OPERATOR’S MANUAL
559X
INCLUDING: SPECIFICATIONS, SERVICE KITS, GENERAL INFORMATION, PARTS, TROUBLESHOOTING
INCLUDE MANUAL: S- GENERAL INFORMATION (PN 97999-624).
RELEASED:
2-3-03
632
REVISED:
9-27-11
(REV. H)
2” AIR MOTOR
50:1 RATIO
0 - 7500 P.S.I. RANGE
5596, 5597, 5598, 5599
CHOP-CHECK GREASE PUMP
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
PUMP DATA
• UseonlygenuineIRR replacementpartstoassurecompatiblepres-
sure rating and longest service life.
• 637385 Pump Rebuild Kit. Includes the necessary soft parts for
normal service of the entire pump.
MODEL 559X
SPECIFICATIONS
Air Inlet (female)
(1/4 - 18 N.P.T.F. - 1)
Model Series . . . . . . . . . . . . . . . . . . 559X
Type . . . . . . . . . . . . . Air Operated, Chop-Check Grease Pump
Ratio . . . . . . . . . . . . . . . . . . . . . . . . 50:1
1-1/4”
(31.8 mm)
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
Material Outlet (female)
(3/8 - 18 N.P.T.F. - 1)
2” N.P.S.M. Bung Adapter
“A”
PERFORMANCE
“B”
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
Figure 1
Displacement In3 Per Cycle . . . . . . . 0.300
8 mm (5/16”) Thru hole
Volume / Cycle . . . . . . . . . . . . . . . . . 6.55 ml (0.22 oz.)
Maximum Delivery / Minute . . . . . . . 4.1 kg (9 lbs)
1
db (A)
Noise Level @ 100 p.s.i. . . . . . . . . . . 85
Accessories Available . . . . . . . 61113 Wall Mount Bracket
NOTE: Dimensions are shown in inches and (mm), supplied for reference only and are typically
rounded up to the nearest 1/16 inch.
66073-1 Air Line Connection Kit
1
Testedwith95086 mufflerassemblyinstalled.
The pump sound pressure level has been updated to an Equivalent Continuous Sound
MODEL
5596
“A” (mm)
27-3/4” (704)
30-1/2” (774)
38-7/16” (976)
48” (1219)
“B” (mm)
WEIGHT (kg)
15 (6.8)
15.9 (7.2)
18.3 (8.3)
21.2 (9.6)
Level (L ) to meet the intent of ANSI S1. 13-1971, CAGI-PNEUROP S5.1 using four
Aeq
16-9/16” (421)
19-5/16” (490)
27-1/4” (692)
36-13/16” (935)
microphone locations.
5597
5598
5599
GENERAL DESCRIPTION
Themodel559Xserieschop-checkgrease pumpisintendedto beused
primarilyforgreasedeliverysystems. Itusescarbonsteelandotherma-
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.
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)
-624).
- S-632General Information Lubrication Piston Pumps (pn 97999
WARNING READ THE GENERAL INFORMATION MANUAL
INCLUDEDFORADDITIONALOPERATINGANDSAFETYPRE-
CAUTIONS AND OTHER IMPORTANT INFORMATION.
INGERSOLL RAND COMPANY LTD
-
209 NORTH MAIN STREET BRYAN, OHIO 43506
(800) 495--0276 D FAX (800)892--6276
E2011
CCN 20083093
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PARTS LIST / 559X
30
1
6
7
31 ,
2
3
4
32
8
9
5
37 ,
13
10
12
33
. 11
34
35
36 ,
14
15
5
4
16
9
8
38
MATERIAL CODE
17
18
7
6
[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
39
42
40
43
19
18
44
46
45
47
49
48
50
20
22
3
21
23
41 ,
51
28 ,
52 ,
29
27
24
25
26
. 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).
54
53
Figure 2
559X
Page 3 of 4
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3. Assemble(46) guideand(45) “U” cupinto (47) valve body, securing
with (44) retaining ring. NOTE: Assemble chamfered corner of (46)
guide into (47) valve body first.
PUMP DISASSEMBLY
NOTE:Allthreadsarerighthand.Refertofigure2(page3).Discon-
nect air supply and relieve all system pressure prior to servicing.
Carefullyremovetheparts,inspectfordamage, nicksorexcessivewear
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. Lightlywedgeaflat 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)gasketand(49)valveseatfrom(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.
4. Assemble (42) guide washer and (44 - 47) foot valve assemblyonto
(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)gasketinto(27)baseandassemble(27)baseto(31)extension
tube. Clamp (27) base horizontally in a vise and tighten (31) exten-
sion tube. NOTE:Torque(31) extensiontube to88.1 -101.7Nm(65
- 75 ft lbs).
11. Push up on (50) primer, exposing (33) piston rod.
12. Assemble (3) gasket to (27) base.
13. Assemble(21)“O”ringto(20)pistonadapterandassemble(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:Assembleeachsleeveintotheendofthecylin-
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).
PUMP REASSEMBLY
TROUBLE SHOOTING
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)ballstopand(40)ballinto(38)plunger, securingwith
(41) primer rod. NOTE: Torque (41) primer rod to 7.9 - 11.3Nm (70 -
100 in. lbs).
2. Thread (36) connector to (38) plunger, using a 7/32” diameter rod
thruthecrossholetotighten.NOTE:Tighten(36)connectorto23.0-
33.9 Nm (17 - 25 ft lbs).
If the pump will not cycle or will not deliver material.
• Becertaintocheckfornon-pumpproblemsincludingkinked,restric-
tiveorpluggedinlet/outlethoseordispensingdevice.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
559X
Page 4 of 4
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