OPERATION

&
MAINTENANCE MANUAL
(UT-13000 SERIES)
FOR FLAT HEAD

CUSTOMER : DALMIA DSP UNIT-1

P. O. NO. : 4460000267/GS03

COMM. NO. : 23.01.2020

PUMP MODEL : UT-13026 (FLAT HEAD)

14/7 MATHURA ROAD, FARIDABAD – 121 003 (HARYANA) – INDIA

PH: 91 – 129 – 2258585, 4046882, FAX: 91 – 129 – 2275877, 2258584

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

LIST OF CONTENTS
S.No. DESCRIPTION PAGE
1 SAFETY REGULATIONS 3-4
2 OPERATING INSTRUCTIONS 5-7
3 SERVICE CHART 8
4 TORQUE RANGE FOR BOLTS & NUTS 9-10
5 LUBRICATION CHART 11
6 H.P. PUMP ASSLY. ARRANGEMENT 12
7 PUMP G. A. DRAWING (FLAT HEAD) 13
8 GEAR END ASSLY. : DRAWING & PARTS LIST 14-16
9 MAINTENANCE INSTRUCTIONS – GEAR END 17-18
10 ROTO SEAL ASSLY. WITH DRAWING & PART LIST 19-20
11 COMPLETE BARE PUMP WITH EXT. FORCE LUB. ARRANGEMENT & PARTS LIST 21-22
COMPLETE BARE PUMP WITH PINION MOUNTED FORCE LUB. ARRANGEMENT
12 23-24
& PARTS LIST
13 OIL FILTER WITH ELEMENT 25
14 PUMP HEAD : FLAT HEAD DRAWING & PARTS LIST 26-30
15 MAINTENANCE INSTRUCTIONS – PUMP HEAD 31
16 PUMP HEAD CARRIER ASSLY. DRAWING & PARTS LIST 32
17 SUCTION MANIFOLD ASSLY. DRAWING & PARTS LIST 33-34
18 CONVERSION KITS : DRAWING & PARTS LIST 35-39
19 MAINTENANCE INSTRUCTIONS – CONVERSION KITS 39
20 PLUNGER COOLING ARRANGEMENT 40
21 PRESSURE REGULATOR ASSLY. DRAWING & PARTS LIST 41-43
22 SAFETY VALVE : DRAWING & PARTS LIST 44-45
23 MOUNTING BLOCK: DRAWING & PARTS LIST 46-47
MAINTENANCE INSTRUCTIONS – PRESSURE REGULATOR, SAFETY VALVE AND
24 47
MOUNTING BLOCK
25 PRESSURE GAUGE AND NEEDLE VAVLE ASSLY. 48
26 H.P.GUN : DRAWING & PARTS LIST 49-51
27 FOOT OPERATED VALVE ASSLY : DRAWING & PARTS LIST 52-54
28 MAINTAINANCE INSTRUCTIONS - H.P GUN & FOOT OPERATED VALVE 55
29 WATER FILTER 56
30 H.P.GUN & SPRAY DRAWINGS 57
31 ACCESSORIES LIST 58-59
32 PRESSURE SWITCH & LOW PRESSURE GAUGE 60
33 TOOL KITS : PARTS LIST & C. S. DRAWING 61-62

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

1. SAFETY REGULATIONS

It is imperative that these regulations are followed in order to ensure safe operating conditions.

Safety regulations concern:

a) Personnel
b) Clothing
c) Work Area
d) Equipment & Accessories

Personnel:

Every work team shall have a responsible supervisor and every operator must have been trained in the
use of the equipment and possess understanding of dangers which exist unless it is properly used.

Clothing:

Water-proof, clothing, including helmet with visor for eye protection and rubber boots with non-slip
soles are necessary.

Work Area :

Should whenever possible be clearly fenced off and/or sign posted. The operator handling the spray gun
must always be under observation and, whenever necessary, protected from slipping or falling by safety
belts lines. There must be proper ventilation when working indoor.

Equipment and Accessories:

To ensure proper and safe functioning of the high-pressure unit and the accessories, inspection by a
qualified person is mandatory before start-up. Connect unit to power and water supply and follow the
check list below:

1. Protect motor from splashing.

2. Suction line. Check for correct size and tightness.
3. Pump Packing
4. Pump Lubrication.
5. Pressure regulator, unloaded ventil. Check for proper functioning.
6. Hoses and hose connections. Threads inspect all High-pressure hoses for freedom from
excessive wear or charge marks.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

7. Spray Guns, foot-operated ventil or any other shut-off device in the high-pressure line.
Functioning and Connections.
8. High Pressure Hoses: Ensure that there is no excessive bending and that chafing against
corners and sharp objects is not possible.
9. Maximum pump operating pressure to be used must not exceed pressure ratings for spray
guns, hoses, valves or other devices in the high pressure line.

IMPORTANT:

• Operating without a shut-off device in the high-pressure line is not permissible.

• The pump safety ventil must correspond to the maximum available working Pressure with a
given pump plunger diameter.

• All high-pressure water jetting operations must be under supervision of a person who can stop
the pump in an emergency.

• The pump requires an inlet pressure of 2-4 bar. The suction line shall be as short as possible.
Avoid T-piece, elbows and other fittings which could create turbulence.

• Clean filtered water supply to minimum 80 microns filtration is to be ensured for feeding the
pump. Flexible hose connections of recommended ratings should be provided between suction
and delivery end connections of the pump and rigid pipe lines. The pipe lines are to be
supported independently so that pipe load and tightening strain is not transmitted to the
pump.

• When using a spray gun jetting, the operator has to consider the reaction force. A firm foot
hold is necessary and the floor should not be slippery.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

2. OPERATING INSTRUCTIONS
1. General.

1.1 Carefully read the instruction.

The instructions must be readily available for all those involved in assembling, operating and
servicing the pump.

1.2 The displacement pump must have a suitable pressure regulating device or
pressure relief valve on the discharge side. This is necessary to eliminate damage to the pump or
piping and to avoid possible injuries to the operating team. Under no circumstances should
valves or stopping devices be installed in the bypass line that connects the pressure regulating
device with a tank on the suction side or leads the bypass water to waste.

1.3 Function of Unloader-cum-pressure Regulator

The main parts of unloader are the regulating rod with a screwed on piston, the seat and the
non-return ventil.

The pressure created by the pump will lift the spring-loaded non-return ventil and forces the
water through a bore to the working unit. At the same time the water flows through a small
bore to the lower side of the piston which screwed to the regulating rod. This pressure now tries
to force the piston including the regulating rod upwards. This would cause the regulating rod to
lift a little and would flow into the bypass unpressurised. The passage of disc springs on top of
the regulating rod and piston from going upwards.

The water has to force its way through a small slit around the seat. In doing so, a pressure is built
up which works against the piston and consequently also against the load of the disc springs. By
tightening the adjusting screw on top of the unloader, the load of the disc springs and
consequently the water pressure is increased. The pressure can now be adjusted to such an
extent that the slit between seat and regulating rod is closed and entire volume of pump is
pressed through the nozzle of the gun or foot ventil.

Additional turning of the adjusting screw would not effect the pressure, however when closing a
gun or nozzle, pressure would be much higher than the actual working pressure.

In this case serious damage could occur since no safety ventil can react fast enough in such a
case.
In practice this means that when turning the pressure adjusting screw the pressure gauge does
not move any further, then the screw should be turned backwards until the pressure gauge
moves backwards a little bit once more.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

When now closing the gun foot ventil, the water flowing in the hose comes to an immediate
standard still. As a result, sudden pressure compared to the working pressure is created. The gun
forces the non-return ventil to close and the pressure will lift the piston with the regulating rod.
The water can enter the bypass freely through the enlarged slit between the regulating rod and
seat. The pump valve works now at inlet pressure only and uses practically no energy.

If the non-return ventil and the corresponding spring are dismounted, the unloader will work as
a regulator. When the gun or foot-ventil is now closed, the piston and regulating rod will lift only
a fraction of a millimeter and the working pressure remains almost constant.

Consequently, an unloader will be used when is only one gun or foot ventil and the gun is to be
continuously used in on-off operation.

When more guns are to be used and continuous operation is intended, a regulator is
recommended.

When using an unloader the pressure can only be adjusted when the gun is open whereas when
using a regulator the pressure can be adjusted either when the gun is shut or open.

1.4 The safety ventil has been adjusted and sealed by the manufacturer to ensure that the
operating pressure for the safety ventil is in accordance with the maximum operating pressure
that can be achieved with the various plunger sets. The safety ventil operating pressure is also in
accordance with the power input of the pump.

When installing a different plunger set to the one that is originally in the pump, the safety ventil
also must be changed to one with the corresponding operating pressure. This method allows the
optimum operating pressure to be achieved and eliminates overloading of the pump as well as
motor or engine.

Safety ventil is not to the maximum operating pressure. Lock nut is used to prevent disturbance
of pressure setting.

1.5 Ensure accessories, hosed, valves guns, etc. correspond with the maximum operating pressures.

1.6 Damage caused by frost can be avoided by draining the pump, the piping and the hoses as well
as accessories in frosty weather.

1.7 The maximum head on the suction side 6 bars. If only higher pressures are available, contact the
manufacturer for suggestions.

1.8 Where the water supply is a problem the installation of a tank on the suction side is
recommended. For details of size and installations, contact the manufacturer.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

2. Starting up the pump

2.1 Fill the casing with the recommended oil to requested oil level.

2.2 Double –check all nuts and bolts, especially at the pump head and make sure all of them are
properly tightened.

2.3 Connect the suction line, which should be as short as possible elastic, and have bend inner
diameter of at least one size larger than the connecting thread at the pump. Air locks must be
avoided. Make sure the suction line is air-tight, so that the pump does not suck in air. To
eliminate vibration with a stationary piping systems always use a suitable hose to connect pump
with rigid stationary system.

2.4 Check whether enough water is in tank on the suction side if the pump operators under suction
conditions (tank half-full).

2.5 Unscrew the hexagon bolt of the unloader until no pressure is applied to the disc springs of the
unloader respectively regulator.

2.6 Make sure the discharge line is open.

2.7 After starting the engine or the motor, close and open the shut-off ventils on the discharge side
(ball valves, guns, dead-man valves etc.). At the same time, turn hexagon bolt on the unloader or
regulator clockwise. Continuously watch the Pressure gauge. After the operating pressure is
achieved the hexagon bolt of the unloader or regulator can be locked by tightening the counter
nut.

Under no circumstances may the operating pressure be adjusted while the shut-off ventils in the
discharge line are closed.
Attention:

If no pressure is indicated although the adjusting bolt of the unloader is screwed into the unloader.
Please repeat the whole procedure from the start several times, until pressure is indicated on the
gauge.

2.8 With installation of long and rigid lines, the use of pulsation dampers is recommended. For size
and installation please contact the manufacturer.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

3. SERVICE CHART
Trouble Shooting

A. Pump does not prime when pressure line closed.

B. Pump does not hold pressure when pressure lines open.
C. Pump is noisy.
D. Pump is get hot.
E. Pump does not prime at all.
F. Oil leaks at piston rods.
G. Pressure Gauge shows unusual pressure.
H. Pressure Regulator not stable.
I. Heavy water leakage at plunger.

Possible Reasons A B C D E F G H I
1. Stop ventil in suction line closed. X X X
2. Suction pipe clogged X X X X
3. Supply tank empty X X X
4. Leak in suction pipe (air sucked in) X X X X
5. Pump head cracked (frost) X X
6. Worn-out packing X
7. Nozzle boring too large or eroded X
8. Nozzle boring too small X X
9. Water in casing X X
10. Worn-out link insert bearings X X
11. Oil level too high X X
12. Wrong type of oil for lubrication X X
13. Air in pump head X X X X
14. Piston rod seal worn out X X
15. Regulating piston jammed X
16. Non-return ventil jammed X
17. Foreign matter caught up in pump valve X X
18. Regulator rod worn out X X X

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

4. TORQUE RANGE FOR BOLTS AND NUTS

Torque Range (Nm)
S.No. Nut /Bolt Size Part Number
(0.01 kpm)
1 M6 8.3 4050141
4050031

2 M8 20 4050215
4050166

3 M 10 40 4050020
4050181
4050053
4050024
4050192

4 M 12 70 4050019
4050025
4050017
4050109
4050242
4050172
4050159
4050163
405012

5 M 14 110 4050161
4050275
4050183
4050185
4050213
4050171
405025

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

6 M 16 17 405003
4050117
4050014
405025
4050259
4050271
4050152
4050165

7 M 18 230 4500015

8 M 20 250 4500004
4050006
4050164
4050243

9 M 24 450 4050021
405021
4050228
4050288

1 foot pound x 1.383 = 1 Nm

NOTE :

CONNETING ROD BOLT

UT – 8000 - 85
UT – 11000 - 210
UT –13000 - 210

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

5. LUBRICATION – DRIVE END

RECOMMENDED LUBRICANTS
PUMP MODEL OIL CAPACITY
OIL GRADE MAKE & NAME OF OIL

UT – 4500 3.5 Ltrs. ISO VG 320 BHARAT PETROLEUM/SERVO

UT – 8000 6 Ltrs. ISO VG 320 --DO--

UT – 11000 8 Ltrs. ISO VG 320 --DO--

UT – 13000 8 Ltrs. ISO VG 320 --DO--

UT – 15000 10 Ltrs. ISO VG 320 --DO--

UT - 25000 12 Ltrs ISO VG 320 -DO-

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

8. GEAR END PARTS LIST (PART NO. 1010238-C)

S.NO. PART NO. DESCRIPTION QTY. UoM
1 1530001 CASING 1 Nos.
2 1530002 CASING COVER 1 Nos.
3
1530264/005/ CRANK SHAFT WITH GEAR WHEEL &
4 1 SET
008 PINION SHAFT
5
6 1530010 BEARING COVER 1 Nos.
7 1530011 BEARING COVER, DRIVE SIDE 1 Nos.
8 1530012 BEARING COVER 1 Nos.
9 1530262-A CONNECTING ROD WITH CAP 3 Nos.
10 4050242 ALLEN BOLT 6 Nos.
11 BIL-1008/04 LOCK WASHER 6 Nos.
*12 1530016 CROSS HEAD PIN 3 Nos.
13 1051322 THRUST DISC 1 Nos.
14 1030182 VENTILATING PLUG 1 Nos.
15 1530019 OIL LEVEL SIGHT GLASSES 2 Nos.
16 1530020 SCREWED PLUG 1 Nos.
17 5031342 CROSS-HEAD WITH SHAFT ASSY. 3 Nos.
18 7004407 SEAL COVER 3 Nos.
19 3050018 SPHERICAL BEARING FOR CRANK SHAFT 2 Nos.
20 3050019 CYLIDERICAL BEARING FOR PINION SHAFT 2 Nos.
*21 3050021 BIG END SHELL BEARING 3 Nos.
*22 3050022 SMALL END BUSH 3 Nos.
23 4050062 HEXAGON SCREW 8 Nos.
24 BIL-1030/02 ALLEN HEAD SCREW 12 Nos.
25 4050238 INTERNAL CIRCLIP 2 Nos.
26 4050240 EXTERNAL CIRCLIP 2 Nos.
27 1530375 PLUG 1 Nos.
28 4050241 INTERNAL CIRCLIP 6 Nos.
29 4050146 HEX. SCREW 8 Nos.
30 4050505 EYE BOLT 2 Nos.
*31 1060153 GASKET, CASING COVER 1 Nos.
32 1530023 SPACER FOR PINION SHAFT 2 Nos.
33 1530024 SPACER FOR PINION SHAFT 2 Nos.
*34 4040114-1 KEY 1 Nos.
*35 1060160 BONDED SEAL 1 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

*36 7005763-1 SEAL RING 3 Nos.

*37 7004280-1 WIPER 3 Nos.
38 7004407-1 RING FOR SEAL COVER 3 Nos.
39 4050082 GRUB SCREW 9 Nos.
40 5031362 ROTO-SEAL ASSLY 1 Nos.
41 4050326 CYLINDER PIN 6 Nos.
42 B002004 ½’’ HEX NIPPLE 2 Nos.
43 B007004 ½’’ EQUAL TEE 1 Nos.
44 5031362-3 FLANGE 1 Nos.
45 BIL-1037/04 HEX BOLT 2 Nos.
A 1060150 O-RING 3 Nos.
B 1060140 O-RING 1 Nos.
C 1060152 RADIAL SHAFT SEAL 1 Nos.
D 1060155 GASKET, BEARING COVER (PINION SHAFT) 2 Nos.
E 1060151 GASKET, BEARING COVER (CRANK SHAFT) 2 Nos.

S.NO. GEAR END (GE) : KIT NO‐SPKIT031302 01 Set UoM

A 1060150 O-RING 3 Nos.
B 1060140 O-RING 3 Nos.
C 1060152 RADIAL SHAFT SEAL 2 Nos.
D 1060155 GASKET, BEARING COVER (PINION SHAFT) 2 Nos.
E 1060151 GASKET, BEARING COVER (CRANK SHAFT) 2 Nos.
F 5031362‐5 GASKET FOR ROTO SEAL ASSLY. 2 Nos.
G 5031365-3 GASKET FOR LUB OIL PUMP MOUNTING 2 Nos.
H 1060223 BACKUP RING 3 Nos.

∗ SPARE PARTS

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

9. MAINTENANCE INSTRUCTIONS – GEAR END 13000

Oil Change
First oil change has to be made after 50 operating hours. When changing oil, the gear housing should
still be warm. After filling the new oil, the pump must operate for two or three minutes without load.
The next oil change taxes place after every 200 operating hours. Regularly check the oil level and
replace missing oil. Also change oil immediately if water determined in the casing.

For type of oil and volume, please check enclosed Lubrication Chart.

Removal of Seal Assembly on Piston Rods

Insert two screwdrivers at the outer diameter of the seal assembly between gear end and seal
assembly. Pull seal assembly forward for removal.

Changing Piston Rod Oil Seals

All seal on the seal cover must be replaced once it has been removed including wiper (if included) and
O-ring. Wiper and seal rings must be arranged with lips in correct direction (see drawing gear).
Mandrel, p/n 1030107 (see tool kit), should be used when fitting new seals to facilitate easy assembly
and to avoid damage to seal lips. The O-ring should be lightly smeared with water repellent grease,
while the oil seals should be smeared with oil on assembly.

To remount oil seal cover, turn crosshead shank backwards, push oil seal cover onto shank using
mandrel, (1030107) and press into gear housing. Thereafter move the pump head including the carrier,
in which the wire clip still remains, onto the studs to the gear case. Screw the carrier onto the gear
case and screw the cap nut onto the studs by applying the torque given on the list of tightening
torques.

Removing and Installing the Crankshaft

Drain the casing oil

Remove gear and cover 1530002 and bearing covers 5031362-1. Unscrew the links and push the cross-
heads forwards as far as possible. Note the marking that identify the link parts. The marks on both
sections of the link must be identical and when assembled must face upward. These parts are
assembling or disassembling ensures that the cylinder pin is in line with the boring.
Push the bearing 3050018 from inside to outside and remove crankshaft.
The re-assembly is done in reverse order.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

Assembly of pinion shaft

Remove casing cover 1530002, Bearing caps 5031365-1 and 1530011, Pull out outer Circlip 4050240
are now unlocked and can be removed. Pull out pinion shaft together with bearing 3050019.

Assembly is done in the reverse order. Take care that the bearings are in the proper position.

Crosshead and Links

After removal of crankshaft and pinion shaft pull out the links together with the cross heads through
the rear part of the gear end.
To separate crosshead and link, remove inner circlips 4050241 push out link pin.
Reassembly in reverse order.

Crossheads and Piston Rods

Spare parts for crosshead and plunger rod are available only as complete unit. Under normal operating
conditions it will never be necessary to exchange crossheads. If abnormal wear occurs, the reason
could be that insufficient oil is in the gear end, or metal particles are in the oil and have damaged the
surfaces of crossheads respectively

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

10. ROTOSEAL ASSEMBLY PART LIST (PART NO. 5031362)

S.NO. PART No. DESCRIPTION QTY. UoM

1 5031362-1 COVER 1 Nos.
2 5031362-4 STOPPER 1 Nos.
3 5031362-2 ROTO SHAFT 1 Nos.
4 1060223 BACK-UP RING 3 Nos.
5 5031362-5 GASKET 1 Nos.
6 1060151 GASKET_BEARING COVER 1 Nos.
7 4050090 HEX SCREW 4 Nos.
8 BIL-1015/03 PLAIN WASHER 4 Nos.
9 1060140 O-RING 1 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

11. COMPLETE BARE PUMP WITH EXT. FORCE LUBRICATION

ARRANGEMENT (PART NO. 5010101)

(BARE PUMP PART NO. 3002001)

(FOR EXT. FORCE LUBRICATION ARRANGEMENT PART NO. 3001001-A)

S.NO. PART No. DESCRIPTION QTY. UoM

1 B070001 OIL COOLER 1 Nos.
2 B039007/01 OIL / WATER COOLING HOSE 3 Nos.
3 B069001 OIL FILTER ASSEMBLY 1 Nos.
4 B039074 BYPASS HOSE 1 Nos.
5 B061003 LUBE OIL PUMP 1 Nos.
6 1030552.01 OIL PRESSURE GAUGE 1 Nos.
7 B039136 OIL PRESSURE SWITCH HOSE 1 Nos.
8 EL-306175 0.75 KW ELECTRIC MOTOR, 3-PHASE 1 Nos.
9 EL01021 OIL PRESSURE SWITCH ( -2 TO 7.5 BAR ) 1 Nos.
10 5032063 ISOLATION VALVE (FOR PR. SWITCH) 1 Nos.
11 B039006/01 COOLING OIL DISCHARGE HOSE 1 Nos.
12 B061003.01 FITTING OF LUBE OIL PUMP 1 SET
13 BIL-1110/09 FLEXIBLE COUPLING 1 Nos.
14 B026011.1 SPIDER FOR COUPLING 1 Nos.
15 B038101 OIL COOLING HOSE 1 Nos.
16 B007004 ½’’ EQUAL TEE 3 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

12. COMPLETE BARE PUMP WITH PINION MOUNTED FORCE

LUBRICATION ARRANGEMENT (PART NO. 5010102)

(BARE PUMP PART NO. 3002001)

(PINION MOUNTED FORCE LUB. ARRANGEMENT PART NO. 3001002-A)

S.NO. PART No. DESCRIPTION QTY. UoM

1 B061003 LUBE OIL PUMP 1 Nos.
2 B039074 BYPASS HOSE 1 Nos.
3 B039006/01 COOLING OIL DISCHARGE HOSE 1 Nos.
4 B061003.01 FITTING OF LUBE OIL PUMP 1 SET
5 B039007/01 HOT OIL DISCHARGE HOSE 1 Nos.
6 1030552.01 LUBE OIL PRESSURE GAUGE 1 Nos.
7 EL01021 OIL PRESSURE SWITCH ( -2 TO 7.5 BAR ) 1 Nos.
8 B069001 OIL FILTER ASSEMBLY 1 Nos.
9 B039136 PRESSURE SWITCH HOSE 1 Nos.
10 B070001 OIL COOLER 1 Nos.
11 B039007/01 OIL / WATER COOLING HOSE 3 Nos.
12 5032063 ISOLATION VALVE 1 Nos.
13 BIL-1030/22 ALLEN BOLT 2 Nos.
14 5031365-3 GASKET 1 Nos.
15 4050134 HEX BOLT 2 Nos.
16 5031365-2 COUPLING BOLT 1 Nos.
17 5031365-1 COVER 1 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

14. FLAT HEAD PUMP PART LIST: PART NO. 1010461-18

S.NO. PART NO. DESCRIPTION QTY. UoM

1 4040142 PUMP HEAD 01 Nos.
2 5031049 CYLINDER SLEEVE 03 Nos.
3 5031050 SPRING SLEEVE 03 Nos.
4 5050042 SPRING 03 Nos.
5 2050071 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

FLAT HEAD PUMP PART LIST: PART NO. 1010461-20

S.NO. PART NO. DESCRIPTION QTY. UoM

1 4040142 PUMP HEAD 01 Nos.
2 5031079 CYLINDER SLEEVE 03 Nos.
3 5031080 SPRING SLEEVE 03 Nos.
4 5050042 SPRING 03 Nos.
5 2050071 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

FLAT HEAD PUMP PART LIST: PART NO. 1010461-22

S.NO. PART NO. DESCRIPTION QTY. UoM
1 4040142 PUMP HEAD 01 Nos.
2 5032094 CYLINDER SLEEVE 03 Nos.
3 5031080 SPRING SLEEVE 03 Nos.
4 5050042 SPRING 03 Nos.
5 2050071 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

FLAT HEAD PUMP PART LIST: PART NO. 1010461-24

S.NO. PART NO. DESCRIPTION QTY. UoM

1 4040142 PUMP HEAD 01 Nos.
2 5031262 CYLINDER SLEEVE 03 Nos.
3 5031263 SPRING SLEEVE 03 Nos.
4 5050042 SPRING 03 Nos.
5 2050071 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

FLAT HEAD PUMP PART LIST: PART NO. 1010461-26

S.NO. PART NO. DESCRIPTION QTY. UoM
1 4040142 PUMP HEAD 01 Nos.
2 1050911 CYLINDER SLEEVE 03 Nos.
3 1050950 SPRING SLEEVE 03 Nos.
4 5050042 SPRING 03 Nos.
5 2050071 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

FLAT HEAD PUMP PART LIST: PART NO. 1010461-28

S.NO. PART NO. DESCRIPTION QTY. UoM

1 4040142 PUMP HEAD 01 Nos.
2 5031250 CYLINDER SLEEVE 03 Nos.
3 5031251 SPRING SLEEVE 03 Nos.
4 5031092 SPRING 03 Nos.
5 5031093 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

FLAT HEAD PUMP PART LIST: PART NO. 1010461-30

S.NO. PART NO. DESCRIPTION QTY. UoM

1 4040142 PUMP HEAD 01 Nos.
2 5031089 CYLINDER SLEEVE 03 Nos.
3 5031090 SPRING SLEEVE 03 Nos.
4 5031092 SPRING 03 Nos.
5 5031093 DISC 03 Nos.
6 2050070 SEAT 03 Nos.
7 5040456 PLUG 03 Nos.
8 4.0742.038 DELRIN RING 03 Nos.
9 1050815 DISCHARGE VENTIL 03 Nos.
10 1530116 VENTIL PLATE 03 Nos.
11 1050902 VALVE GUIDE 03 Nos.
12 1050816 CYLINDER HEAD COVER 03 Nos.
13 4050372 ALLEN BOLT 18 Nos.
14 5050028 SPRING 03 Nos.
A 1060029 O-RING 09 Nos.
B 1060109 BACKUP-RING 09 Nos.

* KIT FOR ALL FLAT HEADS GIVEN BELOW :

S.NO. SPKIT031305 PUMP HEAD KIT 01 SET UoM

A 1060029 O-Ring 09 Nos.
B 1060109 Backup-Ring 09 Nos.
C 1060146 Gasket (Suction Manifold) 01 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

15. MAINTENANCE INSTRUCTIONS PUMP HEAD – FLAT HEAD

Assembly pump head - Gear End
Assembly head carrier 4040066-2 is centered on the stuffing boxes of the pump head. Studs 1050472 bolt
spacer and pump head together. The assembly pumps head – spacer centers on the piston rod seal
assembly 1530022. Hexagon bolts 4050243 and studs 1050472 connect pump head carrier assembly with
the gear end.

Suction and Discharge Valves

Suction and discharge valves are identical and interchangeable. To remove suction valves, Allen screw of
cylinder head cover is unscrewed. The discharge ventil 1050815 with coil springs and discs can how be
pulled out of the pump head using cover puller 1010015.

To pull a suction seat (part no. 2050070) the removal tool 5031185 is screwed into the seat and the
pressure plate slid onto the tool rod. Tightening of the hexagon nut clockwise above the pressure plate will
pull the seat from its conical seat in the pump head.

The above procedure is identical for suction valves and discharge valves. Before reinstalling seats, make
sure the conical surfaces in the pump head as well as on the seat are clean and free of oil or grease.

Using the corresponding tools, the seats are positioned in the pump head. Slight impacts on the tool will
ensure that the seats are properly located.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

16. PUMP HEAD CARRIER ASSLY. (DRG.No.: 4001001-A )

S.NO. PART NUMBER DESCRIPTION QTY. UoM

1 4040066-2 PUMP HEAD CARRIER 1 Nos.
2 4050354-1 INNER CIRCLIP 3 Nos.
3 4050243 HEX SCREW 4 Nos.
4 3030026 PLATE PLUNGER WELL 1 Nos.
5 BIL-1037/01 HEX BOLT 2 Nos.
6 4050026 SCREW SLOTTED HEAD 2 Nos.
7 4040087 COVER PLUNGER WELL 1 Nos.
8 5040004 BRASS HOSE NIPPLE 1 Nos.
9 1050472 STUD 4 Nos.
10 4050164 HEX NUT 4 Nos.
11 BIL-1008/05 SPRING WASHER 2 Nos.
12 4050245 CYLINDER PIN 2 Nos.

17. SUCTION MANIFOLD ASSLY. (DRG.No.: 5001001-A)

ITEM NO. PART NUMBER DESCRIPTION QTY. UoM

1 3040026 SUCTION MANIFOLD 1 Nos.
2 1060146 GASKET SUCTION MANIFOLD 1 Nos.
3 4050192-03 HEX BOLT 8 Nos.
4 4050247 BONDED SEAL 8 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

18. CONVERSION KIT- FLAT HEAD

CONVERSION KITS -13018 Parts No. 5031045-A
S.NO. PART NO DESCRIPTION QTY. UoM
1 5031046 STUFFING BOX 03 Nos.
2 5031047 PRESSURE RING 03 Nos.
3 5031048 SUPPORT RING 03 Nos.
4 210004 PLUNGER SEAL 03 Nos.
5 5031253 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060401 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031306 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060401 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

CONVERSION KITS -13020 Parts No. 5031081-A

S.NO. PART NO DESCRIPTION QTY. UoM
1 5031076 STUFFING BOX 03 Nos.
2 1050298 PRESSURE RING 03 Nos.
3 5031078 SUPPORT RING 03 Nos.
4 1060110 PLUNGER SEAL 03 Nos.
5 1010252 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060402 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031308 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060402 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

CONVERSION KITS -13022 Parts No. 5032092-A

S.NO. PART NO DESCRIPTION QTY. UoM

1 5032093 STUFFING BOX 03 Nos.
2 1050297 PRESSURE RING 03 Nos.
3 5031429 SUPPORT RING 03 Nos.
4 1060111 PLUNGER SEAL 03 Nos.
5 1010255 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060403 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031307 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060403 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

CONVERSION KITS -13024 Parts No. 5031259-A

S.NO. PART NO. DESCRIPTION QTY. UoM

1 5031260 STUFFING BOX 03 Nos.
2 1050051 PRESSURE RING 03 Nos.
3 5031261 SUPPORT RING 03 Nos.
4 1060026 PLUNGER SEAL 03 Nos.
5 1010243 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060404 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031309 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060404 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

CONVERSION KITS -13026 Parts No. 1010617-A

S.NO. PART NO. DESCRIPTION QTY. UoM

1 1050912 STUFFING BOX 03 Nos.
2 1050034 PRESSURE RING 03 Nos.
3 1051039 SUPPORT RING 03 Nos.
4 1060019 PLUNGER SEAL 03 Nos.
5 1010244 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060011/02 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT0313010 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060011/02 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

CONVERSION KITS -13028 Parts No. 5031252-A

S.NO PART NO. DESCRIPTION QTY. UoM

1 5031248 STUFFING BOX 03 Nos.
2 1050035 PRESSURE RING 03 Nos.
3 5031249 SUPPORT RING 03 Nos.
4 1060020 PLUNGER SEAL 03 Nos.
5 1010245 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B 1060398-1 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031311 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 1060398-1 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

CONVERSION KITS -13030 Parts No. 5031091-A

S.NO PART NO. DESCRIPTION QTY. UoM
1 5031086 STUFFING BOX 03 Nos.
2 1050022 PRESSURE RING 03 Nos.
3 5031088 SUPPORT RING 03 Nos.
4 1060004 PLUNGER SEAL 03 Nos.
5 1010246 PLUNGER COMPLETE 03 Nos.
6 BIL-1037/47 HEX BOLT 18 Nos.
7 4050082 GRUB SCREW 03 Nos.
A 1060002 O-RING FOR (SUPPORT RING FACE) 03 Nos.
B BIL-1043/04 O-RING FOR GROOVE 03 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 03 Nos.

S.NO. SPKIT031312 KIT FOR CONVERSION (O-RINGS) 01 SET UoM

A 1060002 O-RING FOR (SUPPORT RING FACE) 09 Nos.
B 209006 O-RING FOR GROOVE 09 Nos.
C 1060382 O –RING FOR (PLUNGER COOLING) 06 Nos.

19. MAINTENANCE INSTRUCTIONS – CONVERSION KITS

CHANGING CONVERSION KIT

Turn the pinion shaft until the plunger to be worked on first is in the utmost forward position in the
pump head. Disconnect plunger from piston rod using a 27 mm wrench. Use ratchet 1030079 to
unscrew the six hexagon bolts BIL-1037/47 of the stuffing box (tool set with ratchet included with
pump).

Attention: The ceramic plungers are sensitive to mechanical damage.

Whenever plunger packings are changed also ‘O’ Ring in the stuffing box must be changed.
Assembling is done in the reverse order.

To improve the running-in of new packings, the pump head should be filled with water before the pump
starts. Water can be fed into the pump by removing the suction valve caps. Pump should run at No Load
condition for approx. ½ Hours and oil should be dropped on ceramic plunger for smoothing of seal.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

21. PRESSURE REGULATOR PART LIST (PART NO. 1010013-A)

S.NO. PART No. DESCRIPTION QTY. UoM

1 5030869/5030869-1 REGULATING BODY 1 Nos.
*2 2050006 SEAT 1 Nos.
*3 2050050 REGULATING ROD 1 Nos.
*4 1050008 VALVE CYLINDER 1 Nos.
5 3040002 SPRING HOUSING 1 Nos.
*6 5050026 SPRING 1 Nos.
*7 1050010 PISTON REGULATING 1 Nos.
8 1050011 SPRING PLATE 1 Nos.
*9 5050002 DISC SPRING 12 Nos.
10 1050012 PRESSURE PLATE 1 Nos.
11 4040006 COVER 1 Nos.
*12 1050013 SCREW PRESSURE ADJUSTING 1 Nos.
13 BIL-1008/04 SPRING WASHER 4 Nos.
14 4050014 HEX BOLT 4 Nos.
15 4050082 GRUB SCREW 1 Nos.
16 5040089 ELBOW 1 Nos.
17 5040522/5040978 ADAPTOR 1 Nos.
18 4.0742.037 DELRIN RING 1 Nos.
19 BIL-1008/11 SPRING WASHER 4 Nos.
20 2654330 HEX BOLT 4 Nos.
21 4050021 LOCKING NUT 1 Nos.
A 1060010 O-RING 1 Nos.
B 1060006 O-RING 1 Nos.
C 1060012 O-RING 1 Nos.
D BIL-1017/04 O-RING 1 Nos.
E 1060113 BACKUP RING 1 Nos.
F 1060114 BACKUP RING 1 Nos.
G 1060008 SEAL 2 Nos.
H 1050054 SUPPORT WASHER 1 Nos.
I 1060009 BACKUP RING 2 Nos.
J 3050001 PRESSURE BEARING 1 Nos.
K 3050002 BEARING RACE UPPER 1 Nos.
L 3050003 BEARING RACE LOWER 1 Nos.
M 4050020 NYLOC NUT ZINC PLATED 1 Nos.

*SPARE PARTS

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

PRESSURE REGULATOR KIT PART LIST

S.NO. PRESSURE REGULATOR ASSY (KIT) - SPKIT030001 1 SET UoM
A 1060010 O-RING 6 Nos.
B 1060006 O-RING 4 Nos.
C 1060012 O-RING 3 Nos.
D 1060013 O-RING 3 Nos.
E 1060113 BACKUP RING 3 Nos.
F 1060114 BACKUP RING 3 Nos.
G 1060008 SEAL 4 Nos.
H 1050054 SUPPORT WASHER 1 Nos.
I 1060009 BACKUP RING 4 Nos.
PRESSURE REGULATOR ASSY (KIT) - SPKIT030002 1 SET
J 3050001 PRESSURE BEARING 2 Nos.
K 3050002 BEARING RACE UPPER 2 Nos.
L 3050003 BEARING RACE LOWER 2 Nos.
M 4050020 NYLOC NUT ZINC PLATED 2 Nos.
VALVE CYLINDER ASSY WITH REGULATOR ROD
1 SET SET
(KIT) - SPKIT1010003
1 1010003 VALVE ASSLY.FOR UNLOADER 1 Nos.
2 2050050 REGULATING ROD 1 Nos.
3 1060009 BACKUP RING 2 Nos.
4 1060113 BACKUP RING 1 Nos.
5 1060114 BACKUP RING 1 Nos.
6 1060008 SEAL 2 Nos.
7 BIL-1017/04 BACKUP RING 1 Nos.
8 1060012 O-RING 1 Nos.
9 5050026 SPRING 1 Nos.
10 4050020 NYLOC NUT 1 Nos.
11 1050008 VALVE CYLINDER 1 Nos.
12 1050010 PISTON REGULATING 1 Nos.
13 1050011 SPRING PLATE 1 Nos.

REGULATING PRESSURE
S.NO. ADAPTOR NO. QTY. UoM
BODY REGULATOR
1 5040522 5030869 1010013-A 1 Nos.
2 5040978 5030869-1 1010013-F 1 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

22. SAFETY VALVE PARTS LIST (PART NO. 1010100-A)

S.NO. PART No. DESCRIPTION QTY. UoM

1 1050191-A SPRING HOUSING 1 Nos.
2 1050192 PRESSERE ADJUSTING SCREW 1 Nos.
3 5050017 DISC SPRING 28 Nos.
4 1050189-A GUIDE STEM 1 Nos.
5 1050196 VALVE HOUSING 1 Nos.
6 2050035 SEAT 1 Nos.
7 1050190 ADAPTOR 1 Nos.
8 5030953 LOCK NUT 1 Nos.
A 1060058 O-RING 1 Nos.
B 1060015 O-RING 1 Nos.
C 1060005 COPPER WASHER 2 Nos.
D 2050029/2050029-05 VALVE 1 Nos.

S.NO. PART No. DESCRIPTION PRESSURE RANGE

A 2050029 VALVE 0-645 Bar
B 2050029-05 VALVE 645-1500 Bar

S.NO. SAFETY VALVE KIT - SPKIT030003 1 SET UoM

A 1060058 O-RING 2 Nos.
B 1060015 O-RING 2 Nos.
C 1060005 COPPER WASHER 4 Nos.
D 2050029 VENTIL 2 Nos.

Page | 45
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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

23. MOUNTING BLOCK PARTS LIST (PART No. 1010103)

S.NO. PART NUMBER DESCRIPTION QTY. UoM
1 4040029 MOUNTING BLOCK 1 Nos.
2 1060006 O-RING 1 Nos.
3 4050162 LOCK WASHER 4 Nos.
4 4050185 HEX BOLT 4 Nos.
5 1060005 COPPER WASHER 4 Nos.

24. MAINTENANCE INSTRUCTIONS

1. PRESSURE REGULATOR
Assembly of Cylinder
Remove spring housing 3040002 together with the disc springs. Using two wrenches, cylinder 1050008
can be pulled out. Remove seat 2050006 using the pulling device and removal tools (seat 2050006 is
also used in the non-return ventil assembly) Clamp the regulating rod in a vice (using aluminum or brass
checks) and unscrew nut 4050020. Together with regulating rod 2050050 the spring-support plate
1051011, regulating piston 1050010, seals 1060008, back-up ranges 1060009 and spring 5050026 can
be removed from cylinder 1050008.
Assembly is done in the reverse order.
Attention: Do not damage the lip seals.

2. SAFETY VENTIL
The safety ventil has been adjusted and sealed by the manufacturer by lock nut 5030953.

Disassembling of the safety ventil can only be done by the manufacturer. Safety ventils in general
operate only once at maximum accuracy and it is recommended to send them to the manufacturer for
readjusting, once they have been in operation.

3. MOUNTING BLOCK
Put O-Ring 1060006 on Mounting Block 4040029 and mount this opposite to unloader as per drawing
and tight with 4 Hex Bolt Part No. 4050185. Now mount pressure gauge of required bar pressure
suitable for particular gauge after putting 1060007 and tight the gauge. Dismantling in reverse order.

Page | 47
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UT PUMPS & SYSTEMS PVT.LTD. Assembly & Working Instructions for
High Pressure Pumps

26. HIGH PRESSURE GUN (PART NO. 1010075)

S.NO. PART No. DESCRIPTION QTY. UoM
1 3040007 GRIP 1 Nos.
2 4040028 VALVE HOUSING 1 Nos.
3 4050127 LOCKING NUT 1 Nos.
4 3030006 TRIGGER GUARD 1 Nos.
*5 3040006 TRIGGER 1 Nos.
*6 4050022 SPIRAL PIN 1 Nos.
7 1050163 SCREW CAP 1 Nos.
*8 1050166 STOP TRIGGER 1 Nos.
9 3040008 SAFETY CLUTCH 1 Nos.
*10 4050130 SPRING DOWEL PIN 1 Nos.
*11 1050165 PUSH ROD 1 Nos.
12 5050046 STOPPER FOR GUN HANDLE 1 Nos.
13 1050331 RETAINER 1 Nos.
14 1050330 HOSE CONNECTOR 1 Nos.
15 1050162 END CAP 1 Nos.
*16 1010089 VALVE ASSEMBLY 1 Set
i 1050164 VENTIL PLATE 1 Nos.
ii 2050017 VENTIL 1 Nos.
*17 2050019 CONUS 1 Nos.
*18 2050018 SEAT 1 Nos.
19 BIL-1030/09 ALLEN HEAD SCREEW 3 Nos.
20 BIL-1008/06 LOCK WASHER 5 Nos.
21 BIL-1030/101 ALLEN HEAD SCREW 2 Nos.
A 1060015 O-RING 1 Nos.
B 1060063 O-RING 1 Nos.
C 1060070 O-RING 1 Nos.
D 1060073 O-RING 1 Nos.
E 1060064 V - RING 1 Nos.
F 1050159 PRESSURE RING 1 Nos.
G 5050013 SPRING 1 Nos.
H 5050016 SPRING 1 Nos.
I 5050020 SPRING 1 Nos.
J 1050160 PRESSURE SCREW 1 Nos.

*SPARE PARTS

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UT PUMPS & SYSTEMS PVT.LTD. Assembly & Working Instructions for
High Pressure Pumps

HIGH PRESSURE GUN KIT PARTS LIST:

S.NO. SPKIT030004 HP GUN / FOV KIT 1 SET UoM
A 1060015 O-RING 6 Nos.
B 1060063 O-RING 6 Nos.
C 1060070 O-RING 1 Nos.
D 1050073 O-RING 1 Nos.
E 1060064 V - RING 6 Nos.
F 1050159 PRESSURE RING 2 Nos.
G 5050013 SPRING 2 Nos.
H 5050016 SPRING 2 Nos.
I 5050020 SPRING 2 Nos.
J 1050160 PRESSURE SCREW 2 Nos.

Page | 51
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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

27. FOOT OPERATED VENTIL (PART NO. 1010094)

S.NO. PART NO. DESCRIPTION QTY. UoM

1 3040009 BASE PLATE 1 Nos.
2 3030009 GUARD PLATE 1 Nos.
3 4040028 VALVE HOUSING 1 Nos.
4 4050127 LOCKING NUT 1 Nos.
5 1050163 SCREW CAP 1 Nos.
6 1050165 PUSH ROD 1 Nos.
7 1050331 RETAINER 2 Nos.
8 1050330 HOSE CONNECTOR 2 Nos.
9 1050162 END CAP 1 Nos.
10 1010089 VALVE ASSEMBLY 1 Set
i 1050164 VENTIL PLATE 1 Nos.
ii 2050017 VENTIL 1 Nos.
11 2050019 CONUS 1 Nos.
12 2050018 SEAT 1 Nos.
13 3040010 PEDAL 1 Nos.
14 4050146 HEX BOLT 1 Nos.
15 4050148 HEX BOLT 2 Nos.
16 4050041 PLAIN WASHER 4 Nos.
17 4050060 COUNTER SUNK SCREW 4 Nos.
18 BIL-1037/09 HEX BOLT 4 Nos.
19 BIL-1008/05 SPRING WASHER 4 Nos.
20 BIL-1014/01 HEX NUT 3 Nos.
A 1060015 O-RING 2 Nos.
B 1060063 O-RING 1 Nos.
C 1060070 O-RING 1 Nos.
D 1060073 O-RING 1 Nos.
E 1060064 V - RING 1 Nos.
F 1050159 PRESSURE RING 1 Nos.
G 5050013 SPRING 1 Nos.
H 5050016 SPRING 1 Nos.
I 1050160 PRESSURE SCREW 1 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

FOOT OPERATED VENTIL PARTS LIST FOR KIT:

S.NO. SPKIT030004 HP GUN / FOV KIT 1 SET UoM

A 1060015 O-RING 6 Nos.
B 1060063 O-RING 6 Nos.
C 1060070 O-RING 1 Nos.
D 1060073 O-RING 6 Nos.
E 1060064 V - RING 2 Nos.
F 1050159 PRESSURE RING 2 Nos.
G 5050013 SPRING 2 Nos.
H 5050016 SPRING 2 Nos.
I 1050160 PRESSURE SCREW 2 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

28. MAINTENANCE INSTRUCTIONS FOOT OPERATED

VENTIL AND HIGH PRESSURE GUN

Gun Housing assembly is common in both FOV & H.P. Gun Fix Seat (2050018) with O-Ring (1060070). In
Gun Housing (4040028). Put O-Ring (1060063), V-Ring (1060064), Back-up Ring (1050159) and insert
Push, Rod (1050165), Screw Push Rod (1050160) and lock with lock Nut (4050127).

Put Valve Assly. (1010089) locating Push Rod and insert springs (5050013, 5050016) and Conus
(2050019). Put End Cap (1050 162) with O-Ring (1060073) and finally tightening the Cap (1050163) on
housing matching with light hand jerk.

Put O-Rings (1060015) on two connectors and put each connector on both sides and tightening with
Retainer (1050331).

For assembling a high-pressure gun, put Grip (3040007), Safety Catch (3040008), Roll Pins (4050130 &
4050022), Trigger (3040006), Trigger Stop (1050166) and Trigger Guard (3030006) and tighten them on
Gun housing as per drawing with socket Head Screws (4050132 & BIL-1030/09), Spring Washers (BIL-
1008/06). Put Guide Plate (7001321) in place.

To assemble a FOV mount the Gun Housing Assembly on Base Plate (3040009) and fix the Pedal
(3040010) by using Bolts (4050148 & BIL-1037/09), Spring Washers (BIL-1008/05) and Nuts (4050127).

Dismantle in reverse order.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

31. ACCESSORIES LIST

S.NO. PART NO. DESCRIPTION
High Pressure Hose, 13MM I.D Fitting M24X1.5/FEM-SWL, length 20M Max.
1 1020011
Operating Pressure 1000 bar/14500 psi.
High Pressure Hose, 13MM I.D Fitting M24X1.5/FEM-SWL, length 15 M Max.
2 1020012
Operating Pressure 1000 bar/14500 psi.
High pressure hose, 13MM I.D fitting M24X1.5/FEM-SWL, length 10 M Max.
3 1020042
Operating pressure 1000 bar/14500 psi.
High pressure hose, 13MM I.D fitting M24X1.5/FEM-SWL, length 5 M Max.
4 1020029
Operating pressure 1000 bar/14500 psi.
High pressure Gun, Model IV hydraulic balanced, suitable up to 1000
5 1010075
bar/14200 psi.
6 1010094 High pressure foot operative valve.
Pipe cleaning flexible lance I.D 6MM with fitting R ¼ Male booth, length 6M
7 1020006
Max. Operating pressure 1000/1100 bar 14500/15950 psi
Pipe Cleaning Flexible Lance I.D 6 MM with Fitting R ¼ Male booth, length 10 M
8 1020006-E
Max. operating pressure 1000/1100 bar 14500/15950 psi
Pipe cleaning flexible Lance I.D 6 MM with fitting R ¼ Male booth, length 15 M
9 1020006-H
Max. Operating pressure 1000/1100 bar 14500/15950 psi
Pipe cleaning flexible Lance I.D 4 MM with fitting R 1/8 Male booth, length 6 M
10 1020004
Max. operating pressure 1000/1100 bar 14500/15950 psi
Pipe Cleaning Flexible Lance I.D 4 MM with Fitting R 1/8 Male booth, length 10
11 1020004-B
M Max. Operating pressure 1000/1100 bar 14500/15950 psi
12 1010132 High pressure sand blaster, Model IV
13 1020028 Sand suction hose, length 5M
14 Special tank cleaning counter balanced nozzle head
15 1050072-A Nipple M24 x 1.5 male R – ¼ “ female
16 1050075-A Nipple M24 x 1.5 male R – R 1/8 " female.
17 1050088 Double Nipple R – ¼ “female.
18 1050087 Double Nipple R 1/8 " female.
19 1050089 Nipple R – ¼ “female – R 1/8 " female.
20 5040007-A Double Nipple M24 x1.5 male.
21 5040522 Nipple M30 x 1.5 – M 24 x 1.5 male both ends.
22 5040978 Nipple M24 x 1.5 – M 22 x 1.5 male both ends.
23 1050091 Double Nipple R ¼ “male.
24 Vacuum nozzle for sand blaster
25 Form 01.00 Round Jet Nozzle R ¼ "
26 Form 02.00 Round Jet Nozzle R ¼ "
27 Form 03.15 Flat Jet Nozzle R ¼ " 150
28 Form 03.30 Flat Jet Nozzle R ¼ " 300

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

S.NO. PART NO DESCRIPTION

29 Form 03.45 Flat Jet Nozzle R ¼ " 450
30 Form 03.60 Flat Jet Nozzle R ¼ " 600
31 Form 03.90 Flat Jet Nozzle R ¼ " 900
32 Form 04.01 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 12mm.
33 Form 04.02 Nozzle Pipe Cleaning welding Type for use with rigid lance.
34 Form 04.03 Nozzle Pipe Cleaning R ¼” female for use with rigid lance OD - 16mm.
35 Form 04.05 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 12mm
36 Form 04.06 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 16mm.
37 Form 04.07 Nozzle Pipe Cleaning R ¼ ” female for use with rigid lance OD - 16mm
38 Form 04.08 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 12mm.
39 Form 04.09 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 12mm.
40 Form 04.10 Nozzle Pipe Cleaning R ¼” female for use with rigid lance OD - 16mm.
41 Form 05.01 Nozzle Pipe Cleaning R 1/8" female for use with rigid lance OD - 4mm.
42 Form 05.02 Nozzle Pipe Cleaning R ¼ ” female for use with rigid lance OD - 6mm.
43 Form 05.03 Nozzle Pipe Cleaning M24 x 1.5 female for use with Hose ID - 13mm.
44 Form 05.04 Nozzle Pipe Cleaning M24 x 1.5 female for use with Hose ID.
45 Form 05.05 Nozzle Pipe Cleaning M30 x 1.5 female for use with Hose ID - 20mm.
46 Form 06.01 Nozzle Pipe Cleaning M24 x 1.5 female for use with Hose ID - 13mm.
47 Form 06.02 Nozzle Pipe Cleaning M30 x 1.5 female for use with Hose ID - 20mm.
48 3060002 Nozzle carrier head 100 mm with round jet nozzles.
49 3060003 Nozzle carrier head 70 mm with round jet nozzles
50 3060009 Nozzle carrier head 60 mm with round jet nozzles
51 3060005 Dragger (MN 29) with 4 round jet nozzles
52 B015006 Hose Brass Nipple
53 B039001 Flexible Hose ID – 50, Length - 5m
54 B039005 Flexible Hose ID – 25, Length - 5m
55 EL02006 Controller (ON/OFF) for Temp.
56 B001004 Elbow ½’’ BSP
57 UTP-322 Connector ½’’ BSP X (M18x1.5)
58 UTP-322/04 Adaptor 3/8" (M) X (M18x1.5)
59 B002004 Hex Nipple ½’’ BSP
60 UTP-265/05 Hex Nipple 3/8" X ½’’ BSP
61 EL12001 Booster Pump (300 LPM)
62 EL12008 Booster Pump (510 LPM)
63 EL12013 Booster Pump (318 LPM)
64 EL12023 Booster Pump (618 LPM)
65 EL12009 Booster Pump (510 LPM)
66
67
68

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

32. PRESSURE SWITCH & PRESSURE GAUGES:

S.NO. PART NO. DESCRIPTION QTY. UoM

1 EL01021 PRESSURE SWITCH FOR OIL & WATER(-2 to 7.5 Bar) 02 Nos.
2 1030504 PRESSURE GAUGE (0-10 BAR) 01 Nos.
3 1030552.01 PRESSURE GAUGE (0-20 BAR) 01 Nos.

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UT PUMPS & SYSTEMS PVT. LTD. Assembly & Working Instructions for
High Pressure Pumps

33. TOOL KIT PART LISTS (DRG. No. - 5031186)

S.NO. PART NO. DESCRIPTION QTY. UoM
1 1010015 Assy. + Removal Tool 01 Nos.
2 5030707 Puller Assy. 01 Nos.
3 1030008 Puller for unloader seat 01 Nos.
4 1130100 Socket 22mm 01 Nos.
5 1130099 Rachet handle size 10” 01 Nos.
6 1130092 D/E spanner 36/41 01 Nos.
7 1130093 D/E spanner 24/27 01 Nos.
8 1130094 D/E spanner 17/19 01 Nos.
9 1130095 D/E spanner 46/50 01 Nos.
10 1130096 D/E spanner 10/11 01 Nos.
11 1130191 D/E spanner 30/32 01 Nos.
12 1130259 D/E spanner 8/9 01 Nos.
13 1130098 Allen key 03mm 01 Nos.
14 1130097 Allen key 05mm 01 Nos.
15 UTP-238/03 Allen key 12mm 01 Nos.
16 1130133 Allen key 14mm 01 Nos.
17 5030987 Tool Box 01 Nos.
18 1030107 Mandrill for Oil seat 01 Nos.
19 5031185 Seat removal tool assly. 01 Nos.

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