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ITW 104020, Instruction Manual, Page: 3 / 28

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Instruction Manual 

 

 

 

Page 3 of 28 

Issue: 1.2

 

\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx 

Index 

Section 

 

1.1 General 

Description 

1.2 Operating 

Principle 

1.3 Specifications 

1.4 

Dimensions and Mounting Details 

 

 

 

 

2.1 

Important Safety Information 

 

 

 

 

3.1 

Installation - General 

 

 

 

 

4.1 

Parts Lists Main Pump 

4.2 

Parts Lists Air Motor

 

4.3 

Parts Lists Fluid Section

 

4.4 

Parts Lists Reference

 

 

 

 

 

5.1 

Maintenance – Air Motor Assembly Procedure 

5.2 

Maintenance – Fluid Section Assembly 

5.3 

Maintenance – Final Pump  Assembly 

 

 

6.1 

Maintenance - General 

6.2 

Maintenance - Fault Finding 

 

 

 

 

7.1 

Spare Parts Lists 

7.2 Accessories 

 

 

 

 

 

 

 

Summary of Contents for 104020

Page 1: ...Instruction Manual For Maple 60 Pump Model 104020 ...

Page 2: ...Atmospheres BS EN 13463 5 2005 Providing all conditions of safe use stated within the product manuals have been complied with and that the final equipment into which this product is installed has been re assessed as required in accordance with essential health and safety requirements of the above standards directives and statutory instruments and also installed in accordance with any applicable lo...

Page 3: ...nsions and Mounting Details 2 1 Important Safety Information 3 1 Installation General 4 1 Parts Lists Main Pump 4 2 Parts Lists Air Motor 4 3 Parts Lists Fluid Section 4 4 Parts Lists Reference 5 1 Maintenance Air Motor Assembly Procedure 5 2 Maintenance Fluid Section Assembly 5 3 Maintenance Final Pump Assembly 6 1 Maintenance General 6 2 Maintenance Fault Finding 7 1 Spare Parts Lists 7 2 Access...

Page 4: ...and lapped steel spool and sleeve air valves to control the air motor reversal providing reciprocating motion The air valve design patent pending ensures a positive magnetic detent for the main and pilot air valves thus removing the possibility for a stall condition The air motor also utilises the Binks Low Ice quick exhaust technology to prevent air valve freezing conditions when high cycle speed...

Page 5: ... in position by a magnetic detent The main spool valve is air piloted and contains two exhaust ports Both the pilot valves and the main spool valve are easily removable There are no external air pilot hoses The air logic and exhaust ports are internal Simply mounting the spool valve and the pilot valves assures that the logic circuits are connected properly The air cylinder exhaust air is channell...

Page 6: ... Litres min 24 0 US Gall min Maximum Recommended Continuous Cycle Rate Maximum Recommended Intermittent Cycle Rate 20 Cycles min 40 Cycles min Fluid Inlet Outlet Connections 1 1 2 Sanitary Air Volume cycle 0 7 SCFM 19 8 L m 45PSI 3 1 Bar 1 4 SCFM 39 7 L m 90 PSI 6 2 Bar Air Flow 15 cycles min 6 bar Air Flow 30 cycles min 6 bar 21 CFM 595 L min 42 CFM 1190 L min Air Quality ISO 8573 1 Class 3 3 2 D...

Page 7: ...rd Original Pump Unit Maple 60 R1 2 docx Dimensions and Mounting Details Section 1 4 For Piped Exhaust Air remove mufflers and add 192803 Plug and Hose Adapter 192779 for 1 NB Hose or 192820 for 1 NB Hose Note For Pump fluid pressures above 13 bar use 1 NB Alternate Mounting ...

Page 8: ... following instructions are ignored Installation and maintenance should only be carried out by suitably qualified personnel 1 Before attempting any work on a high pressure system ensure material pump hydraulics compressed air motor are isolated where relevant 2 Relieve all pressure from the system Note It is possible for pressure to get locked into a system therefore ensure all sections of the sys...

Page 9: ...smoke in the spray dispense area Do not turn on or off any light switch in the spray dispense area while operating or if fumes are present Do not operate a gasoline engine in the spray dispense area Hot Surface Hazard The electric motor becomes hot during operation and the heat may be transferred to other connected equipment To reduce the risk of burning yourself do not touch the motor surfaces wh...

Page 10: ... Connect a suitable 3 8 NB air hose and Pressure Filter Regulator to the air motor Filter rated at minimum 1000 L min No additional air lubrication is required as piston o ring lubricant is applied during assembly or repair If an air lubricator is used to prolong piston seal life for example continuous duty at high pump cycle rates then this must be maintained as the lubricant removes the piston s...

Page 11: ...0 R1 2 docx Parts List Section 4 1 Parts List 104020 Main Pump Assembly ITEM PART No DESCRIPTION QTY REMARKS 1 AIR MOTOR ASSEMBLY 1 2 FLUID SECTION ASSEMBLY 2 90 192821 MUFFLER 2 91 192008 1 5 SANITARY GASKET PTFE 4 92 192009 1 1 1 2 SANITARY CLAMP 4 93 192895 INLET MANIFOLD 1 94 192896 OUTLET MANIFOLD 1 ...

Page 12: ...4 11 165963 M8 HEX NUT 18 12 165965 M10 x 16 HEX HEAD SET SCREW STST 4 13 165975 M16 x 60 GRUBSCREW STST 1 14 165977 M8 x 90 CAP HD SCREW ST ST 2 15 192147 LABEL 1 16 192765 PILOT SPOOL ASSEMBLY 2 17 192814 BELLOWS LEAK DETECTION HOSE 1 18 192815 1 8R 6MM PUSH IN ELBOW 2 19 192881 KNIFED BELLOWS 2 20 192882 SHAFT 2 21 192883 CYLINDER 1 22 192884 END PLATE LH 1 23 192885 END PLATE RH 1 24 192886 AI...

Page 13: ...Instruction Manual Page 13 of 28 Issue 1 2 Argon automotive_ftp Manuals Word Original Pump Unit Maple 60 R1 2 docx Parts List Section 4 2 Air Motor Assembly ...

Page 14: ... 40 162732 Ø69 x 3 O RING 2 41 0115 010426 Ø30 x 2 O RING 2 42 163951 M6 x 16 SOCKET HEAD SETSCREW 12 43 191242 DIAPHRAGM 2 44 192651 1 8 BSPP PLUG 2 45 192899 MAIN VALVE BODY ASSY 1 46 192905 EXHAUST PLATE 1 47 193132 QEV CARTRIDGE ASSEMBLY 2 48 193096 1 2 BSP AIR INLET 1 49 0115 010425 VALVE BLOCK END CAP 1 50 0115 010431 SPACER 2 51 0115 010427 VALVE BUMPER 2 52 0115 010428 MAGNET 2 53 0115 010...

Page 15: ...Instruction Manual Page 15 of 28 Issue 1 2 Argon automotive_ftp Manuals Word Original Pump Unit Maple 60 R1 2 docx Parts List Section 4 2 192897 Main Air Valve Assembly ...

Page 16: ... WASHER ST ST 4 65 165978 M14 x 40 CAP HD SCREW ST ST 8 66 171784 1 750 ST ST BALL 1 67 171788 1 375 ST ST BALL 1 68 192551 HEXAGON PLUG 1 4 BSP 1 69 192595 OUTLET CHECK 1 70 192626 OUTLET CAGE 1 71 192629 INLET SPRING KEEP 2 72 192631 INLET BALL SEAT 1 73 192632 OUTLET BALLSEAT 1 74 192646 Ø50 5 x 1 78 O Ring 1 75 192647 Ø50 5 x 2 62 O Ring 1 76 192648 Ø41 0 x 1 78 O Ring 1 77 192889 FLUID PISTON...

Page 17: ......

Page 18: ...r reference and identification only If the pilot spool is removed from the air motor for inspection it is recommended that the 3 off O ring seals H are replaced and lightly greased Spare Pilot Valves are fitted with the 3 off O ring 192773 ITEM PART No DESCRIPTION QTY REMARKS H 192773 Ø17 O RING 3 When the valve is removed from the air motor protect the magnet from any form of contamination Metall...

Page 19: ...es are inline 6 Insert 5 off short tie rods 30 and 4off long tie rods 31 through the end plates Fit 18 off washers 9 over the ends of the tie rods Apply Loctite 243 to the LH end of the tie rods and add grease type to the other end Fit domed nuts 11 onto the LH loctited end and screw on as far as possible screw on the remaining domed nuts and tighten in cross over sequence together to 22Nm 7 Apply...

Page 20: ...49 then fit O ring 41 lubricate with grease type and assemble into housing 6 Position diaphragm 43 into QEV cartridge 47 and fit into housing ensure transfer holes are inline ensure diaphragm is centrally located 7 Fit exhaust plate 46 to manifold 28 with 6 off screws 42 using Loctite 222 tighten to 12Nm 8 Fit 2 off O rings 40 around QEV cartridges and fit the exhaust plate and manifold over the Q...

Page 21: ...ng 74 and inlet seat 72 into piston 78 4 Fit piston keep plate 81 and assemble with 5 off screws 61 use Loctite 222 on the threads Tighten evenly to 12Nm 1 Assemble the outlet ball check place spring 60 spring keep 71 and ball 67 into outlet check casting 69 2 Fit O ring seal 76 and outlet seat 73 into outlet cage 70 3 Assemble the outlet check and outlet cage together and position onto the outlet...

Page 22: ...ections are being assembled tighten by holding one piston with its 14mm hexagon socket and torque the other piston using its socket 4 Lightly grease with type the pistons and fit the piston seals 77 wear lip pointing away from the shaft thread 5 Fit outlet cylinder sub assembly over the seal secure with lightly greased 4off M14x40 caphead screws 65 and assemble with 4off Ø14 washers 63 to hold the...

Page 23: ...struction Manual Page 23 of 28 Issue 1 2 Argon automotive_ftp Manuals Word Original Pump Unit Maple 60 R1 2 docx Maintenance Section 5 4 Disassembly Procedure Removal of a single fluid piston 22mm SPANNER ...

Page 24: ...mechanical noise Check for excessive fluid pressure pulsation 6 Monthly Test Perform a pump stall test to ensure correct operation If pump does not stall check fluid piston seals and ball checks replace as required If air is escaping through exhaust check air motor piston seal and quick exhaust diaphragm replace as required 12 to 36 Months Typically 10 million Pump Cycles dependant on air quality ...

Page 25: ... Air valve e Check for constant exhaust air when pump is not running Check replace QE diaphragms f Inspect clean and or replace balls and seats Pump runs but has excessive pulsation a Air getting into fluid line air supply restricted b Obstructed fluid ball checks c Worn piston seals Worn failed air motor shaft seals Worn loose air motor shaft seal components Worn fluid piston and or seal d Air ex...

Page 26: ...Fluid Piston Seal Kit Fluid Piston seals Fluid O rings Ball Check Springs Manifold seals 250633 Fluid Section Overhaul Kit Fluid Piston seals Fluid O rings Ball Check Springs Manifold seals Balls and Seats Bellows 250634 Air Motor Seal Kit Air Piston Seals Shaft seals and bearings All O rings QEV diaphragms 250635 Control Valve Kit Pilot Valves inc O rings Main Valve inc O rings Check Main Parts L...

Page 27: ...ption Remarks 192008 1 Sanitary Gasket 192009 1 Sanitary Clamp 502679 Seal Insertion Tool For Shaft seal 6 502682 Bellows Assembly Tool 502681 Bellows Assembly Spigot AGMD 010 Kluber Isoflex Topas NB 52 Grease type 50 ml Tube 192779 Exhaust Tube Adapter 1 NB hose For piped exhaust 192820 Exhaust Tube Adapter 1 NB hose For piped exhaust 192803 1 Manifold Plug For piped exhaust ...

Page 28: ...e Finishing Ringwood Road Bournemouth Dorset BH11 9LH UK Tel 44 0 1202 571 111 Fax 44 0 1202 573 488 General e mail info itwautofinish eu Web http www itwautofinish eu ITW Automotive Finishing 163 171 Av des Auréats 26014 Valence cedex FR Téléphone 33 0 4 75 75 27 53 Télécopie 33 0 4 75 75 27 79 General e mail info itwautofinish eu Web http www itwautofinish eu ITW Automotive Finishing registered ...

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