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cg-550/030/a/gt/hp maintenance & operating
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1. 5 Fig 2 qh i 4 1 2 3 2 A os A D B no Fig 4 i Fig 3 ate S ol 4 SECTION 6 AIR MOTOR INSTRUCTIONS AIR MOTOR Operating and Maintenance Instructions Construction Your air motor is a precision built rotary type motor The vanes will last 5 000 15 000 hours depending upon speed method of oiling operating pressure and the precautions taken in maintaining the motor The type of shaft seal used does not lend itself to operating pressures above 100 PSI Guarantee Air motors are guaranteed against defects in material or workmanship normal wear of parts excluded for a period of one year from factory ship date Unit failing within warranty will be rebuilt or replaced at manufacturer s discretion F O B factory Maximum liability not to exceed original purchase price of unit involved Allowing excess moisture or foreign particles from the air line to enter the motor will nullify the guarantee Installation Install a moisture trap and filter in the air line ahead of motor For efficiency of output and control of speed use air lines the same size as or the next pipe size larger than the intake port of the motor If operating intermittently without automatic air line oiler place motor in accessible position for easy lubrication A single rotation motor will operate properly in only one direction A reversible motor will work equally well in both directions A 4 way valve which can be connected by
2. Dimensions 76 X 31 X 51 78 with water batcher Weight 750 lbs SECTION 2 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS GENERAL WARNING NEVER PUT HANDS OR TOOLS IN MIXERS OR PUMP UNLESS PRIMARY POWER SOURCE IS SHUT OFF AND DISCONNECTED FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND OR DAMAGE TO THE MACHINE SET UP In general the most important factors in setting up are proximity to the work and access to materials and water supply consideration should be given to the disposal of waste materials and wash out residue It is always best to keep grout lines as short as possible to reduce pumping distances This is particularly important when pumping hard to pump materials such as sanded grouts and pre blended materials The source of solid materials cement fly ash sand etc should be readily accessible and an adequate supply of water should be available for mixing and clean up When planning a project for high production rates it is well to remember that the greatest consumption of time occurs when charging the mixers A proper set up can reduce this to a minimum START UP After set up visually inspect that there are no foreign objects or old set up materials in either the pump or the mixer s then make all necessary connections With operating levers valves or handles in either NEUTRAL or OFF position and the primary power source turned OFF fill the pu
3. FITTINGS HOSES MOTORS RESERVOIR AND FILTERS MAY BE HOT TO PREVENT INJURY TOUCH ONLY THE HANDLES PROVIDED LET THE HYDRAULIC COMPONENTS COOL BEFORE SERVICING THE EQUIPMENT WARRANTY STATEMENT ChemGrout Inc warrants that equipment shall be free from defects in material workmanship or components The period of this warranty shall be limited to 90 days from the date of purchase and the extent of ChemGrout s liability shall be limited to replacement of components that have been proven faulty No claims in excess of component replacement value will be recognized Specifically excluded from this warranty is normal wear resulting from the mixing and pumping of abrasive slurries or damage to the equipment as a result of improper use SAFETY Various guards shields grates and screens are provided over moving parts such as sheaves couplings augers paddles belts etc to guard against injury to operators while the equipment is in operations Warning stickers are provided to remind operators of the potential hazards Operators are advised to utilize appropriate personal safety equipment including but not limited to saftey glasses or goggles dust masks or respirators gloves and or rain gear and hard hats when operating this equipment LIABILITY It is understood and agreed that ChemGrout is relieved of any and all liability that may arise from personal injury or damage to property as a direct or proximate result of the remova
4. piping to both air ports of the motor will make reversing possible When coupling or connecting the motor to a driven member avoid any end or side thrust on the shaft and especially do not hammer on shaft Operation The starting torque is less than running torque and could vary depending on the position at which the vanes stop in relation to the air intake port The speed and torque can be regulated by using a pressure regulator or a simple shut off valve to obtain desired power and conserve air For moderate speeds under 2 000 RPM or intermittent operation 1 squirt of oil in bearing oilers per day will suffice For continuous duty or frequent high speed operation use an automatic air line oiler set to feed 1 3 drops per minute The bearings will receive oil from the rotor chamber during automatic oiling Use SAE No 10 oil Lubrication is necessary for the bearings shaft seals and rust prevention Excessive moisture in the air line can cause rust formation in motor and might also cause ice to form in muffler due to expansion of air through the motor The moisture problem can be corrected by installing a moisture separator in the line and also by installing and after cooler between the compressor and air receiver ChemGrout Servicing If the motor is sluggish or inefficient try flushing with solvent in well ventilated area Disconnect the air line and muffler and add several teaspoons full of solvent Rotate the shaft by hand in bo
5. CG 550 030 A GT HP MAINTENANCE amp OPERATING INSTRUCTIONS WITH REPAIR PARTS LIST SERIAL SAFETY DATA PLEASE READ AND HEED THE FOLLOWING IMPORTANT SAFETY NOTICES BEFORE PLACING MACHINE IN SERVICE x NOTICE PROPER PERSONAL PROTECTIVE EQUIPMENT INCLUDING BUT NOT LIMITED TO GOGGLES DUST MASKS OR RESPIRATORS GLOVES HARD HAT BOOTS AND RAINGEAR MUST BE WORN WHEN OPERATING THIS EQUIPMENT k NOTICE FOLLOW MATERIAL MANUFACTURER S INSTRUCTIONS FOR PROPER MATERIAL USE AND RECOMMENDATIONS FOR SAFETY EQUIPMENT AND PROCEDURES WARNING NEVER PUT HANDS OR TOOLS IN MIXERS OR PUMP UNLESS PRIMARY POWER SOURCE IS SHUT OFF AND DISCONNECTED AND KINETIC ENERGY DISSIPATED ON ELECTRICALLY POWERED EQUIPMENT USE PROPER LOCK OUT TAG OUT PROCEDURES FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND OR DAMAGE TO THE MACHINE WARNING NEVER ATTEMPT TO DISCONNECT OR OPEN THE COUPLING ON ANY PART OF THE PUMP DISCHARGE SYSTEM WHILE PUMP IS IN OPERATION OR IF THE DISCHARGE SYSTEM IS UNDER PRESSURE FOR ANY REASON WARNING NEVER OPERATE MACHINE WITHOUT THE VARIOUS GUARDS SHIELDS AND OTHER SAFETY EQUIPMENT WITH WHICH THE MACHINE WAS ORIGINALLY EQUIPPED IN PLACE AND FUNCTIONAL WARNING ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED ELECTRICIAN WARNING HYDRAULIC COMPONENTS INCLUDING BUT NOT LIMITED TO VALVES
6. VSA ALT 061 8CHECK DESCRIPTION Grout Pump Hopper Screen Hopper 6 Slide Valve Assembly Discharge Gate Gasket T Bolt Gasket Clamp 8 X 7 Air Cylinder Grout Pressure Relief Valve Exhaust Silencer Yo Muffler Replacement Element Mixer Air Motor Gast Air Motor Repair Kit Gast Motor only Alternate Air Motor Ingersoll Rand Repair Kit Ingersoll Rand 34 ASL Air Line Oiler 15 1 Gearbox Gearbox Base 1 Paddle Coupling Mixer Paddle Paddle Bushing Paddle Pin Mixer Guard Bag Breaker Cover For 27 Mix Tank Mixer Air Valve 2 Victualic Clamp 1 1 4 Part A Evertite Coupling 2 to 1 Reducer Mixer Cover 1 Air Connection 30 Mesh Air Filter 1 Air Line Filter 1 Air Line Lubricator 1 Filter Regulator Lubricator Assembly Pump Control Valve Directional Control Valve 1 8 Brass Check Valve Machine may be equipped with Gast or I R motor Complete sets of warning labels are available upon request ChemGrout SECTION 5 GROUT PUMP INSTRUCTIONS CG 030 A HP Parts Diagram REF CG 030 A HP COMPONENT PARTSLIST PART NO DESCRIPTION 21030REDUCER 02C CG 030 Reducer 3 X 2 Victaulic 24030RBOLT CG030 Reducer Bolt 3 8 16 X 3 1 3 21050REDUCE1 1 4 2 Victaulic X 1 1 4 NPT Reducer 542VICT 77 2 Victaul
7. characteristics which must be well understood to insure a successful application FLOW In general most materials need to be of a flowable or pourable consistency for successful pumping This means that if the material can be poured out of a pail or bucket it can likely be pumped The exception to this requirement is repair mortars which tend to be mixed in a thicker consistency and require special pumping techniques Materials that contain aggregates pump best and perform best when the consistency is kept to the lower range of pourable that is not too wet SETTING TIME Some materials contain accelerating admixtures to reduce the setting time This is particularly true of repair mortars and other spray applied materials so that strength gain can be fairly rapid It is important to keep moving when using these types of materials Once the material is mixed it must be pumped immediately and kept in motion and subsequent batches must be mixed and pumped as rapidly as possible Any delays in the application process could result in plugged hoses and equipment Temperature also has an effect upon these materials to the extent that exposure of the hose to the sun on a hot day will accelerate the set time even more therefore this should be avoided It may even be necessary in some cases to cool the material the mix water or even the hose itself PUMPING DISTANCE Pumping distances should always be kept to a minimum and hoses should run as strai
8. ct and manually drain hose Reconnect grout hose Begin mixing by introducing first water then solid materials to mixer Mix until smooth and creamy then discharge into hopper and begin pumping see IMPORTANT NOTICES below Cleanup Pour water into 5 and pump until discharge is clear Stop pump disassemble wash and clean Reassemble pump immediately when clean to prevent loss of parts Important Notices Some pre blended grouts not pumpable Granular particles in grout must be well graded Maximum particle size in slurry 3 16 5 cm Grout mix must not be too wet See section on grout mix recommendations PROBLEM Pumps water O K will not pump grout Pump stalls on discharge stroke Pump runs but does not discharge Piston will not reverse direction Pump strokes unevenly or too slowly SERVICE GUIDE PROBABLE CAUSE Grout mix too thick does not enter pump chamber Aggregate too large prevents ball from seating Aggregate segregations in Discharge hose Sand Plugs Grout material has excessive Coefficient of internal friction Pump discharge or hose plugged with grout Grout not entering pump Chamber Directional valve spool stuck Misadjusted shuttle valve SOLUTION Add water to grout mix but be careful not to dilute mix so Much as to cause aggregate to segregate Change to smaller aggregate or screen out larger particles Drain residual water from Dischar
9. er through Port B driving the piston forward while exhaust air is exiting from Port A through the timing valve 1 While in motion the air pressure at pilot ports 4 and 5 is equal to line air pressure FIGURE 2 In Figure 2 the piston has traveled to its fully extended length and engaged poppet valve 2 allowing the escape of a small amount of air from the pilot system Release of this air has reduced the air pressure at timing valve pilot port 5 resulting in a pressure imbalance causing the timing valve spool to shift directing drive air through Port A reversing direction of piston travel FIGURE 3 As the piston rod retracts air pressure in the pilot system is again equal to line pressure and exhaust air is expelled from the rear of the cylinder through Port B while drive air is entering the cylinder through Port A FIGURE 4 The piston has reached its maximum retraction travel and engaged poppet valve 3 resulting in a reduction of air pressure at pilot port 4 This causes the timing valve spool to shift directing drive air to the cylinder through Port B The piston is now moving forward again as exhaust air exits the cylinder through Port A TIMING SEQUENCE DIAGRAM CHEMGROUT AIR POWERED PISTON AND PLUNGER PUMPS 2 3 E E B B y 1 I ne Care i SE alle AS Dale Fig 1 DL
10. g results RECOMMENDATIONS When using air powered equipment some simple rules and procedures will help assure a successful job 1 Keep compressor properly serviced with adequate fuel and engine oil and keep compressor oil at proper levels Drain condensation from receiving tank before start up 2 Keep hose runs between compressor and machine as short as practical 3 Use air hose that is rated for the pressure capacity of the compressor and of sufficient diameter to transport the volume of air that the compressor is rated to deliver In other words use a BIG hose 4 Never use air supply hose for any other purpose and always blow the hose out before connecting to equipment at the start of a working shift Recommendations For Air Operated Equipment cont d 5 Keep equipment and line oilers full and clean filters and mufflers daily The object is to provide an unrestricted flow of air TO and FROM the machine move it from the compressor to the machine as fast as possible and when you re finished with it get rid of it as fast as possible Also remember that everything needs lubrication including air motors and cylinders so keep the oilers full 6 One final word in temperate geographical zones work is often done in temperatures between about 40 degrees F and 60 degrees F with relative humidity that may reach as much as 100 percent Because air is heated as it s compressed and cools rapidly as it expands like at the exhaus
11. ge hose prior to pumping grout Aggregate improperly graded change aggregate Some premixed grout materials are not pumpable See section on grout mix recommendations Disconnect discharge hose check pump clean out hose Grout too thick or obstruction in hopper Shift spool manually with small diameter object such as a nail or awl Readjust shuttle valve adjusting screws 13 turn out to increase speed and in to decrease speed SERVICE GUIDE cont d PROBLEM Pump does not run Low discharge Grout or fluid leakage around piston Excessive piston wear PROBABLE CAUSE Insufficient air supply Pump fluid end plugged Directional valve spool stuck Obstruction in air supply line or filter Low air pressure Excessive clearance between piston and sleeve Dirty or scored sleeve SOLUTION Check air at Require 30 CFM at 100 PSI source Remove staples 3 disassemble pump and check sleeve 3 for obstruction Shift spool manually with small diameter object such as a nail Disconnect air line determine clear Remove cover and clean air filter Check air supply pressure pressure Should be 100 PSI Replace piston cups Clean residual material from sleeve 8 or replace sleeve if scored EXPLANATION OF AIR CYLINDER TIMING SEQUENCE DIAGRAM VALID FOR CG 030 AND ALL AIR DRIVEN RECIPROCATING PUMPS FIGURE 1 In this picture air is entering the cylind
12. ght as possible no matter what material is being used Sometimes circumstances require longer than usual hose lengths when this occurs every effort should be made to use every advantage possible to insure a successful application Some materials simply cannot be pumped for long distances so it s best to know the proposed material characteristics before attempting a production procedure ChemGrout MIXING AND PUMPING SUGGESTIONS Cont d GENERAL PROCEDURES Before attempting to mix and pump production materials it is prudent to rinse the mixer and charge the pump hopper with sufficient water to thoroughly flush the pump and all grout lines This is to purge the grouting system of any residual materials or scale that may exist Once that is completed remove the grout hose from the pump and drain out all water by elevating one end or by progressively elevating the entire hose starting at one end and proceeding to the other Next mix a slurry composed of portland cement in approximate proportions of 6 1 2 to 7 1 2 gallons of water to one bag 94 lbs of cement and pump this through the grouting system This is to remove any residual water from the hose lubricating it for the production material to follow Now the production grout may be mixed and pumped immediately behind the slurry mix which is thus evacuated from the hose and may be retrieved in a bucket Do not attempt to pump production material through a dry hose Finally one
13. ht enough to prevent leakage Section 5 CLEAN UP After disposing of excess production materials carefully wash out mixer tanks paddles and baffles into the pump hopper and pump the resulting washout material through the grout hoses to a suitable disposal site Continue this operation until only clear water is discharged It is advisable to drain all residual wash water from the pump and all hoses when washout is complete CAUTION NEVER RUN PUMP WITHOUT FLUID AS IT WILL CAUSE SEVERE DAMAGE TO PISTON AND SLEEVE SECTION 3 GROUT SUGGESTIONS Please note that the information contained in this section is general in nature and not specific to geothermal materials which possess their own unique characteristics and preparation procedures MIXING AND PUMPING SUGGESTIONS NOTE The suggestions offered herein are intended as an aid to help the operator identify some of the factors that need to be taken into consideration when mixing and pumping cementitious grouts Because a wide variety of materials are available for many different applications it is incumbent upon the operator to become familiar with the specific characteristics of the material he intends to use MATERIALS Among the commercially manufactured materials available in today s market are materials for structural repairs floor toppings high strength non shrink grouts manhole and sewer lining mortars and other specialty materials Each of these materials has unique
14. ic Coupling With Gasket 33EV11 4ABR 1 1 4 Part A Evertite Coupling 84030RELIEF Grout Pressure Relief Valve 21030STAPLE CG 030 Staple Pin 33EV3GASK Coupling Gasket 21030BALL 2 5 8 Polyurethane Ball See Main Parts List See Main Parts List 21030BALLSEAT3 21030RING 21030TEE 24030TBOLT 21030SLEEVE 21030CYLBKTA 21030CYLBKTAHP 07030PIST 21030PISTBP 21030PISTSP 21030PISTCUP 243 4X10JAMNUT 21030AIRADAPT O6NAN500NO06 O6FRL1 O6NAR5000N010 06NAL5000N010 O6NAF5000N010 841BBALL 33AM13 O6CYL8X7 O6CRAP2 O6NVSA ALT 06VR370 292160 061 8CHECK Hopper Hopper Screen CG 030 Ball Seat O Ring For Ball Seat CG 030 Tee Hopper Ball Retainer 3 8 16 X 4 1 2 CG 030 Sleeve CG030 Air Cylinder Bracket CG030 Air Cylinder Bracket Adapter Piston Assembly parts 10A to 11 CG 030 Piston Backer Plate CG 030 Piston Spacer Plate CG 030 Piston Cup Piston Nut CG 030 Piston Adapter Exhaust Silencer 1 Filter Regular Lubricator 1 Regulator 1 Lubricator 1 Filter 1 Ball Valve 1 Air King Fitting 8 Bore X 7 Stroke Air Cylinder 30 Mesh Air Filter 1 2 Pos 4 Way Dir Ctrl Valve Air Bleeder Valve directional control Pressure Gauge 1 8 Check Valve 030 GROUT PUMP Maintenance Daily add oil SAE 10 or SAE 20 at 15 Drain filter 16 Operation Connect air line to 18 and grout line to 1 Pour 5 gallons water in hopper 5 Start pump by opening valve 17 and pump out water Disconne
15. l of protective guards shields etc the ignoring of warning signs and the lack of common sense procedures SECTION 1 2 TABLE OF CONTENTS SUBJECT GENERAL DESCRIPTION OPERATING INSTRUCTIONS GROUT SUGGESTIONS DIAGRAM amp REPAIR PARTSLIST GROUT PUMP INSTRUCTIONS AIR MOTOR INSTRUCTIONS SECTION 1 GENERAL DESCRIPTION CG 550 030 A GT HP GENERAL DESCRIPTION The ChemGrout Model CG550 030 A GT HP is a pneumatically powered skid mounted cement grout plant specially designed and constructed for application in the geothermal industry The machine consists of one 70 gallon capacity vertical shaft paddle mixer and one CG 030 single acting piston type grout pump An oversize 6 diameter mixer discharge gate facilitates discharge of thick mixes into a 50 gallon capacity hopper situated directly above the pump The grout pump is driven by a 8 diameter self reciprocating cylinder which allows the pump to produce discharge rates up to 16 GPM and pressures up to 700 PSI The extra large capacity hopper makes continuous operation possible A 30 gallon capacity water batcher OPTIONAL is installed over the mixing tank to facilitate quick batching All pump components are assembled with horseshoe shaped pins making assembly and disassembly for cleaning and maintenance easily accomplished with no special tools required Simplicity of design and construction ensures years of dependable service with proper and timely maintenance
16. last word about procedures Occasionally no mater how conscientious an operator may be a hose will get plugged Once this happens the only sure way to remove the plug is to empty it of material Beating on it with a hammer or running over it with a vehicle will not usually be successful A prudent operator will be prepared for such eventuality by having readily available a sufficient length of small diameter stiff tubing hose or plastic pipe to which he can rapidly connect a water source and flush the grout from the hose ADDITIONAL SUGGESTIONS HOMEMADE GROUT Sometimes commercially prepared grouts are not readily available and in these cases it may be necessary to formulate and produce the material on site This can be done quite successfully but certain basic principles must be observed The resultant material should exhibit the following characteristics 1 A stable suspension of solids that does not separate while at rest 2 Color must be predominantly that ofthe cement used 3 Fluid enough to pour from a container but not too wet Thick batter consistency or thicker CEMENT There are several types of Portland cements manufactured to satisfy a variety of specific requirements such as high early strength sulfate resistance and other needs The most common of these is Type Portland and is that which is most frequently used in the production of cementitious grout WATER In most instances the water to be used for the pr
17. mp hopper with clear water NOTE It may be necessary to elevate the discharge hose during this operation to prevent water exiting through the ball valves OPERATING INSTRUCTIONS cont d Turn on the primary power source and observe that conditions are normal and machine is ready to run Check each mixer for proper operation by running the mixer in both forward and reverse directions if unit is so constructed as to allow reverse direction Next start the delivery pump to discharge the water that was previously introduced into the pump hopper This is an ideal opportunity to check the grouting system to determine that all lines and hoses are clear and unobstructed Pump condition may also be checked at this time by testing discharge pressure When it is determined that all systems are normal shut off the pump and drain the water from the pump and all lines NOTE Some pre blended materials and some on site mixes of sand and cement tend to separate and clog the hoses upon contact with residual water To prevent this occurrence it s a good procedure to mix and pump out a cement water slurry prior to mixing and pumping the production material to lubricate the pump and hoses PRODUCTION During the production phase of the work monitor pump and mixer performance continuously being alert to any signs of abnormality Keep mixers free of material build up keep the outside of the machine clean and keep pump packing lubricated and just tig
18. oduction of grout should be clean and free of sulfates or other dissolved chemicals If available potable water is ideal Since the water to cement ratio is the most important factor in the quality of the material in its final state the water content should be kept to the minimum that will produce materials with the characteristics listed above ADMIXTURES Admixtures are available to modify and enhance the grout mixture These include plasticizers water reducing agents expansive agents anti washout ingredients set time modifiers and others Each of these admixtures are designed to impart specific properties to the grout If used at all they should be used only with a full understanding of their effects and only according to the manufacturers recommendations FLYASH In some parts of the country flyash a byproduct of coal burning power stations is available This material has often been used to enhance the properties of cementitious grouts or in some cases to reduce the cement fraction Use of this material should be approached with CAUTION since ash from some sources have in recent years been observed to cause FLASH SET in grout mixes If the use of this product is anticipated trial mixes should be made to prove their applicability ADDITIONAL SUGGESTIONS Cont d SAND Sand is often used in grout formulations either to increase the volume of the material thus reducing the cost or to act as an aggregate in the case of high s
19. rily for conventional portland cement based grouts It is recognized that geothermal work utilizes special mixes therefore it is incumbent upon the operator to learn the characteristics of the material he will be using ChemGrout lt 53 gt 2 D un un ei a w v 2 w a U S Standard Sieve Numbers 30 Materials with gradation curves to the right of these limits usually ARE pumpable Materials with gradation curves to the left of these limits usually are NOT pumpable 0 5 Particle Size in Millimeters Percent Retained by Weight SECTION 4 DIAGRAM amp REPAIR PARTS LIST 22 19 23 3A 3B 199 20 La D 33 14 7 28 28A 32 A et ICH Eu CG 550 030 A GT REF CG 550 030 A GT HP COMPONENT PARTSLIST PART 63030A 21030SCN50 21030HOP50 846SLIDE 546GATEGASK 33TBC7112 O6CYL8X7 84030RELIEF O6NAN5000NO06 06MO5 06MO5A 046AMNRV11 04K208 045M6AMAN 04SM6AMA TK1 06LUB15 30SWO50T 21WINBASE 21PADCPLGH 2130PAD 21PADBUSH 21PADPIN 2130BAGBKR 2130COV 84BBLV50 542VICT 77 33EV11 4ABR 21050REDUCE1 1 4 2130DUSTCOV 33AM13 O6CRAP2 O6NAF5000N010 O6NAL5000N010 O6FRL1 841BBALL O6N
20. sed air powered equipment is used it is the air compressor which is the primary motive force to drive the equipment Whether the compressor is driven by a diesel or gas engine or an electric motor is immaterial The important factor is its capacity to provide a sufficient QUANTITY of air expressed in terms of CUBIC FEET PER MINUTE at a specific PRESSURE usually expressed in terms of POUNDS PER SQUARE INCH Thus compressors are usually rated in terms of X CFM at Y PSI For example 250 CFM at 120 PSI Occasionally you may see a horsepower rating but it is much more common for compressors to be rated as previously described In any event the capacity to do work is directly related to the VOLUME and PRESSURE of the compressed air supply Air powered equipment is designed to accomplish specific tasks and therefore requires a specific MINIMUM VOLUME of compressed air at a specific PRESSURE With any air powered equipment it s perfectly acceptable to use a compressor with a higher volumetric capacity than the equipment requires since the equipment will only use the amount of air that it needs however the stated pressure capacity of the equipment should not be exceeded by more than 10 Excess pressure can be harmful to the seals of air motors and cylinders and will significantly shorten the service life of the equipment Attempts to run pneumatically powered equipment on compressors of lower capacity than required will likely yield disappointin
21. t muffler of your grout plant be on the lookout for ice Since the expanding moist air can cool to temperatures below the freezing point ice will frequently form around the exhaust ports of air motors and cylinders when this happens a restriction is created that may severely impair the operation of the equipment The introduction of an Anti freezing agent such as Tannergas through special dispensers made for that purpose is the best way to prevent ice formation under these conditions If this isn t available obtain and install an additional line oiler immediately after the compressor and keep it filled with ethylene glycol anti freeze
22. th directions for a few minutes again connect the air line and apply pressure slowly until there is no trace of solvent in exhaust air Keep face away from exhaust air Check the muffler felts for grease dirt etc If dirty wash them in solvent Replace the felts and connect the muffler Re lubricate the motor with a squirt of oil in the chamber and bearings oilers If the vanes need replacing or foreign particles are present in motor chamber an experienced mechanic may remove the end plate opposite the drive shaft end Don t pry with a screw driver as it will dent the surface of the plate and body causing leaks A puller tool should be used which will remove the end plate while maintaining the position of the shaft New vanes should have the edge with corners cut on angle or the notched edge if reversible towards the bottom of the vane slot New gaskets should be the proper thickness onion skin otherwise motor will operate inefficiently and waste air The end plates should be replaced carefully using an arbor press with a pusher acting on both races of the bearing while supporting the opposite drive end of the shaft rigidly This will eliminate brinelling of the bearings and misalignment of rotor Recommended solvent for air motors and lubricated pumps is Gast Flushing Solvent part AH255 or any non toxic non flammable industrial cleaning solvent DO NOT USE KEROSENE SPECIAL INSTRUCTIONS AIR OPERATED EQUIPMENT Whenever compres
23. trength structural grouts If the use of sand is anticipated several factors must be considered such as the shape size and gradation of the sand to be used In general the sand should be clean well graded and of rounded natural shape Angular particles such as those found in manufactured sands should be avoided Of all of the considerations when anticipating the use of sand in a grout mixture intended to be pumped one of the most important is gradation Gradation of a sand sample is determined by a sieve analysis which reveals the percentages of each individual particle size of which the sand is composed Laboratory tests and field experience shows that some sand gradations will pump better than others and some will pump only with difficulty if at all Sample sieve analysis data is offered herein as a guide to choosing sand that has a good chance of producing a strong pumpable grout mix Another factor to take into consideration when choosing a sanded grout over a slurry grout is the volume or amount of sand that can be used in the mix This will vary as a function of the gradation but in general will usually be in the proportion of 1 1 2 to 2 times the cement content by VOLUME In rare cases it may be possible to exceed this proportion but caution should be exercised Grouting Sand Gradation Specifications Sieve Size Passing 8 100 16 90 100 30 55 80 50 30 55 100 10 30 200 0 10 NOTE The suggestions above are prima
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