Instruction Manual For Maple 15 - Pump Model 104009
Instruction Manual Page 2 of 28 Issue: 2.
Instruction Manual Index Section 1.1 1.2 1.3 1.4 General Description Operating Principle Specifications Dimensions and Mounting Details 2.1 Important Safety Information 3.1 Installation - General 4.1 4.2 4.3 4.4 Parts Lists Main Pump Parts Lists Air Motor Parts Lists Fluid Section Parts Lists Reference 5.1 5.2 5.3 Maintenance – Air Motor Assembly Procedure Maintenance – Fluid Section Assembly Maintenance – Final Pump Assembly 6.1 6.2 Maintenance - General Maintenance - Fault Finding 7.1 7.
Instruction Manual General Description – Section 1.1 High Quality materials and surface treatments are used in the construction of this pump to ensure both extended operational life and good future appearance. The Maple pump is a horizontal piston pump for pumping Solvent / Waterborne Paints, Solvents and other suitable materials. An Ø125 x 50mm stroke air motor is used to drive two fluid sections giving a combined output of 0.375 L per cycle.
Instruction Manual Operating Principle – Section 1.2 The Assembly comprises of:• • • • • • • Central Air Piston and ‘change over’ Valves 2 off Quick Exhaust and muffler assembly 2 off Dynamic Chambers and Fluid Pistons 2 off Fluid Pressure Chambers each complete with Suction and Pressure Ball Check Valve Assemblies 1 off Fluid Inlet Manifold 1 off Fluid Outlet Manifold Support Bracket The Pumps have horizontally opposed positive displacement pistons connected to a common reciprocating air motor piston.
Instruction Manual Specification – Section 1.3 Specification 50 mm 1.97 ins Pump Nominal Stroke Pump Ratio 3:1 0..375 Litres 0.10 US Gall Nominal Flow Volume / Cycle Fluid Output @ 60 cycles/min 22.5 Litres / min 6.0 US Gall / min Maximum Recommended Continuous Cycle Rate 20 Cycles /min Maximum Recommended Intermittent Cycle Rate 40 Cycles /min Fluid Inlet / Outlet Connections 1” Sanitary 0.17 SCFM (4.8 L/m) @ 45PSI (3.1 Bar) 0.33 SCFM (9.3 L/m) @ 90 PSI (6.
Instruction Manual Dimensions and Mounting Details – Section 1.4 For Piped Exhaust Air, remove mufflers and add 192803 Plug and Adapter 192779 for 1” NB Hose Page 7 of 28 Issue: 2.
Instruction Manual Important Safety Information - Section 2.1 Directions for Working Safety This Product has been constructed according to advanced technological standards and is operationally reliable. Damage may, however, result if it is used incorrectly by untrained persons or used for purposes other than those for which it was constructed. The locally current regulations for safety and prevention of accidents are valid for the operation of this product under all circumstances.
Instruction Manual Important Safety Information - Section 2.1 Fire, Explosion and Electric Shock Hazard Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. When installed and operated in accordance with its instructions, the pump is approved for operation in Zone 1 (Europe) & Division 1 (North America), hazardous locations.
Instruction Manual Installation – Section 3.1 Mount the pump securely and position the pump at a convenient height (below the lid height of the paint container), to allow for maintenance, visual observation, and periodic inspection. The wall mount bracket is included with all pumps. Exhaust silencer kits are available for these pumps if the air exhaust is required to be piped away from the pump rather than exhausting locally through the mufflers.
Instruction Manual Parts List – Section 4.1 Parts List - 104009 Main Pump Assembly ITEM PART No DESCRIPTION 1 ------ AIR MOTOR ASSEMBLY 1 2 ------ FLUID SECTION ASSEMBLY 2 81 82 192777 192834 MUFFLER INLET MANIFOLD 2 1 83 84 85 192835 192009 192206 OUTLET MANIFOLD SANITARY CLAMP SANITARY GASKET 1 4 4 Page 11 of 28 QTY REMARKS Issue: 2.
Instruction Manual Parts List - Air Motor Assembly ITEM PART No 3 0115-010102 161998 161993 161994 DESCRIPTION QTY REMARKS MAIN AIR VALVE ASSEMBLY Ø125 x 2 O-RING Ø20.35 x 1.78 O-RING Ø4.47 x 1.78 O-RING 1 2 2 4 161995 162707 162703 162704 Ø19.5 x 3.
Instruction Manual Parts List – Section 4.2 Air Motor Assembly Page 13 of 28 Issue: 2.
Instruction Manual Parts List – Section 4.2 Parts List - 0115-010102 Main Air Valve Assembly ITEM PART No DESCRIPTION 40 41 42 43 0115-010097 0115-010015 0115-010016 0115-010017 VALVE BLOCK ASSEMBLY SPOOL & SLEEVE ASSEMBLY BUMPER MAGNET 1 1 2 2 44 45 46 0115-010018 192813 0115-010020 END CAP QE VALVE CAGE QEV DIAPHRAGM 2 2 2 47 48 49 50 0115-010021 0115-010049 0115-010073 171612 Ø36 x 1.
Instruction Manual Parts List – Section 4.2 0115-010102 Main Air Valve Assembly Page 15 of 28 Issue: 2.
Instruction Manual Parts List – Section 4.
Instruction Manual Page 17 of 28 Issue: 2.
Instruction Manual Maintenance – Section 5.1 - Assembly Procedure Pump Assembly – Air Motor Ensure all parts are clean and degreased. 1. Push bearings (10) into end plates (24) and insert ‘O’ rings (4) into the large grooves, applying a light coating of grease type #. 2. Apply light coating of grease type # to the seal groove of the piston and insert the ‘O’ ring portion of the piston seal (8), apply a little more grease to the top of the ‘O’ ring.
Instruction Manual Maintenance – Section 5.1 - Assembly Procedure Pump Assembly – Air Motor – Control Valves Pilot Valves (30) - Lightly grease threads and o-rings (grease type #) fit the two pilot valve assemblies into the end plates. Tighten to 0.4Nm (do not over tighten this will damage the valve assembly) Main Valve (3):1. Ensure all parts are free from contamination especially the magnets (43) 2. Lightly grease valve bore of housing (40) and oring of spool assembly (41) Use grease type # 3.
Instruction Manual Maintenance – Section 5.2 - Assembly Procedure Pump Assembly – Fluid Section - Ball Checks Assemble the Piston 1. Insert spring (55) and spring keep (68) into the piston 2. Place the ball (61) against spring keep. 3. Fit the ‘O’ ring (72) and inlet seat (70) into the piston (66). 4. Fit piston keep plate (67) and assemble with 5 off M5x25 caphead screws (56) use Loctite 222 on the threads. Tighten evenly to 8Nm. Assemble the outlet ball check 1.
Instruction Manual Maintenance – Section 5.3 - Assembly Procedure Pump Assembly – Fluid Section / Air Motor 1. Mount inlet cylinders (65) onto air motor end plates and over each shaft and bellows. Secure loosely with lightly greased 4off M10x35 cap head screws (60) and 4off Ø10 washers (58). Do not tighten at this stage as this may lead to bellows damage when assembling the piston to the shaft. 2.
Instruction Manual Maintenance – Section 5.4 - Disassembly Procedure Removal of a Single Fluid Piston Slide Inlet Cylinder out to expose shaft Hold Shaft with 16mm Spanner Turn Piston with 14mm Allen Key Page 22 of 28 Issue: 2.
Instruction Manual Maintenance – Section 6.1 – General The working life and thus the expected life prior to replacement of parts within a Paint Pump are greatly affected by three main factors: • • • Abrasiveness of Fluid Pumped Pump Duty Cycle Fluid Pressure Output requirement Maintenance Schedule Inspection Daily Operation Check for any general fluid or air leakage.
Instruction Manual Maintenance – Section 6.2 – Fault Finding Symptom Possible Cause Remedy Pump will not ‘Prime’ a. Air getting into the suction hose/manifold b. Worn piston seals c. Ball checks not seating correctly a. Check seals and hose connections b. Replace piston seals c. Inspect, clean/replace balls/seats Pump will not run a. No Air or Fluid supply a. Check air and fluid supply ball valves and supply hoses. b. Replace Piston seal c.
Instruction Manual Spare Parts List - Section 7.1 Recommended Replacement Spares Kits for Maple 15 Pump Kit No. Part No.
Instruction Manual Accessories - Section 7.2 Accessories / Maintenance Part No.
Instruction Manual Page 27 of 28 Issue: 2.
Instruction Manual Justus-von-Liebig-Straße 31, 63128 Dietzenbach. DE Tel. +49 (0) 6074 403 1 Fax. +49 (0) 607 403 300 General e-mail: info@finishingbrands.eu Ringwood Road, Bournemouth, Dorset BH11 9LH. UK Tel. +44 (0)1202 571 111 Fax. +44 (0)1202 573 488 General e-mail: info@finishingbrands.eu 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@finishingbrands.eu USA Canada Customer Service 195 Internationale Blvd.
