Flo-tech DK301-000 Setup guide

REPAIR INSTRUCTIONS
Rev 1
MODEL : DK301-000
30:1 Ratio Pump
3000PSI (21.0 MPa, 210 bar) Maximum Fluid Working Persure
100psi (0.7 MPa, 7bar) Maximum Air Input Pressure
This manual contains important warning and
information.
Read and keep reference.

WARNING
INJECTION
HAZARD
Spray from the spray gun, hose leaks or ruptured
components can inject fluid into your body and
cause extremely serious injury, including the need
for amputation. Splashing fluid in the eyes or on the
skin can also cause can also cause serious injury.
_ Fluid injected into the skin is a serious injury. The
injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
_ Do not point the gun at anyone or any part of the
body.
_ Do not put hand or fingers over the spray tip.
_ Do not stop or deflect leaks with your hand, body,
glove or rag.
_ Do not “blow back” fluid; this is not an air spray
system.
_ Always have the tip guard on the spray gun when
spraying
_ Check the spray gun diffuser (if so equipped)
operation weekly. Refer to the gun manual.
_ Be sure the spray gun safety knob operates
before operating the gun.
_ Lock the spray gun safety knob when you stop
spraying.
_ Tighten all fluid connections before each use.
_ Check the hoses, tubes and couplings daily.
Replace worn or damaged parts immediately.
Permanently coupled hoses cannot be
repaired.
_ Handle and route hoses and tubes carefully.
Keep hoses and tubes away from moving parts
and hot surfaces. Do not use the hoses to pull
equipment. Do not expose FLOTECH hoses to
temperatures
above 150_F (66_C) or below –40_F (–40_C).
EQUIPMENT
MISUSE
HAZARD
Equipment misuse can cause the equipment to
rupture, malfunction, or start unexpectedly
and result in serious injury.
_ This equipment is for professional use only.
_ Read all instruction manuals, tags, and labels
before operating the equipment.
_ Use the equipment only for its intended
purpose. If you are uncertain about the
usage, call your distributor.
_ Do not alter or modify this equipment. Use
only genuine FLOTECH parts and
accessories.
_ Check the equipment daily. Repair or replace
worn or damaged parts immediately.
_ Do not exceed the maximum working
pressure of the lowest rated system
component. This equipment as a 5000 psi
(345bar) maximum working pressure.
_ Do not lift pressurized equipment.
_ Route the hoses away from the traffic areas,
sharp edges, moving parts, and hot surfaces.
Do not expose FLOTECH hoses to
temperatures above 150_F (66_C) or below –
40_F (–40_C).
_ Do not use the hoses to pull the equipment.
_ Use fluids or solvents that are compatible with
the equipment wetted parts. See the
Technical Data section of all the equipment
manuals. Read the fluid and solvent
manufacturer’s warnings.
_ Fluid hoses must have spring guards on both
ends to protect them from rupture caused by
kinks or bends near the couplings.
_ Comply with all applicable local, state and
national fire, electrical and other safety
regulations.
TOXIC
FLUID
HAZARD
Hazardous fluids or toxic fumes can cause a
serious injury or death if splashed in the eyes or
on the skin, inhaled, or swallowed.
_ Know the specific hazards of the fluid you are
using.
_ Store hazardous fluid in an approved container.
Dispose hazardous fluid according to all local,
state and national guidelines.
_ Always wear protective eyewear, gloves, clothing
and recommended by the fluid and solvent
manufacturer.
FIRE
AND
EXPLOSION
HAZARD
Improper grounding, poor air ventilation, open
flames, or sparks can cause a hazardous
condition and result in fire or explosion and
serious injury.
_ Ground the equipment and the object being
sprayed.
_ Provide fresh air ventilation to avoid the
buildup of flammable fumes from solvent or
the fluid being sprayed.
_ Extinguish all the open flames or pilot lights in
the spray area.
_ Electrically disconnect all the equipment in
the spray area.
_ Keep the spray area free of debris, including
solvent, rags, and gasoline.
_ Do not turn on or off any light switch in the
spray area while operating or if fumes are
present.
_ Do not smoke in the spray area.
_ Do not operate a gasoline engine in the spray
area.
_ If there is any static sparking while using the
equipment, stop spraying immediately.
Identify and correct the problem.
MOVING
PARTS
HAZARD
Moving parts, such as the air motor piston and the
secondary pump lever and connecting rod area,
can pinch or amputate fingers.
_ Do not operate the equipment with the air motor
plates removed.
_ Keep your body and tools clear of any moving
parts when starting or operating the equipment.

Operation
1. Lock the spray gun trigger safety.
2. Close the red-handed bleed-type master air valve
3. Unlock the gun trigger safety.
4. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.
5. Lock the gun trigger safety.
6. Open the drain valve having a container ready to catch the drainage.
7. Leave the drain valve open until you are ready to spray again.
If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve
pressure gradually, then loosen completely. Now clear the tip or hose.
Packing
nut
/
wet
-
cup
Before starting, fill the packing nut 1/3 full with TSL or compatible solvent. To
reduce the risk of serious injury whenever you are instructed to relieve
pressure, always follow the pressure relief procedure. The packing nut is
torqued at the factory and is ready for operation If is becomes loose and there
is leaking form the throat packings, relieve pressure, then torque the nut to
136-149N.m using a wrench. Do this whenever necessary. Do not over tighten
the packing nut.
Flush the Pump Before first Using
The pump is tested with lightweight motor oil, which is left in to protect the pump parts.
If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent before using the pump. If the
pump is being used to supply a circulating system, allow the solvent to circulate until the pump is thoroughly flushed.
Flush the pump.
- Before the first use.
- When changing colors or fluids.
- Before fluid can dry or settle out in a dormant pump(check the pot life of catalysed fluids)
- Before storing the pump
Flush whit a fluid that is compatible whit fluid you are pumping and whit the wetted parts in your system.
Check whit a fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.
Technical Data
Category
P
-
TYPE
AIR
MOTOR
M
-
TYPE
AIR
MOTOR
301
Maximum fluid working pressure
21
MPa
210
bar
10
MPa
100
bar
Maximum air input pressure 0.7 MPa, 7 bar
Ratio 30:1 15:1
Air inlet size 1/2 in. npt(f)
Fluid inlet size 3/4 in npt
Maximum operating temperature 82°C (180°F)
Wetted parts
Carbon Steel; Alloy Steel; S45C, 415,440: Zinc and
Nickel Plating; Ductile Iron; Tungsten Carbide; PTFE;
Leather

Parts drawing and Parts List for Air Motor DK301-100
No
Part
No
Description
Qty
1 DK30-101 NUT, cylinder cap 1
2 DK254-22 O-RING 1
3 DK30-103 CYLINDER, motor 1
4 DK30-104 ACTUATOR, valve 1
5 DK30-105 YOKE 1
6 DK30-106 PIN, toggle 2
7 DK30-107 ARM, toggle 2
8 DK30-108 SPRING 2
9 DK30-109 ROCKER, toggle 2
10 DK30-110 POPPET, valve 2
11 DK30-111 TRIP ROD 1
12 DK30-112 NUT, adjusting 4
13 DK30-113 GROMMET, rubber 2
14 DK30-114 LOCKWIRE 2
15 DK30-115 POPPET, valve 2
16 DK30-116 STEM, valve 2
17 DK30-117 SCREW 2
18 DK30-118 CLIP, spring 2
19 DK30-119 PISTON 1
20 DK30-120 O-RING ,piston 1
21 DK254-30 GASKET, copper 1
22 DK30-122 ROD, piston 1
23 DK30-123 O-RING 1
24 DK30-124 SEAL 1
25 DK30-125 BASE 1
26 DK30-126 RETAINER 1
27 DK30-127 SNAP RING 1
28 DK30-128 WASHER 8
29 DK30-129 SCREW 8
30 DK30-130 PLATE, muffler 2
31 DK254-48 SCREW 20
Note : part marked in color are the repair parts
Replacement Danger and Warning labels, tags and cards
are available at no cost.
These parts are included in repair kit : DK301-AM which may be purchased separately.
Always use genuine FLOTECH parts.

Parts drawing and Parts List
101
103
104
106
105
102
No
Part
No
Description
Qty
101
DK301-100 AIR MOTOR
1
102
DK301-200 DIS. PUMP ASS’Y
1
103
DK30-201 SEAL(O-RING)
1
104
DK30-202 COTTER PIN
1
105
DK30-203 NUT
3
106
DK30-225 TIE ROD
3
DISCONNECTING THE DISPLACEMENT PUMP
1.
Flush the pump if possible. Stop the pump at the bottom of
its stroke. Relieve the pressure.
2.
Disconnect the air and fluid hoses. Remove the pump from
its mounting. Note the relative position of the pump’s fluid
outlet to the air motor’s air inlet.
3.
Unscrew the tie rod locknuts (105) from the tie rods (106).
Remove the cotter pin (104). Unscrew the displacement
rod (13) from the air motor (101).
Carefully pull the displacement pump (102) off the air
motor (101).
4.
Refer to for displacement pump service.
To service the air motor, refer to the air motor service.
RECONNECTING THE DISPLACEMENT PUMP
1.
Place it on the rod. The align pump’s fluid outlet to the air
motor’s air inlet was noted under Disconnecting the
Displacement pump. Position the displacement pump on
The tie rod.
2.
Screw the locknuts onto the tie loosely.
Screw the displacement rod into the shaft of the air motor
until the pin holes align the cotter pin.
3.
Mount the pump and reconnect all hoses. Reconnect the
ground wire if it was disconnected during repair. Torque the
packing nut/wet–cup (24) to 18–20 ft–lb (24–27 N.m). Fill
the wet–cup with FLOTECH Throat Seal Liquid or
compatible solvent.
4.
Tighten the tie rod locknuts (105) evenly, and torque to 25–
30 ft–lb (34–41 N.m).
5.
Start the pump and run it at about 40 psi (280 kPa,2.8 bar)
air pressure, to check that it is operating properly.

Displacement
Pump Service
Disassembly
When disassembling the pump, lay out all removed
parts in sequence, to ease reassembly.
Clean all the parts thoroughly when disassembling.
Check them carefully for damage or wear, replacing
parts as needed.
1.
Remove the displacement pump from the air
motor
as explained.
2.
Unscrew the intake valve housing (19) from the
pump housing (9). If it is difficult to remove, squirt
penetrating oil around the threads and gently tap
around the valve housing with a plastic hammer
to
loosen it.
3.
Remove the ball stop pin (15), o–ring(17),
retainer (16), and ball (18), ball guide(22), from
the intake housing (19).
4.
Loosen the packing nut (24). Push the
displacement
rod (12) down as far as possible, then pull it out
the bottom of the pump housing (9).
5.
Secure the flats of the displacement rod (12) in a
vise. Screw the piston stud(14) out of the rod .
Remove the ball(13), reatainer(21), packings(5,6)
And glands(4,7).
6.
Remove the packing nut (24), throat packings
(5.6)
and glands (4,7) from the pump housing (9).
7.
Inspect all parts for damage. Clean all parts and
threads with a compatible solvent before
assembling. Inspect the polished surfaces of the
displacement rod (12) and sleeve (11) for
scratches,
scoring or other damage, which can cause
premature packing wear and leaking. To check,
run a finger over the surface or hold the part up
to the
light at an angle. Be sure the ball seats of the
piston and intake housing are not chipped or
nicked. Replace any worn or damaged parts.
NOTE: If the sleeve (11) needs replacement and is
hard to remove, contact your FLOTECH
distributor.
Reassembly
1.
Lubricate the throat packings and install them in
The outlet housing (9) one at a time as follows,
with the lips of the v–packings facing down: the
male gland (4), one teflon (6), two leather(5),
one teflon (6), one leather (5), one teflon (6),
and the female gland (7). Install the packing nut
(24) loosely. See the throat packing detail.
2.
If you removed the sleeve (11), reinstall it in the
pump housing (9), making sure to replace the
gasket (10). Be sure the tapered end of the
sleeve
faces down, toward the pump intake.
3.
Lubricate the piston packings and install them
onto
the piston stud (14) one at a time in the
following
order, with the lips of the v–packings facing up:
the
female gland (7), one Teflon (6), two leather (5),
one Teflon (6), one leather (5), one Teflon (6),
the male gland (4), and the packing retainer
(21). See the piston packing detail.
4.
DO NOT use thread sealant on the piston
stud(14)
Install the piston ball (13) on the piston and
screw
the piston valve assembly into the displacement
rod (12). Torque to 65–75 ft–lb (88–102 N.m).
5.
Insert the displacement rod (12) into the bottom
of
the pump housing (9), being careful not to
scratch
the sleeve (11). Push the rod straight up until it
protrudes from the packing nut (24).
6.
Install the ball (18), o–ring (17), retainer(16),
and ball stop pin (15), ball guide(22), in the
intake valve housing (19). Apply thread
lubricant and Screw the intake housing into the
pump housing (9). Torque to 75–100 ft–lb
(102–136 N.m).
7.
Reconnect the displacement pump to the air
motor as explained.

Technical
Data
Maximum fluid working pressure 3600 psi (25.0 MPa, 250 bar.
Maximum air input pressure 120 psi (0.8 MPa, 8 bar.
Pump cycles per 1 gallon (3.8 liters) 60.
Maximum flow at 60 cycles/min 1 gallon (3.8 liters) ..
Recommended speed for optimum pump life 15–25 cycles/min;.
0.25 to 0.42 gpm (0.9 to 1.6 liters/min)
Air consumption approx. 35 scfm (0.98 min)
at 1 gpm (3.8 liters/min) at 100 psi (0.7 MPa, 7 bar) air pressure
Weight approx. 24 lb (11 Kg)
Dimensions
Mounting
Hole
Layout

Parts drawing and Parts List
301 DISPLACEMENT PUMP
Note : part marked in color are the spare parts
These parts are included in repair kit : DK301-LA
which may be purchased separately.
Always use genuine parts
No
Part
No
Description
Qty
4
DK30-204 GLAND , male
2
5
DK30-205 V-LEATHER
6
6
DK30-206 V-TEFLON
6
7
DK30-207 GLAND , female
2
8
DK30-208 NIPPLE
1
10 DK30-209 PUMP HOUSING
1
11 DK30-210 SEAL(TEFLON)
1
12 DK30-211 SLEEVE
1
13 DK30-212 DIS. ROD
1
14 DK30-213 BALL(5/16”)
1
15 DK30-214 VALVE PISTON
1
16 DK30-215 PIN
1
17 DK30-216 RETAINER
1
18 DK30-217 SEAL(TEFLON)
1
19 DK30-218 BALL(1/2”)
1
20 DK30-219 INTAKE
1
22 DK254-02 UNION
1
23 DK30-221 WASHER
1
24 DK30-222 GUIDE , BALL
1
25 DK30-223 PLUG
1
26 DK30-224 PACKING , NUT
1

SURGE TANK ASS’Y (DK301-
300)
REGULATOR ASS’Y(DK301-400)
No PART NO. DESCRIPTION Q’TY
1 DK301-301 PLUG 1
2 DK301-302 BOWL 1
3 DK254-303 SPRING 1
4 DK-KS2202 STRAINER #60 1
5 DK186-075 SUPPORT 1
6 DK301-306 PACKING,O-RING 1
7 DK301-307 NIPPLE 1
8 DK301-308 MANIFOLD 1
9 DK301-309 UNION 1
10 DK254-308 BALL VALVE 1
No PART NO. DESCRIPTION Q’TY
1 DK301-401 NIPPLE 1
2 DK301-402 VALVE 1
3 DK301-403 ELBOW 1
4 DK301-404 AIR REGULATOR & GUAGE
1
5 DK301-405 AIR COUPLER 1

SUCTION ASS’Y(DK301-500)
CART ASS’Y(DK301-600)
No PART NO. DESCRIPTION Q’TY
1 DK-KS22903 3/4" FILTER 1
2 DK301-502 SUPPORT PIPE 1
3 DK301-503 ELBOW 1
4 DK301-504 SUCTION HOSE 1
No PART NO. DESCRIPTION Q’TY
1 DK301-601 CART & HANDLE 1
2 DK301-602 TIRE 2
3 DK301-603 SANP RING 2
1
3
2

FLOTECH Standard Warranty
FLOTECH warrants all equipment referenced in this document which is manufactured by FLOTECH and bearing its name to be
free from
defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special,
extended,or limited warranty published by FLOTECH, FLOTECH will, for a period of twelve months from the date of sale, repair
or replace any part of the equipment determined by FLOTECH to be defective. This warranty applies only when the equipment
is installed, operated and maintained in accordance with FLOTECH written recommendations.
This warranty does not cover, and FLOTECH shall not be liable for general wear and tear, or any malfunction, damage or wear
caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident,
tampering, or substitution of non–FLOTECH component parts. Nor shall FLOTECH be liable for malfunction, damage or wear
caused by the incompatibility of FLOTECH equipment with structures, accessories, equipment or materials not supplied by
FLOTECH, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment
or materials not supplied by FLOTECH.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized FLOTECH
distributor for verification of the claimed defect. If the claimed defect is verified, FLOTECH will repair or replace free of charge
any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the
equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which
charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE.
FLOTECH sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees
that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to
person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be
brought within one (1) years of the date of sale.
FLOTECH MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH
ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY FLOTECH. These items sold, but not manufactured by FLOTECH (such as electric
motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. FLOTECH will provide purchaser with reasonable
assistance in making any claim for breach of these warranties.
In no event will FLOTECH be liable for indirect, incidental, special or consequential damages resulting from FLOTECH
supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of
contract, breach of warranty, the negligence of FLOTECH or otherwise.
FLOTECH Information
TO PLACE AN ORDER OR FOR SERVICE, contact your FLOTECH distributor, or call these numbers to identify
the nearest
distributor.
SPEEDO MARINE (PTE) LTD
No.11 Tuas Link 2 Singapore 638559
TEL: [phone] FAX: [phone]
E-mail : [email protected]
http://www.speedo.com.sg