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SERVICE AND OPERATING MANUAL
Model SMA3-A
SLUDGEMASTER
®
PLEASE NOTE!
The photos shown in this manual are for general instruction only. YOUR SPECIFIC
MODEL MAY NOT BE SHOWN. Always refer to the parts list and exploded view drawing
for your specific model when installing, disassembling or servicing your pump.
OPERATING INSTRUCTIONS
This pump has been tested prior to shipment from factory. The oil reservoir has been
partially filled at testing with Warren Rupp Air Motor Lubricant and should be completely
filled before operation. When reservoir is full, the pump will not require refilling for
approximately 50 hours of use. (See Lubrication Instructions.)
OPERATION
Your SludgeMaster is equipped with a muffler located at side of unit. Air exhaust port
is located at top of muffler and a ¾" NPT thread is provided to extend exhaust port above
liquid being pumped. Exhaust port must be extended above liquid to prevent liquid
and foreign material from entering air motor when not in operation. This can be
done with a standard pipe, rigid plastic pipe, or hose as desired.
Connect air supply to air inlet fitting and submerge into liquid to be pumped. Unit
requires 70 CFM maximum at 80 PSI (5.51 bar) air pressure. Operation at pressures in
excess of 120 PSI (8.27 bar) is not recommended.
When handling liquid with large stones or similar solid objects, it is desirable to run unit
at full speed. This provides greater inertia for handling heavy foreign objects without
stoppage due to lodging between impeller and pump casing.
Should a foreign object lodge and prevent pump from rotating, insert a rod or bar
through hole provided at bottom of strainer into impeller vanes and bump impeller
backwards (clockwise facing strainer end) until free. Strainer can be removed when
necessary; however, this normally will not be required.
IMPORTANT
Read these instructions completely,
before installation and start-up. It is
the responsibility of the purchaser to
retain this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.
CAUTION
This unit is pressurized internally to
line pressure so never operate without
installing all of the bolting which is
originally supplied.
LUBRICATION
The only regular servicing required is maintaining oil reservoir which is just as
important on this unit for proper lubrication as the oil supply is for an engine. A one
quart capacity oil reservoir is provided for bearing and shaft seal lubrication and provides
oil for automatic air motor lubricator. Five drops of oil per minute is automatically
dispensed into air stream for continuous air motor lubrication and to prevent rust formation
due to moisture which is present in any air supply. Check and refill reservoir to oil fill plug
level regularly with WARREN RUPP AIR MOTOR LUBRICANT, STANDARD OIL OF
OHIO “INDUSTRON 44,” or an equivalent lightweight oil with rust inhibitor. The
automatic oiler will consume approximately 1 pint (473 cc) of oil in 50 hours of operation.
Oil reservoir should be completely drained and refilled after approximately 100 hours
operation to remove accumulated moisture.
It is beneficial to pour a little oil into air inlet connection and run for a few minutes before
storing for long periods.
This unit is not harmed by running without liquid.
DISASSEMBLY
Remove upper row of six bolts and lift off air motor and upper housing assembly. Filter
element and filter housing are now exposed and can be removed. Lower half of jaw type
coupling is threaded on pump shaft and is removed by inserting drift pin through hole
in shaft to prevent rotation while turning coupling counterclockwise with pipe wrench.
DO NOT USE JAWS OF COUPLING TO LOOSEN AS THEY CAN BE BROKEN.
Remove spacer (item 25 on Repair Parts List) from shaft and remove governor
housing assembly by lifting with screwdriver from each side. This is done by inserting
screwdriver under male connectors (see Figure 1) and prying down on intermediate
housing. Intermediate housing can now be removed by removing lower row of six bolts.
Figure 1
Figure 2
Versa-Matic Pump, A Unit of IDEX Corporation • 6017 Enterprise Drive • Export, PA 15632-8969 USA • (724) 327-7867 • Fax (724) 327-4300 • www.versamatic.com
7/02
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Remove strainer assembly secured with four cap nuts. Impeller is removed by
inserting block of wood, hammer handle, or similar object between impeller vane and
pump casing (see Figure 2) to prevent rotation and turn shaft counterclockwise from
air motor end with drift pin inserted through hole in shaft. Remove shaft assembly from
volute casing by removing snap ring above oil seal, bump shaft and bearing from
casing. Rotating portion of shaft seal can now be removed from shaft and stationary
seal seat can be removed from casing.
REASSEMBLY
When installing shaft seal on shaft use a lightweight oil and locate seal at extreme end
of shaft so that carbon face of seal will contact seal seat before bearing enters housing
bore during assembly. This eliminates the possibility of carbon washer falling out of
position in seal cage while bumping shaft and bearing assembly into correct position.
Push oil seal and retainer into bore above bearing and install snap ring. Install governor
weights, spool and spring if removed. Lay o-ring into casing bore and install intermediate
housing. Install o-ring and drop governor housing into position and push down into place.
Slide sleeve and spacer onto shaft with spacer and shaft holes in alignment. Install
coupling and tighten securely with drift pin and pipe wrench with same procedure as
removal. (See Figure 3.) Insert o-ring into filter housing bore and press filter element and
housing into position as shown. (See Figure 4.) Install o-ring into intermediate bore and
o-ring on to counter bore at upper end of filter housing. Assembly is now ready to receive
air motor and housing assembly. If coupling half on air motor shaft is removed, make
certain coupling is relocated to correct position as indicated dimensionally in Figure 5.
Line up coupling jaws for engagement by using bolt holes of castings as a reference.
Rubber spider should be installed in lower coupling half. Lower air motor and housing into
place slowly to feel for correct coupling engagement. When coupling is properly engaged,
assembly can be pushed down by hand. DO NOT FORCE ASSEMBLY TOGETHER
WITH BOLTS. If air motor assembly is lifted back up in attempting to engage blind
coupling, make certain that o-ring on top end of filter housing is still in position. If o-ring is
out of position during this blind assembly, air will by-pass the governor and over-speeding
can occur. Fill with recommended oil and run unit without pumping to check for possible
oil leakage at shaft seal or o-ring joints. Turn air supply on slowly to make certain that
governor is operating properly.
Figure 3
WARRANTY
This unit is guaranteed for a period of five years against defective material and
workmanship.
PERMANENT INSTALLATIONS
NOTE: As mentioned, the SMA3-A pump does require that oil be in the reservoir for
bearing and motor lubrication. For permanent installations remove item 66, then plug the
hole with a
an in-line oiler (type oil as recommended) is used in the air supply to the pump. Set
lubricator at a usage rate of 1 pint (473 cc) every 50 hours. The motor will then be
lubricated by the in-line oiler and the bearing by the oil in the reservoir.
1
/8" pipe plug, part number 618-002-330. Fill the reservoir and make sure that
Figure 4
Figure 5
7/02
Figure 6 Spider insert.
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SERVICE AND OPERATING MANUAL
Model SMA3-A
SLUDGEMASTER
®
ITEM TOTAL
NO. PART NUMBER DESCRIPTION RQD.
1 180-002-155 Volute Casing 1
2 258-003-010 Suction Cover 1
3 444-002-010 Impeller 1
4 612-002-080 Wear Plate 1
5 430-008-155 Motor Housing 1
6 775-002-155 Filter Spool 1
7 800-003-330 Strainer Assembly 1
8 430-007-155 Intermediate Housing 1
9 730-009-120 Shaft 1
10 430-010-150 Bearing Housing 1
11 720-002-000 Shaft Seal 1
12 070-002-000 Ball Bearing 1
13 755-001-000 Sleeve 2
14 552-001-000 Oil Seal 1
15 670-004-162 Seal Retainer 1
16 914-002-330 Governor Weight 2
17 590-002-115 Governor Pin 1
18 675-001-115 Retaining Ring 2
19 775-003-162 Governor Spool 1
20 780-002-115 Governor Spring 1
21 670-003-115 Spring Retainer 1
22 255-001-000 Coupling Assembly 1
22-1 770-013-000 Spider Insert (see Figure 6) 1
23 320-002-000 Filter Element 1
25 770-001-162 Spacer 1
26 525-003-000 Air Motor Assembly 1
Consists of:
26-1 AD-665 Body 1
26-2 AD-666 End Plate, Drive 1
26-3 AD-651 End Plate, Dead 1
26-4 AD-652 Rotor Assembly 1
26-5 AD-691 Vane 4
26-6 AD-692 Spring, Vane 4
26-7 AD-655-A Push Pin 2
26-8 AD-638-A Bearing, Drive 1
26-9 AC-437 Bearing, Dead 1
26-10 AC-849 Seal, Shaft 1
26-11 AB-162 Pin, Dowel 5
26-12 AD-641-F Gasket, End Plate 2
26-13 AD-642-A End Cap, Dead 1
26-14 AD-643 End Cap, Dead 1
26-15 AD-644 End Cap, Gasket 1
26-16 560-003-360 O-Ring 1
27 530-001-000 Muffler Assembly 1
Consists of:
27-1 560-010-360 O-Ring 2
27-2 538-001-555 Nipple 1
27-3 860-009-150 Tube 1
27-4 165-001-155 Cap, Upper 1
27-5 165-002-155 Cap, Lower 1
27-6 685-001-080 Rod 1
27-7 546-002-115 Cap Nut 1
27-8 901-024-180 Sealing Washer 2
Repair Parts shown in bold face (darker)
type are more likely to need replacement
after extended periods of normal use.They
are readily available from most Warren Rupp
distributors. The pump owner may prefer to
maintain a limited inventory of these parts in
his own stock to reduce repair downtime to
a minimum.
IMPORTANT: When ordering repair parts
always furnish pump model number, serial
number and type number.
MATERIAL CODES
The Last 3 Digits of Part Number
000... Assembly, sub-assembly; and some purchased items
010... Cast Iron
015... Ductile Iron
080... Carbon Steel , AISI B-1112
100... All oy 1 0
110... All oy Type 316 Stainless Steel
112... Alloy “C”
114... 303 Stainless Steel
115... 302/304 Stainless Steel
117... 440-C Stainless Steel (Martensitic)
120... 416 Stainless Steel (Wrought Martensitic)
123... 410 Stainless Steel (Wrought Martensitic)
148... Hardcoat Anodized Aluminum
149... 2024-T4 Aluminum
150... 6061-T6 Aluminum
151... 6063-T6 Aluminum
152... 2024-T4 Aluminum (2023-T351)
154... Alm ag 3 5 A lum inum
155 or 156...356-T6 Aluminum
157... Die Cast Aluminum Alloy #380
159... Anodized Aluminum
162... Brass, Yellow, Screw Machine Stock
165... Cast Bronze, 85-5-5-5
170... Bronze, Bearing Type, Oil Impregnated
180... Copper Alloy
310... PVDF Coated
330... Plated Steel
331... Chrome Plated Steel
332... Electroless Nickel Plated
335... Galvanized Steel
354... Inje cti on Mo lded #203-40 Santoprene —
Duro 40D + /-5. Color coded: RED
357... Rupplon (Urethane Rubber)
Color coded: PURPLE (Injection mold)
358... Rupplon (Urethane Rubber)
Color coded: PURPLE (Some Applications)
(Compression Mold)
360... Buna-N Rubber. Color coded: RED
363... Viton (Fluorel). Color coded: YELLOW
364... E.P.D.M. Rubber. Color coded: BLUE
365... Neoprene Rubber. Color coded: GREEN
366... Food Grade Neoprene. Color coded: WHITE
370... But yl Rubber. Color coded: BROWN
405... Cellulose Fibre
408... Cork and Neoprene
425... Compressed Fibre
465... Fibre
500... Delrin 500
505... Acrylic Resin Plastic
540... Nylon
550... Polyethylene
555... PVC
570... Rulon II
580... Ryton
590... Valox
591... Nyl atron G-S
592... Nylatron NSB
600... PTFE (virgin material) Tetrafluoracarbon (TFE)
601... PTF E (Bronze and moly filled)
602... Filled PTFE
603... Blue Gylon
604... PTF E — Dia phr agm
Delrin, Viton and Hytrel are registered tradenames of
E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of Polymer Corporation.
Ryton is a registered tradename of Phillips Chemical Co.
Valox is a registered tradename of General Electric Co.
7/02
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ITEM TOTAL
NO. PART NUMBER DESCRIPTION RQD.
28 406-001-000 Handle Assembly 1
29 866-007-162 Male Connector 2
30 312-007-180 Elbow 1
31 200-004-330 Muffler Clamp 1
32 115-004-080 Bracket 1
33 254-004-000 Coupler 1
35 312-006-000 Elbow, Motor 1
36 312-004-162 Elbow, Motor Housing 1
37 200-005-115 Hose Clamp 2
38 427-006-000 Hose, ¾ I.D. 1
39 675-006-000 Retaining Ring 1
40 675-005-000 Retaining Ring 1
41 675-003-080 Retaining Ring 2
42 360-004-440 Gasket 6 Minimum
43 560-013-360 O-Ring 1
44 560-007-360 O-Ring 1
45 560-012-360 O-Ring 1
46 560-009-360 O-Ring 2
47 560-006-360 O-Ring 1
48 560-008-360 O-Ring 1
49 560-005-360 O-Ring 1
51 618-005-330 Pipe Plug ½" NPT 1
52 312-008-335 Street Elbow 1
53 170-033-330 Capscrew 4
54 170-006-330 Capscrew 12
55 170-005-330 Capscrew 3
56 546-001-115 Cap Nut 2
57 170-002-330 Capscrew 1
58 545-003-330 Hex Nut 2
59 900-001-330 Lock Washer 5
60 901-014-180 Washer, Sealing 3
61 901-009-330 Flat Washer 2
62 900-005-330 Lock Washer 11
63 170-007-115 Capscrew 2
64 901-024-180 Sealing Washer 2
65 861-001-000 Metering Tube Assembly 1
66 312-003-000 Elbow 1
67 866-006-162 Male Connector 2
68 430-009-155 Governor Housing 1
69 560-011-360 O-Ring 1
70 670-002-162 Retainer, Seal Ring 1
71 675-004-000 Ring, Retainer 1
72 675-002-165 Seal Ring 1
73 740-002-115 Shim (.010) 3
74 740-003-115 Shim (.030) 2
75 901-005-330 Flat Washer
3
/8"4
76 170-008-115 Capscrew 10
77 860-022-180 Tubing, Soft Copper 2
78 170-063-330 Capscrew, Hex Head 1
535-002-000 (NOT SHOWN) 1
705-002-000 (NOT SHOWN) 4
Repair Parts shown in bold face (darker)
type are more likely to need replacement
after extended periods of normal use.They
are readily available from most Warren Rupp
distributors. The pump owner may prefer to
maintain a limited inventory of these parts in
his own stock to reduce repair downtime to
a minimum.
IMPORTANT: When ordering repair parts
always furnish pump model number, serial
number and type number.
MATERIAL CODES
The Last 3 Digits of Part Number
000... Assembly, sub-assembly; and some purchased items
010... Cast Iron
015... Ductile Iron
080... Carbon Steel , AISI B-1112
100... All oy 1 0
110... All oy Type 316 Stainless Steel
112... Alloy “C”
114... 303 Stainless Steel
115... 302/304 Stainless Steel
117... 440-C Stainless Steel (Martensitic)
120... 416 Stainless Steel (Wrought Martensitic)
123... 410 Stainless Steel (Wrought Martensitic)
148... Hardcoat Anodized Aluminum
149... 2024-T4 Aluminum
150... 6061-T6 Aluminum
151... 6063-T6 Aluminum
152... 2024-T4 Aluminum (2023-T351)
154... Alm ag 3 5 A lum inum
155 or 156...356-T6 Aluminum
157... Die Cast Aluminum Alloy #380
159... Anodized Aluminum
162... Brass, Yellow, Screw Machine Stock
165... Cast Bronze, 85-5-5-5
170... Bronze, Bearing Type, Oil Impregnated
180... Copper Alloy
310... PVDF Coated
330... Plated Steel
331... Chrome Plated Steel
332... Electroless Nickel Plated
335... Galvanized Steel
354... Inje cti on Mo lded #203-40 Santoprene —
Duro 40D + /-5. Color coded: RED
357... Rupplon (Urethane Rubber)
Color coded: PURPLE (Injection mold)
358... Rupplon (Urethane Rubber)
Color coded: PURPLE (Some Applications)
(Compression Mold)
360... Buna-N Rubber. Color coded: RED
363... Viton (Fluorel). Color coded: YELLOW
364... E.P.D.M. Rubber. Color coded: BLUE
365... Neoprene Rubber. Color coded: GREEN
366... Food Grade Neoprene. Color coded: WHITE
370... But yl Rubber. Color coded: BROWN
405... Cellulose Fibre
408... Cork and Neoprene
425... Compressed Fibre
465... Fibre
500... Delrin 500
505... Acrylic Resin Plastic
540... Nylon
550... Polyethylene
555... PVC
570... Rulon II
580... Ryton
590... Valox
591... Nyl atron G-S
592... Nylatron NSB
600... PTFE (virgin material) Tetrafluoracarbon (TFE)
601... PTF E (Bronze and moly filled)
602... Filled PTFE
603... Blue Gylon
604... PTF E — Dia phr agm
Delrin, Viton and Hytrel are registered tradenames of
E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of Polymer Corporation.
Ryton is a registered tradename of Phillips Chemical Co.
Valox is a registered tradename of General Electric Co.
7/02
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©2002 Versa-Matic Pump. All rights reserved.
SludgeMaster™ is a tradename of Warren Rupp, Inc.
7/02
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