OLIVALS FM-II

AIR OPERATED FLUSH PUMP

Operation and Maintenance Manual

www.olivals.com

OLIVALS SDN. BHD.

9159, Jalan Bandar 4, Taman Melawati, 53100 Kuala Lumpur, MALAYSIA
Tel : +60 3 4108 3270 Fax : +60 3 4107 4144
 OLIVALS FM-II AIR OPERATED FLUSH PUMP

GENERAL SPECIFICATIONS:

Pressure Rating : Max. 1000 Bar

High Pressure Gauge : 0-1000 Bar/Psi, 100 mm Dia. Stainless Steel
Air Pressure Gauge : 0 -12 Bar/Psi
Pressure Ratio : 1 : 130
High Pressure Outlet : 1/4” HP FEM.
Air Drive Inlet Port : 1/4” Bsp C/W Quick Nipple 315 Series
Air Drive Section: All Parts In Non-Corrosive Material
Including Air On/Off Valve
High Pressure Section: All Parts In Stainless Steel Including
High Pressure Relief Valve
Tank Capacity : 6.5 Litres
Weight : 17 Kg
Overall Dimension : W = 265 mm ; D = 265 mm ; H = 650 mm

OPERATING INSTRUCTION (Refer Fig 1 for item reference):

Please read the following instructions carefully before operating the pump unit.

PREPARATION OF THE PUMP UNIT

1. Make sure that the unit is filled with OLIVALS VF Valve Flush by observing the Tank Level
Gauge No. (13). Should the unit not be filled completely, add OLIVALS VF Valve Flush
through the Filler Cap No. (12)
2. Make sure the air ON/OFF Valve No. (5) is set in OFF position. This prevents the unit to
start working immediately when connecting the air supply.

CONNECTION OF PUMP UNIT

1. Connect the air supply hose to the air inlet Port No. (1)
2. Connect the high pressure hydraulic hose to the high pressure Outlet Port No. (8) The
pump unit is now ready for operation.

START OPERATION OF PUMP UNIT

1. Observe the reading of the Air Pressure Gauge No. (4)
2. Set the air drive pressure by turning the knob of the Air Regulator No. (3) clockwise.
3. Turn the Air ON/OFF Valve No. (5) slowly to ON position and the pump starts operating.
4. Close the high pressure Relief Valve No. (9) and the hydraulic pressure may now be seen
on the High Pressure Gauge No. (7).
5. If higher pressure or lower pressure is required, adjust the air drive pressure by turning
the Air Regulator Knob No. (3)
6. 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 increased of air drive
pressure, the pump will start automatically again.

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 OLIVALS FM-II AIR OPERATED FLUSH PUMP

STOP OPERATION OF PUMP UNIT

1. Set the Air ON/OFF Valve No. (5) to OFF position.

2. High pressure in the hydraulic system will be released by setting the High Pressure Relief Valve
No. (9) to OPEN position. The High Pressure Gauge No. (7) will now show 0 Bar pressure.

3. The hydraulic hose and air hose may now be disconnected.

NOTE:
1. The pump unit can deliver a maximum output pressure of 1300 Bar(18,850 psi) at maximum 10
Bar (145 psi) of air drive pressure. The unit is preset for maximum pressure of approximately 1000
bar at 5.5 bar air Drive pressure. The Air Safety Relief Valve will start opening at about 5.2 bar
pressure.

2. The Air Safety Relief Valve No. (10) may be readjusted for higher or lower pressure by loosening
the Hex. Lock Nut first. Then turn the Cap Nut clockwise to increase or anti-clockwise to decrease
the setting pressure. Once the setting pressure is obtained, locked the cap nut by tightening the
Hex. Lock Nut.

Figure 1: Pump Unit Diagram

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 OLIVALS FM-II AIR OPERATED FLUSH PUMP

SAFETY HAZARDS

During pump operation both the drive part and the high-pressure part are under pressure. Hence, it has
to be borne in mind that any gases or liquids emerging due to a defect or during normal
operation are also under high pressure and must not be collected or diverted by objects or body parts.
Rather, it has to be seen to it that any defective pump is immediately depressurised and repaired.
Maintenance and repair work may only be performed at depressurised units.

SAFETY AT PLACE OF INSTALLATION

FM-II pumps must not be operated in closed containers because the escaping drive air may burst the
container.
Die hydraulic bolted connections at intake and pressure fittings must not be unscrewed, even if such
facilitates installation of a unit. All bolted connections must have tight seats in order to avoid
leakages and damage.
The pumps have to be installed in such a manner that their operating elements and bolted connections
are freely accessible at any time.

COMPRESSED-AIR SYSTEM

It is recommended to use for the compressed air connection one of our air control units, consisting of
filter, water separator, shutoff valve, pressure controller, pressure gauge and, if need be, safety valve. In
case that there is no maintenance unit used the quality of compressed air has to be ensured according to
our requirements.

COMPRESSED-AIR QUALITY

Solid matter:
Maximum particle size: 5 μm
Maximum particle concentration: 5 mg/m3

Dew point:
+ 10°C = water content 9.4g/m3
up to +2°C = water content 5.6g/m3

COMPRESSED-AIR OILER

Normally, a compressed-air oiler is not necessary. All moving pump parts are treated with a special grease
during assembly.
The grease may gum when the pump is operated with extremely dry air over a longer period. In such case
it is recommendable to use a compressed-air oiler.

Caution! After a compressed-air oiler is used once the respective pump must not be operated without an
oiler since it purges the entire grease from the pump and thus there is no continuous lubrication any
longer. Re-lubrication with OLIVALS grease will put things right.
Upon use of a compressed-air oiler the oil content of the air should be 1-5 mg/m3.

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 OLIVALS FM-II AIR OPERATED FLUSH PUMP

START-UP
Trouble-free operation requires a de-airing of the pump and the pertaining hydraulic system which is
performed by operating the pump at a low stroke frequency. The latter is achieved by reducing the drive
pressure or limiting the volume flow.
The pumps do not prime against an existing operating pressure at the outlet fitting. The high-pressure
side can be de-aired, e.g., by loosening of the pressure pipe. This facilitates priming of the pump.

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.

WARRANTY

We grant for our products a warranty of 12 months on material and manufacturing quality, starting upon
the shipment date of a unit. Any defects that are due to improper handling or malfunctions or use of
inadmissible liquids, foreign matter in the drive or pumping media or exceeding of the maximum
operating pressure are not subject of our warranty. Wear parts, such as sealings, guiding elements, etc.,
are exempted from our warranty.

REPAIR

All repair work has to be performed by qualified specialist personnel under extremely clean conditions.
Already minor impurifications may cause severe damage at the micro-finished hydraulic and pneumatic
components.
You can purchase all component parts of our pumps as spare parts from us. For ordering, please, use the
respective stock numbers from the drawings that we ship with each pump. Typically, there are more than
one sealing defective or worn, this is why we have compiled different sets of sealings.
The compositions of these sets of sealings can be also be gathered from the drawings as can be
the respective stock numbers. Please, make sure to indicate the serial number of the pump when
ordering spare parts. The serial number can be gathered from the pump machine plate and has
also been stamped as a stamp number on the pump housing (as a 6-digit number).
It goes without saying that the most convenient option for you is to ship a defective unit to us. It is then
repaired by our qualified personnel in rooms where there is no metal-cutting machining and
thus under extremely clean conditions. We will send you a cost estimate upon request and after this has
been confirmed repair the units as fast as possible and ship them back to you.

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OLIVALS FM-II AIR OPERATED FLUSH PUMP

Fig 2: Pump’s Diagram

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 OLIVALS FM-II AIR OPERATED FLUSH PUMP
SPARE PARTS LIST
Fig 3: Spare Parts Diagram

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 OLIVALS FM-II AIR OPERATED FLUSH PUMP
PARTS LIST
Pos 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
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

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