GAMA 2:1, G-50 H, G-30 H, G-250 H, G-140 H, G-125 A, G-200 A, ES-125 A, VR, COMPACT, EASY-SPRAY Transfer Pump Service Manual

Components and
Service Manual
Transfer Pump 2:1
1.8 Revision 01/04/15
Ref. NR-00061-ENG
Before installing and operating the pump, carefully read the technical and
safety documentation in this manual. Special attention should be paid to
the information in order to know and understand the handling and
conditions of use of the pump. All of the information is aimed at
enhancing user safety and avoiding possible faults due to incorrect use of
the pump.
Service and
Components Manual
GUARANTEE
GARRAF MAQUINARIA, S. A. (hereinafter “GAMA”) grants this Limited Guarantee to the original buyer
(hereinafter the “Client”) for the unit and the original accessories given with the unit (hereinafter the
“Product”) against any fault in the design, materials or manufacture of the Product at the time of the first
purchase by the user and for a duration of two (2) years thereafter.
If during the guarantee period and under normal conditions of use, the Product should fail to work correctly
due to defects of design, material or manufacture, the authorised distributor of the country where the
GAMA Product or technical assistance service has been purchased shall repair or replace the Product in
accordance with what is established in the following
CONDITIONS
a) The validity of this guarantee will be subject to the presentation of the original invoice issued by
the GAMA authorised distributor for the sale of the Product along with the Product handed over
for repair or replacement, which must show the date of purchase and the serial number. GAMA
reserves the right to refuse to give the guarantee service when the indicated data fail to appear
on the invoice or have been modified after the purchase of the Product.
b) The repaired or replaced Product will continue to maintain the original guarantee for the time
remaining until the end of the guarantee or for three (3) months from the repair date, if the
remaining period of the original guarantee were shorter.
c) This guarantee will not be applied to the faults in the Product caused by its faulty installation, the
natural wear and tear of the components, any use other than that considered normal for this
Product or which should fail to strictly comply with the instructions of use provided by GAMA; due
to accident, carelessness, adjustments, alterations or modifications of the Product not authorised
by GAMA or due to the use of accessories, heating devices, pumping equipment and/or
dispensers that have not been approved or manufactured by GAMA.
d) The guarantee applicable to the components and accessories forming part of the Product and
which have not been made by GAMA will be limited to the guarantee offered by the original
manufacturer thereof.
GAMA WILL NOT RECOGNISE ANY EXPRESS ORAL OR WRITTEN GUARANTEES OTHER THAN THIS PRINTED LIMITED
GUARANTEE. ALL IMPLICIT GUARANTEES, INCLUDING, WITHOUT LIMIT, ADAPTATION FOR A SPECIFIC USE, ARE SUBJECT
TO THE DURATION OF THIS WRITTEN GUARANTEE. GAMA DOES NOT ASSUME ANY KIND OF COMMITMENT OR
RESPONSIBILITY FOR ALL POSSIBLE DAMAGE OR EXPENSE CAUSED BY FAULTS IN THE OUTPUT OF THE PRODUCT, ITS
WORKING OR THE DISPENSING OF MATERIAL THROUGH THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ALL
EXPENSES CAUSED BY DAMAGE TO PEOPLE OR PROPERTY. EQUALLY, GAMA WILL IN NO CASE ACCEPT LIABILITY FOR
THE LOSS OF SPECULATIVE PROFITS OR COMMERCIAL LOSSES. ALL REPAIRS OR REPLACEMENT OF FAULTY PRODUCTS
WILL CONSTITUTE THE COMPREHENSIVE FULFILMENT OF GAMA'S OBLIGATIONS WITH RESPECT TO THE CLIENT. GAMA
DOES NOT IN ANY WAY GUARANTEE THE SUITABILITY OR APTITUDE OF ITS PRODUCT FOR ANY PARTICULAR PURPOSE
OR APPLICATION.
All of the information provided on components which have not been manufactured by GAMA and which is
based on reports received from the original manufacturer, though considered precise and reliable, is
provided without any guarantee or responsibility of any explicit or implicit kind.
All concession, sale or financial leasing of the Product by GAMA in no case explicitly or implicitly
constitutes any authorisation, acceptance or concession for the use of any rights or patents, nor does it
encourage, nurture or back their infringement.
The restrictions on the guarantee suppose no limitation on the legal rights of the consumer established in
applicable national legislation, nor do they affect any rights derived from the bargain and sale agreement
between the consumer and supplier.
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All of the information provided in this Service Manual has been included in the confidence that it
is true, although it does not constitute any responsibility or implicit or explicit guarantee. GAMA
reserves the right at any time and without prior warning to make all improvements and
modifications necessary to this Service Manual, in order to rectify any possible typographical
errors, increase the information contained or insert the changes caused to the characteristics
and performance of the unit.
SAFETY AND HANDLING
This chapter contains important information regarding the safety, handling and use of the
transfer pump.
Before installing and starting up the pump, carefully read all the technical
and safety documentation included in this manual. Special attention
should be paid to the information in order to know and understand the
handling and conditions of use of the pump. All of the information is
aimed at enhancing user safety and avoiding possible faults due to
incorrect use of the pump.
A WARNING! establishes information to alert on a situation that might cause serious
injuries if the instructions are not followed.
A PRECAUTION! establishes information that indicates how to avoid damage to the
pump or how to avoid a situation that could cause minor injuries.
A NOTE is relevant information on a procedure being carried out.
Careful study of this manual will help you to become more acquainted with the pump and the
procedures. Following the instructions and recommendations here will reduce the potential risk
of accidents in installing, using or maintaining the pump, and will give you the problem-free
operation for a longer time, greater output and the possibility of detecting and resolving
problems quickly and simply.
Keep this Service Manual for future consultation of useful information at all times. If you lose the
manual, ask for a new copy from your local GAMA distributor or make direct contact with Garraf
Maquinaria, S. A.
These instructions must be complemented by the national requisites in order to prevent
accidents and protect the environment.
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When working with the pump, it is essential to dress suitably and use personal protective
equipment, including the unlimited use of gloves, protective goggles, safety footwear and face
masks. Use breathing equipment when working with the pump in enclosed or insufficiently
ventilated atmospheres. The introduction and monitoring of safety measures must not be limited
to those described in this manual. Before starting to use the pump, a rigorous analysis must be
made of the risks derived from the products to be dispensed, the type of application and the
working environment.
To prevent all possible body harm caused by incorrect handling of the raw
materials and solvents used in the process, carefully read the safety
information provided by your supplier.
Deal with all waste according to each country's current regulations.
The high speed of the product flowing through the conducts might cause
static electricity shown by small shocks and sparks. The pump should be
grounded.
WARNING! In potentially explosive atmosphere, the ground connection
must be made before the pump is brought into operation.
To avoid damage caused by the impact of pressurized fluids, do not open
any connection or perform maintenance work on components subject to
pressure until the pressures have been completely eliminated.
Use suitable protection when operating, maintaining or remaining in the
operating area of the pump. This includes, but is not limited to, the use of
masks, protective goggles, gloves, shoes and safety clothing.
Do not touch the sleeve of the pneumatic motor. The air decompression
that drives the piston cools the surface considerably after a few minutes
of operation, which might cause freezing in contact with the skin. Use
gloves or allow the surface to warm in all maintenance work.
To prevent serious harm by crushing or loss of limbs, do not work with
the unit without the safety protections duly installed on all moving parts.
Make sure that all of the safety protections are correctly fitted after all
repair or maintenance work.
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TYPICAL INSTALLATION
Figure 1. Typical Installation in a G-50 H with recirculation.
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DESCRIPTION
The GAMA 2.25:1 pump is a pneumatically-driven, double effect, alternating pump used for
moving liquids with a maximum viscosity of 2,000 mPas.
The compressed air causes the alternating rising and falling movement in the pneumatic piston,
which is transmitted by means of a connection rod to the plungers of the upper and lower
chamber of the pump, thereby sucking and driving the fluid.
The fluid output pressure is 2.25 times higher than the air pressure causing the movement of
the pneumatic piston.
All materials coming into contact with the fluid are made in stainless steel of the highest quality.
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OPERATION DIAGRAM
Figure 2. Operation Diagram
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PNEUMATIC MOTOR OPERATION
Process of reversing the movement of the pneumatic piston.
 The pump movement is reversed thanks to a floating mechanism in the pneumatic
piston. When it rises, the air in the lower chamber of the piston pushes it upwards, the air in
the upper chamber is decompressed and released from the motor through the piston shaft.
 When the piston makes contact with the upper spring, a valve is opened inside it that
allows the air entering the motor to go straight into the upper chamber, thus pushing the
piston down.

When the piston makes contact with the lower spring, the internal valve is closed and
the air pressure pushes the piston upwards, whereas the pressurized air in the upper
chamber is released through the piston shaft.
PUMPING MECHANISM OPERATION
Up stroke (see Figure 2 left side)
 The lower plunger of the pump rises and keeps the valve of the upper plunger closed,
pushing the product in the upper chamber to the pump outlet (volume “B”). The depression
produced in the lower chamber of the plunger in the rising movement opens the ball of the
lower valve, thus sucking the fluid in from the vessel (volume “A”).
Down stroke (see Figure 2 right side)
 The lower plunger of the pump moves downwards and exerts pressure on the lower
ball, closing it mechanically. The same downwards movement opens the ball of the upper
valve, allowing the fluid from volume “A” into the intermediate chamber and the surplus
material (half of volume “A”) is moved to the pump outlet (volume “C”).
N.B.: The pump only sucks material when it rises (Volume “A”), but drives material
when it rises (Volume “B”) and when it falls (Volume “C”).
Volume “A” = Volume “B” + Volume “C”.
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TECHNICAL SPECIFICATIONS
Pressure ratio: _________________________________2.25:1 (@ 7 bar air – 15.7 bar product)
Maximum fluid pressure: _________________________________________________22.5 bar
Maximum air inlet pressure: ________________________________________________10 bar
Maximum fluid temperature: _________________________________________________85ºC.
Maximum outlet volume: ________________________________________________20.8L./min
Piston movement: __________________________________________________101.6mm (4”)
3
Suction volume (only rising): _______________________________________________206cm
3
3
Transfer volume (by stroke/cycle): ____________________________________103cm /206cm
Volume of consumed air (by stroke/cycle) @ 7 bar: ____________________________1.6L/3.2L
N. cycles to transfer 1 litre: ___________________________________________________4.85
Weight: ________________________________________________________10.5Kg (23.15lb)
Air connection: _________________________________________________________1/4”NPT
Product outlet connection: ________________________________________________3/4”NPT
Noise level @ 7 bar (air): ________________________________________________85 (A) dB
DIMENSIONS
PU-04002
mod. 54” (1371.6)
PU-04003
mod. 46” (1168.4)
A.
1371.6 mm (54")
1168.4 mm (46”)
B
876 mm (34.5”)
673 mm (26.5”)
C
244.5 mm (9.62”)
244.5 mm (9.62”)
D
842 mm (33.15”)
639 mm (25.16”)
Figure 3. General Dimensions
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KITS LIST OF TRANSFER PUMPS
Table 1. Kits List of Transfer Pumps
According to model Unit, Length & Pump Size
PU-04002
(54” Pump)
PU-04003
(46” Pump)
Hoses Length
3,5 mts.
Hoses Length
5 mts.
Hoses Length
3,5 mts.
Hoses Length
5 mts.
G-140 H
G-250 H
G-30 H
G-50 H
NE-00040
NE-00040-01
NE-00040-02
-
G-125 A
G-200 A
VR
NE-00041
NE-00041-03
-
-
-
-
-
COMPACT
ES-125 A
NE-00041-01
EASY-SPRAY
(without tanks)
NE-00041-02
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TRANSFER PUMPS KITS
Table 2. Transfer Pump Kit NE-00040, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For hydraulic
machines except for VR model:
MA-00034
1x machine / 1x 2 Pumps
Air supply connection kit for
hydraulic machines except for
VR model:
MA-00035
1x machine / 1x 2 Pumps
Product hose:
MA-00026
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
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Table 3. Transfer Pump Kit NE-00040-01, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For hydraulic
machines except for VR model:
MA-00034
1x machine / 1x 2 Pumps
Air supply connection kit for
hydraulic machines except for
VR model:
MA-00035-1
1x machine / 1x 2 Pumps
Product hose:
MA-00026-01
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
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Table 4. Transfer Pump Kit NE-00040-02, Parts List
PU-04003
Short Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For hydraulic
machines except for VR model:
MA-00034
1x machine / 1x 2 Pumps
Air supply connection kit for
hydraulic machines except for
VR model:
MA-00035
1x machine / 1x 2 Pumps
Product hose:
MA-00026
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
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Table 5. Transfer Pump Kit NE-00041, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For pneumatic
machines and VR model:
MA-00032
1x machine / 1x 2 Pumps
Air supply connection kit for
pneumatic machines and for VR
model:
MA-00033
2x machine / 1x Pump
Product hose:
MA-00026
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
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Table 6. Transfer Pump Kit NE-00041-01, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For pneumatic
machines and VR model:
MA-00032
1x machine / 1x 2 Pumps
Air supply connection kit for
pneumatic machines and for VR
model:
MA-00033
2x machine / 1x Pump
Product hose:
MA-00026
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
Air Distributor:
RA-00095
2x máquina / 1x bomba
NE-00068
1x máquina / 1x 2 bombas
RA-00054
1x máquina / 1x 2 bombas
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Table 7. Transfer Pump Kit NE-00041-02, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For pneumatic
machines and VR model:
MA-00032
1x machine / 1x 2 Pumps
Air supply connection kit for
pneumatic machine Easy Spray:
MA-00035-3
1x machine / 1x 2 Pumps
Product hose:
MA-00026
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
Air Connection for Easy Spray:
RA-00135
RA-00109
RA-00048
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1x machine / 1x 2 Pumps
1x machine / 1x 2 Pumps
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Table 8. Transfer Pump Kit NE-00041-03, Parts List
PU-04002
Standard Transfer Pum Assy
2x Machine
Connection kit for air
compressor. For pneumatic
machines and VR model:
MA-00032
1x machine / 1x 2 Pumps
Air supply connection kit for
pneumatic machines and for VR
model:
MA-00033-4
2x machine / 1x Pump
Product hose:
MA-00026-01
2x machine / 1x Pump
Product outlet connection:
RA-00212
2x machine / 1x Pump
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INSTALLATION
Reception
Although all precautions are taken in packing and sending in the factory, the goods must be
checked when they are received. Make sure that all the parts and accessories on the remittance
are correct and have not been damaged in transport.
In the package, along with the pump you must receive 2 tools for tightening the stop valves (HT00077).
Storage
If the pump is going to be stored before installation, leave it in a clean and dry place. Do not
remove the protection caps from the connections to prevent dirt from entering the pump.
Assembly
1. Screw the clip of the transfer pump onto the drum. Make sure
the corresponding seal is included. Insert the pump with its
seal into the clip and the drum, close the two staples to hold
the pump to the clip.
2. Screw the 1/4”NPT-1/4”BSP thread adapter and the ball valve
on to the pump, placing sealing paste or teflon tape on the
threads to ensure that the unit is properly sealed. Make sure
that the ball valve is closed. Do not connect the network air
supply yet.
N.B.: The thread adapter and the ball valve are not supplied with
the pump. These parts are included in Transfer Pump Kits (See
Table 1).
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3. Screw the RA-00012 product outlet connector on the 3/4”NPT
thread of the pump.
N.B.: The connector is not supplied with the pump. This Part is
included in Transfer Pump Kits (see Table 1)
The high speed of the product flowing through the conducts might cause
static electricity shown by small shocks and sparks. The pump should be
grounded with a wire connected to mass on the fixture provided.
WARNING! In potentially explosive atmospheres or with flammable
products, the ground connection must be made before the pump is
brought into operation.
4. A wire may be used with a peeled end, which is inserted through the protection in the
drill hole provided and fixed with the bolt (figure on the left), or, if you prefer, a wire may
be used with a terminal for M5 bolt, which is fixed as shown in the drawing (figure on
the right).
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5. Screw MA-00026 product hose on the pump
connection and the machine valve. Place
sealing paste or Teflon tape on the threads
to ensure that the unit is sealed.
N.B.: The MA-00026 hose is not supplied with the pump. This Part is included in the
Transfer Pump Kits (see Table 1).
6. Open the ball valve on the machine
inlet.
7. Now connect the air supply hose and
open the air valve on the machine to
start the transfer pump.
Do this by slowly opening the valve
until the pump piston begins to move.
Use the valve opening to control the
speed of the pump.
The transfer pump is used to transfer both isocyanates and polyols.
However, once one of the two products has passed through it, it is
recommendable to identify it by marking it clearly and visibly in order to
know which product it contains or which product has been transferred.
Any mistake putting it into the wrong product drum or attaching the
wrong hose connection would contaminate the pump and render it
useless.
Never allow the pump to continue working without product, as this could
rapidly damage the seals. Stop the pump if you see that it accelerates fast
or moves too rapidly.
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N.B.: For the installation of the kit NE-00041-01, mount the items NE-00068 (1x), RA00054 (1x) and RA-00095 (2x) inserted in the machine after the air filter as the following
figures show.
Figure 4. Compact
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Figure 5. Easy-Spray
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STOPPING METHOD
When you want to stop the pump, shut off the air supply with the ball valve, and then disconnect
the air connector.
If the pump is going to be shut down for a short time, it is best not to empty it as this prevents air
and damp from entering and avoids any contamination.
If the pump is to be shut down for a long period of time, it must be completely emptied of
product and carefully and thoroughly cleaned with a cleaning agent (DOP). It must then be
stored in a clean, dry place.
WARNING! Do not touch the sleeve of the pneumatic motor. The air
decompression that drives the piston cools the surface considerably after
a few minutes of operation, which might cause freezing in contact with the
skin. Use gloves or allow the surface to warm in all maintenance work.
CLEANING
Cleaning is understood as the cleaning that has to be done before using a different product or
when a long period of inactivity is expected for the pump and the metering unit.
Follow the recommended procedure in the order indicated to perform the cleaning when you
have to change the components of the system:
a) Place two drums of DOP cleaning agent near the metering unit.
b) Remove the gun and leave the coupling block connected to the hoses.
c) Remove the transfer pumps from the drums of product and place them in the drums of DOP
cleaning agent.
d) Place a vessel under the coupling block to gather up the products contained inside the
machine.
e) Open the taps of the coupling block and start up the metering unit.
Make sure the machine product inlet valves and the air inlets valves to the pumps are open.
f) Allow the products to come out until you see that only DOP cleaning agent comes out free of
impurities.
g) Close the taps of the coupling block and stop the metering unit.
h) Close the air inlet taps to the pumps and place the transfer pumps in the drums of the new
products.
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i) Place a vessel under the coupling block to collect the DOP cleaning agent.
j) Open the taps of the coupling block and start up the metering unit.
k) Open the air inlet valves to the pumps.
m) Allow DOP cleaning agent to come out until you see that only the new products come out.
n) When the products come out without the contamination produced by the effect of the DOP
cleaning agent, the cleaning process is complete and you can proceed as normal.
If a long period of inactivity is expected, it is advisable to suck in DOP cleaning agent and leave
it inside the pump. It must then be stored in a clean, dry place.
N.B.: Keep all hazardous fluids in suitable containers. These products have to be
eliminated according to the current laws of each country.
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DISMANTLING AND MAINTENANCE
WARNING! Before dismantling the pump or carrying out maintenance on it, disconnect
the air supply and depressurise the pump.
N.B.: All of the threads of the different components in the pump are tightened
clockwise.
N.B.: If you are going to replace a kit of seals, replace all of those included in the kit
supplied. Although there may seem to be seals in a good state, the combination of new
seals with seals that have been worn by the accumulated work can cause the pump to
work badly.
1. To facilitate the pump dismantling and assembly, place it in a vice, holding it by the
triangular base of the body, having previously removed the polycarbonate protections.
Before fixing the pump in a vice, remember to remove the three
polycarbonate protections.
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2. Unscrew the pump suction valve using a
42mm or 1 5/8” spanner (not supplied).
Use a belt spanner (not supplied) to loosen the
valve, if necessary, placing it as close as
possible to the end of the pipe in order to avoid
deformations.
The pneumatic cylinder contains pressurised air that must be removed
before dismantling. All failure to observe this step can cause serious
injuries.
3. Depressurise the pneumatic cylinder as
follows:

Disconnect the air supply.

Open the air inlet valve.

Loosen the purging screw of the
pneumatic cylinder on the top cover.
Now you can dismantle the pump.
4. hold the air sleeve and unscrew it
from the lower cover.
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5. Use the two 8 mm (or 5/16”) pins for unscrew the lower chrome guide of the plunger.
WARNING! Do not use the hexagonal geometry of the upper nut of the plunger to
loosen and unscrew the rod as this can cause irreparable damage to the plunger interior
mechanism.
6. Remove the pin fixing the piston and the rod.
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7. Loosen the nut holding the stop
valve, push the rod and remove
the lower plunger from the pump
through the lower suction sleeve.
8. Inspect the seals and replace as necessary.
Pay special attention to the direction of the seals when fitting.
9. Lubricate and fit all parts in reverse order to the process described above.
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TROUBLESHOOTING
Problem
Cause
The supply air pressure is very
low
Check the air supply line and
increase the diameter of the
supply pipe.
Increase the inlet pressure.
The supply air flow is insufficient
Check the air supply line and
increase the diameter of the
supply pipe.
Open the air inlet valve
completely.
Worn pneumatic piston seals
Replace all worn seals
Lack of product
Add product
Lower valve worn or partially
obstructed
Remove the valve, clean it and
replace all worn parts as
necessary
Upper valve worn or partially
obstructed
Remove the valve, clean it and
replace all worn parts as
necessary
Lower valve worn or partially
obstructed
Remove the valve, clean it and
replace all worn parts as
necessary
Product outlet line obstructed
Disconnect the outlet hose, feed
the product with minimum
pressure and check whether the
flow increases
The supply air pressure is too low
Increase the air pressure.
Upper chamber piston seal loose
or worn
Tighten or replace the seal
The pump does not
work
The pump works too
fast
The pump works, but
not enough product
comes out
The pump loses
product above the
upper chamber
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COMPONENT IDENTIFICATION
Figure 6. General Diagram.
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Figure 7. Details of Diagram of Upper Plunger (Pneumatic).
Figure 8. Details of Diagram of Lower Plunger.
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Table 9. List of Components
Pos.
Reference
Qty.
Suction Valve Unit (includes Pos.1.1 to 1.4)
PU-04002-009
1
1.1
Valve Body
PU-04002-010
1
1.2
Ball
PU-04000-090
1
1.3
Pin
TN-00308
1
1.4
O-ring (*)
OR-00107
1
1
Description
2
Pump Base seal (*)
PU-04000-040
1
3
Pump Body Unit (includes Pos.3.1 and 3.2)
PU-04002-001
1
3.1
Pump Body
PU-04002-002
1
3.2
Pump Body Interior Sleeve
PU-04002-008
1
OR-00009
1
4
O-ring (*)
5
Pump Suction Sleeve
See Table 10
1
6
Pump Plunger Cover
PU-04000-053
1
7
Pump Lower Plunger Guide (*)
PU04000-067
1
8
Lower Pump Lip Seal (*)
PU-04000-070
1
9
Ball
PU-04000-090
1
10
O-ring (*)
OR-00107
1
11
Pump Body Unit (includes Pos.11.1 to 11.6)
PU-04002-031
1
11.1
Pump Rod
PU-04002-032
1
11.2
Lower Plunger Head
PU-04002-033
1
11.3
Pump Upper Stop Valve Plunger
PU-04002-034
1
11.4
O-ring (*)
OR-00114
1
11.5
Pin
TN-00302
1
11.6
Pin
TN-00303
1
11.7
Washer
TN-00145
1
11.8
Lock Nut
TN-00165
1
12
Pump Upper Plunger Stop Valve (*)
PU-04000-069
1
13
Stop Valve Nut
PU-04000-059
1
14
Trap
TN-00304
1
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Pos.
Reference
Qty.
Pump Flange Unit (includes Pos.15.1 to 15.5)
See Table 11
1
15.1
Pump Coupling Body
See Table 11
1
15.2
Pump Base seal (*)
PU-04000-040
1
15.3
Pump Flange Staple
PU-04002-040
2
15.4
Round Head Bolt
TN-00020
4
15.5
Washer
TN-00139
4
15
Description
16
Pump Outlet Body Cover
PU-04002-012
1
17
Test Seat Seal
PU-04000-068
1
18
Bolt
TN-00306
3
19
Bolt
TN-00248
1
20
Air Cylinder Stay
PU-04000-063
3
21
Pneumatic Plunger Unit (includes Pos.21.1 to 21.12)
PU-04002-018
1
21.1
Pneumatic Plunger Body
PU-04002-019
1
21.2
O-ring (*)
OR-00108
3
21.3
Plunger Lower Disk
PU-04002-020
1
21.4
O-ring (*)
OR-00109
1
21.5
Upper Plunger Disk Unit (includes Pos. 21.5.1 to 21.5.4)
PU-04002-021
1
21.5.1
Upper Disk (#)
PU-04002-022
1
21.5.2
Plunger Interior Core (#)
PU-04002-023
1
21.5.3
Upper Plunger Stop (#)
PU-04002-024
1
21.5.4
Sealing Resin (#)
-
1
OR-00110
1
PU-04002-025
3
21.6
O-ring (*)
21.7
Pneumatic Plunger Spacer
21.8
Allen Bolt
TN-00285
1
21.9
Pin
TN-00307
1
21.10
O-ring (*)
OR-00111
1
21.11
Plunger Guide (*)
PU-04002-026
1
21.12
Allen Bolt
TN-00298
3
22
Lip Seal (*)
PU-04002-013
1
23
Stop Valve Lower Support
PU-04002-014
1
24
Stop Valve Segment (*)
PU-04002-015
3
25
Stop Valve Upper Support
PU-04002-016
1
26
Stop Valve Nut
PU-04000-061
1
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Pos.
Description
Reference
Qty.
PU-04002-017
1
OR-00112
1
27
Air Cylinder Base
28
O-ring (*)
29
Cylinder Base Seal (*)
PU-04000-081
2
30
Pneumatic Cylinder Sleeve
PU-04000-062
1
31
Lower Spring
PU-04000-073
1
32
Pneumatic Plunger Shaft Unit (includes Pos.32.1 to
32.2)
PU-04002-028
1
32.1
Air Plunger Shaft (#)
PU-04002-029
1
32.2
Guide Insert (#)
PU-04002-030
1
33
O-ring (*)
OR-00113
1
34
Pin
TN-00301
1
35
Pneumatic Rod Head
PU-04002-027
1
36
Trap
TN-00299
1
37
Cylinder Pan Conic Spring
PU-04000-072
1
38
Cylinder Pan Unit (includes Pos.38.1 to 38.2)
PU-04002-035
1
38.1
Air Cylinder Pan (#)
PU-04002-036
1
38.2
Elastic Stopper (#)
PU-04002-037
1
39
Air Purge Bolt Seal (*)
PU-04000-077
1
40
Air Purge Bolt
PU-04000-057
1
41
Rod Protection
PU-04002-042
3
42
Protection Bolt
TN-00317
3
All parts marked with (*) can be supplied separately or as part of a kit.
All parts marked with (#) cannot be supplied separately.
Table 10. Variants depending on pump size
Size
Suction Sleeve
Qty.
Pump 54”
PU-04002
PU-04002-011
1
Pump 46”
PU-04003
PU-04002-041
1
N.B.: The 54” and 46” pumps contain the same parts, except for that indicated in Table
10.
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Table 11. Pump Flange Unit
POS.15
POS.15.1
PU-04002-038
PU-04002-039
PU-04002-038A
PU-04002-039A
PU-04002-038B
PU-04002-039B
PU-04002-038C
PU-04002-039C
PU-04002-038D
PU-04002-039D
Pump
Minimal High of Tank
(*)
PU-04002 (54”)
858 mm
PU-04003 (46”)
655 mm
PU-04002 (54”)
843 mm
PU-04003 (46”)
640 mm
PU-04002 (54”)
793 mm
PU-04003 (46”)
590 mm
PU-04002 (54”)
748 mm
PU-04003 (46”)
545 mm
PU-04002 (54”)
688 mm
PU-04003 (46”)
485 mm
N.B.:
The Standard Pumps included the Flange Unit PU-04002-038. If you need another model,
please consult with our Marketing Department.
(*) The dimensions of the tank can change ±5 mm
Table 12. KT-00097 (Pneumatic Plunger Seal Kit)
Pos.
Description
Reference
Qty.
21.2
O-ring (*)
OR-00108
3
21.4
O-ring (*)
OR-00109
1
21.6
O-ring (*)
OR-00110
1
21.10
O-ring (*)
OR-00111
1
21.11
Plunger Guide (*)
PU-04002-026
1
Table 13. KT-00098 (Upper Stop Valve Kit)
Pos.
Description
Reference
Qty.
22
Lip Seal (*)
PU-04002-013
1
24
Stop Valve Segment (*)
PU-04002-015
3
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Table 14. KT-00099 (Pump Lower Plunger Kit)
Pos.
Description
Reference
Qty.
7
Pump Lower Plunger Guide (*)
PU04000-067
1
8
Lower Plunger Lip Seal (*)
PU-04000-070
1
Table 15. KT-00100 (Pump Upper Plunger Kit)
Pos.
Description
11.4
O-ring (*)
12
Pump Upper Plunger Stop Valve (*)
Reference
Qty.
OR-00114
1
PU-04000-069
1
Table 16. KT-00101 (Transfer Pump Seal Complete Kit)
Pos.
Description
1.4 (10)
O-ring (*)
2 (15.2)
Pump Base seal (*)
Reference
Qty.
OR-00107
2
PU-04000-040
2
OR-00009
1
4
O-ring (*)
7
Pump Lower Plunger Guide (*)
PU04000-067
1
8
Lower Plunger Lip Seal (*)
PU-04000-070
1
OR-00114
1
11.4
O-ring (*)
12
Pump Upper Plunger Stop Valve (*)
PU-04000-069
1
17
Test Seat Seal
PU-04000-068
1
21.2
O-ring (*)
OR-00108
3
21.4
O-ring (*)
OR-00109
1
21.6
O-ring (*)
OR-00110
1
21.10
O-ring (*)
OR-00111
1
21.11
Plunger Guide (*)
PU-04002-026
1
22
Lip Seal (*)
PU-04002-013
1
24
Stop Valve Segment (*)
PU-04002-015
3
28
O-ring (*)
OR-00112
1
29
Cylinder Base Seal (*)
PU-04000-081
2
33
O-ring (*)
OR-00113
1
39
Air Purge Bolt Seal (*)
PU-04000-077
1
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Table 17. List of Complements
Description
Reference
Qty.
Tin of Lubriplate Grease 397 g
BI-00008
1
Tin of Lubriplate Grease 49 g
BI-00009
1
Teflon Sealing Paste 50 ml
BI-00016
1
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CONTENT
Guarantee __________________________________________________________________ 2
Safety and Handling __________________________________________________________ 3
Typical Installation ___________________________________________________________ 5
Description _________________________________________________________________ 6
Operation Diagram ___________________________________________________________ 7
Pneumatic Motor Operation ___________________________________________________ 8
Pumping Mechanism Operation ________________________________________________ 8
Technical Specifications ______________________________________________________ 9
Kits List of Transfer Pumps __________________________________________________ 10
Transfer Pumps Kits ________________________________________________________ 11
Installation_________________________________________________________________ 18
Stopping method ___________________________________________________________ 22
Cleaning __________________________________________________________________ 22
Dismantling and Maintenance_________________________________________________ 24
troubleshooting ____________________________________________________________ 28
Component Identification ____________________________________________________ 29
Content ___________________________________________________________________ 37
Illustrations List ____________________________________________________________ 37
List of Tables ______________________________________________________________ 38
ILLUSTRATIONS LIST
Figure 1. Typical Installation in a G-50 H with recirculation. _________________________ 5
Figure 2. Operation Diagram ___________________________________________________ 7
Figure 3. General Dimensions__________________________________________________ 9
Figure 4. Compact ES-125 A Assy _____________________________________________ 21
Figure 5. Easy-Spray Assy ___________________________________________________ 21
Figure 6. General Diagram. ___________________________________________________ 29
Figure 7. Details of Diagram of Upper Plunger (Pneumatic). ________________________ 30
Figure 8. Details of Diagram of Lower Plunger. __________________________________ 30
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LIST OF TABLES
Table 1. Kits List of Transfer Pumps ___________________________________________ 10
Table 2. Transfer Pump Kit NE-00040, Parts List _________________________________ 11
Table 3. Transfer Pump Kit NE-00040-01, Parts List _______________________________ 12
Table 4. Transfer Pump Kit NE-00040-02, Parts List _______________________________ 13
Table 5. Transfer Pump Kit NE-00041, Parts List _________________________________ 14
Table 6. Transfer Pump Kit NE-00041-01, Parts List _______________________________ 15
Table 7. Transfer Pump Kit NE-00041-02, Parts List _______________________________ 16
Table 8. Transfer Pump Kit NE-00041-03, Parts List _______________________________ 17
Table 9. List of Components __________________________________________________ 31
Table 10. Variants depending on pump size _____________________________________ 33
Table 11. Pump Flange Unit __________________________________________________ 34
Table 12. KT-00097 (Pneumatic Plunger Seal Kit)_________________________________ 34
Table 13. KT-00098 (Upper Stop Valve Kit) ______________________________________ 34
Table 14. KT-00099 (Pump Lower Plunger Kit) ___________________________________ 35
Table 15. KT-00100 (Pump Upper Plunger Kit) ___________________________________ 35
Table 16. KT-00101 (Transfer Pump Seal Complete Kit) ___________________________ 35
Table 17. List of Complements ________________________________________________ 36
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