Ingersoll-Rand 559 Series User manual

E2011 CCN 20083093
(800) 495--0276 DFAX (800)892--6276
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET BRYAN, OHIO 43506
www.ingersollrandproducts.com
OPERATOR’S MANUAL 559X
RELEASED: 2-3-03
REVISED: 9-27-11
(REV. H)
CHOP-CHECK GREASE PUMP
2” AIR MOTOR
50:1 RATIO
0 - 7500 P.S.I. RANGE
INCLUDE MANUAL: S- GENERAL INFORMATION (PN 97999-
INCLUDING: SPECIFICATIONS, SERVICE KITS, GENERAL INFORMATION, PARTS, TROUBLESHOOTING
5596, 5597, 5598, 5599
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
•UseonlygenuineIRRreplacement partstoassurecompatiblepres-
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.......................
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 In3Per Cycle 0.300.......
Volume / Cycle 6.55 ml (0.22 oz.).................
Maximum Delivery / Minute 4.1kg(9lbs).......
Noise Level @ 100 p.s.i. 85
..........
Accessories Available 61113 Wall Mount Bracket.......
66073-1 Air Line Connection Kit
The pump sound pressure level has been updated to an Equivalent Continuous Sound
Level (LAeq) to meet the intent of ANSI S1. 13-1971, CAGI-PNEUROP S5.1 using four
microphone locations.
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 ma-
terials 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 accesso-
ries which will best match the application. All accessories must be able
to withstand the maximum pressure developed by the pump.
PUMP DATA
MODEL 559X
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)
NOTE: Dimensions are shown in inches and (mm), supplied for reference only and are typically
rounded up to the nearest 1/16 inch.
Figure 1
Air Inlet (female)
(1/4 - 18 N.P.T.F. - 1)
Material Outlet (female)
(3/8 - 18 N.P.T.F. - 1)
2” N.P.S.M. Bung Adapter
8 mm (5/16”) Thru hole
“B”
“A”
1-1/4”
(31.8 mm)
IMPORTANT
This is one of two documents which support the pump. Replace-
ment copies of these forms are available upon request.
=559X Model Operator’s Manual (pn 97999-1033)
-S- General Information Lubrication Piston Pumps (pn 97999
WARNING READ THE GENERAL INFORMATION MANUAL
INCLUDEDFORADDITIONALOPERATINGANDSAFETYPRE-
CAUTIONS AND OTHER IMPORTANT INFORMATION.
-
632
db (A)
Testedwith95086 mufflerassemblyinstalled.
1
1
632 -624).
624).
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559X
Page2of4
PARTS LIST / 559X
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
1Carriage Bolt (1/4” - 20 x 9” long) (4) 94333 [C]
2Upper Cap (1) 94307 [Z]
n3Gasket (2) 94311 [B]
4Sleeve (2) 94316 [Br]
n5“O” Ring (1/16” x 11/16” o.d.) (4) Y325-15 [B]
n6“O” Ring (1/8” x 3/4” o.d.) (4) Y325-206 [B]
7Spool (2) 94310 [D]
n8“U” Cup (1/8” x 3/4” o.d.) (2) Y240-7 [B]
n9“O” Ring (0.106” x 0.587” o.d.) (2) 15066-PM [B]
10 Cylinder (1) 94249 [A]
11 Adapter (1) 94447 [C]
n12 “O” Ring (1/16” x 3/4” o.d.) (1) Y325-16 [B]
n13 “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]
n18 “U” Cup (3/16” x 2” o.d.) (2) Y240-23 [B]
19 Piston (1) 94780 [D]
20 Piston Adapter (1) 94388 [C]
n21 “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]
n23 “O” Ring (3/32” x 13/16” o.d.) (1) Y325-114 [B]
n24 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]
n30 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]
n32 Gasket (1) 70837 [Co]
33 Piston Rod (1) 95137 [C]
34 Pin (1) 94786 [C]
n35 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]
n42 Guide Washer (1) 95131 [Co]
43 Spacer (1) 72392-1 [C]
n44 Retaining Ring (0.877” o.d.) (1) 76243-1 [C]
n45 “U” Cup (1/8” x 13/16” o.d.) (1) Y186-54 [B]
n46 Guide (1) 95132 [T]
47 Foot Valve Body (1) 95133 [SH]
FootValve Assembly (includes44
- 47)
(1) 67242
n48 Gasket (1) F21-65 [Co]
49 Valve Seat (1) 6797 [C]
50 Primer (1) 94400 [C]
n51 Retainer Ring (1) 94397 [C]
52 Primer Tube (1) 94399 [C]
K53 Bung Assembly (includes 54) (1) 67145-2 [ZA]
K54 Thumb Screw (1/4”-20x1”) (3) Y66-59-C [C]
nGadus S2 U1000 Grease Packet (1) 94833
nParts in Repair Kit 637385
KNot included with models 5597
OPERATING AND SAFETY PRECAUTIONS
WARNING EXCESSIVE INLET PRESSURE. Can cause ex-
plosion resulting in severe injury or death. Do not exceed maxi-
mum 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 aregu-
lator to limit air supply pressure to the pump.
WARNING EXCESSIVE MATERIAL PRESSURE. Can cause
equipment failure resulting in severe injury or property dam-
age. Do not exceed the maximum material pressure of any
component in the system.
Replacement warning label is available upon request, PN \ 94520.
PUMP RATIO X
INLET PRESSURE TO PUMP MOTOR =MAXIMUM PUMP FLUID PRESSURE
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.
NOTICE: Thermal expansion can occur when the fluid in the materi-
al 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.
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559X Page3of4
PARTS LIST / 559X
1
6
.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).
2
3
4
10
7
8
9
9
8
7
6
31 ,
32
37 ,
28 ,
40
19
18
3
46
18
17
16
13
.11
21
23
38
45
33
47
49
43
5
30
5
4
15
14
20
24
27
29
51
52 ,
48
54
53
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
22
34
35
25
26
36 ,
41 ,
Figure 2
50
44
42
39
12
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559X
Page4of4
PUMP DISASSEMBLY
NOTE: All threads are right hand. Refer to figure 2 (page 3). Discon-
nect air supply and relieve all system pressure prior to servicing.
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 re-
move (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) pis-
ton rod.
12. Using (33) piston rod, push down on (36) connector until it bottoms.
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) prim-
er 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 in the cross hole in (36) connector and a
9/16” wrench on the flats of (38) plunger, unthread and remove (36)
connector from (38) plunger. NOTE: Do not 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.
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 - 11.3 Nm (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).
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) con-
necting pin and (35) cotter pin.
9. Assemble (32) gasket and (31) extension tube to (37) lower suction
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) exten-
sion 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” ring to (20) piston adapter and assemble (20) pis-
ton 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 cylin-
der nearest the exhaust hole.
16. Replace (6 and 9) “O” rings and (8) “U” cups on (7) spools and as-
semble (7) spools into (10) cylinder from 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 cap and assemble (2) upper cap 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).
TROUBLE SHOOTING
If the pump will not cycle or will not deliver material.
•Be certain 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
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