. System may be under pressure and can cause injury. 3. 4. 5. 6. 7. Remove the E-Ring (APP-9102), lift up the Sleeve (APP-9109) and remove the two Connectors (APP-9096). Remove the four Hex Head Bolts (02705-14) holding the fluid section to the Pump Mount Plate (CCP-1008). Remove the four Hex Head Bolts (F-HB-06C-16) holding the fluid section to the Support Plate (CCP-1009). Remove the two Hex Nuts (7201-1-12) from the Support Rod (APD-1003) Shift the Ram Control valve into the Ram up position, move the ram up until the pump mount plate will allow the pump fluid section to be removed. Note: As you disassemble, lay the parts out on a towel or rag in the order you take them apart. This will help you remember how they go back together. Inspect each part for wear or damage and note parts that require replacement. FLUID SECTION DISASSEMBLY PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. If not already done, move the pump to the bottom of the down stroke. Remove Hex Cap Screw (F-HB-06F-12) from the bottom of the Priming Rod (CCPLS1027-SS). If the Priming Rod (CCPLS-1027-SS) spins put a wrench on the wrench flats of the Priming Rod just above the Priming Piston (CCPLS-1023-SS). Remove the Backup Washers (CCPLS-1028-SS), Relief Washer (CCPLS-1025) and the Priming Piston (CCPLS-1023-SS) from the Priming Rod (CCPLS-1027-SS). Unscrew the four Hex Nuts (7201-1-10) from the end of the Tie Rods (CCPLS-1020). Pull the Priming Valve Housing (CCPLS-1026-SS) off the Tie Rods CCPLS-1020) and out of the Foot Valve Housing (CCPLS-1019-SS). Remove Lower Valve Seat (CCPLS-1018-SS) from out of the end of the Foot Valve Housing (CCPLS-1019-SS). Slide the Foot Valve Housing (CCPLS-1019-SS) off the Cylinder (CCPLS-1008-SS). Unscrew the Tie Rods out of the Outlet Body (CCPLS-1007-SS). Pull the Intake Valve (CCPLS-1031-SS) assembly off the Priming Rod (CCPLS-1027SS). Unscrew the Intake Valve Packing Nut (CCPLS-1016-SS) from the Intake Valve (CCPLS-1017-SS) Remove the Lower Intake Valve Seal (CCPLS-1015) from inside the Intake Valve (CCPLS-1017-SS). Slide the Valve Stop (CCPLS-1014-SS) off the Priming Rod (CCPLS-1027-SS). Pull the Cylinder (CCPLS-1008-SS) out of the Outlet Body (CCPLS-1007-SS) and off the Piston Cups (CCPLS-1009). Remove the Packing Nut (CCPLS-1006) from the top of the Outlet Body (CCPLS1007-SS). Pull the Displacement Rod (CCPLS-1013-SS) from the V Packing (CCPLS-1002) and Outlet Body (CCPLS-1007-SS), and set aside for now. Remove the Rod Bushing (CCPLS-1001) from the top of the Outlet Body (CCPLS1007-SS). Remove the Spring Support Ring (CCPLS-1005) and Wave Springs (CCPLS-1029) from inside of the Outlet Body (CCPLS-1007-SS). Remove the Female Compression Ring (CCPLS-1003-SS), Male Compression Ring (CCPLS-1004-SS) and V Packing (CCPLS-1002) from inside of the Outlet Body (CCPLS-1007-SS). Note: If the parts are hard to remove from the top of the Outlet Body use a wood or plastic dowel to push the parts out from the bottom. Cleaning with a solvent will help loosen stuck parts. Displacement Rod Disassembly – Note: Clean and inspect all parts for wear and damage. Replace damaged parts and all parts provided in the repair and seal kits. 1. 2. 3. Unscrew the Lower Piston Body (CCPLS-1012-SS) from the Upper Piston Body (CCPLS-1011-SS). Use caution, the piston ball may fall out and become damaged. If the ball falls onto a hard surface it may become scratched or get a flat spot on it. Remove the Piston Ball (9201-2-36) and Ball Check Spring (3102-16-1) from the Upper Piston Body (CCPLS-1011-SS). Remove the Piston Cups (CCPLS-1009), Piston Cup Spacer (CCPLS-1010-SS) and Piston Cup Backup Ring (CCPLS-1021-SS) from the Lower Piston Body (CCPLS1012-SS). CHAPTER 2 CHOP CHECK PUMP FLUID SECTION ASSEMBLY FLUID SECTION ASSEMBLY PROCEDURE: Displacement Rod Assembly 1. 2. 3. 4. 5. Mount the Displacement Rod (CCPLS-1013-SS) in a vise by the wrench flats. Apply a small amount of Loctite to the threads of the Upper Piston Body (CCPLS1011-SS) and thread it into the Displacement Rod (CCPLS-1013-SS). Insert Ball Check Spring (3102-16-1) into the Upper Piston Body (CCPLS-1011), larger end first. Apply a light coat of red grease (6706-2-1) to Piston Ball (9201-2-36) and place it into the Upper Piston Body (CCPLS-1011-SS), on top of the Ball Check Spring (3102-161). Press Piston Ball Seat (CCPLS-1022-SS) into Lower Piston Body (CCPLS-1012-SS), with chamfer towards the ball. See below Note: Use caution not to damage the ball seat area. PISTON BALL SEAT – CCPLS-1022-SS LOWER PISTON BODY – CCPLS-1012-SS 6. Slide Piston Cup Backup Ring (CCPLS-1021-SS) over the lower Piston Body (CCPLS-1012-SS) ridged side up. 7. Apply red grease (6706-2-1) into the Piston Cups (CCPLS-1009). Slide one Piston Cup (CCPLS-1009) with the cup side up over the lower Piston Body (CCPLS-1012SS) onto the Piston Cup Backup Ring (CCPLS-1021-SS). 8. Slide the Piston Cup Spacer (CCPLS-1010-SS) onto the Lower Piston Body (CCPLS1012-SS) so that the narrow end is inside the Piston Cup. 9. Place the other Piston Cup (CCPLS-1009) with the cup side up, over the Lower Piston Body (CCPLS-1012-SS) down onto the Piston Cup Spacer (CCPLS-1010-SS). 10. Now thread the Lower Piston Body (CCPLS-1012-SS) into the Upper Piston Body (CCPLS-1011-SS). Note: Use caution not to over tighten the lower Piston Rod as it will damage the lip of the piston cups. 11. Apply a small amount of Loctite to the threads of the Priming Rod (CCPLS-1027-SS). Thread Priming Rod (CCPLS-1027-SS) into the Lower Piston Body (CCPLS-1012SS). Remove the Piston Rod from the vise and set aside. Outlet Body Assembly – 1. Pack red grease (6706-2-1) into all of the V packing (CCPLS-1002) and Female Compression Ring (CCPLS-1003-SS). 2. Apply a light film of red grease (6706-2-1) to the inside of the packing area of the Outlet Body (CPLS-1007-SS). 3. Put together all four V Packing (CCPLS-1002) with the Male Compression Ring (CCPLS-1004-SS) on one end and the Female Compression Ring (CCPLS-1003-SS) on the other. 4. Put this V Packing Assembly into the Outlet Body (CCPLS-1007-SS) with the Male Compression Ring (CCPLS-1004-SS) going in first. 5. Apply a light film of red grease (6706-2-1) to the ten Wave Springs (CCPLS-1029) and insert them into the Outlet Body (CCPLS-1007-SS) onto the V Packing set. 6. Put Spring Support Ring (CCPLS-1005) into the Outlet Body (CCPLS-1007-SS) on top of the Wave Spring set. 7. Insert Rod Bushing (CCPLS-1001) into the Outlet Body (CCPLS-1007-SS) onto the Spring Support Ring. 8. Apply a little red grease (6706-2-1) to the threads of Packing Nut (CCPLS-1006) and thread it into the Outlet Body (CCPLS-1007-SS), just enough to contact the Rod Bushing (CCPLS-1001), do not tighten at this point. 9. Apply a light film of red grease (6706-2-1) to the Displacement Rod (CCPLS-1013-SS) and to the Priming Rod (CCPLS-1027-SS). 10. Apply a light film of red grease (6706-2-1) to the Outlet Body (CCPLS-1007-SS) where the Cylinder o-ring will be installed. Note: It would be helpful to put the Outlet Body into a vise at this point, if the fluid section has been removed from the pump mount bracket. 11. Gently insert the Displacement Rod (CCPLS-1013-SS) assembly into the Outlet Body (CCPLS-1007-SS) and thru the V Packing (CCPLS-1002) from the outlet side. 12. Lightly grease both O-Rings (O-V-144) and install onto the Cylinder (CCPLS-1008SS). 13. Firmly press the Cylinder (CCPLS-1008-SS) over the Priming Rod and onto the Piston Cups (CCPLS-1009), then into the Outlet Body (CCPLS-1007-SS). 14. Install the Valve Stop (CCPLS-1014-SS) onto the Priming Rod (CCPLS-1027-SS) up to the bottom of the Cylinder (CCPLS-1008-SS). Intake Valve Assembly – 1. 2. 3. 4. Apply a light film of red grease (6706-2-1) to the inside of the Intake Valve (CCPLS1017-SS). Lightly grease and install Lower Intake Valve Seal (CCPLS-1015) into the Intake Valve (CCPLS-1017-SS). Apply a drop of Loctite to the threads of the Intake Valve Packing Nut (CCPLS-1016SS) and thread it just a little ways into the Intake Valve (CCPLS-1017-SS). Take the Intake Valve (CCPLS-1017-SS) assembly and install it onto the Priming Rod (CCPLS-1027-SS), with the Intake Valve Packing Nut going on first. 5. Finish tightening the Intake Valve Packing Nut (CCPLS-1016-SS) into the Intake Valve (CCPLS-1031). Slide it up against the Valve Stop (CCPLS-1014). Final Assembly – 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Apply a light film of red grease (6706-2-1) to the inside of both ends of Foot Valve Housing (CCPLS-1019-SS). Slide the correct end of Foot Valve Housing (CCPLS-1019-SS) over the Priming Rod and Intake Valve and onto the Cylinder (CCPLS-1008-SS). Apply a light film of red grease (6706-2-1) to O-Ring (0-V-145) and install onto Lower Valve Seat (CCPLS-1018-SS). Install Lower Valve Seat (CCPLS-1018-SS) over the Priming Rod and into the Foot Valve Housing (CCPLS-1019-SS). Install the four Tie Rods (CCPLS-1020) into the Outlet Body (CCPLS-1007-SS) and tighten. Apply red grease (6706-2-1) to O-Ring (0-V-150) and install onto Priming Valve Housing (CCPLS-1026-SS). Install the Priming Valve Housing (CCPLS-1026-SS) and O-Ring (0-V-150) over the Priming Rod and into the Foot Valve Housing (CCPLS-1019-SS) and onto the Tie Rods (CCPLS-1020). Align the notch in the Priming Valve Housing opposite the outlet hole in the Outlet Body. Thread the four Hex Nuts (7201-12-8) onto the Tie Rods (CCPLS-1020) and tighten them firmly against the Priming Valve Housing (CCPLS-1026-SS). Apply a thin film of red grease (6706-2-1) to Piston Seal (CCPLS-1024) and install onto Priming Piston (CCPLS-1023-SS). Adjust the Displacement Rod (CCPLS-1013-SS) in the pump so just the wrench flats are exposed out of the Packing Nut (CCPLS-1006). Place the Priming Piston (CCPLS-1023-SS) onto the Priming Rod (CCPLS-1027-SS). Place onto Hex Cap Screw (F-HB-06F-12) one Backup Washer (CCPLS-1028-SS) the Relief Washer (CCPLS-1025) and the last Backup Washer (CCPLS-1028-SS). Apply a drop of Loctite to the threads of Hex Cap Screw (F-HB-06F-12) and thread it into the end of the Priming Rod (CCPLS-1027-SS). Tighten only till the Priming Rod (CCPLS-1027-SS) starts to spin. Use caution not to over tighten, the Relief Washer may become damaged. CHAPTER 3 CHOP CHECK PUMP DRAWINGS: CHOP CHECK PUMP FLUID SECTION SS CCPLS-1000-SS CHOP CHECK PUMP REPAIR KIT CCPLS-1000-RK 34 8 6 13 34 5 14 1 35 (10) 33 15 3 16 2 4 17 19 7 20 20 18 36 37 13 26 11 20 31 20 31 29 30 SEE NOTE 1 10 26 9 9 31 27 22 21 23 12 24 ET TL TOP VIE OF U O BOTTOM FLANGE 28 28 25 27 32 MAGNUM VENUS PRODUCTS CHOP CHECK PUMP FLUID SECTION SS REV. - NOTE: 1. INSTALL WITH RIDGES UP CCPLS-1000-SS CHOP CHECK PUMP FLUID SECTION CCPLS-1000-SS PARTS LIST ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART NO. QTY CCPLS-1001 CCPLS-1002 CCPLS-1003-SS CCPLS-1004-SS CCPLS-1005 CCPLS-1006 CCLPS-1007-SS CCPLS-1008-SS CCPLS-1009 CCPLS-1010-SS CCPLS-1011-SS CCPLS-1012-SS CCPLS-1013-SS CCPLS-1014-SS CCPLS-1015 CCPLS-1016-SS CCPLS-1017-SS CCPLS-1018-SS CCPLS-1019-SS CCPLS-1020 CCPLS-1021-SS CCPLS-1022-SS CCPLS-1023-SS CCPLS-1024 CCPLS-1025 CCPLS-1026-SS CCPLS-1027-SS CCPLS-1028-SS 9201-2-36 3102-16-1 7201-1-10 F-HB-06F-12 CCPLS-1029 O-E-144 O-E-018 O-E-145 O-E-150 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 1 4 1 10 2 1 1 1 DESCRIPTION ROD BUSHING - DISPLACEMENT ROD V PACKING FEMALE COMPRESSION RING MALE COMPRESSION RING SPRING SUPPORT RING PACKING NUT OUTLET BODY CYLINDER PISTON CUP PISTON CUP SPACER UPPER PISTON BODY LOWER PISTON BODY DISPLACEMENT ROD VALVE STOP LWR INTAKE VALVE SEAL INTAKE VALVE PACKING NUT INTAKE VALVE LOWER VALVE SEAT FOOT VALVE HOUSING TIE ROD PISTON CUP BACKUP RING PISTON BALL SEAT PRIMING PISTON PISTON SEAL RELIEF WASHER PRIMING VALVE HOUSING PRIMING ROD BACKUP WASHER 1-1/4" DIA BALL BALL CHECK SPRING HEX NUT HEX CAP SCREW WAVE SPRING O-RING O-RING O-RING O-RING Corporate HQ/Mfg. th 5148 113 Ave. Clearwater, FL 33760 USA Ph: (727) 573-2955 Fax: (727) 571-3636 E-mail: [email protected] Manufacturing/Sales 1862 Ives Ave. Kent, WA 98032 USA Ph: (253) 854-2660 Fax: (253) 854-1666 Web: www.mvpind.com
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