Ingersoll-Rand 5596-1 User Manual

OPERATOR’S MANUAL 5596-1

INCLUDING: SPECIFICATIONS, SERVICE KITS, PLACING INTO SERVICE, TROUBLESHOOTING

INCLUDE MANUAL: 559X Basic Pump (pn 97999Ć1033), 636077ĆX Z" Swivel (pn 97999Ć42), 636111 Control Handle
(pn 97999Ć16), SĆ633 GENERAL INFORMATION (97999Ć625)

5596-1 GREASE PUMP SYSTEMS

RELEASED: 2-3-03
REVISED:
(REV. A)

SPECIFICATIONS

Model Series 5596Ć1. . . . . . . . . . . . . . . . . . . .

Type Air Operated, 35 lb.. . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Pump System

Ratio 50:1. . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Diameter 2" (5.08 cm). . . . . . . . . . . . . . .

Stroke 3" (7.62 cm). . . . . . . . . . . . . . . . . . . . . . .

Air Inlet (female) 1/4 Ć 18 N.P.T.F. Ć 1. . . . . . . . . . . . . . . .

Material Outlet (female) 3/8 Ć 18 N.P.T.F. Ć 1. . . . . . . . . .

Pump Construction Carbon Steel. . . . . . . . . . . . .

Weight 26.85 lbs (12.2 kg). . . . . . . . . . . . . . . . . . . . . . . . .

PERFORMANCE

Air Inlet Pressure Range 0 Ć 150 p.s.i. (0 Ć 10.3 bar). . . . . . . . .

Fluid Pressure Range 0 Ć 7500 p.s.i. (0 Ć 517.2 bar). . . . . . . . . . .

Displacement In

Maximum Delivery / Minute 9 lbs (4.1 kg). . . . . . .

Noise Level @ 100 p.s.i. 85 db(A). . . . . . . . . .

3

Per Cycle 0.300. . . . . . .

SERVICE KITS

• Use only genuine IRR replacement parts to assure compatible presĆ

sure rating and longest service life.

• 637385 Pump Rebuild Kit. Includes the necessary soft parts for

normal service of the entire pump.

28Ć7/8"

(733.4 mm)

PUMP DATA

MODEL 5596Ć1

1

4

7

2

3

6

5

GENERAL DESCRIPTION

5596Ć1 Portable Lubrication System. Includes a 50:1 pump, follower
plate and drum cover plus a hose and gun.

IMPORTANT
This is one of five documents which support the pump system. ReĆ
placement copies of these forms are available upon request.

= 5596Ć1 Model Operator's Manual (pn 97999Ć1034)

- 559X Model Operator's Manual (pn 97999Ć1033)

- 636077ĆX Z" Swivel (pn 97999Ć42)

- 636111 Control Handle (pn 97999Ć16)

- SĆ633 General Information Lubrication Piston Pumps (pn 97999Ć625)

OPERATING AND SAFETY PRECAUTIONS

WARNING

INCLUDED FOR OPERATING AND SAFETY PRECAUTIONS
AND OTHER IMPORTANT INFORMATION.

READ THE GENERAL INFORMATION MANUAL

FIGURE 1

8

MAJOR COMPONENTS

Item Description (size in inches) (Qty) Part No.

1 Basic 50:1 Grease Pump (1) 5596
2 Cover & Hardware (1) 94420
3 Follower Plate (1) 640095Ć2ĆB
4 Handle (1) 94334
5 Grease Gun (1) 636111
6 10 Foot Material Hose (1) 624201Ć10
7 Adapter (1/8 Ć 27 x 3/8 Ć 18 N.P.T.F.) (1) 76493
8 Z Ć Swivel (1) 636077

INGERSOLL-RAND COMPANY

P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151

& [phone] D FAX [phone]

E2003 D PRINTED IN U.S.A.

PLACING INTO SERVICE

WARNING

plosion resulting in severe injury or death. Do not exceed maxiĆ
mum operating pressure of 7500 p.s.i. (517.2 bar) at 150 p.s.i.
(10.3 bar) inlet air pressure. Do not run pump without using a
regulator to limit air supply pressure to the pump.

INLET PRESSURE TO PUMP MOTOR

Pump ratio is an expression of the relationship between the pump motor area and
the lower pump end area. EXAMPLE: When 150 p.s.i. (10.3 bar) inlet pressure is
supplied to the motor of a 50:1 ratio pump it will develop a maximum of 7500 p.s.i.
(517 bar) fluid pressure (at no flow) - as the fluid control is opened, the flow rate will
increase as the motor cycle rate increases to keep up with the demand.

WARNING

equipment failure resulting in severe injury or property damĆ
age. Do not exceed the maximum material pressure handling
capability of any component in the system.

Thermal expansion hazard. This can occur when the fluid in the maĆ
terial line is exposed to elevated temperatures. Example: Material
line located in a nonĆinsulated roof area can warm due to sunlight.
Install a pressure relief valve in the pumping system if this condition
could exist.

AIR AND LUBRICATION REQUIREMENTS

Filtered air will help extend the life of the pump, allowing the pump to opĆ
erate more efficiently and yield longer service life to moving parts and
mechanisms.

EXCESSIVE INLET PRESSURE. Can cause exĆ

PUMP RATIO X

EXCESSIVE MATERIAL PRESSURE. Can cause

MAXIMUM PUMP

=

FLUID PRESSURE

• Use an air line filter to provide good quality clean and dry air, install it

up stream from the air regulator.

• Use an air regulator on the air supply to control the pump cycle rate,

install the regulator as close as possible to the pump.

• In most installations, lubrication is not required. If the pump needs to

have lubrication, install an air line lubricator between the pump and
the air regulator and supply it with a good grade of nonĆdetergent oil
or other lubricant compatible with Nitrile seals. Set at a rate not to
exceed one drop per minute.

OPERATION

STARTĆUP

1. Turn the air regulator to 0" pressure setting. Connect the air hose.

2. Prime the pump by cycling slowly, raising the pressure to 20 Ć 30
p.s.i. (1.4 Ć 2.1 bar). Cycle the pump until the test grease and any
trapped air has been purged from the system.

3. Close the dispensing device. Allow the pump to build line pressure
and stall. Check for any leaks and reĆtorque fittings if needed. Adjust
air pressure upward as required for the application.

NOTICE: If the pump does not prime soon after initial startĆup, establish
what the problem is to prevent unnecessary damage to the pump plungĆ
er.

SHUTDOWN

• Disconnect the air supply from the pump if it is to be inactive for a few

hours. Open the dispensing device to relieve line pressure.

SERVICE

Refer to the basic pump manual for service instructions which also covĆ
ers disassembly and reassembly for installation of the rebuild kit.

TROUBLE SHOOTING

If the pump does not cycle or will not deliver material.

• Be certain to check for nonĆpump problems including kinked, restricĆ

tive or plugged inlet / outlet hose or dispensing device. Depressurize
the pump system and clean out any obstructions in the inlet / outlet
material lines.

• Check all seals, including track gaskets.

INSTALLATION

Assemble components included in the package as shown in the figure 1
(page 1). NOTE: In rigid plumbing applications, use flexible material and
air supply hoses when attaching the pump to prevent damage by vibraĆ
tion.

1. Thread the pump bung adapter into the pump cover, insert the pump
into the bung and then secure with the thumb screws provided.

2. Install the handle and secure with the four nuts provided with the
cover.

3. Install the outlet adapter, material hose, swivel and gun.

4. Lay the follower on top of a full bucket of grease, feed the lower
pump end into the follower and secure the cover with the thumb
screws.

5. Attach a coupler to the air supply hose and a connector to the pump
air inlet adapter.

6. Connect the material hose to the pump outlet. Tighten all fittings.
Use caution not to damage threads.

PAGE 2 OF 2

PN 97999Ć1034

5596Ć1