Repair Parts Sheet Turbo II Air Pumps: L2533 Rev. O 04/01 For Date Codes Beginning With The Letter "O"
Repair Parts Sheet Turbo II Air Pumps: L2533 Rev. O 04/01 For Date Codes Beginning With The Letter "O"
L2533 Rev. O 04/01 For Date Codes Beginning with the Letter "O"
NOTE: Storing the pump in the vertical position may cause it to loose its prime. If pump looses its prime:
1. Remove cover.
2. Remove relief valve.
3. Fill chamber with oil
4. Replace relief valve. Apply Loctite 545 to threads and torque to 10–12 ft-lbs. [14–16 Nm]
5. Replace pump cover. Tighten every other fastener around the perimeter of the cover in one continuous direction.
® TURBO II
Contents
Figure 1 — Treadle Assembly, T Version ...................... 2 Figure 7 — Air Motor Assembly ....................................8
Figure 2 — Treadle Assembly, M, C, S Version .............3 Figure 8 — Release Valve .............................................9
Figure 2a & 2b – Handle Assembly, R Version..............4 Figure 9 — Manual Valve ............................................10
Figure 3 — Cover Assembly..........................................5 Figure 10 — Pump Manifolds, PAS Version.................11
Figure 4 — Hydraulic Section Detail .............................6 Figure 11 — Pump Manifold, PAC Version ..................11
Figure 5 — Seal Push Tool............................................7 Table 1 — Relief Valve Setting ....................................12
Figure 6 — Seal Push Tool............................................7 Table 2 — Repair Kit Application .................................12
93
100
Both Sides - 99
52
Figure 1
2
104
C A 97
B B 107
102
106
105
SECTION B-B
C
A 104
103 SECTION C-C
SECTION A-A
94 95 96
Figure 2
3
30 - Torque 25-30 in. lbs. 142 - Torque 3-4 ft. lbs.
Connect Air Supply [2,8-3,2 Nm] [4-5 Nm]
to either .250 NPT Port.
RET ADV
Repair Parts List for Figure 2a
Item Part Number Qty. Description
Connect red hose here.
Torque 16-19 ft. lbs. [22-25 Nm]. 29 DC2355186 1 Valve Spacer
30 DA5938028 2 Hi Lo Screw
29 142 B1320028 4 10-32 x .38 Screw
REF4601F1
L2434F2
*146
C*
Torque (3) to 10-12 ft. lbs.
156 155 B* [14-16 Nm]. 145
157
Torque to 10-12 ft. lbs. - 153 * B = Blue Hose
[14-16 Nm]. * C = Clear Hose
* R = Red Hose
Torque to 16-19 ft. lbs. - 154
[22-26 Nm].
4
73 CAUTION: Do not attempt to remove
or otherwise service the air-switch button
65
66 - Apply 17-19 in-lbs. [2 Nm] (item 73). Removal will damage the
64 sealing surfaces molded in the
of torque
63 reservoir cover.
62
61
Install screw until O-Ring 72
is firmly seated.
71
87 - Bend clip to retain 70
motor assembly.
SECTION C-C
SECTION B-B
67
66 - Apply 17-19 in-lbs. [2 Nm]
of torque
See Note #1
60
68
86 - Apply adhesive side of
69
gasket to cover
Figure 3
5
14 – See note #1
15 – See note #1
12 14 – See note #1
11 13 – See note #3
10
9
20
See note #3 – 8
21
7
See note #2 – 6 22
23 – See note #1
18 – See note #4
11
17 – Bearing to be installed with
19
chamfer to the outside
9 7 16 – Install U-cup with groove
side towards mounting
See note #3 – 8 1 bracket.
2
3 – See note #1
5 – Sharp edge 4
See note #5 – 24
away from
mounting bracket 26
See note #5 – 25
Figure 5
6
Repair Parts List for Figure 4
Item Part Number Qty. Description Item Part Number Qty. Description
1 DC114030 1 Hydraulic Cylinder, Turbo 10 KSI 17 ★ CB624108 1 Bearing 10 KS
DC116030 1 Hydraulic Cylinder, Turbo 3 KSI ★ DA9056108 1 Bearing 3 KSI
DC115030 1 Hydraulic Cylinder, Turbo 5 KSI ★ DA5352155 1 Bearing 5 KSI
2 DA4298108 1 Washer 18 ★ DA1204044 1 Bearing Retainer 10 KSI
3 ★ B1258503 2 O-Ring ★ DA7888044 1 Bearing Retainer 3 KSI
4 DA4287111 1 Mtg. Bracket ★ DA1204044 1 Bearing Retainer 5 KSI
5 DA4343044 1 Bowed Ret. Ring 19 ★ DA6911210 1 Conical Spring
6 DA8802900SR 1 Relief Valve Assy 20 DA4285110 1 Spring
7 ★ DA3811167 2 Copper Gasket 21 DA6600108 1 Rubber Washer 10 KSI
8 DC283290SR 2 Seat DA9280108 1 Rubber Washer 3 KSI
9 ★ B1007016 2 1/4" Dia. Ball DA5976108 1 Rubber Washer 5 KSI
10 ★ DA4874110 1 Conical Spring 22 DA4284108 1 Spring Washer, Turbo, 10 KSI
11 ★ DA3682013 2 Ball Guide DA9281108 1 Spring Washer, Turbo, 3 KSI
12 ★ DC170167 1 Copper Gasket DA4628108 1 Spring Washer, Turbo, 5 KSI
13 DC5268SR 1 Pressure Tube 10 KSI 23 CB180040 1 Plunger, 10 KSI
14 ★ DA4974367 2 Backup Ring CB185040 1 Plunger, 3 KSI
15 ★ B1016803 2 O-Ring – Global DA1219040 1 Plunger, 5 KSI
16 ★ CB918041 1 U-Cup 10 KSI 24 ★ B1221503 1 O-Ring Ref. C403503
★ DA9269476 1 Rod Seal 3 KSI 25 DC442900SR 1 Intake Tube Assy
★ DA5351476 1 Step Seal 5 KSI 26 ★ DC4440 1 Poppet
★ Items included as part of Repair Kits: (DC2222900K, 10,000 Series); (DC2220900K, 3,000 series); (DC2221900K, 5,000 series)
Also included in complete Pump Repair Kit, see Table 2, page 12.
0.74 ø
0.765 ø
0.63 ø
0.82 ø
0.65 ø
1.30
0.275 ø
0.30 ø
0.37 0.10
0.90
Figure 5
[25,4 Dia.]
[19,1 Dia.]
[11,7 Dia.]
[15,9 Dia.]
1.00 Dia.
.625 Dia.
.425 Dia.
.460 Dia.
.75 Dia.
15˚
Mat'l Plastic
Blend
.815
Dimensions in in. [mm] [20,7]
Mat'l Steel
Figure 6
7
38 – See note #2
42
See note #6 – 43
See note #5 – 41
See note #4 – 39
34 – See note #2
36
33 – See note #2 35
38 37
32
31
30 – See note #1
44
See note #3
Notes:
1. Apply 12–14 in-lbs. [1 Nm] of torque to Item #30
2. Lubricate seals with a moderate amount
of DS-ES grease.
3. Lubriate seal and bore with a light coating of
See note #7 – 49 HF 100 Hydraulic Fluid.
4. Install Item #39 into Item #40 until firmly seated.
5. Install screws in an "X" pattern.
48
Apply 39–44 in-lbs. [5 Nm] of torque to Item #41.
See note #2 and #7 – 47 Check torque of first screw.
6. Bend legs on Item #43 to retain clip after assy.
7. After installing the air motor and Item #46 on the
mounting bracket (not shown), assemble Item
#47 and #48 then apply 30–40 in-lbs. [4 Nm] of torque
to Item #48.
Figure 7
8
Notes:
1. Torque Item #19 to 72–78 ft-lbs. [98-105 Nm] with threads lubricated
2. Torque Item #11 to 17–19 in-lbs. [2 Nm]
3. Lubricate all seals and mating surfaces w/DS-ES
Grease prior to ass'y. unless otherwise noted.
4. Prior to assembling Item #6 seat, coin seat with a
ø .219 ball to a force of 95–105 lbs. [ 444 N]
2
1
12
13
3
14 4
See note 4
15 5
16 6 – See note 5
19 7
See note 1
17 8
9
18
10
Figure 8
9
1
2 – Loctite 222
18
4 19
5 20
19
6
22
7
8
23
25
24
10
31
Plugged
12 at factory
13
14
15 28
26
16
27
17
Notes:
1. Apply Loctite PST59241 or Vibraseal on
threads of Item #28 NPT plugs only
2. Torque Item #27 to 22-26 in-lbs. [3 Nm]
Figure 9
IMPORTANT
Do not attempt to repair the pump by substituting another valve. The 4-way manual valve used on Turbo II pumps
is not interchangeable with a standard Enerpac VM-4 valve. Using a valve that is not designed for this mounting
configuration may result in the reservoir becoming pressurized during operation.
10
Repair Parts List for Figure 9
Item Part Number Qty. Description Item Part Number Qty. Description
1 A8076048 1 Screw 17 B1109057 1 Roll Pin
2 B1086108 1 Washer 18 DA9560041 3 Shear Seal
3 Y325070 1 Handle 19 ★B1011564 6 Back-Up Washer
4 A8005071 1 Disc 20 ★B1006503 3 O-Ring
5 B1006016 1 7/32" Ball 22 ★CB28110 3 Spring
6 ★A8039110 1 Spring 23 CH539190 1 Body
7 B1389028 4 Bolt 24 B1326028 2 Bolt
8 B1126057 1 Roll Pin 25 ★B1111803 4 O-Ring
9 CB324001 1 Valve Cap 26 DA5132840SR 1 Manifold - NPT Ports
10 ★B1269503 1 O-Ring DA9745840SR 1 Manifold - BSPP Ports
11 CB327101 1 Bearing Plate 27 DC1523028 4 Screw
12 CB328281 1 Bearing 28 CS235006 2 Plug - BSPP Ports
13 CH536104 1 Shaft R515245-2 2 Plug - NPT Ports
14 ★B1012564 1 Back-Up Washer 30 DA5579026 1 Decal VM4 (not shown)
15 ★B1007503 1 O-Ring 31 B1051057 1 Pin
16 CH542950SR 1 Disc Assembly
★ Indicates parts included in complete Pump Repair Kit, see Table 2 page 12.
Pump Manifolds
70
2
PAS Models 16
17 PAC Models 71
102
69
WARNING
EXTERNAL VALVING REQUIRED
TO RELEASE PRESSURE.
(SEE INSTRUCTION MANUAL) 102
13
7
78
Figure 10
Figure 11
11
Table 1 - Relief Valve Settings
Relief Valve
Pump Model Pressure Rating
Pressure Setting
PA_G1______ 10,000 psi 10,400 to 11,000 psi
PA_G5______ 5,000 psi 5,200 to 5,700 psi
PA_G3______ 5,000 psi 5,200 to 5,700 psi
For standard models with special pressure settitngs,
the model number will have a “dash” followed by 4 more digits to indicate the pressure setting.
To determine the pressure settings locate the model number stamp. The model number wil be in the format PAYYYYYY-XXXX,
where XXXX is the maximum pressure rating. The relief valve should be set from (XXXX= 250 psi to (XXXX) + 750 psi).