Air-Driven High-Pressure Liquid Pump

OLIVALS FM II

Operation Manual
Doc. No: ESS-WH-OM-004 / Rev. No: 00

Website: www.essemgroup.net
Email: enquiry@essemgroup.net

ESSEM CORPORATION SDN. BHD.

C-7-1 Block C, Melawati Corporate Centre, Taman
Melawati, 53100 Kuala Lumpur, Malaysia.
Tel: +603 4101 0200 Fax: +603 4101 0210
 CONTENTS

1.0 INTRODUCTION …………………………………….. 3

2.0 SAFETY PRECAUTIONS ……………………………. 4
3.0 PRODUCT FEATURES …………………...……….. 5-6
4.0 SPECIFICATIONS ………………………………….. 7
5.0 OPERATION ………………………………….……… 8
5.1 BEFORE OPERATING THE PUMP …..…………. 8
5.2 OPERATING THE PUMP …………………….….. 9
5.3 STOP OPERATING THE PUMP ……………….... 10
6.0 MAINTENANCE …………………………………….. 11
7.0 TROUBLESHOOTING ……………………………….. 12 - 14
8.0 ASSEMBLY ……………………………………….…... 15 - 19

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
2
 1. INTRODUCTION

The Olivals FM II Air-Driven High-Pressure Liquid Pump has been

designed and engineered to be compact and lightweight while providing the
necessary amount of applied pressure. With the pumps capability to convert
compressed air into hydraulic power, Olivals FM II pump will satisfy any
application need for pressurizing up a component and holding it at a set
pressure for any sustained period of time. The ease of installation and
operation of the pump makes it a reliable, efficient and cost-effective solution
for various fluid and pressure applications – even in explosion-proof areas.

These applications include:

• Flushing and lubrication

• Wellhead & downhole equipment control
• Pressure & leakage tests
• Valve actuation
• Chemical injection
• Product testing such as calibration, setting, etc.
• Hydraulic-operated tools such as hydraulic jacks, lifts, cutter, wrench,
etc.

This operation manual describes the mechanism of the product and provides
instructions for its correct use. All users and operators of this product must read
this operation manual carefully before using this product. Please use within the
recommended parameters as specified (if stated).

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 2. SAFETY PRECAUTIONS

• In order to protect the product and system, please use the product in
accordance with the instructions.
• Essem shall not be responsible for any incidental or abnormal operation for
breach of any express or implied warranty on this product or any part thereof.
• Please contact Essem Corp. for any troubleshooting, replacement of
components or consumable parts.
• Operators in charge of installation, operation and maintenance of this product
during the period of use, should be fully trained for the correct / optimal
performance of these tasks.
• Keep the product away from excessive heat or fire
• Always operate the product within the pressure vs. temperature range
• This product is not designed to handle impacts of any kind. Avoid throwing or
dropping the product.
• Please ensure proper Personnel Protective Equipment (PPE) are used when
operating this product.
• Beware of pinch point hazards while operating the equipment.
• Ensure all fluid connections are securely tightened prior to equipment usage.
• Inspect the equipment regularly for any repair or replacement of worn or
damaged parts.

Essem will not assume any responsibility for consequential damage or injury caused
by:

• unauthorised modification of the product and the accessories supplied

• improper operating or operating conditions

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 3. PRODUCT FEATURES

• The Olivals FM II Air-Driven High-

Pressure Liquid Pump assembly utilizes
Maximator M111 pump as per Figure 2.
• Single-acting with one air-driven piston.
• Fully integrated, protected and
calibrated pressure gauge and
controls.
• Supplied with air inlet connector, air
filter, regulator, pressure gauges, on/off
control valve and reservoir tank.
• All pumps are supplied with full test
certificates.
• Operation with compressed air allows
use in explosion-proof areas.

Figure 1: Olivals FM II Pump. • Pump automatically stops operating

upon reaching pre-selected final
pressure.
• No power consumption during
long pressure holding periods.
• No heat generation during
pressure holding period.
• Easy installation and trouble-
free handling of pumps.
• Low maintenance thanks to
reliable, easy-to-install Figure 2: Maximator M111 Pump.
devices.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 Air ON/OFF
Valve

Manual Hand
Pump

Air Pressure
Gauge
Pressure
Outlet
Release Valve
Pressure
Gauge

Level
Indicator Reservoir
Tank

Figure 3: Olivals FM II Pump (Front View).

Air Inlet
Port
Hydraulic
Air Filter & Pump
Regulator
Reservoir
Tank Cap Outlet
Port

Tank Draining
Port

Figure 4: Olivals FM II Pump (Side View).

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 4. SPECIFICATIONS

MODEL: OLIVALS FM II

Bare Pump Model: Maximator M111

Max Operating Pressure: 18,850psi or 1300 bar

Operating Air Pressure Range: 14.5 - 145 psi or 1 – 10 bar

Max Operating Temperature: -20 - 60 Deg. Celcius

Pressure Ratio: 1:130

Displacement Volume: 1.0 cm3

Output Capacity: 0.48 l/min

Reservoir Tank Capacity: 9 Liters

Liquid Inlet Size: 3/8 “BSP

Discharge Outlet Size: 3/8 “BSP

Air Supply Inlet Size: 3/8 “BSP

All parts in stainless steel

Pumping Section Materials:
including relief valve

All parts in non-corrosive material

Air Drive Section Materials:
including ON/OFF valve

650 mm x 265 mm x 265 mm

Dimension:
(Height x Length x Width)

Net Weight: 17 kg

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 5. OPERATION
5.1 BEFORE OPERATING THE PUMP
1. Check sufficient clean liquid is present in the tank. Top up with acceptable liquid if
required.

• Do not allow the pump to run dry without any liquid in the reservoir tank as this
could damage the pump.

2. Ensure the air on/off valve is in off position to prevent the pump from working immediately
after connecting to an active air supply.
3. Rotate the air regulator control knob anti-clockwise until the handle becomes free.
4. Connect a suitable air supply /hose to the air inlet port.

• Ensure compressed air supply do not exceed 145 psi or 10 bar.

5. Connect a suitably rated hydraulic hose or tubing to the outlet port.

• Hydraulic hoses, tubing, adaptors / crossovers, couplings and fittings must

have a pressure rating equal to or higher than the maximum output pressure of
the pump.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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5.2 OPERATING THE PUMP
1. Observe the air pressure gauge to ensure presence of compressed air supply.
2. Rotate the air regulator control knob clockwise slowly until pump begins to
reciprocate (pump should start at 10 to 15 psi under normal condition).
3. Turn the air ON/OFF valve to ON position.
4. Close the pressure release valve and run pump until all air is purged from the circuit.
5. If higher pressure is required, adjust the air drive pressure by slowly rotating the air
regulator knob to control the level of required air drive pressure.

• The pump will stop automatically, when the required hydraulic pressure is
obtained and hold it infinitely. If any pressure drops in the hydraulic system or
an increase of air drive pressure, the pump will start automatically again.
• If the test object is large in volume, it will take a while before any pressure builds
up in the system and register on the pressure gauge.
• Check for any leaks from any connection during pumping.
• Ensure all pressure gauges used are calibrated.

• Do not pump contaminated liquid.

• Do not leave the pump operating unattended as this may lead to over-
pressurization of the test object.
• Overpressure could cause equipment damage and personnel injury.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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5.3 STOP OPERATION OF THE PUMP
1. Turn the air ON/OFF valve to OFF position.
2. Rotate the air regulator knob anti-clockwise until air pressure gauge reads zero
pressure.
3. Slowly open the pressure release valve until the outlet pressure gauge reads zero
pressure.
4. If necessary, disconnect the hydraulic hose from the outlet port.
5. If necessary, disconnect the air supply from the air inlet port.

• Be careful of any trapped pressure during disconnection.

• Be careful of pinch point hazard while handling the equipment.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 6. MAINTENANCE
• The air drives of all pumps are pre-treated with HD grease and do not require
any other type of lubrication. Only during pump overhauls the main block
valve and air piston should be treated with acid- and silicone-free grease.
• The muffler and air filter should be cleaned regularly to maintain the
performance and efficiency of the pump.
• Frequently drain / empty the retained water in the reservoir of the air filter
during operation.
• Check the injection hose periodically for any cracks, leaks or worn parts as
it is a consumable part.
• Ensure the pressure gauges used during operation are calibrated to ensure
accurate readings.
• Inspect all parts for any wear / damage. Replace as necessary.
• Tighten any loose or leaking fittings, screws and connections.
• After prolonged service, the pump will require servicing and new seals may
be required.
• Conduct annual pressure test on the system to ensure the system’s pressure
release valve, check valves, connections and performance are fit-for-
operation.

• Essem will not be held liable for any damages resulting from
improperly performed assembly, maintenance or repair work on the
equipment.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 7. TROUBLESHOOTING

• A basic troubleshooting and corrective measures can be referred as the following

procedure. However, do note that any repair or troubleshooting works has to be
performed by qualified personnel under safe conditions to ensure proper handling
of the pump.

• Continued operation in an abnormal condition may result in

malfunctions and damage of products.
• Incorrect troubleshooting works may result to personnel injury
and equipment damage.
• Do not attempt to repair or modify the product by yourself.

• It is advisable to contact Essem Corp. for any troubleshooting,

replacement of components or consumable parts.
• Please do contact Essem Corp. for further enquiry.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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Table 1: Troubleshooting Guide.

SYMPTOM POSSIBLE CAUSE SOLUTION

Friction of o-rings on • Re-lubricate.

control slide valve is too • Replace o-rings on control
high. slide valve.
Pump fails to work at low
air pressure.
• Change o-rings.
O-rings swell due to use of
• Use acid- and silicone-free
wrong oil or lubricant.
lubricant.

Air escapes through • Replace o-rings on

plunger guide in top cap.
Pump only operates at
high air pressure.
Air escapes through filter
disc in bottom cap.
extension of the plunger.
• Replace o-rings on air
piston.

Exhaust or control slide

• Use water separator to de-
valve covered with ice.
Pump does not operate water compressed air.
or can only operate
slowly. Formation of residue in the • Clean the silencer.
silencer. • Replace, where applicable.

O-rings on the control slide • Change and grease o-

Pump does not operate. valve are defective. rings.
Air escapes through the
exhaust. O-ring on air piston is
• Change and grease o-ring.
defective or worn out.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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Cont. Table 1: Troubleshooting Guide.

SYMPTOM POSSIBLE CAUSE • SOLUTION

Pump does not operate.

• Check pilot valve.
Air escapes through
Pilot valve hangs up. • Change pilot valve and
plunger guide in top
seal, where applicable.
cap.

• Clean control slide valve

Pump does not operate.
and sleeve
Air flows through small Control slide valve hangs
• Check and, if necessary,
boring on control slide up.
replace o-rings and sleeve.
valve housing.
• Lubricate.

• Clean and grease pilot

Pump does not operate.
valve.
Air escapes through Pilot valve in top or bottom
• Check for abrasion and
small boring in bottom cap hangs up.
replace, if required.
cap.

• Clear and grease pilot

Pilot valve in top or bottom
valve and, if required,
Pump operates with high cap is defective.
replace it.
frequency and short
strokes. O-ring on plunger piston in
• Replace and grease o-ring.
top cap is defective.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 8. ASSEMBLY

Item No. Qty Description Item No. Qty Description

1 1 Air Inlet Port Pressure Release
9 1
2 1 Air Filter & Regulator Valve
3 1 Air Exhaust 10 1 Air Relief Valve
4 1 Air Pressure Gauge 11 1 Reservoir / Tank
5 1 Air ON/OFF Valve 12 1 Cap
6 1 Pump 13 1 Level Indicator
Outlet Pressure 14 1 Suction Filter
7 1
Gauge
8 1 Outlet Port

Figure 5: Olivals FM II Process Flow Diagram.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 Figure 6: Pump Unit Drawing.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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 Figure 7: Pump Unit Part List Drawing.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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Table 2: Pump Unit Part List.

NO. QTY PARTS NO. DESCRIPTION REMARK

1 1 3610.3284 :VP 10.07.14 Top Cap
2 1 3610.0502 :VP 10.07.02.02 Guide rod bushing
3 1 3660.0512 :OR 80.14.49.01 O-Ring
4 2 3660.0221 :OR 70.715.15.01 O-Ring
5 1 3610.0129 :VP 10.02.06 Hex head screw
6 1 3610.0128 :VP 10.02.05 Cover plate
7 2 3610.0127 :VP 10.02.04 Pilot screw
8 2 3610.1264 :VP 10.18.49 Gasket
9 2 3610.0130 :VP 10.02.07 Spring
10 2 3610.3180 :VP 10.02.47 Pilot Tappet
11 2 3660.0101 :OR 70.00.62.01 O-Ring
12 2 3610.3181 :VP 10.02.48 Seal
13 2 3660.0843 :OR 70.01.24.01 O-Ring
14 1 3610.0586 :VP 10.09.14 Pressure tube
15 1 3610.0102 :VP 10.01.03 Spool valve housing G3/8
16 1 3610.0100 :VP 10.01.01 Spool valve sleeve
17 4 3660.0111 :OR 60.01.62.01 O-Ring
18 1 3610.0110 :VP 10.01.11 Spool
19 1 3660.0109 :OR 70.01.42.01 O-Ring
20 5 3660.0505 :OR 80.08.39.01 O-Ring
21 1 3610.0104 :VP 10.01.04 Spool plug
22 2 3660.0112 :OR 70.01.72.01 O-Ring
23 1 3610.0109 :VP 10.01.10 Snap ring
24 4 3660.0103 :OR 70.00.82.01 O-Ring
25 5 3660.0106 :OR 70.01.12.01 O-Ring
26 3 3610.0107 :VP 10.01.07 Hex socket screw
27 1 3610.0108 :VP 10.01.09 Muffler
28 1 3610.0178 :VP 10.03.15 Air cylinder
29 1 3610.1045 :VP 10.14.31 Plunger
30 1 3610.0766 :VP 10.13.11 Air piston
31 1 3660.0207 :OR 70.23.22.01 O-Ring
34 1 3610.3069 :VP 10.04.143 Bottom cap
35 1 3610.0581 :VP 10.09.10 Pressure tube
36 1 3610.0182 :VP 10.03.19 Mounting bracket
37 4 3610.1069 :VP 10.15.02 Hex head screw
38 2 3610.0185 :VP 10.03.21 U-Washer
39 4 3610.0184 :VP 10.03.20 Spring washer
41 1 3610.0400 :VP 10.05.57 Pump head

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
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Cont. Table 2: Pump Unit Part List.

NO. QTY PARTS NO. DESCRIPTION REMARK

42 1 3660.0119 :OR 70.02.32.01 O-Ring
43 1 3610.0444 :VP 10.06.12 Nut
44 1 3610.0443 :VP 10.06.11 Cap nut
45 1 3660.0116 :OR 70.02.02.01 O-Ring
46 1 3610.1057 :VP 10.14.42.01 Packing ring
47 1 3610.0894 :VP 10.13.26 Glide ring
49 1 3610.1424 :VP 10.06.47 Retainer ring
50 1 3610.1414 :VP 10.06.39.05 Seal
51 2 3610.0397 :VP 10.05.50 Ball bracket
52 2 3610.0399 :VP 10.05.52 Spring
53 2 3610.0359 :VP 10.05.16 Ball
54 1 3610.0422 :VP 10.05.69.01 Inlet gland G3/8
55 1 3610.0425 :VP 10.05.72 Outlet gland G3/8
56 1 3610.0406 :VP 10.05.59 Pump head w. side inlet
57 1 3610.1058 :VP 10.14.42.02 Washer
58 2 3660.0247 :OR 75.01.42.03 O-Ring
59 1 3660.0319 :OR 75.10.92.03 O-Ring
60 1 3610.1417 :VP 10.06.02.01 Back up

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
19
 ESSEM CORPORATION SDN. BHD.
C-7-1 Block C, Melawati Corporate Centre,
Taman Melawati, 53100 Kuala Lumpur,
Malaysia.
Tel: +603 4101 0200 Fax: +603 4101 0210

Website: www.essemgroup.net
Email: enquiry@essemgroup.net

All rights reserved. No part of this manual may be reproduced, copied or transmitted
in any form or by any means electronic or mechanical, including photocopy,
recording, taping, or by any information storage and retrieval system, in English or
in other languages, without written permission from the publisher.
Figure 12: Lincoln Pump Tube Exploded View.

OLIVALS FM II
AIR-DRIVEN HIGH-PRESSURE LIQUID PUMP
20