Ingersoll-Rand 5597, 5598, 5596, 5599 User Manual

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Page 1

OPERATOR’S MANUAL 559X

INCLUDING: SPECIFICATIONS, SERVICE KITS, GENERAL INFORMATION, PARTS, TROUBLESHOOTING

INCLUDE MANUAL: S- GENERAL INFORMATION (PN 97999-

632

624).

RELEASED: 2-3-03 REVISED: 9-27-11

(REV.

2” AIR MOTOR

5596, 5597, 5598, 5599

50:1 RATIO 0 - 7500 P.S.I. RANGE

CHOP-CHECK GREASE PUMP

READ THIS MANUAL CAREFULLY BEFORE INSTALLING,

OPERATING OR SERVICING THIS EQUIPMENT.

It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.

SERVICE KITS

• Useonly genuine IRR replacement parts to assure compatiblepres-

sure rating and longest service life.

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

normal service of the entire pump.

SPECIFICATIONS

Model Series 559X..................

Type Air Operated, Chop-Check Grease Pump.............

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

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

Stroke 3” (7.62 cm)......................

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

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

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

Dimensional Data see chart..............

Weight see chart.......................

...........

PUMP DATA

MODEL 559X

Air Inlet (female)

(1/4 - 18 N.P.T.F. - 1)

1-1/4”

(31.8 mm)

Material Outlet (female)

(3/8 - 18 N.P.T.F. - 1)

2” N.P.S.M. Bung Adapter

“A”

PERFORMANCE

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

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

Cycles / Minute Rec’d @ Working Flow 80.. Displacement In

Per Cycle 0.300.......

Volume / Cycle 6.55 ml (0.22 oz.).................

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

Noise Level @ 100 p.s.i. 85

..........

db (A)

Accessories Available 61113 Wall Mount Bracket.......

-1 Air Line Connection Kit

66073

Testedwith95086 mufflerassemblyinstalled.

The pump sound pressure level has been updated to an Equivalent Continuous Sound Level (L microphone locations.

) to meet the intent of ANSI S1. 13-1971, CAGI-PNEUROP S5.1 using four

Aeq

GENERAL DESCRIPTION

The model 559X series chop-check grease pump is intended to be used primarily for grease delivery systems. It uses carbon steel and other materials which make it compatible with most petroleum based lubrication products. NOTE: If this pump was purchased separately (not part of a system), consult your sales representative for compatible dispensing accessories which will best match the application. All accessories must be able to withstand the maximum pressure developed by the pump.

“B”

Figure 1

8 mm (5/16”) Thru hole

NOTE: Dimensions are shown in inches and (mm), supplied for reference only and are typically

rounded up to the nearest 1/16 inch.

MODEL “A” (mm) “B” (mm) WEIGHT (kg)

5596 27-3/4” (704) 16-9/16” (421) 15 (6.8) 5597 30-1/2” (774) 19-5/16” (490) 15.9 (7.2) 5598 38-7/16” (976) 27-1/4” (692) 18.3 (8.3) 5599 48” (1219) 36-13/16” (935) 21.2 (9.6)

IMPORTANT This is one of two documents which support the pump. Replacement copies of these forms are available upon request.

= 559X Model Operator’s Manual (pn 97999-1033)

- S- General Information Lubrication Piston Pumps (pn 97999

632

WARNING

READ THE GENERAL INFORMATION MANUAL

-624).

INCLUDEDFORADDITIONALOPERATINGANDSAFETYPRECAUTIONS ANDOTHER IMPORTANT INFORMATION.

INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET BRYAN, OHIO 43506

 (800) 495--0276 D FAX (800)892--6276

www.ingersollrandproducts.com

E2011 CCN 20083093

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PARTS LIST / 559X

Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]

1 Carriage Bolt (1/4” - 20 x 9” long) (4) 94333 [C] 2 Upper Cap (1) 94307 [Z]

n 3 Gasket (2) 94311 [B]

4 Sleeve (2) 94316 [Br]

n 5 “O” Ring (1/16” x 11/16” o.d.) (4) Y325-15 [B] n 6 “O” Ring (1/8” x 3/4” o.d.) (4) Y325-206 [B]

7 Spool (2) 94310 [D]

n 8 “U” Cup (1/8” x 3/4” o.d.) (2) Y240-7 [B] n 9 “O” Ring (0.106” x 0.587” o.d.) (2) 15066-PM [B]

10 Cylinder (1) 94249 [A] 11 Adapter (1) 94447 [C]

n 12 “O” Ring (1/16” x 3/4” o.d.) (1) Y325-16 [B] n 13 “O” Ring (1/16” x 7/16” o.d.) (1) Y325-11 [B]

14 Muffler Housing (1) 95086 [C] 15 Foam Liner (2) 94402 16 Retaining Ring (1) 94406 [C] 17 Washer (1) 94515 [C]

n 18 “U” Cup (3/16” x 2” o.d.) (2) Y240-23 [B]

19 Piston (1) 94780 [D] 20 Piston Adapter (1) 94388 [C]

n 21 “O” Ring (3/32” x 1” o.d.) (1) Y325-117 [B]

22 Dowel Pin (1/4” o.d. x 7/8” long) (1) Y148-37 [C]

n 23 “O” Ring (3/32” x 13/16” o.d.) (1) Y325-114 [B] n 24 Rod Seal (1) 95139 [U]

25 Washer (1) 94785 [C] 26 Spring (1) 94705 [C] 27 Base (1) 67241 [C/Z] 28 Nut (1/4” - 20) (4) 93828 [SS] 29 Ground Screw (#10 - 32 x 1/4”) (1) 93005 [C]

n 30 Gasket (1) 70834 [Co]

31 Extension Tube

models 5596 (7.531’’) (1) 94401-2 [C] models 5597 (10.281’’) (1) 94401-6 [C] models 5598 (18.219’’) (1) 94401-3 [C] models 5599 (27.781’’) (1) 94401-4 [C]

n 32 Gasket (1) 70837 [Co]

33 Piston Rod (1) 95137 [C] 34 Pin (1) 94786 [C]

n 35 Cotter Pin (1/16” x 1/2” long) (1) Y15-21 [C]

36 Connector - 5596 (3.457”) (1) 94340-2 [C]

models 5597 (6.207”) (1) 94340-6 [C] models 5598 (14.145”) (1) 94340-3 [C] models 5599 (23.707”) (1) 94340-4 [C]

Piston & Tube Assembly (in-

cludes 37 - 41)

(1) 67262

37 Lower Suction Tube (1) [C] 38 Plunger (1) [C] 39 Ball Stop (1) 83276 [C] 40 Ball (9/32” dia.) (1) Y16-209 [C] 41 Primer Rod (1) 95134 [C]

n 42 Guide Washer (1) 95131 [Co]

43 Spacer (1) 72392-1 [C]

n 44 Retaining Ring (0.877” o.d.) (1) 76243-1 [C] n 45 “U” Cup (1/8” x 13/16” o.d.) (1) Y186-54 [B] n 46 Guide (1) 95132 [T]

47 Foot Valve Body (1) 95133 [SH]

FootValveAssembly(includes 44

- 47)

(1) 67242

n 48 Gasket (1) F21-65 [Co]

49 Valve Seat (1) 6797 [C] 50 Primer (1) 94400 [C]

n 51 Retainer Ring (1) 94397 [C]

52 Primer Tube (1) 94399 [C]

K 53 Bung Assembly (includes 54) (1) 67145-2 [ZA] K 54 Thumb Screw (1/4”-20x1”) (3) Y66-59-C [C]

n Gadus S2 U1000 Grease Packet (1) 94833 n Parts in Repair Kit 637385

K Not included with models 5597

OPERATING AND SAFETY PRECAUTIONS

WARNING

plosion resulting in severe injury or death. Do not exceed maximum operating pressure of 517 bar (7500 p.s.i.) at 10.3 bar (150 p.s.i.) inlet air pressure. Do not run pump without using a regulator to limit air supply pressure to the pump.

WARNING

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

Replacement warning label is available upon request, PN \ 94520.

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EXCESSIVE INLET PRESSURE. Can cause ex-

EXCESSIVE MATERIAL PRESSURE. Can cause

INLET PRESSURE TO PUMP MOTOR

PUMP RATIO X

Pump ratio is an expression of the relationship between the pump motor area and the lower pump end area. EXAMPLE: When 10.3 bar (150 p.s.i.) inlet pressure is supplied to the motor of a 50:1 ratio pump it will develop a maximum of 517 bar (7500 p.s.i.) 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.

MAXIMUM PUMP

FLUID PRESSURE

NOTICE: Thermal expansion can occur when the fluid in the material lines is exposed to elevated temperatures. Example: Material lines located in a non-insulated roof area can warm due to sunlight. Install a pressure relief valve in the pumping system.

559X

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PARTS LIST / 559X

. 11

31 ,

37 ,

36 ,

5 4

MATERIAL CODE

[A] = Aluminum [B] = Nitrile [Br] = Brass [C] = Carbon Steel [Co] = Copper [D] = Acetal [SH] = Hard Stainless Steel [SS] = Stainless Steel [T] = PTFE [U] = Polyurethane [Z] = Zinc [ZA] = Zinc / Aluminum Alloy

. TORQUE REQUIREMENTS ,

(11) Adapter, 7.9 - 9.0 Nm (70 - 80 in. lbs). (28) Nuts, 9.0 - 10.2 Nm (80 - 90 in. lbs). (31, 37, 52) 88.1 - 101.7 Nm (65 - 75 ft lbs). (36) Connector, 23.0 - 33.9 Nm (17 - 25 ft lbs). (41) Primer rod, 7.9 - 11.3 Nm (70 - 100 in. lbs).

Figure 2

28 ,

41 ,

52 ,

559X Page3of4

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PUMP DISASSEMBLY

NOTE: All threads are right hand. Refer to figure 2 (page 3). Disconnect air supply and relieve all system pressure

Carefully remove the parts, inspect for damage, nicks or excessive wear and determine if any parts will need replacement.

1. Using a 7/8”wrench, unthread and remove (11) adapter, containing (12 and 13) “O” rings, releasing (14) muffler housing.

2. Using a 7/16” wrench, remove (28) nuts.

3. Remove four (1) bolts, (2) upper cap and (3) gasket.

4. Remove (10) cylinder, containing (4) sleeves and (7) spools.

5. Using (1) bolt, push (7) spools and (4) sleeves out “sleeve” end of (10) cylinder.

6. Remove (16) retaining ring, (17) washer and (19) piston.

7. Remove (22) dowel pin, releasing (20) piston adapter.

8. Remove (3) gasket.

9. Clamp (31) extension tube horizontally in a vise. Unthread and remove (27) base, (30) gasket, (26) spring and (25) washer. NOTE: Remove (24) rod seal only if replacement is necessary.

10. Pull up on (33) piston rod to reveal (35) cotter pin.

11. Remove (35) cotter pin and (34) connecting pin, releasing (33) piston rod.

12. Using (33) piston rod, push downon (36) connector until itbottoms.

13. Remove (51) retainer ring.

14. Push (50) primer up into (52) primer tube.

15. Lightly wedge a flat blade screwdriver between (50) primer and (52) primer tube, so (50) primer unthreads with (52) primer tube.

16. Insert a 5/16” diameter rod thru the cross holes in (52) primer tube and use the rod to unthread and remove (52) primer tube.

17. Remove (43) spacer, (48) gasket and (49) valve seat from (52) primer tube.

18. Remove (44 - 47) foot valve assembly from (41) primer rod.

19. Remove (44) retaining ring, releasing (45) “U” cup. NOTE: Do not remove (46) guide unless replacement is necessary.

20. Remove (42) guide washer.

21. Clamp (37) lower suction tube horizontally in a vise. Unthread and remove (31) extension tube and (32) gasket.

22. Using a 7/32” diameter rod inthe cross hole in (36) connector anda 9/16” wrench on the flats of (38) plunger, unthread and remove (36) connector from (38) plunger. NOTE: Donot damage the o.d. of (38) plunger in any way.

23. Using a 5/32” diameter rod in the cross hole of (41) primer rod and a 9/16” wrench on flats of (38) plunger, unthread and remove (41) primer rod, releasing (40) ball and (39) ball stop.

prior to servicing.

3. Assemble(46) guide and (45) “U” cup into (47) valve body, securing with (44) retaining ring. NOTE: Assemble chamfered corner of (46) guide into (47) valve body first.

4. Assemble(42) guide washer and (44 - 47) foot valve assembly onto (41) primer rod.

5. Assemble (43) spacer, (48) gasket and (49) valve seat onto (41) primer rod.

6. Thread(50) primer onto (41) primer rod, securing with (51)retainer ring.

7. Thread (52) primer tube to (37) lower suction tube and tighten. NOTE: Torque (52) primer tube to 88.1 - 101.7 Nm (65 - 75 ft lbs).

8. Assemble(33) piston rod to (36) connector, securing with (34) connecting pin and (35) cotter pin.

9. Assemble(32) gasket and (31) extension tube to (37) lowersuction tube and tighten. NOTE: Torque (31) extension tube to 88.1 - 101.7 Nm (65 - 75 ft lbs).

10. Assemble (23) “O” ring, (24) rod seal, (25) washer, (26) spring and (30) gasket into (27) base and assemble (27) base to (31) extension tube. Clamp (27) base horizontally in a vise and tighten (31) extension tube. NOTE: Torque(31) extension tube to 88.1 - 101.7 Nm (65

-75ftlbs).

11. Push up on (50) primer, exposing (33) piston rod.

12. Assemble (3) gasket to (27) base.

13. Assemble (21) “O” ringto (20) piston adapter and assemble (20) piston adapter to (33) piston rod, securing with (22) dowel pin.

14. Replace (18) “U” cups on (19) piston and assemble (19) piston onto (20) piston adapter, securing with (17) washer and (16) retaining ring.

15. Replace (5) “O” rings on (4) sleeves and assemble (4) sleeves into (10) cylinder. NOTE: Assemble each sleeve into the end of the cylinder nearest the exhaust hole.

16. Replace (6 and 9) “O” rings and (8) “U” cups on (7) spools and assemble (7) spools into (10) cylinderfrom the opposite end as the (4) sleeve went in.

17. Assemble (10) cylinder onto the pump, being careful when sliding over the lips of (18) “U” cups. NOTE: Be sure (3) gasket is seated properly.

18. Replace (3) gasket on (2) upper capand assemble (2) uppercap to (10) cylinder.

19. Assemble (1) bolts to pump, securing with (28)nuts. NOTE: Torque (28) nuts to 9.0 - 10.2 Nm (80 - 90 in. lbs).

20. Replace (12 and 13) “O” rings on (11) adapter.

21. Assemble (15) foam liners to (14) muffler housing.

22. Assemble (14) muffler housing to (10) cylinder, securing with (11) adapter.NOTE: Torque(11) adapter to 7.9 - 9.0 Nm(70 - 80 in. lbs).

PUMP REASSEMBLY

NOTE: Thoroughly clean and lubricate all seals and bores with Shell Gadus S2 U1000 upon assembly. Replace all soft parts with new ones included in the repair kit. Note: Refer to the illustration(fig-

ure 2, page 3) for “U” cup lip seal direction.

1. Assemble(39) ball stop and (40) ball into (38) plunger, securing with (41) primer rod. NOTE: Torque (41) primer rod to 7.9 - 11.3Nm (70 100 in. lbs).

2. Thread (36) connector to (38) plunger, using a 7/32” diameter rod thru the cross hole to tighten. NOTE: Tighten (36) connector to 23.0 -

33.9 Nm (17 - 25 ft lbs).

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TROUBLE SHOOTING

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

• Becertain to check for non-pump problems including kinked, restric-

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.

• Check direction of “U” cup lips.

PN 97999-1033

559X