CAR WASHER -

TRIPLE PLUNGER PUMP

MODEL: HL 03 045
TPL NO: S11015 & S11017

SERVICE & SPARE PARTS MANUAL

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ATS ELGI LIMITED

Coimbatore - 641 021, India

Printing Status

R00 - Jan - 2013

Contact info:

ATS ELGI LIMITED

Kurichy, Coimbatore - 641 021, India

Phone : +91 - 422 - 2589999

Fax : +91 - 422 - 2589800

E-mail : [email protected]

Toll Free : 1800 - 425 - 3544

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 CONTENTS

S.No Description Page no

1. General assembly 4

2. Sub assembly 5

3. General spare parts list 9

4. Scope of supply 15

5 Customer scope 16

6. Technical data 16

7. Service instruction 17

8. Preventive maintenance schedule 21

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1. GENERAL ASSEMBLY

Sl.No. DESCRIPTION Qty. PART No.

1 CRANK CASE ASSY 1 110359790
2 MANIFOLD ASSY 1 110359780
3 VALVE ASSY 6 110461690
3 VALVE ASSY 6 110461690
4 PLATE WASHER M8 8 000997008
5 M22 X 1.5 PLUG 6 110459260
6 O RING - M22 PLUG 6 110459370
7 ALLEN BOLT M8 X 70 8 000976092
8 FLEXIBLE COUPLING 1 110460220

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2. SUB ASSEMBLY
2.1 CRANKCASE SUB ASSEMBLY

Sl.No. DESCRIPTION Qty. PART No.

1 CRANKCASE 1 110357850
2 BUSH PAP 18 20 P10 3 110459330
3 OIL SEAL A P A 18 30 7 3 110459550
4 CONNECTING ROD ASSY 3 110461680
5 O RING - PISTON GUIDE 3 110459340
6 SEAL RING PLUNGER 3 110459150

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7 CRANKSHAFT 1 110357860
8 TAPER ROLLER BEARING 2 000903103
9 SIDE COVER 1 110357820
10 O RING - SIDE COVER 2 110459380
11 OIL SEAL A P A 25 52 7 1 110459560
12 KEY 8x7x25 1 120453200
13 SPRING WASHER M8 12 000997108
14 BOLT HEX. M8 X 30 2 000916117
15 SEPERATING WASHER 3 110459320
16 PLUNGER CERAMIC 3 110459120
17 COPPER WASHER PLAIN - M8 3 000995058
18 LOCK NUT - M8 3 000958058
19 GASKET BACK COVER 1 110459270
20 BACK COVER 1 110357880
21 OIL LEVEL INDICATOR 1 110460240
22 GRAPHITE RING 1 110460270
23 ALLEN SCREW M8X20 12 000983083
24 BREATHER PLUG 1 110460230
25 3 HP MOTOR FLANGE - FACE MOUNT 1 110459820
26 1/4” PLUG 1 150480370

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2.2 CONNECTING ROD ASSEMBLY

Sl.No. DESCRIPTION Qty. PART No.

1 CONNECTING ROD 1 110459190
2 PISTON GUIDE 1 112400020
3 PIN CONNECTING ROD 1 110459170

2.3 MANIFOLD ASSEMBLY

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 Sl.No. DESCRIPTION Qty. PART No.
1 MANIFOLD-ANODISING 1 110359410
2 SEAL KIT 3 110459420
3 BOTTOM BRASS RING 3 110459170
4 O RING - BOTTOM BRASS RING 3 110459350
5 LOW PRESSURE - NBR SEAL 3 110459180
6 UPPER BRASS RING 3 110459160
7 3/8” PLUG 1 110426520
8 WASHER COPPER 3/8” 1 130526120
9 1/2” PLUG 1 110510330
10 WASHER COPPER 1/2 “ 1 130525620

2.4 VALVE SPARE KIT (CODE: X110043)

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3. GENERAL SPARE PARTS LIST

S.NO PART NO DESCRIPTION Q T Y / REPRESENTATION

PUMP

1 110357820 SIDE COVER 1

2 110359410 MANIFOLD 1

3 X110048 CRANK CASE ASSY 1

4 110357860 CRANK SHAFT 1

5 110357880 BACK COVER 1

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6 110459120 PLUNGER CERAMIC 3

7 110459150 SEAL RING PLUNGER 3

8 110459160 UPPER BRASS RING 3

9 110459170 BOTTOM BRASS RING 3

CONNECTING ROD
10 X110051 3
ASSY

11 X110043 VALVE KIT SPARE 6

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12 110459260 M22 X 1.5 PLUG 6

13 110400019 BACK COVER GASKET 1

14 110459320 SEPERATING WASHER 3

15 110459550 OIL SEAL A P A 18 30 7 3

O RING - PISTON
16 110459340 3
GUIDE

17 110459370 O RING - M22 PLUG 6

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18 110459380 O RING - SIDE COVER 2

19 112400020 SEAL SPARE KIT 1

20 110459560 OIL SEAL A P A 25 52 7 1

OIL LEVEL INDICATOR

21 110460240 1
¼

22 150480370 PLUG 1/4” BSP 1

23 120453200 KEY 8x7x25 1

24 110460230 BREATHER PLUG 3/8 1

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25 000903103 BEARING 30205 2

26 110459820 MOTOR FLANGE 1

27 110459580 3HP MOTOR 1

28 110357790 HOSE ASSY 6MTRS 1

29 110460720 TRIGGER GUN 1

30 110460710 NOZZLE 1

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31 110460000 UNLOADER VALVE 1

FLEXIBLE COUPLING
32 110460220 1
D24-28

33 110457370 STD GUN 1 STD GUN

34 110461340 PRESSURE REGULATOR 1

35 110461510 4 WAY CROSS 1

36 110461660 GAUGE CONNECTOR 1

37 110423770 TEE WITH FILTER 1

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 MANIFOLD SEAL
38 M000009380 1
REMOVING TOOL

CRANKCASE SEAL
39 M000009216 1
REMOVING TOOL

WATER SEAL
40 M000009381 1
REMOVING TOOL

4. SCOPE OF SUPPLY-S11015

SNO ITEM QTY

1 Triple Plunger Pump Unit 1
2 Motor With Coupling 1
3 Hose (Length 6 M) 1
4 Base Frame 1
5 Unloader Valve (110460000) 1
6 Trigger Gun (110460720) 1
7 Suction Pipe With Filter Assembly 1
8 Motor Mounting Flange 1

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4.1 SCOPE OF SUPPLY-S11017

SNO ITEM QTY

1 Triple Plunger Pump Unit 1
2 Motor With Coupling 1
3 Hose (Length 6 M) 1
4 Base Frame 1
5 Pressure regulator valve (110461340) 1
6 Gun Assembly (110457370) 1
7 Suction Pipe With Filter Assembly 1
8 Motor Mounting Flange 1

5. CUSTOMER SCOPE

S.No. Description Qty.

1 3 Φ DOL STARTER 1 Nos.
2 PLUMBING LINES ---
3 SAE 30 (or) Equivalent Oil 500 ml

6. TECHNICAL DATA

No. Description Unit Data

1 Model - HL 03 045
2 Type Reciprocating
3 No. of plungers No. 3
4 Speed rpm 1440
5 Displacement lpm 18± 3%
6 Max. Working Pressure kgf/cm2 45± 3%
7 Crankcase oil capacity ml. 500± 25

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8 Oil grade SAE 30 or equivalent
9 Type of arrangement Horizontal
10 Water Inlet Size 1/2” BSP
11 Outlet Size 3/8” BSP
12 Type of drive Direct coupling
13 Direction of rotation Bidirection
14 Type of mounting Horizondal
15 Delivery hose No. 1
a) Type SAE 100 R1 AT
b) Length mm 6000
16 Gun
a) No. of guns No. 1
b) Nozzle type Adjustable spray / jet
17 Motor Details
a) Type TEFC
b) Voltage V 415
c) Phase Ph 3
d) Frequency Hz 50 approx
e) Class of insulation B
f) Power HP 3
g) Speed rpm 1440
18 Overall dimensions L x B x H mm 860 x 300 x 300
19 Net. weight kg 50 approx
20 TPL Number (Unloader valve Model) S11015
21 TPL Number (Safety valve Model) S11017

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7. ATS Plunger Pump Service Instruction
7.1 Replacing pump valves

1. All inlet and discharge valves can be serviced without disturbing the
inlet or discharge plumbing

2. To service the valves, remove valve caps.

3. Remove the valve assembly from the valve cavity.

4. Remove o-ring from valve cavity.

5. Replace the new valve assembly into valve cavity.

6. Install valve cap and ensure torque as per the Torque specifications.

7. NOTE: Use Loctite 243 thread locker or equivalent for all valve caps.

7.2 Replacing ceramic plunger

1. Separate the manifold from crank case by loosening the manifold bolts

2. It may be necessary to hammer the manifold lightly with a plastic or

rubber mallet to loosen.

CAUTION: Do not damage plungers when removing the manifold.

3. After removing the manifold. Inspect ceramic plungers. Plunger

surfaces should be smooth and free from scoring and cracks. IF NOT,
replace plunger.

4. Follow below steps if you are replacing the ceramic plunger

5. Remove plunger nut, then remove plunger from the piston Guide.

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6. Install new o-ring, Seal ring Plunger on Piston guide

7. NOTE: Grease should be applied on the o ring surface

8. Insert the ceramic plunger into the piston guide followed by nut.

9. NOTE: Use Loctite 270 threads locker or equivalent on all plunger

nuts or Manifold bolts.

7.3 Replacing seal kit

1. Follow the 1st and 2nd steps in 7.2, remove the manifold.

2. Remove the Bottom brass ring by using seal removal tool. (Ref Fig.1)

CAUTION: Do not use any other tools like screw driver to remove
bottom brass ring. Otherwise warranty voids.

Fig .1

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3. Remove the worn out seal(low pressure seal & high pressure seal)
using special tool from the manifold

4. Press the new high pressure seal(3 piece) into the manifold

5. Insert upper brass ring.

6. Install o ring into the bottom brass ring followed by low pressure seal.

7. Apply grease on the o ring surface and press the bottom brass ring
into the manifold

8. Assemble the manifold assembly in to the crankcase by locating

three plungers

9. NOTE: It may be necessary to tap manifold lightly with a plastic or

rubber mallet. Tighten the bolts as the torque specifications.

7.4 Torque specification

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 TORQUE
POS. DESCRIPTION
N.m lbf.ft Thread Lock
1 Head Bolts 25 19 -
2 Valve Caps 50 38 Loctite 243
3 Inlet Cap 50 38
Loctite 270
4 Outlet Cap 35 26
5 Bearing Flange Bolts 25 19 -
6 Rear Cover Bolts 11 9 -
7 Plunger Bolts 15 11 -

8. PREVENTIVE MAINTENANCE SCHEDULE

Check Daily Weekly 50 Hrs 500 Hrs 1500 Hrs 3000 Hrs
Clean Filters 

Oil Level/Quality 

Oil Leaks 

Water Leaks 

Plumbing 

Initial Oil Change 

Oil Change 

Seal Change 

Accessories 

Valve Change 

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