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GB7 Service manual (English)
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1. configuration if a divorced section is fitted Refer drawing in Section 4 5 067 033 5 039 SPE 40 ITEM3 SPE amp 01 ITEM 5 Page 18 of 18
2. wA WAN TE AALL MODEL 7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL YEAR 2000 GB7 GROUT PUMP UA OPERATION amp MAINTENANCE MANUAL 2000 Whtye Hall Australia Pty Limited Unit 2 81 83 Station Road Seven Hills 2147 PO Box 425 Seven Hills NSW Australia 2147 Phone 61 02 9838 4420 Fax 61 02 9838 4460 Email info whyte hall com Web www whyte hall com INDEX SECTION 1 INTRODUCTION 3 2 SPECIFICATIONS 3 3 INSTALLATION 4 4 OPERATION 6 5 FLUSHING amp CLEANING PUMP 8 6 CLEARING BLOCKAGES 8 7 SERVICING AND AIR MOTOR DISASSEMBLY 9 8 TESTING 11 9 PARTS BREAKDOWN 12 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 2 of 18 GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 1 INTRODUCTION The GB7 Grout Pumps The GB series Grout Pumps are high performance robust pumps specifically designed to meet the rugged and demanding conditions within the mining and construction industries Various mixtures such as grout water cement gunite type materials are delivered via a 25mm 1 or 32mm 174 hose 1 1 The Operation amp Maintenance Manual The information contained in this document is only intended to be a guide in assisting in the safe operation of the Grout Pump Information quoted is a general recommendation only At all times proper safe work practices should be observed all Statutory guidelines and regulations should
3. Part No SPE042 Toggle Arm Part No SPE062 Shuttle Bar Part No 5 058 and Trip Rod Part No 5 025 from the Piston Part No SPEO54 Check the Shuttle Bar Part No 5 58 is firmly supported by the Spring Clips Part No SPEO41 but slides in and out easily Replace if necessary Check the Exhaust Valves Part No 5 059 for cracking You should also check around the exhaust and inlet ports on the Piston No SPEO54 for pitting Replace if necessary Unscrew the Throat Nut Part No SPEO76 in the base Part No 5 030 replace the U Seal Part No 5 073 and Wiper Seal Part No SPE0777 Caution WHEN REFITTING THE THROAT NUT Part SPE076 DO NOT OVERTIGHTEN Reassemble parts Reverse order to the above When reassembling the valve mechanism must be adjusted so there is a 3mm clearance between the inlet seal Part No SPEO069 and it s seat underside of the Piston No 5 54 As shown in figure 3 F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 Page 10 of 18 WAN TE AALL GB7 GROUT PUMP GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 5 70 SPE047 x 5 059 SPE054 Figure 3 0 8 TESTING This section is a general guide to assist with the testing of the GB7 Grout Pump to ensure maximum performance is achieved 8 1 Set the pump up for testing as outlined in section 4 1 to 4 10 8
4. be met when operating the GB7 Grout Pump 2 SPECIFICATIONS 2 1 The GB Grout Pump is constructed of Fire Retardant Anti Static materials and has been specifically designed for use in hazardous work environments such as Underground Coal Mines 2 2 The following specifications are an extract of tests performed by a leading Australian University Air Consumption Water 60 P S I o1m hr 30 Pump Performance Rate pumping Water o3lt min 12 GPM Rate pumping Grout 23lt min 5 GPM Maximum Discharge Maximum Pump Pressure 14MPA 2000 P S I F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 3 of 18 GB7 GROUT PUMP GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 2 3 Performance Graph Figure 1 0 ra co gt L iuis 278828 o Hur NH CCC Tee r aa er TPT HII LI pet 4 A EX LLL E SRS A ARS Se d MB pee L FILIIS THREE H E m m E E FIL rd Se LI a CO T LIE mu EL ma pss p E ia za ne Big Mb e
5. wear suitable Eye protection should any spraying be done WARNING Serious personal injury ma occur if the correct safety equipment is not worn while operating this machine CLAW COUPLINGS CLAW COUPLINGS om DISCHARGE HOSE DISCHARGE NOZZLE BALL VALVE USED TO CONTROL DISCHARGE Figure 2 0 A GB7 GROUT PUMP F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 6 of 18 GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 Connect the delivery and discharge hoses to pump before opening the compressed airline ensure the valve on the discharge end of the discharge hose is open and the hose is secured or being held by the operator Slowly open the air supply valve The pump should begin to run smoothly Run the pump until water flows from the discharge hose Turn off the air supply to the pump Close the valve on the discharge end of the discharge hose Restart the pump via the air supply valve The pump should stall immediately Ensure there are no leaks from the upper body of the pump CAUTION In this mode the pump can build 2000 Psi between the pump and the discharge valve To commence pumping slowly open the discharge valve the pump should begin to pump smoothly again The pump can be operated as a remote unit simply by opening and closing the discharge valve Shut off the air supply
6. 2 The pump should run at low speed without jerking if not check the O Rings Part No 5 061 amp SPEO066 for wear Check the correct size has been used 8 3 Delivery rate at fast speed should be reasonably even if not check the Foot Valve Part No SPE093 9 4 Run pump to stall condition This done by closing off the outlet end of the discharge hose 8 5 The Check the pressure in the discharge hose on the up and down stroke of the piston Pressure readings should as follows Piston up stroke 5000 kPa Piston Down stroke 3000 kPa F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 doc Page 11 of 18 GB7 GROUT PUMP GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 M 9 6 The pump must not leak air the top or bottom of it s stroke if it does check the rings Part No 5 061 8 SPEO066 and check the bore of the Cylinder Part No SPEO049 8 7 The pump must have sharp change over at the top and bottom of the Piston stroke If not check the Inlet Valves No 5 069 and the outlet valve No 5 059 9 PARTS BREAKDOWN 9 1 GB Grout Pump parts list Part No Item No Description 5 11 1 Pump Piston SPE013 2 Seat Throflow SPE016 3 Body Piston 5 025 4 5 5 Base SPE033 6 Adaptor Riser Tube SPE035 7 Cover Plate SPE036 8 Screw Coverplate SPE038P 9 screw Cylinder Plastic SPE038A 10 Screw Cyli
7. Male Nipple 1 9 2 GB Grout Pump Service Repair Seal Kit Part No SPE310 Part No ITEM DESCRIPTION Qty ea SPE046 18 Grommet 2 SPE059 24 Exhaust Valve 2 SPE061 25 O Ring Air Piston 1 SPE064 27 O Cyclinder Seal 1 5 066 28 Ring Base Seal 2 SPE067 29 O Ring Adaptor 1 SPE068 30 Rubber Washer Tube 1 SPE069 31 Inlet Valve 2 SPE073 34 U Seal c w O Ring 1 SPEO77 36 Wiper Seal 1 5 079 38 O Ring Cap Nut 1 SPE083 39 O Foot Valve 1 SPE305A 49 One Piece Cup Seal 1 9 3 GB Grout Pump Piston Head Assembly No 5 009 ITEM DESCRIPTION Qty ea SPEO016 03 Body Piston ThruFlow 1 5 11 01 Pump Piston 1 SPE305a 49 One Piece Cup Seal 1 SPE013 02 Seat ThruFlow 1 Peng 9 4 GB Grout Pump Foot Valve Assembly Part SPE094 Part No ITEM DESCRIPTION Qty ea SPE083 39 O Ring Foot Valve 1 5 090 45 Ball Stop 1 5 089 44 Ball Inlet 1 5 093 46 Foot Valve 1 5 096 48 Pin Sieve Lock 1 5 095 47 Sieve Inlet 1 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 13 of 18 OPERATION amp MAINTENANCE MANUAL 2000 GB7 GROUT PUMP UA 10 GB7 GROUT PUMP ASSEMBLY SCHEMATIC SECTION 1 n SECTION 2 OH SECTION 3 0 21 F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 PARIS LIST Page 14 of 18 GB7 GROUT PUMP UA OPERATION amp MAINTENANCE MANUAL 2000 SECTION 1 SPEQ7S8 m SPE 043 SPE 056 i
8. SPE 047 SPEO47 SPE 058 SPE 046 SPEO46 SPE059 j lt 059 SPE047 1 SPEO SPE SPE SPE 062 045 044 SPE 025 SPE 061 T SPEO 40 1 SPE 041 _ SPE 054 SPE 069 L rt 4 SPE 07 U F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 15 of 18 GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 N SECTION 2 Luc SPE 064 SPED77 ns SPE 066 A a SPE 076 PE 066 039 SPE 938 Mir WH SPE WH 918 322 91 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 16 of 18 GB7 GROUT PUMP UA OPERATION amp MAINTENANCE MANUAL 2000 SECTION 3 SPE 067 L SPE 033 C SPE unos d d SPE 039 086 SPE 038A SPE 084 SPE 085 SPE 016 M SPE 011 m b SPE 305A SPEO09 SPE 013 B SPE 088 2222 083 090 SPE 089 SPE 093 SPE094 SPE 096 SPE 095 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 17 of 18 GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 STEEL VERSION SECTION 5 SPE 054 H SPE 407 2 a SPE 072 SPE 407 ITEM 1 SPE 401 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc WAN TE AALL CONFIGURATION DIVORCED SECTION Note The following parts are not required for the standard pump
9. nder 25mm SPE039 11 Washer Cylinder SPE040 1 12 Screw Spring Clip 5 41 13 Spring Clip SPE042 14 Shuttle Toggle SPE043 15 Pin Toggle SPE044 16 Rocker Toggle SPE045 17 Spring SPE046 18 Grommet 5 047 19 Locknut Valve Stem SPE049P 20 Cyclinder SPE054Cl 21 Piston SPE056 22 Lockwire SPE058 23 Shuttle Bar SPE059 24 Exhaust Valve SPE061 25 Ring Air Piston SPE062 26 Arm Toggle SPE064 27 O Cylinder Seal 5 066 28 Ring Base Seal 5 067 29 Ring Adaptor SPE068 30 Rubber Washer Tube 5 069 31 Inlet Valve 5 070 32 Valve Stem 5 072 33 Displacment SPE073 34 U Seal c w O Ring 5 076 35 Throat Nut F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Qty each NO GB7 GROUT PUMP A NO AO AN PO PO B PAO VN ND NO VP VN CO CO 5 A a A Page 12 of 18 GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 SPEO77 36 Wiper Seal 1 SPE078 37 Cap Nut 1 5 079 38 O Ring Cap Nut 1 SPE083 39 O Foot Valve 1 SPE084 40 Conrod 1 SPE085 41 Locknut Piston Head 1 SPE086 42 Locknut Rod 1 SPE088 43 Riser Tube SQ Thread 1 5 089 44 Ball Inlet 1 5 090 45 Ball Stop 1 SPE093 46 FootValve SQ Thread 1 5 095 47 Sieve Inlet 1 5 096 48 Pin Sieve Lock 2 SPE305A 49 One Piece Cup Seal 1 SPE319 50 1 4 BSP Male Type Coupling 1 SPE322 51 BSP Ball Valve 20mm 1 WH918 52 3 8 BSP Minsup Cooupling 1 SPE322 1 53 Ya 3 8 BSP
10. pump from the container Drain pump by turning it upside down 6 CLEARING BLOCKAGES This section is a guide to assist with potential blockages that may occur while operating the pump 6 1 If a blockage occurs follow the steps listed below 6 2 Shut off the air supply to the pump Disconnect air supply hose and discharge hose 6 3 Remove sieve No SPE095 and clean 6 4 Unscrew Foot Valve Assembly Part 5 094 and clean 6 5 Unscrew and remove the Riser Tube Part No SPE088 and clean 6 6 Clean the piston head assembly No 5 009 F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 8 of 18 GB7 GROUT PUMP GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 6 6 8 7 Clean and flush Pump discharge port Reassemble the above and test the pump with water as explained in section 4 SERVICING AND AIR MOTOR DISASSEMBLY This section is a general guide to assist with the Servicing and the general maintenance of the Grout Pump 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 1 9 Carry out steps in section 6 3 to 6 5 Pull the Displacement Rod Part No 5 072 as far as it will go and unscrew the Lock Nut Part No SPE086 Push the Piston Part No 5 054 to the upside of the otroke Unscrew the Cap Nut Part No SPEO78 out of the Cylinder head Part 5 49 Grip the Trip Rod Part No SPE025 with padded pliers scre
11. r n CoC et dil RE ACEBEEELEEHE LET LELTI S m i LE SII ILLI 4 me RECEP CE et 25 380 DELIVERY VOLUME Pressure vs Flow for Water and Grout Various inlet air pressures 3 INSTALLATION In order to ensure the maximum performance and life from the GB7 Grout Pump it is essential that the following points be strictly observed 3 1 Remove the 7 Grout Pump from it s packaging and ensure all packaging and fastening materials are removed from the unit 3 2 This unit may be operated in any work environment provided adequate airline lubrication is supplied As the GB Grout Pump piston is totally enclosed and sealed it can be used in any environment within the temperature limits of 12 C to 80 C GB7 GROUT PUMP F Whyte Hall Whyte Hall Master Docs GB7 MODEL GB7 Manual 2000 doc Page 4 of 18 GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 3 3 3 4 3 5 3 6 MAXIMUM working pressure bar 100 p s i Air Supply amp Circuit The Air supplied to GB7 Grout Pump must be clean and relatively dry An airline filter and lubricator should be fitted in the air supply line and located before the first control valve of the system If the rated performance of the unit is to be obtained all valves hoses and pipework of the air supply m
12. to the pump and ensure all the pressure has been released from the discharge hose To empty the water from the pump turn the grout pump upside down Open the discharge hose and drain hose Mix the grout cement mixture making sure all lumps are removed especially from corners and sides of container Place the pump base into the mixture and follow steps 4 2 to 4 10 as required to operate the pump It may be necessary to initially hand feed mixture into the foot valve WARNING IF THE PUMP IS NOT BEING USED FOR MORE THAN FIVE 5 MINUTES REMOVE THE PUMP FROM MIXTURE AND FLUSH WITH WATER F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 Page of 18 587 GROUT PUMP GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 9 FLUSHING amp CLEANING PUMP To ensure the 7 Grout Pump is ready for trouble free operation and peak performance the following steps should be followed when cleaning the pump 5 1 Place the pump into container of water and start the pump following the basic operation steps in section 4 6 to 4 10 5 2 is advisable to stall and quickly open the discharge valve a number of times while flushing the pump this ensures the pump and hoses are totally clean and free of buildup 5 3 Use the pressurized water to hose down and clean pump and mixing equipment 5 4 Turn off the pump 59 Ensure air supply has been cut off 5 6 Disconnect hoses and remove the
13. ust be of adequate size Valves should be sited as close as possible to the GB Grout Pump To ensure peak performance at all times it is recommended bore airline is supplied to the unit Coupled via Type A claw coupling The air supply should be capable of supplying a minimum of 14 5It sec 31CFM 415kPa 60p s i Before final connection to the GB7 Grout Pump blow out all airlines to remove loose scale swarf dirt moisture or abrasive dust which may be present squirt a few drops of oil into the units inlet port Airline Filtration Use a 64 micron filter The airline filter should be drained regularly and the element examined for signs of clogging F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 Page 5 of 18 WAN TE AALL GB7 GROUT PUMP GB7 GROUT PUMP MY OPERATION amp MAINTENANCE MANUAL 2000 4 This unit should only be operated by persons suitably qualified to do so It is always advisable to test the pump using water prior to pumping grout or other mediums 4 7 4 2 4 3 4 4 AIR INLET OPERATION Place the pump upright in a container of water 201 Minimum Ensure the unit is securely fastened in place oecure the airline in place using the recommended air supply configuration given in oection 3 Always secure the coupling with a Safety locking Pin Type A or other suitable locking assemblies Observe hearing protection warning and
14. w Cap Nut off the Trip Rod Remove screws Part No SPE038 holding the Cylinder Part No 5 049 to the Base Carefully pull Cylinder straight up off the Piston Part No SPE054 Do not tilt the Cylinder as it may damage the Cylinder wall Pull the Piston Part No SPE054 complete with displacement rod SPEO72 out of the Base Part No SPEO030 Check polished surfaces of the Piston Part No 54 Displacement Rod Part No SPE072 and Cylinder wall Part No 5 049 for marks and or scratches Replace parts if necessary Hold the Piston Part No SPEO054 in a suitable vice preferably a padded vice Push down on the Shuttle Toggle No SPE042 until it snaps down the Toggle Arms Part No SPE062 Remove the Lock Wires Part No SPE056 unscrew the top Valve Stem Locknuts Part No SPE047 unscrew the Valve Stems Part No F Whyte Hall Whyte Hall Master Docs GB7 MODEL Manual 2000 doc Page 9 of 18 WAN TE AALL GB7 GROUT PUMP GB7 GROUT PUMP OPERATION amp MAINTENANCE MANUAL 2000 7 10 7 11 7 12 7 13 7 14 7 15 7 16 070 out of the Grommets No 5 046 and the bottom Lock Nuts No SPE047 Take the Inlet Valve Seals Part No 5 069 off the Valve Stems Part No 5 070 compress them firmly checking for cracks Replace if necessary Carefully remove the Toggle Rockers Part No SPE044 Spring Part No SPE045 Toggle Shuttle
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