VBA-MM-N016-E
Maintenance Manual
Booster Regulator
VBA11A
－Contents－
1. Foreword････････････････････････････････････P.1
2. Maintenance of cylinder and body･･････････････ P.2
3. Maintenance of governor･･････････････････････ P.4
4. Replacement parts list････････････････････････ P.5
1. Foreword
When the booster regulator is disassembled and reassembled for maintenance, read and follow this
manual.
The maintenance period depends on the air quality and operating conditions, but when either of the
following situations occurs, the booster regulator should be considered to be reaching the end of its life, and
maintenance should be performed sooner.
1. The handle is bleeding all the time.
2. Exhaust sound can be heard at intervals of 10 to 20 seconds without air consumption on the
secondary side.
Start
Preparation ・ Check that air pressure is exhausted from the IN and OUT sides.
・ Disconnect piping. The size of tool prepared for disconnection should be suitable
for the type of piping.
Removal
・ Remove the tank (VBAT05*, 10∗) from the booster regulator. For removal, use a
hexagon wrench.
Disassembly
・ The tools prepared for disassembling the booster regulator should be as shown in
◆Necessary tools◆ on the applicable pages.
・ Disassemble in accordance with the procedure from page 2 to 5.
Replacement ・ Wipe off any dirt from the sliding face and dust from the mesh filter.
・Check the condition of parts. If there are any scratches or abrasion, replace the
part with a new one listed on page 6.
・If the silencer is clogged inside, replace it as well.
・ Gather replacement parts to one place to prevent them getting mixed up during
reassembly.
Reassembly ・ Assemble in accordance with the procedure from page 2 to 5.
・ At the end, check you have not forgotten to assemble any parts or tighten
any screws.
Mounting
・ Put back the disassembled parts to their original position.
Inspection
-1-
Supply air, rotate the handle clockwise and set the pressure.
・
Check for external leakage with soapy water.
・
If any abnormal phenomenon is seen, please contact SMC sales branch.
・
Finish
-2-
2. Maintenance of cylinder and body
2.1 Maintenance of cylinder
◆Necessary tools◆
Socket wrench, Nominal 10mm (2pcs)
Hexagon wrench, Nominal 5mm
Looseness preventive adhesive (Loctite 263, etc.)
Grease package (Multi-purpose2, etc.)
◆Disassembly procedure◆
1) Check air pressure is exhausted from the IN and OUT sides.
2) Remove the pressure gauge and the silencer first if they are mounted.
3) Remove the eight hexagon socket head cap screws (8) on the left and the right with a hexagon wrench.
4) Remove the cover (6) and the cover C assembly (9).
5) Loosen one of the piston nuts (7) or (15) with a socket wrench, and remove one of the pistons (4) or (10).
(Remove only one of the piston nuts either on the left hand side or the right hand side.)
◆Maintenance and check◆
1) Check there is no abrasion, deterioration and deformation of any part. If there is, replace it with new one.
2) If there is any part whose motion is not smooth, wipe off dirt and apply grease.
3) If you move onto maintenance of the body, refer to 2.2 Maintenance of body (P.3).
◆Reassembly◆ ! Caution! Assembly parts are different depending on lot.
Lot No. PR or before (Fig. 1-1)
1) Apply grease to the part marked with in Fig. 1-1.
2) Put the piston rod (3) through the body (1), and mount the piston (4) and the piston B (10) with the plate
(12) inserted to the piston with the smaller diameter (piston B) (10).
3)Apply one drop of Loctite to the thread of the piston nuts (7) and (15), and tighten it with a socket
wrench.（Torque 3.9Nm）The piston is not fixed completely (idles) if it is assembled correctly. Do
not tighten it over the necessary torque.
4) Mount the cover (6) and the cover C assembly (9) to the body (1) after the cover gasket (2) is mounted
to the cover (6) and the cover C assembly (9).
5) Fix the cover (6) by tightening four hexagon head bolts (8) on each side of the cover C assembly (9)
(eight bolts in total). (Torque 3Nm)
(8)
(6)
(7)
(5)
(4)
Fig.1-1 (2)
Lot No. PR or before
(2)
(10) (3)
(15) (12)
(10)
(11)
(13) Apply grease to the part seal
(8)
(1)
(9)
Apply grease to the piston rod.
Apply grease to the part seal
Apply grease to the part cover
-3-
Lot No. PS or later (Fig. 1-2)
1) Apply grease to the part marked with in Fig. 1-2.
2) Put the piston rod (3) through the body (1), and mount the piston (4), ring (14) and the piston B (10) with
the plate (12) inserted to the piston with the smaller diameter (piston B) (10).
3) Apply one drop of Loctite to the thread of the piston nuts (7) and (15), and tighten it with a socket wrench.
(Torque 3.9Nm) The piston (4) should be firmly fixed when correctly assembled. The piston B
(10) should be loosely mounted when correctly assembled. Do not tighten piston B (11) over
the correct torque setting.
4) Mount the cover (6) and the cover C assembly (9) to the body (1) after the cover gasket (2) is mounted
to the cover (6) and the cover C assembly (9).
5) Fix the cover (6) by tightening four hexagon head bolts (8) on each side of the cover C assembly (9)
(eight bolts in total). (Torque 3Nm)
(8)
(6)
(7)
(5)
(4)
Fig.1-2 (2)
Lot No. PS or later
(2)
(3)
(12)
(10)
(15)
(11)
(13) Apply grease to the part seal
(8)
(1)
(9)
Apply grease to the piston rod.
Apply grease to the part seal
Lot No. PS or later
Apply grease to the part cover
(10)
(14)
(15)
Mount a ring (14) on the side
of the piston B (10).
.
◆Check◆
1) Check the bolts and nuts are tightened to adequate torque.
2) Supply air and check pressure setting can be performed.
3) Check there is no leakage from connected parts with soapy water.
-4-
Replacement of the Piston and Piston Rod ( Fig. 1-3)
1) Prepare the piston parts kit (KT-VBA11A-28).
2) Replace the rod seal with a new seal.
Replacement procedure of the rod seal, refer to section 2.2 Maintenance of body.
3) Apply grease to the cover (6), cover C assembly (9) and piston rod (3) (the part indicated by
in Fig. 1-3).
4) Put the piston rod (3) through the body (1), and mount the piston (16), and piston B (17) with the plate
(12) inserted to the piston with the smaller diameter (17) (piston B).
(Piston B (17) is shipped in the state that installed in a piston rod (3).)
5) Apply one drop of Loctite to the thread of the piston nut (7), and tighten the piston nut (7) onto the
piston (16) side, and piston nut (15) onto the piston B (17) side with a socket wrench. (Tightening
torque: 3.9 Nm)
The piston (16) should be firmly fixed when correctly assembled. The piston B (17) should be
loosely mounted when correctly assembled. Do not tighten piston B (17) over the correct
torque setting.
6) Mount the cover (6) and the cover C assembly (9) to the body (1) after the cover gasket (2) is mounted
to the cover (6) and the cover C assembly (9).
7) Fix the cover (6) by tightening four hexagon head bolts (8) on each side of the cover C assembly (9)
(eight bolts in total). (Torque 3 Nm)
(8)
(6)
Fig.1-3
(7)
(16)
(2)
(3)
(2)
(12)
(15) (17)
(8)
Apply grease
to the piston rod.
(9)
Apply grease to the(1)
piston rod.
Apply grease
to the part cover
◆Check◆
1) Check the bolts and nuts are tightened to adequate torque.
2) Supply air and check pressure setting can be performed.
-5-
3) Check there is no leakage from connected parts with soapy water.
-6-
2.2 Maintenance of body
◆Necessary tools◆
Flat blade screwdriver
Pair of tweezers
Turbine oil (Turbine oil 32 class 2, Exxon Mobile or similar)
Grease package (Multi-Purpose 2, etc)
◆Disassembly◆
1) Remove the side plate (2) and the side plate D (19) on the left and right .
2) Remove the side plate insert C (3) and the side plate insert D (4) on the left and right with a flat blade
screwdriver.
3) Take out the check valves (5) through (7) from the body (1).
4) Take out the switch valves (9) though (13) from the body (1).
5) Take out the rod seal (14) from the body (1) with a pair of tweezers.
◆Maintenance and check◆
1) Check there is no abrasion, deterioration and deformation of any part. If there is, replace it with new one.
2) The end of IN port has a mesh filter built in. Remove dust from the filter by air blowing.
3) If there is any part whose motion is not smooth, wipe off dirt and apply grease. Apply one drop of
Turbine oil to the switch valve.
◆Reassembly◆
1) Mount the switch valves (9) through (13). (These are precision parts and should be handled with care.)
2) Mount the check valves (5), (6) and (7) on the left when facing to the front of Figure 2, and mount the
side plate insert C (3) with the side plate gasket C (17) and the side plate gasket D (18) mounted, then
mount the side plate (2) on them. The mounting directions of the check valves (5) are different.
Mount them in the correct orientation.
3) Mount the side plate insert D (4) on the right when facing to the front of Figure 2, with the side plate
gasket A (15) and the side plate gasket B (16) mounted, then mount the side plate D (19) on them.
◆Check◆
1) Check the springs are mounted in place and the check valve (5) and switch valve (9) move smoothly.
(14)
(5) (19)
(6)
(12) (7)
(16)
(10) (13)
(9) (4)
(10)
(11)
(12) (15)
*Mesh filter
(1)
(6)
(5)
(17)
(3)
(13) Fig.2
(18)
(2) -7-
3. Maintenance of governor
◆Necessary tools◆
Phillips screwdriver
Pair of needle nose pliers
◆Disassembly◆
1) Check air pressure is exhausted from the IN and OUT sides.
2) Rotate the handle counterclockwise back to the end (in the negative direction).
3) Remove four cross recessed round head screws (12) with the Phillips driver.
4) Remove the bonnet assemblies (10) and (11), the regulating screw assembly (9), the regulating spring
(8), the regulating piston assembly (7), the relief spring (6) and the relief valve (5).
5) Remove the governor chamber assembly (4), the valve assembly (3) and the valve spring (2) with a pair
of needle nose pliers.
◆Maintenance and check◆
1) Check there is no abrasion, deterioration and deformation of any part. If there is, replace it with new one.
2) If there is any part whose motion is not smooth, wipe off dirt and apply grease.
◆Reassembly◆
1) Mount the valve spring (2) and the valve assembly (3) to the body (1), and then fit the governor chamber
assembly (4) to the body.
2) Mount the relief spring (6) and the relief valve (5) to the regulating piston assembly (7), and then, put
them into the governor chamber assembly (4). Put the regulating spring (8) and the regulating screw
assembly (9) on them.
3) Put on the bonnet assemblies (10) and (11) and tighten them with four cross recessed round head
screws (12) using the Phillips screwdriver. (Torque 0.76Nm)
◆Check◆ (12)
1) Check the cross recessed round head screws (12) are
(11)
tightened and supply air.
2) When air pressure is supplied, it will start to relieve air. (10)
Quickly rotate the handle in the clockwise direction (in
the positive direction) until it stops relieving air.
(9)
3) Check pressure setting to the necessary pressure can
be performed with the handle.
4) Check there is no leakage from connected parts with (8)
soapy water.
(7)
(6)
(5)
(4)
(3)
(2)
* Maintenance of the governor can be
performed without removing the cover part.
(1)
Fig.3
-8-
4. Replacement parts list
The replacement parts can be ordered with the following part numbers.
Each set includes the components shown on the right of this table. Refer to the drawing number and item
number in this manual to check each part.
Component
Part Description Drawing Item
Description Qty.
No. No.
Piston seal 1 Fig.1 (5)
Piston seal 1 Fig.1 (11)
Rod seal 1 Fig.2 (14)
Cover gasket 2 Fig.1 (2)
Valve assembly 1 Fig.3 (3)
Booster regulator
KT-VBA11A-20 maintenance Governor chamber assembly 1 Fig.3 (4)
parts set Check valve 2 Fig.2 (5)
Valve spring 1 Fig.3 (2)
Cover C assembly 1 Fig.1 (9)
Plug 1 Fig.1 (13)
Grease package 1 － －
Switch valve assembly 1 Fig.2 (9)
Exhaust sleeve 2 Fig.2 (10)
KT-VBA11A-2 Switch valve set Travel spring 1 Fig.2 (11)
Push rod 2 Fig.2 (12)
O-ring 2 Fig.2 (13)
Governor chamber assembly 1 Fig.3 (4)
Valve assembly 1 Fig.3 (3)
Governor Valve spring 1 Fig.3 (2)
KT-VBA10A-3
chamber set Regulating piston assembly 1 Fig.3 (7)
Relief valve 1 Fig.3 (5)
Relief spring 1 Fig.3 (6)
Piston seal 1 Fig.1 (5)
Piston seal 1 Fig.1 (11)
KT-VBA11A-4 Seal kit Rod seal 1 Fig.2 (14)
Cover gasket 2 Fig.1 (2)
Grease package 1 － －
Check valve 2 Fig.2 (5)
Check valve
2 Fig.2 (6)
Check valve spring
Plunger 1 Fig.2 (7)
Side plate insert C 1 Fig.2 (3)
KT-VBA11A-5 Check valve set Side plate insert D 1 Fig.2 (4)
Side plate gasket A 1 Fig.2 (15)
Side plate gasket B 1 Fig.2 (16)
Side plate gasket C 1 Fig.2 (17)
Side plate gasket D 1 Fig.2 (18)
Grease package 1 － －
Bonnet 1 Fig.3 (10)
KT-VBA10A-6 Bonnet set
Handle 1 Fig.3 (11)
-9-
Component
Part Description Drawin Item
Description Qty
g No. No.
Piston A assembly 1 Fig.1-3 (16)
Piston nut 1 Fig.1-3 (7)
Piston rod 1 Fig.1-3 (3)
Piston B assembly 1 Fig.1-3 (17)
Ring (Included in the piston B
KT-VBA11A-28 Piston parts kit 1 Fig.1-2 (14)
assembly)
Piston nut 1 Fig.1-3 (15)
Cover gasket 1 Fig.1-3 (2)
Rod seal 2 Fig.2 (14)
Grease package 1 － －
- 10 -
