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Comet HPP H-150/3 UAP FDE Repair Manual

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REPAIR MANUAL
H-150/3 UAP FDE
IV
GENERATION

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Summary of Contents for Comet HPP H-150/3 UAP FDE

  • Page 1 REPAIR MANUAL H-150/3 UAP FDE GENERATION...
  • Page 3 INDEX ASSEMBLING THE UAP FDE G-IV PLUNGER KIT ASSEMBLING THE UAP FDE G-IV PUMP HEAD POWER END PARTS CONNECTING RODS OIL SEAL CAGE PUMP HEAD PLUNGER KIT SELF CENTERING G-IV...
  • Page 4 ASSEMBLING THE UAP G-IV PLUNGER KIT ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) ARRANGE ALL PLUNGER KIT COMPONENTS ON THE SEPARATE ALL SUPPORT FLANGE COMPONENTS ON WORK BENCH. THE WORK BENCH. Fig. 01 Fig. 02 SEPARATE THE FLANGE WITH SLIDING BUSHING INSERT THE LOW PRESSURE SEAL WITH THE OPENED SIDE TURNED TO THE SUPPORT FLANGE (APPLY AND OVERLAP THE O-RING (APPLY “ROCOL”...
  • Page 5 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) USE THE SPACER AND THE SEEGER RING TO FIX INSERT THE O-RING INTO THE SUPPORT FLANGE THE ASSEMBLED PARTS. SEAT (SEE THE PICTURE). APPLY “ROCOL” TYPE GREASE TO SEAL. Fig. 05 Fig.
  • Page 6 ASSEMBLY PROCEDURE FOR PISTON KIT UAP IV FDE (P-16) CHECK HOLE ALIGNMENT (VERTICAL). INSERT THE ALLEN SCREW WITHOUT HEAD AND FIX IT. Fig. 09 Fig. 10 INSERT THE LOWER SUPPORT RING INTO THE INSERT THE SEALING BUSHING, PUTTING THE SUPPORT FLANGE, WITH THE BEVEL FACING LARGER FACE ON THE FLANGE.
  • Page 7 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) COOLING HOLES ALIGNED APPLY “ROCOL” TYPE GREASE ON THE THREAD PUT THE SUPPORT FLANGE ON THE SLEEVE, CAREFULLY POSITIONING THE SEALING BUSHING, OF THE M10 SCREWS THAT FIX THE SUPPORT KEEPING THE COOLANT HOLES ALIGNED FLANGE WITH THE SLEEVE, TIGHT “X”...
  • Page 8 ASSEMBLY PROCEDURE FOR PISTON KIT UAP IV FDE (P-16) INSERT THE O-RING ON THE PLUNGER. INSERT THE SECOND BACK RING ON THE PLUNGER. Fig. 17 Fig. 18 Fig. 05 INSERT THE GIV SELF-CENTERING ADAPTER ON I N S E R T T H E S L E E V E A S S E M B L E D W I T H THE SET.
  • Page 9 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) UPPER SUPPORTING RING SCRAPER RING BRAIDED PACKING NYLON TOOL ARRANGE THE SEALING KIT ON THE WORK BENCH (ASSEMBLY SEQUENCE). Fig. 21...
  • Page 10 ASSEMBLY PROCEDURE FOR PISTON KIT UAP IV FDE (P-16) INSER THE FIRST BRAIDED PACKING AND USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM. Fig. 22...
  • Page 11 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) INSERT THE SECOND BRAIDED PACKING PAYING ATTENTION TO KEEP ITS CHANFER AT A 180° WITH RESPECT TO THE CHAMFER OF THE FIRST BRAIDED PACKING. USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM.
  • Page 12 ASSEMBLY PROCEDURE FOR PISTON KIT UAP IV FDE (P-16) INSERT THE SCRAPER RING AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 24...
  • Page 13 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) INSERT THE UPPER SUPPORTING RING (KEEPING THE SMALL RAYS OF THE FACE FACING DOWN) AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 25...
  • Page 14 ASSEMBLY PROCEDURE FOR PISTON KIT UAP IV FDE (P-16) INSERT THE SPRING INSERT THE SPRING GUIDE Fig. 27 Fig. 26 Fig. 05 ASSEMBLE THE FRONTAL SLEEVE ON THE PRESS IT UNTIL IT REACHES THE BOT TOM PLUNGER USING THE ARROWS AS REFERENCE AND ROTATE 90°...
  • Page 15 ASSEMBLY PROCEDURE FOR PLUNGER KIT UAP IV FDE (P-16) INSERT THE O-RING ON THE FRONTAL SLEEVE TIGHT COOLING SYSTEM CONNECTIONS. (APPLY “ROCOL” TYPE GREASE TO SEAL). Fig. 30 Fig. 31 Fig. 05 ASSEMBLED PISTON Fig. 33...
  • Page 16 ASSEMBLING THE UAP G-IV PUMP HEAD (P-16) SEPARATE THE HINGES, THE GUIDE PIN, THE SCREWS, THE PISTON KIT AND THE HEAD TO MOUNT THEM; ASSEMBLE THE HINGES. Fig. 01 FIT THE HINGE GUIDE PIN AND ASSEMBLE THE HEAD. Fig. 02...
  • Page 17 ASSEMBLING THE UAP G-IV PUMP HEAD ARRANGE AND MOUNT THE SELF-CENTERING WITH THE FEMALE SIDE ON THE GUIDE PISTONS. Fig. 03 REFRIGERATION FACING THE OIL DUCT ARRANGE AND ASSEMBLE THE PLUNGER KITS. USE “ROCOL” TYPE GREASE TO PREVENT DAMAGE TO SEALS DURING ASSEMBLY. Fig.
  • Page 18 ASSEMBLING THE UAP G-IV PUMP HEAD POSITION THE PLUNGER KITS ALIGNING THE ROD WITH THE SELF-CENTERING, AND FINISH THE ASSEMBLY WITH THE HOOK SPANNER; ROTATE THE PUMP SHAFT TO Fig. 05 FACILITATE FITTING. ALIGN THE FACES OF THE PLUNGER KITS SLEEVES. LEVELING IS NECESSARY FOR A PERFECT SETTLEMENT IN THE ASSEMBLY OF THE HEAD VALVES.
  • Page 19 ASSEMBLING THE UAP G-IV PUMP HEAD ARRANGE THE INTELLIVALVES. Fig. 07 FIX THE INTELLIVALVE MANUALLY IN THE HEAD HOLE, EXERCISING LIGHT FORCE WITH YOUR HANDS TO FIT THE VALVE TO THE HEAD (USE “ROCOL” TYPE GREASE ON ALL Fig. 08 SEALING RINGS TO PREVENT DAMAGE TO THE ASSEMBLY).
  • Page 20 ASSEMBLING THE UAP G-IV PUMP HEAD CHECK THE INTELLIVALVE ASSEMBLY: ITS OUTSIDE SURFACE MUST BE A LITTLE BIT FURTHER IN COMPARISON WITH THE PUMP HEAD SURFACE. CHECK IF THE VALVE IS Fig. 09 COMPLETELY MOUNTED. REPEAT THE PROCESS FOR THE OTHER TWO INTELLIVALVES. Fig.
  • Page 21 ASSEMBLING THE UAP G-IV PUMP HEAD CAREFULLY MANEUVER THE HEAD TO ACCOMMODATE IT FITTING WITH THE SLEEVE Fig. 11 ARRANGE THE M24 SCREWS, DISTANCE BUSHINGS AND PRESSURE WASHERS, FOR FIXING THE HEAD. (APPLY COPPER GREASE ON THE Fig. 12 THREAD OF THE SCREWS)
  • Page 22 ASSEMBLING THE UAP G-IV PUMP HEAD TIGHT “X” WITH 100Nm, 250Nm AND 400Nm TORQUE STEPS. Fig. 13 ARRANGE THE M24 SCREWS FOR FIXING THE HEAD PISTON KIT. (APPLY COPPER GREASE ON THE SCREWS THREADS). Fig. 14...
  • Page 23 ASSEMBLING THE UAP G-IV PUMP HEAD TIGHTEN THE SCREWS IN “X” ON THE FLANGE, FOLLOWING THE STEPS OF 100NM, 200NM, AND FINALLY 350NM. Fig. 15 REPEAT THE PROCESS FOR THE OTHER TWO PLUNGERS. ASSEMBLE THE BACK RING AND OVERLAP WITH O’RING ON THE FRONT FLANGE (APPLY “ROCOL”...
  • Page 24 ASSEMBLING THE UAP G-IV PUMP HEAD APPLY COPPER GREASE ON THE THREAD OF THE M12 SCREWS THAT FIX THE FRONT FLANGE WITH THE MANIFOLD. TIGHT “X” TO A TORQUE OF 100Nm. Fig. 17 REPEAT THE PROCESS FOR THE OTHER TWO FLANGES. ASSEMBLE THE SUCTION DUCT;...
  • Page 25 POWER END PARTS - CODE Q2310100110823...

  • Page 26: Power End Parts

    POWER END PARTS ITEM CODE DESCRIPTION QTY. Q231010007710 CRANKSHAFT H100/2 – H150/3 Q231010010740 PRESSURE SWITCH Q231010010971 OIL SEAL CAGE Q231010011110 PISTON GUIDE H100/2 – H150/3 Q231010011120 CONNECTING ROD H100/2 – H150/3 Q231010019600 CASE H100/2 – H150/3 (VERTICAL / HORIZONTAL) Q231100001960 PISTON ROD PIN Q231110007170 H100/2 –...
  • Page 27 POWER END PARTS ITEM CODE DESCRIPTION QTY. Q231300001060 O-RING Q231300001110 O-RING Q231300001760 CUPPER RING Q231300002130 O-RING Q231300002160 O-RING Q231300003810 O-RING Q231300005020 ROTO GLYD Q231300005350 OIL SEAL Q231300005360 O-RING Q231300005820 O-RING Q231300008480 O-RING Q231300009550 O-RING Q231700001160 BEARING Q231700001250 BEARING CONNECTING ROD Q231700001350 PISTON ROD SLEEVE Q231700001380...
  • Page 28 CONNECTING RODS - CODE Q231010011120 BOLT TORQUE: 110 N 3 SETS PER PUMP ITEM CODE DESCRIPTION QTY. Q231110022250 ARM OF CONNECTING ROD Q231110022260 BEARING OF CONNECTING ROD Q231200001870 HEX BOLT M12x70 Q231200001900 TOOTHED WASHER M12 Q231200008810 ELASTIC GUIDE BUSHING ATTENTION! ASSEMBLE WITH NUMBERS FACING THE SAME SIDE Attention!
  • Page 29 OIL SEAL CAGE - CODE Q231010010971 ITEM CODE DESCRIPTION QTY. Q231200001070 WASHER Q231110044260 OIL SEAL CAGE Q231300011340 OIL SEAL Q231300011210 SLIDING RING Q231300001910 O-RING Q231200001540 SEEGER RING Q231200007960 SCREW M8X20mm Q231300001170 O-RING * Note: Common wear parts or disposable...
  • Page 30 PUMP HEAD - CODE Q231010017212...
  • Page 31 PUMP HEAD - CODE Q231010017210 ITEM CODE DESCRIPTION QTY. Q231010017101 INTELLIVALVE UAP IV Q231010023020 DISASSEMBLING TOOL Q231110034230 MANIFOLD UAP IV Q231110036680 FRONTAL FLANGE UAP IV Q231110036920 SPACING BUSHING G-IV Q231110043810 SUCTION DUCT INOX Q231200001070 SPRING WASHER M8 Q231200002930 ALLEN SCREW M12x35mm Q231200009980 ALLEN SCREW M24x180mm Q231200003630...
  • Page 32 PLUNGER KIT (P-16) - CODE Q231010018461 SEALING KIT (P-16) CODE Q2310200021610...
  • Page 33 Ø Nominal Appropriate Critical Change -0,01 -0,07 16 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 200 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-16) - CODE Q231010018461 ITEM CODE DESCRIPTION QTY. Q231010018470 PLUNGER D.16 UAP IV Q231010029380 SUP.
  • Page 34 SELF CENTERING G-IV - CODE Q231010016940 ITEM CODE DESCRIPTION QTY. Q231200002970 ALLEN SCREW M14x30mm Q231110036110 CONNECTION BUSHING (G-IV) Q231110040020 SELF CENTERING SUPPORT (G-IV) Q231110010280 NYLON CYLINDER Q231110007240 BACK UP RING (G-IV) Q231300003610 O-RING Q231110038030 SELF CENTERING UPPER SUPPORT (G-IV)
  • Page 36 Comet S.p.a. - Via G. Dorso, 4 42124 Reggio Emilia - ITALY Tel. +39 0522 386111 Export: e-mail: export@comet.re.it › fax 0039 0522 386280 Italia: e-mail: vendite@comet.re.it › fax 0039 0522 386300 www.comet-spa.com...