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Hydro Pump does not Reciprocate      
Probable Cause
Solution
Digital Over Pressure Protection System Not Powered on Power On the Digital Over Pressure Protection System
Relevant Test Option from Digital Over Pressure Protection System Not Selected Select the Relevant Test Option (Water) in the Digital Over Pressure Protection System
Insufficient / Unavailable Dive Air Check Drive Air Isolation Valve. Open the valve if it is closed.

Check the Drive Air Supply, ensure the available pressure is between 7 to 10 bar
Hydro Pump Air shuttle valve is sticking. Remove and clean air valve and housing assembly and its shuttle valve components.

Adjust air lubricator.
Connecting rod is improperly adjusted or bent (may occur after pump overhaul). Readjust rod and nut. Refer the Hydro Pump Manual.

Straighten or replace rod.
Hydro Pump Spring in shuttle valve is broken. Replace spring.
Hydro Pump Reciprocates but does not deliver Fluid      
Probable Cause
Solution
Fluid supply is low. Add fluid as required.
Fluid supply line to pump inlet check valve is clogged. Remove and clean line. Check reservoir, its inlet filter and outlet for accumulation of foreign matter. Clean as required.
Foreign matter is lodged in pump inlet and outlet check valves. Remove and clean check valves. Replace o- rings  on poppets
Hydro Pump Reciprocates but does not deliver / hold Pressure      
Probable Cause
Solution
Drain or Depressurizing Valve is Open Ensure that the drain / depressurizing valve is closed tightly and does not leak.
Leakage or blockage at inlet or outlet Check Valve of the Hydro Pump Remove and clean the Hydro Pump Check Valves. Look for foreign matter logged in sealing areas.
Replace damaged or worn o-rings
High Pressure Seals of The Hydro Pump damaged Replace High Pressure Seals. Refer Hydro Pump Manual.
Low Pressure seals of the Hydro Pump damaged Replace Low Pressure Seals. Refer Hydro Pump Manual.
Water / Hydraulic Fluid in Exhaust Air Muffler      
Probable Cause
Solution
Excessively wet Drive Air. Drain water from Drive Air Line.
Damaged Seals in Pump Fluid Body. Replace Fluid Body Seals. Refer Hydro Pump Manual.
Pump Fluid Piston Scored. Inspect Fluid Piston for score marks; polish repair or replace fluid piston. Hydro Pump Manual.
Gas Air Booster does not Reciprocate      
Probable Cause
Solution
Digital Over Pressure Protection System Not Powered on Power On the Digital Over Pressure Protection System
Relevant Test Option from Digital Over Pressure Protection System Not Selected Select the Relevant Test Option (Air) in the Digital Over Pressure Protection System
Insufficient / Unavailable Dive Air Check Drive Air Isolation Valve. Open the valve if it is closed.

Check the Drive Air Supply, ensure the available pressure is between 7 to 20 bar.
Blockage in the drive Air Filter Check and clean air filter.
Gas Air Booster Air shuttle valve is sticking. Remove and clean air valve and housing assembly and its shuttle valve
components.

Replace shuttle assembly if required.
Connecting rod is improperly adjusted or bent (may occur after pump overhaul). Readjust rod and nut. Refer the Gas Booster Manual.

Straighten or replace rod.
Gas Air Booster Reciprocates but does not deliver / hold Pressure      
Probable Cause
Solution
Insufficient / Unavailable Pre-Charged Air Check pre-charge pressure, replace source if necessary, or Turn on supply. Insufficient supply gas filtration is a leading cause of seal and check valve failure.

Check the cleanliness of pre-charge poppet seat.
Drain or Depressurizing Valve is Open Ensure that the drain / depressurizing valve is closed tightly and does not leak.
Leakage or blockage at inlet or outlet Check Valve of the Gas Booster Remove and clean the Gas Booster Check Valves. Look for foreign matter logged in sealing areas.

Replace damaged or worn o-rings.
High Pressure Seals of The Gas Booster damaged Replace High Pressure Seals. Refer Gas Booster Manual.
Low Pressure seals of the Gas Booster damaged Replace Low Pressure Seals. Refer Gas Booster Manual.
System does not Hold Pressure      
Probable Cause
Solution
Drain or Depressurizing Valve is Open Ensure that the drain / depressurizing valve is closed tightly and does not leak.
Accumulator relief Valves are open / are leaking. Check Accumulator Relief valves. Increase setting if valves open pre-maturely.

Dismantle & polish valve disc & nozzles if valves are leaking.

Replace Valves if necessary.
One or more Isolation Valves are leaking Close all Isolation Valves tightly so as to allow 0 leakage. 

Repair / Replace leaking valves.
One or more System fittings are leaking Check all system fittings for leakage. Tighten if necessary.
Auto Clamping Piston Seals are damaged or worn out. Remove & check Auto clamping piston seals. Replace I damaged or worn-out
Auto Clamping Cylinder is Scored Check Auto Clamping Cylinder for score Marks, Polish if necessary.
 
 
 
 
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