Ingersoll-Rand LM2305A-X-B Operating And Safety Precautions, Pump Disassembly, Pump Reassembly

OPERATING AND SAFETY PRECAUTIONS

WARNING READ THE GENERAL INFORMATION MANUAL INCLUDED FOR ADDITIONAL OPERATING AND SAFETY PRE- CAUTIONS AND OTHER IMPORTANT INFORMATION.

WARNING EXCESSIVE INLET PRESSURE. Can cause ex- plosion resulting in severe injury or death. Do not exceed maxi- mum operating pressure of 750 p.s.i. (51.7 bar) at 150 p.s.i. (10.3 bar) inlet air pressure. Do not run pump without using a regula- tor 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.

PUMP RATIO X	=	MAXIMUM PUMP
INLET PRESSURE TO PUMP MOTOR		FLUID PRESSURE

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 5:1 ratio pump it will develop a maximum of 750 p.s.i. (51.7 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.

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.

Replacement warning label (pn 94520) is available upon request.

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 (12) adapter and (11 and 13) “O” rings, releasing (15) muffler housing.

2.Using a 7/16” wrench, remove (36) 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.Pull up on (21) piston and (22) lower cap, allowing access to (25) bushing.

7.Using a 1-5/8” wrench, unthread (25) bushing and pull (28) piston rod and components from pump.

8.Clamp on flats of (28) piston rod in a vise. Using an 11/16” wrench on flats of (30) cup follower, unthread and remove from (28) piston rod.

9.Clamp on flats of (30) cup follower in a vise. Using a 1-1/2” wrench, unthread and remove (34) inner check seat, releasing (32) washer, (33) ball and (31) piston cup.

10.Remove (25) bushing from (28) piston rod.

11.Remove (24) “O” ring and (26) packing from (25) bushing.

PUMP REASSEMBLY

NOTE: Thoroughly clean and lubricate all seals. Replace all soft

parts with new ones included in the repair kit. Note: Refer to the il- lustration (figure 2, page 3) for “U” cup lip seal direction.

1.Replace (27) “O” ring on (28) piston rod.

2.Replace (20) “U” cups on (21) piston and assemble (21) piston onto

(28)piston rod, securing with (19) washer and (18) retaining ring.

3.Assemble (3) gasket to (22) lower cap and assemble (22) lower cap and (23) “O” ring onto (28) piston rod.

4.Assemble (33) ball and (31) piston cup to (30) cup follower, securing with (32) washer and (34) inner check seat.

5.Replace (26) packing in (25) bushing.

6.Replace (24) “O” ring on (25) bushing and assemble (25) bushing onto (28) piston rod.

7.Clamp on flats of (28) piston rod in a vise.

8.Assemble (29) rod and (30) cup follower to (28) piston rod and tight- en by using a 1-1/2” wrench on (34) inner check. NOTE: Torque (34) check seat to 65 ft lbs (88.1 Nm).

9.Clamp (39) tube horizontally in a vise.

10.Assemble (28) piston rod and components into (35) base.

11.Using a 1-5/8” wrench, thread (25) bushing into (35) base until it “bottoms”. NOTE: Be careful not to raise any burrs on flats of (25) bushing.

12.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.

13.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.

14.Assemble (10) cylinder onto the pump, being careful when sliding over the lips of (20) “U” cups. NOTE: Be sure (3) gasket is seated properly.

15.Replace (3) gasket on (2) upper cap and assemble (2) upper cap to

(10)cylinder.

16.Assemble (1) bolts to pump, securing with (36) nuts. NOTE: Torque

(36)nuts evenly to 80 in. lbs (9 Nm).

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

18.Assemble (16) foam liners and (17) edge trims to (15) muffler hous- ing.

19.Assemble (15) muffler housing to (10) cylinder, securing with (12) adapter. NOTE: Torque (12) adapter to 80 in. lbs (9 Nm).

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 97999-1134
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