High Pressure

Airpump
Maintenance Manual

©New Concept Mining 2013 Document: MM5E

Issued: 11/04/2013
Rev: 1
Warning: Please carefully read and understand all safety instructions before
attempting to operate this machine. Failure to follow the exact instructions may
result in serious personal injury.

• Always keep your workbench clean.

• Avoid dangerous working environments.
• Do not operate equipment or perform maintenance on equipment under the influence
of drugs, alcohol or medicine.
• Keep all visitors to your working area at a safe distance. Visitors to wear the
appropriate PPE.
• Use only original New Concept Mining spare parts. Failure to do this may result in
serious damage to the pump, pistol and other equipment or injury to the operator, and
will affect the manufacturer’s guarantee.
• Never attempt to repair the High Pressure Airpump (HAP) whilst in operation.
• Ensure that the HAP and accessories comply with the local health and safety
regulations and any other law governing your specific area of industry and operation.
• Do not exceed the rated capacity of any component.
• Do not transform or alter the HAP, its components, optional equipment or accessories
without prior New Concept Mining authorization. Non-authorized alterations will
result in lapse of the guarantee, serious damage to the equipment making it unsafe or
affecting the performance of the pump.
• For any further information regarding training and operation, please contact your local
New Concept Mining agent.

Make sure you wear the required personal protective equipment.

NOTE: If all appropriate procedures have not been followed, THE MANUFACTURER
SHALL NOT ACCEPT GUARANTEE CLAIMS. Likewise, if original New Concept
Mining spares are not used for the repairs and maintenance of the equipment,
THE MANUFACTURER SHALL NOT ACCEPT GUARANTEE CLAIMS.

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Issued: 11/04/2013
Rev: 1
 High Pressure Air Pump – Maintenance Manual

Table of Contents

1. Introduction and General Information 2

2. Standard guarantee 2

3. Disclaimer 2

4. Document revision 2

5. Part Lists and Diagrams 2

6. Description 6

7. Maintenance procedures 6
a. Disassembling 6
b. Assembling 17

8. Testing the High Pressure Airpump 31

9. Technical specifications 31

10. Troubleshooting 32

11. Abbreviations 33

12. Notes 33

NOTE: We are continuously updating our manuals in order to supply our clients with the best technical
information available. Parts of this manual may contain information not corresponding with the current
configuration of New Concept Mining products. Please contact your local New Concept Mining representative
for the latest information on our products innovations and new updated versions of our manuals.

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 High Pressure Air Pump – Maintenance Manual

1. Introduction and General Information

The purpose of this Manual is to provide the Maintenance Technician with detailed information, which will
help him to obtain the best performance of the HAP. The following Parts List and Diagrams will facilitate the
process of placing orders for parts required and in servicing the HAP.

In order to obtain the best performance and longest life of the product, the pump must be serviced periodically
and operated in accordance with the instructions.

Make sure to wear the appropriate personal protective equipment when performing maintenance work.

Carefully read this Manual before attempting to repair the HAP and keep it at hand as reference while attending
to any repair problem.

2. Standard Guarantee
New Concept Mining does not guarantee that the products here represented are for sale or that such products
are appropriate for any particular purpose, and there are no explicit or implicit guarantees made by New
Concept Mining except the following standard guarantee.

New Concept Mining guarantees that the material and manufacturing of each product and accessory is sold
defect free. The guarantee covers the normal use and service of the product for 90 days from the first day of
use, but not exceeding 6 months after shipping the product from the New Concept Mining factory.

This guarantee is limited to the replacement or repair work conducted in our workshops in Johannesburg,
South Africa, or in a designated workshop nominated and approved by the company, of such parts marked
as faulty, being the material or workmanship, by the inspector at purchase, subjected to the condition that the
faulty part or parts are returned to the place of inspection.

This guarantee is only applicable to new or unused products and accessories, which have not been altered,
transformed, tampered with or in any way repaired, after shipping from the manufacturing plant of New
Concept Mining.

3. Disclaimer
The purchasing party agrees that under no circumstance, will New Concept Mining be held responsible for
any cost increases, loss of profit, loss of clients or any other damage/defect, resulting directly, indirectly,
unexpectedly or consequentially.

4. Document Revision
As we are always improving and revising our products and documentation this document will change at any
time without notice.

Although we would like to ensure that all our customers have up to date documentation, it is not always
practical and possible to get this right, and therefore it is the responsibility of the user of this document to
ensure that he/she has the latest revision of this document at all times, especially before making use of it.
Please contact your local NCM agent to find out if any new revisions of this document have come out.

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 FOR DETAILED VIEW
SEE PAGE 5
11

12

3
3

10B

Parts List
10
ITEM DESCRIPTION QTY DRAWING NO STOCK CODE
10A 1 Filter Phantom Assembly 1 AP GA0007 APFILLAS
High Pressure Air Pump – Maintenance Manual

2 Actuator Phantom Assembly 1 HAP GA0006 HAPACTASS

3 Cylinder Phantom Assembly 1 HAP GA0002 HAPCYLASS
5. Parts List and Diagrams

8 4 1" BSP Socket Cap 2 1" BSP red plastic plug AP1PP
5 1" BSP Socket 2 1" Socket AP1SOC
6 6 Strap Bracket Screws 2 M8X16 Capscrews HP8X16
7 7 Airpump Strap 1 AP C0046 APSTRAP
8 Plastic Rear Housing 1 HAP C0008 HAPRHOU
5
9 Plastic Front Housing 1 HAP C0007 HAPFHOU
10 Mounting Plate Screws 3 M6X12 Capscrews AP6X12

Rev:
4
10A Mounting Plate Washers 3 M6X1.5mm Washers AP6FW

Issued:
10B Mounting Plate Nyloc Nuts 3 M6 Nylock Nuts M6NY
11 Water line/Air line 1 AP C0001 AP10TU

1
12 Clamp Ring 1 AP C0048 APCRING

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PART LISTS AND DIAGRAMS
 PART LISTS AND DIAGRAMS

17
10
16
9A
9
15
8
14

7 13

12

4
11
18

Parts List
ITEM DESCRIPTION QTY DRAWING NO STOCK CODE
1 Push Fitting 1 AP C0003 AP1410S
2 Flip Flop Cap 1 AP C0027 APFFCAP
3 Flip Flop Cap 'O' Ring 1 Ø22x2 sect.(90 Shore) APFFCO
5 Flip Flop Inlet Seal 1 AP C0029 APFFIS
6 Actuator Rear Housing Assembly 1 AP GA0021 APARH
7 Flip Flop Valve Gasket 1 AP C0030 APFFVG
High Pressure Air Pump – Maintenance Manual

8 Flip Flop Body 1 AP C0026 APFFBOD

9 Flip Flop Valve Washers 3 M6 Washer AP6FW
6
9A Flip Flop Valve Screws 3 M6 x 16 Capscrews AP6X16
9B Flip Flop Valve Nyloc Nuts 3 M6 Nyloc Nuts M6NY
10 Flip Flop Phantom Assembly 1 AP GA0010 APFFASS
9B
19 11 Actuator Housing Clamp 1 As Purchased APACLP
12 Diaphragm 1 AP C0015 APDIA
20
13 Diaphragm Plate 1 AP C0017 APDPLT

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5
14 Exhaust Closed Spring 1 AP C0019 APECSPR

Issued:
4
3 15 Piston 1 HAP C0002 HAPPIST
16 Diaphragm Spring 1 AP C0018 APDSPR

1
2
17 Actuator Front Housing Assembly 1 AP GA0022 APAFH
1
18 Brake Housing Bolt Assembly 1 As Purchased APABOLT

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19 Sintered Silencer 1 AP C0054 APSSILENCER

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20 Silencer Seal 1 AP C0053 APSSEAL
 8
10
11

13
4

14

7
17

3 7

12

2
14

16

5
1
15

6 Parts List
ITEM DESCRIPTION QTY DRAWING NO STOCK CODE
5
1 Guide Bush Nut 1 AP C0009 APBNUT
2 Guide Bush 1 HAP C0003 HAPGBUSH
3 Guide Bush Seal Kit 1 HAP C0010 HAPSKIT
4 Cylinder 2 HAP C0001 HAPCYL
5 Push On Fitting 1 AP C0002 AP1410E
6 Check Valve Inlet 1 AP C0012 APCVINL
High Pressure Air Pump – Maintenance Manual

7 Check Valve Ball 2 Ø10 S/Steel Ball HPBALL

8 Check Valve Spring 1 HP C0013 HPIDSPR
9 Check Valve Body 1 AP C0011 APCVBOD
10 Check Valve 'O' Ring 1 Ø9.25x1.78 sect. ( 90 Shore) HPBO
11 Check Valve Insert 1 AP C0013 APCVINS
12 Dowety Washer 1 1/2" Dowety Washer AP12DOW
13 Staple Lock Fitting 1 M C0008 NC8FEM38
14 Dowety Washer 2 3/8" Dowety Washer HP38DOW

Rev:
15 Inlet Check Valve Spring 1 AP C0050 APCVSPR

Issued:
16 Cylinder Attachment 1 HAP C0005 HAPCATT
17 Seal Retainer Assembly 1 HAP GA0011 HAPSRET

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PART LISTS AND DIAGRAMS
 High Pressure Air Pump – Maintenance Manual

6. Description
The High Pressure Airpump is basically a water intensifier device. It uses a diaphragm to pump high-pressure water, so
it does not require lubrication. The pump has a strap and a handle for easy transportation and is sufficiently sturdy to
withstand damage.

An NCM Safety Pistol MUST be used with the HAP.

7. Routine Maintenance
It is essential to routinely examine and disassemble the pump to ensure its good operation and optimum life span of the
components. We recommend that frequently used pumps be subjected to scheduled checks, at least every 90 days and
all details be carefully recorded.

Maintenance of every pump follows the same pattern, that is, cleaning of the exterior, disassembling, thorough cleaning
of the parts, inspection, replacement of the necessary parts, reassembling and testing.

a. Disassembling
Requirements:

• Housing press
• APBNUT spanner
• 17-19mm Split ring spanner
• 10mm spanner
• 375mm/15" shifting spanner
• 250mm/10" shifting spanner
• Ring/flat spanners (R/F-Spanner) No. 11, 14, 16, 17, 19, 24, 30 and 32.
• Pneumatic impact wrench
• No. 24 socket
DISASSEMBLY

• No. 14 socket
• Screwdriver 10mm x 300mm
• Screwdriver 4.5mm x 10mm
• Hammer
• 4 pound hammer
• Rubber mallet
• Allen Key No. 5
• Allen Key No. 6
• Bronze rod – 14mm diameter x 200mm long
• Support blocks (TK SJ)
• Long nose pliers
• Punch
• Flip flop valve holding tool
• Teflon thread tape
• Lubricant 1: Copper Slip
• Lubricant 2: AGIP - GR MU EP 2 - Multipurpose Grease - Lithium base with EP properties - NLGI2
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DISASSEMBLY
Always ensure you wear the prescribed personal protective equipment such as gloves, safety goggles,
earplugs and safety shoes during maintenance or repair work to the pump.
Please refer to Parts Lists and Diagrams for detail on stock codes.

1. Clean the pump’s exterior surface 2. Place a staple lock fitting (NW6STAPLE) in the hydraulic hose connector,
and place the pump vertically in then loosen it using the 375mm/15" shifting spanner.
the bench vise.

3. Remove the front housing (HAPFHOU). 4. Turn the pump around in the bench vise, and using the
No. 6 Allen key, loosen the two strap bracket screws
(HP8X16).

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5. If necessary, gently tap the rear housing (HAPRHOU) with a hammer to loosen it, and then remove the rear housing.

6. Turn the pump around in the bench vise again. 7. Loosen the securing nuts on all of the HPWTUBE and

AIRTUBE using a No.17mm split ring / ring open-end spanner.

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DISASSEMBLY
8. Remove the water line (HPWTUBE) as shown.

9. Remove the air line (AIRTUBE) as shown. 10. Use a screwdriver to pull up and remove the two filters
(APBAG).

11. With the No.5 Allen Key and No.10mm spanner loosen the mounting plate screws (AP6X12), and remove
the filter phantom assembly (APFILASS).

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12. Remove the silencer seal (APSSEAL). 13. Remove the sintered silencer (APSSILENCER).

14. Using a No.24mm spanner loosen the flip flop cap 15. Remove the flip flop cap (APFFCAP) and flip flop
(APFFCAP). cap ‘O’ ring (APFFCO).

16. Using the 10mm x 300mm screwdriver loosen and remove the poppet screw (APFFIP).

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DISASSEMBLY
17. Using a No.14mm and No.15mm spanner loosen the 18. Place the airpump actuator assembly in the
brake housing bolt assembly (APABOLT). special airpump press tool and lock in place.

19. Remove the brake housing bolt assembly (APABOLT). 20. Open and remove the actuator housing clamp
(APACLP).

21. Remove the airpump actuator assembly from the 22. Separate the actuator rear housing assembly
special airpump press tool. (APARH) from the actuator front hosing assembly
(APAFH).

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23. Proceed to dismantle the actuator as shown.

24. Place the cylinder assembly in the bench vise and using a APBNUT spanner loosen the guide bush nut (APBNUT).
Now remove the actuator front hosing assembly (APAFH).

25. Remove the piston guide bush (HAPGBUSH). 26. Using a No.14mm spanner loosen and remove the 90º
fitting (AP1410E).

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DISASSEMBLY
27. With No.24mm and No.30mm spanners remove the check valve inlet (APCVINL), dowety washer (AP12DOW),
ball (HPBALL) and spring (APCVSPR).

28. Remove the HAP cylinder attachment (HAPCATT) and the dowety washer (AP38DOW) using the No.30mm
spanner.

29. Using a No.24mm spanner loosen the check valve 30. Remove the check valve body (APCVBOD).
body (APCVBOD).

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30. Remove the check valve spring (HPIDSPR), the check valve ball (HPBALL) and check valve insert (APCVINS).

31. Secure the piston in the bench vise using the support 32. Using a No.32mm spanner loosen the flip flop
blocks (TK SJ). phantom assembly (APFFASS) from the piston
(HAPPIST), diaphragm (APDIA) and the diaphragm
plate (APDPLT).

33. Remove the flip flop phantom assembly (APFFASS). 34. Remove the diaphragm (APDIA) and the diaphragm
plate (APDPLT) from the piston (HAPPIST).

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DISASSEMBLY
35. Remove the spring (APECSPR) from the interior of the 36. Insert the a bronze aluminium rod into the cylinder
piston (HAPPIST).

(HAPCYL) and push until the entire HAP seal retainer 37. Remove the ‘O’ ring from the seal retainer.
(HAPSRET) and guide bush (HAPGBUSH) are out.

38. Remove the flat back-up ring from the seal retainer. 39. Split the seal retainer (HAPSRET) into two parts.

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40. Using the small screwdriver or similar tool remove the 41. Using the small screwdriver or similar tool remove
rod glyder seal and ‘O’ ring from the one part of the the turcite wear strip from the other side of the seal
seal retainer. retainer.

42. Using the small screwdriver remove the excluder wiper and its ‘O’ ring from the piston guide bush.

43. Remove the turcite wear strip from the piston guide bush.

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b. Assembling
Before starting the assembling work:

Ensure all components are thoroughly washed in

solvent and air dried or wiped dry with a clean cloth.
Inspect all components and replace all worn and
damaged components before re-assembling the
HAP. Ask your local NCM agent for suggested repair
kits. Carefully re-assemble the HAP, do not push or
force the components in place. Ensure all rotating or
sliding components are properly aligned.

1. Take the guide bush (HAPGBUSH) and using the long

nose pliers, fit the big turcite wear strip into the far

inner groove, insert the excluder wiper ‘O’ ring into the near inner groove and then fit the excluder wiper over the
excluder wiper ‘O’ ring. Only use brand new genuine NCM spares.

ASSEMBLY

2. Do the same with the seal retainer (HAPSRET). Using the long nose pliers fit the small turcite wear strip into
the internal shallow groove.

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3. Then insert the required ‘O’ ring and Rod Glyder Seal into the open recess of the one part of the seal retainer.

4. Push the two halves of the seal retainer (HAPSRET) 5. Place the required ‘O’ ring onto the seal retainer.
together as shown.
ASSEMBLY

6. Place the square backup ring onto the seal retainer. 7 Ensure the ‘O’ ring is kept on the rod glyder seal side
and the square backup ring is on the turcite wear strip
side of the seal retainer. Only use brand new genuine
NCM spares.
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8. Apply lubricant 2 to the inside and outside of the seal retainer (HAPSRET).

9. Apply lubricant 2 to the inside and outside of the piston guide bush (HAPGBUSH).

ASSEMBLY

10. Insert the seal retainer (HAPSRET), turcite wear strip side and backup ring side facing upwards as indicated,
into the cylinder (HAPCYL). Use a rubber mallet to tap in place.

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11. Now insert the piston guide bush (HAPGBUSH) into the (HAPCYL). Ensure that the seals end of the HAPGBUSH is
facing upwards.

12. Get these parts shown above ready for assembly. 13. Fit the new dowety washer (AP38DOW) on the cylinder
attachment (HAPCATT), apply threadlock 3247 to the
thread of the cylinder attachment.
ASSEMBLY

14. Tighten the cylinder attachment (HAPCATT), onto the cylinder (HAPCYL) using a No.30mm spanner.
Torque setting 70Nm – maximum 100Nm.

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15. Fit the spring (APCVSPR) inside the cylinder 16. Fit the check valve ball (HPBALL) inside the cylinder
attachment (HAPCATT). attachment (HAPCATT). Always use a new spring and

ball from the repair kit. 17. Fit a new dowety washer (AP12DOW) on the check
valve inlet (APCVINL), apply threadlock 3247 to its
thread.

ASSEMBLY

18. Screw the check valve inlet (APCVINL) into the cylinder attachment (HAPCATT) and tighten with a No.24mm
spanner.

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19. Get these parts shown above ready for assembly. 20. Insert the new check valve ‘O’ ring (HPBO) into the
check valve insert (APCVINS).

21. Fit the check valve insert (APCVINS), the check valve ball (HPBALL) and the check valve spring (HPIDSPR) inside the
cylinder.
ASSEMBLY

22. Screw the check valve body (APCVBOD) into place in the cylinder (HAPCYL) and tighten with a No.24mm spanner.
Should there be a water leak between the body and the cylinder when testing the pump, apply white teflon tape to
the body’s thread.

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23. Fit the flip flop gasket (APFFVG) over the flip flop body 24. Push the flip flop body (APFFBOD) through the
(APFFBOD). actuator rear housing assembly as shown.

25 Align the holes in the flip flop body, the flip flop gasket 26 Screw flip flop valve nyloc nuts (N6NY) on to the flip
and the actuator rear housing assembly. Insert the flip flop valve screws (AP6X16).
flop valve screws (AP6X16) with washers (AP6FW).

ASSEMBLY

27 Tighten the flip flop valve screws with a No.10mm spanner and a No.6 allen key.

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28. Place the diaphragm plate (APDPLT) on the diaphragm (APDIA) and push the flip flop phantom assembly
(APFFASS) through as shown.

29. Insert the exhaust closed spring (APECSPR) into the 30. Apply threadlock 3247 to the APFFASS.
piston (HAPPIST). A new spring must be used from the
repair kit.
ASSEMBLY

31. Screw the flip flop phantom assembly (APFFASS) into 32. Secure the piston in the bench vise using the support
the piston (HAPPIST). blocks (TK SJ).

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33. Using a No.32mm spanner tighten the piston retainer 34. Fit the actuator rear housing assembly to the flip
(APPRET). flop phantom/diaphragm/piston assembly as shown
above.

35. Apply threadlock 3247 to the thread of the flip flop inlet poppet (APFFIP), screw it into the APFFASS and

ASSEMBLY

tighten with the 10mm x 300mm screwdriver. 36. Fit the airpump cylinder assembly to the
actuator front housing assembly.

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37. Fit the guide bush nut (APBNUT) to the airpump cylinder assembly and tighten using a APBNUT spanner.

38. Place the diaphragm spring (APDSPR) over the piston and join the two sides of the actuator housing.
ASSEMBLY

39. Place the airpump actuator assembly in the special airpump press tool and lock in place.
IMPORTANT: NOTE THE CORRECT ALIGNMENT OF THE ACTUATOR REAR HOUSING ASSEMBLY
AND THE CHECK VALVE INLET.

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40. Attach the actuator housing clamp (APACLP). Gently 41. Attach the brake housing bolt assembly (APABOLT) to
tapping it on with a hammer will ensure a snug fit. the actuator housing clamp.

42. Fit a new flip flop cap ‘O’ ring (APFFCO) to the flip flop 43. Fit the flip flop cap to the flip flop body.
cap (APFFCAP).

ASSEMBLY

44. Tighten the flip flop cap using a No.24mm spanner. 45. Fit the sintered silencer (APSSILENCER).

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46. Fit the silencer seal (APSSEAL). 47. Attach the filter phantom assembly (APFILASS) to the
actuator phantom assembly.

48. With the No. 5 Allen Key and No.10mm spanner tighten 49. Apply teflon tape around the push on fitting
the mounting plate screws (AP6X12) to the mounting (90º elbow).
plate nyloc nuts. Make sure the mounting plate washers
are on the screw side and not the nut side.
ASSEMBLY

50. Screw the push on fitting into the check valve inlet and tighten with a No.14mm spanner.

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51. Attach the HPWTUBE as shown above and tighten the securing nuts using a No.17mm ring open-end spanner
or No.17mm split ring spanner.

52. Attach the air line (AIRTUBE) as shown above and 53. Fit two new filter bags (APBAG) into the assembly and
tighten the securing nuts.

ASSEMBLY

The HAP must now be tested before

continuing the final assembly.
(See Section 8 for the complete testing
procedure and Section 10 for
Troubleshooting)

tap them in properly with a rubber mallet.

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54. Once the HAP has passed testing, fit the rear housing (HAPRHOU) over the air and water inlet pipes. Line up the
orientation slot on the name plate part of the strap (APSTRAP) with the orientation node on the rear housing and
drive the two screws (HP8X16) into position using the No. 6 Allen Key. NOTE: Strap plate and housing must match
pump water (short) and air (long) pipes.

55. Put Teflon tape around the air and water inlet threads, and screw the 56. Fit the front housing.
appropriate size hose connectors into place.
ASSEMBLY

57. Insert the clamp ring (APCRING) and the dowety washer (HP38DOW) over the hydraulic hose connector (NC8FEM38)
thread and ensure that the strap (APSTRAP) is in position. Put a staple lock fitting (NW6STAPLE) into the NC8FEM38,
and using a 375mm/15" shifting spanner, screw the NC8FEM38 into the check valve body (APCVBOD). The high
pressure Airpump is now fully assembled.

The HAP must now be finally tested as per Section 8.

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8. Testing the High Pressure Airpump (HAP)

1. Always ensure that the re-assembled pump is fully operational before it leaves the repair workshop.
2. Ensure you are wearing the proper PPE before starting testing; Overalls, goggles, earmuffs and gloves.
3. You need a test bench with water and compressed air outlets.
4. You need a calibrated pressure gauge (0 –40MPa).
5. Ensure you have a High Pressure Safety Pistol SP88 with SAFRVAL25 (preset).
6. Connect suitable hoses to the inlet and outlet of the SP using suitable staple locks.
7. Connect the outlet hose end to a suitable nozzle.
8. Connect the nozzle to a suitable calibrated gauge.
9. The SP complete with hoses and nozzle is called the “Pistol Assembly”.
10. Connect water supply to HAP inlet connection.
11. Ensure that the air pressure to be used in testing the HAP is regulated to 3.5 – 5 bar.
12. Connect air supply to the HAP inlet connection.
13. Open the water supply.
14. Open the air supply.
15. The pump should start pumping automatically. Water should squirt out of the HAP outlet. See “Section 10” of
this manual for “Troubleshooting” issues.
16. Close the air supply.
17. Close the water supply.
18. Connect the loose end of the inlet hose from the Pistol Assembly to the outlet of the HAP using a staple lock pin.
19. Operate the HAP by operating the trigger on the SP.
20. Check for leaks at all connections between the HAP, SP and Nozzle. Also check for leaks at the water
and air inlet connections. This system must be leak free otherwise the test will be inaccurate.
21. The pressure on the gauge must register a pressure of 26–28MPa and there should be no leaks coming from any
part of the HAP assembly for the unit to pass the test. The HAP must be operated a few times to be sure that
the unit is actually functioning correctly. See “Section 10” of this manual for “Troubleshooting” issues.
22. Once testing has been successfully completed close off the air and then the water supplies and thereafter
disconnect all pipes and hoses attached to the HAP used for testing.
23. If unit has already been finally assembled then the test results can be recorded against the HAP-Serial Number
and then HAP is ready for dispatching.

9. Technical Specifications
Specification Unit Low pressure pump High pressure pump
Minimum air pressure input bar 3.5 3.5
Maximum air pressure input bar 7 7
Minimum water pressure input bar 2 2
Maximum water pressure input bar 18 18
Water pressure output 33:1 80:1
Mass kg 11.24 12.01

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 High Pressure Air Pump – Maintenance Manual
Problem
• Water leakage while pump is on
• Water leakage while pump is off
• Water fails to come out during
pumping
• The pump does not reach the
appropriate pressure
• Water leakage through the water
hose connector and the pump
• Difficulty when trying to remove the
nozzle of the Hydrabolt/jack pot
after pumping
• Water leakage through the nozzle
• Pump doesn’t operate
• When connected to the Pistol
Assembly the HAP operates
without the SP being triggered
• HAP doesn’t reach pressure
• Erratic operation
10. Troubleshooting
Cause Solution
• Worn seals, gasket or ‘O’ rings • Replace them
• Damaged water line
• Damaged AP10TU
• Water and air lines incorrectly • Re-connect the hoses
connected
• Damaged AP10TU • Replace
• Insufficient water intake • Supply correct volume of water
• Check the water filter as it might be
blocked
• The intake valve does not open • Replace the valve
correctly
• Air/water line incorrectly fitted • Reconnect
• Insufficient air pressure • Supply the correct air pressure
• Pistol set incorrectly • Reset Pistol
• Damaged ‘O’ ring • Replace the ‘O’ ring
• Incorrect hose connector size • Make sure you are using the
correct size
• Connection of the leaking water • Replace the connector
hose
• The safety pistol is not releasing • Service
pressure when trigger is released
• Incorrect nozzle • Make sure you are using the
correct nozzle
• Damaged mouth piece seal • Replace the seal
• APFFIS damaged • Replace APFFIS
• Flip Flop Valve stuck • Replace Flip Flop Valve
• Actuator misaligned • Re-align housings and APDIA
• Actuator housing halves misaligned • Strip assembly, realign housings
and re-assemble
• Seals damaged in the (APGBUSH) • Replace seals
• Water leak in system • Check system
• Actuator housing halves misaligned • Strip assembly, realign housings
and re-assemble
• Exhaust “Closed” and “Open” • Swop springs around
springs swopped around
• Pistol set incorrectly • Set Pistol or service
• Flip Flop Valve tight or stuck • Replace Flip Flop Valve
• Actuator alignment • Reset alignment
Document: MM5E
32 Issued:
Rev:
11/04/2013
1
 High Pressure Air Pump – Maintenance Manual

11. Abbreviations

SP = Safety Pistol

HAP = High Pressure Airpump

AP = Airpump

NCM = New Concept Mining

12. Notes

Document: MM5E
33 Issued:
Rev:
11/04/2013
1