Troubleshooting (precise dispensing system)

About IHI failure handling

IHI will replace a defective part in the event of a trouble attributable to IHI which occurs within one year from the delivery of new product.

For any failure of product caused by other reasons, IHI will respond to it by repairing or updating.

If you wish us to examine a failure cause, an additional fee may be required.

* Please note that a failure cause may not be identified depending on the product condition.

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Troubleshooting (precise dispensing system) Contents

ACG type pneumatic pump

Equipment description

ACG type pneumatic pump
(1)
Connecting port for air piping A2
(2)
Connecting port for air piping A1
(3)
Standard opening 3.4
(4)
Discharge port
(5)
Adjusting screw for suction tube height
(6)
Air vent plug
(7)
Follower plate
(8)
Pail can (not included)

Troubleshooting guide

Symptom Cause Countermeasure
Air-operated pump operating at abnormally high speed.
  • (1) Pump sucking air or remaining grease level low.
  • (2) Foreign material caught by the check valve in the suction port at the end of suction tube.
  • (3) Follower plate is caught on the way. Because the viscosity of grease is high (sticky).
  • (1) Remove the follower plate, level the grease surface till air trap is eliminated, then set the follower plate again. When the remaining grease level is low, replace with the new pail can.
  • (2) Disassemble and clean.
  • (3) Remodel pump for weight pressurizing method by remodeling kit B (Sold separately : Code No.RK465300) of optional parts.
Low-level switch activated, but large amount of grease remains in the pail can. Faulty position setting of the low-level switch. Loosen U-bolt fixing the switch support and reset the switch to the appropriate position.
Grease flowing from the drain port on the side of pump body. If the grease amount is so large as to fill up the port, the internal seal is worn out. Disassemble the pump body and replace the seal.
Grease flowing from the vent port on the side of dispenser. No particular problem if the grease amount is not so much as to fill up the port.
If it is so much as to fill up the port, the internal seal is worn out.
CLOSE the air circuit of the pump and dispenser, remove the residual pressure in the grease line to zero, and remove the dispenser.
Then, disassemble the dispenser and remove grease accumulated in the lower portion of air cylinder.
Replace the seal if it is damaged or worn out.
Dispensing capacity fluctuating. Air trap formed in the piping between the dispenser and coating jig. Operate the dispenser continuously till air trap is eliminated.
Air accumulated in the dispenser. Loosen the air vent screw and operate the dispenser to vent air together with grease.
Supply pressure to the pump low. Check the set value of air regulator.
Grease dripping out from the nozzle at the end of dispenser. Either the nozzle inside diameter is small or the hole diameter at nozzle outlet is extremely small. The inside diameter is generally about 2 mm at the smallest. Check the diameter.

ACV type dispenser

Equipment description

ACV type dispenser
Mark Name Purpose and functions
1 Body A Upper main body, in which the air piston is incorporated.
2 Body B Lower main body, in which the main and pilot plungers are incorporated.
3 Indicator rod case The indicator rod coupled with the main piston allows visual confirmation of the operation.
4 Adjusting screw for dispensing capacity Screw to adjust the dispensing capacity. The capacity decreases as the screw is tightened.
5 Lock nut Fix firmly with this nut after adjustment of the dispensing capacity.
6 Air vent screw Loosen this screw to vent air along with grease filling before initial filling of grease in the piping.
7 Individual dispenser mounting holes Fix the dispenser with cross-recessed pan head machine screws or hexagonal socket-headed bolts (M4).
8 Mounting holes for manifold Fix the dispenser with cross-recessed pan head machine screws attached to the manifold.
9 Fluid inlet Connect the piping from the air-operated pump to this connecting port (Rc1/8).
10 Dispensing outlet Screw in a fitting (R1/8) of copper tube or nylon tube.
11 Air connection (Port A1) Connect the air piping from the air solenoid valve (SOL-V1).
12 Air connection (Port A2) Connect the air piping from the air solenoid valve (SOL-V2).
13 Vent ports Port to open the air cylinder bottom to the atmosphere and to drain grease accumulated in the plunger. Grease may come out when the operation frequency exceeds 500,000 cycles.

Troubleshooting guide

Symptom Cause Countermeasure
《Case 1》

Grease discharged from the nozzle end during Standby

  • (1) The pilot plunger may be worn out or damaged when grease is discharged continuously.
  • (2) Air layer is formed in the nozzle when grease is only dripping.
  • (3) The hole size at a nozzle end is too thin to stop dripping.
  • (1) The part replacement is impossible. Replace the dispenser as a set.
  • (2) Operate the dispenser till there is no air layer left.
  • (3) The hole size (diameter) must be 1 mm or more.
《Case 2》

Grease not dispensed even when the indicator rod is operating.

The pilot plunger has lowered without return.
(The pilot plunger stick due to foreign materials)
  • (1) Remove three bolts connecting the main bodies “A” and “B” and separate the main bodies. Pull out the pilot plunger manually and check the plunger and main body “B” hole for damage.
  • (2) When the same phenomena occur even after overhaul and cleaning, replace with the new one.
《Case 3》

The indicator rod not operating

The main plunger has lowered without return.
(The main plunger stick due to foreign materials)
  • (1) Remove 3 bolts connecting the main bodies “A” and “B” and separate the main bodies. Pull out the main plunger manually and check the plunger and main body “B” hole for damage.
  • (2) When the same phenomena occur even after overhaul and cleaning, replace with the new one.
《Case 4》

Large amount of grease discharged through the vent port in the side of dispenser

  • (1) The packing on top of the plunger worn out when grease is discharged continuously.
  • (2) When grease has accumulated so much as to block the vent port, the accumulated grease is due to the plunger movement.
  • (1) Remove 3 bolts connecting the main bodies “A” and “B” and separate the main bodies. Pull out 2 plungers and remove the retaining rings and packings. Replace the packings with new one. *Please install the packing (the lip side faces downward).
  • (2) Separate the main body according to the same procedure as above and pull out the plungers. Clean the main body “B”top surface and air piston inside and outside surfaces with waste cloth. (In this case, do not remove the packings and retaining rings.)
《Case 5》

Air leaked from around the Indicator rod of indicator rod case

The packing worn out inside the indicator rod case. Insert a spanner into the hexagonal section and remove the indicator rod case.Replace with new indicator rod case. In this case, assemble so that the indicator rod case window comes in the front.
(Replacement of the packing only in the indicator rod case cannot be made.)
《Case 6》

Dispensing capacity fluctuating

Air layer formed in the piping between the dispenser and dispensing jig. Keep the dispenser operating till the air layer is eliminated.
Either air is trapped in the dispenser or grease is solidified. Operate the dispenser to vent air.
Loosen the air vent screw in the bottom of dispenser and discharge grease.
The tact time too short for the hard grease. The grease suction time must be longer. Set the controller timer (t4) longer than previously and recheck.

CVM type dispenser

Equipment description

CVM type dispenser
Mark Name Purpose and functions
1 Main block Incorporates a main plunger to dispense the grease.
2 Indicator rod case Enables visual check of the operation by means of an indicator rod connected with the main plunger.
3 Adjusting screw for dispensing capacity Screw to adjust the dispensing capacity. The capacity decreases when the screw is tightened.
4 Lock nut After adjustment of the dispensing capacity, fix firmly with this nut.
5 For mounting holes For fixing of the dispenser with a hexagon socket head cap screw (M5).
6 Pilot block Incorporates the pilot plunger to change over the passage to the main block.
7 Air cylinder Cylinder to drive the pilot plunger vertically. Can be changed in position by 90 degree.
8 Grease inlet One inlet (Rc1/4) on each of right and left sides. Any one of these inlets can be used. Plug (high pressure) the inlet that is not to be used.
9 Dispensing outlet Screw in a fitting (Rc1/8) such as copper tube and nylon tube.
10 Air ports Connect the air piping from the air solenoid valve. Connect the N/O(normally open) side to the lower part (B) and N/C (normally close)side to the upper part (A).
11 Drain port Drain port to discharge accumulated grease from the pilot plunger.The accumulated grease may be drained when the operation frequency exceeds 500,000 cycles.
12 Tie bolts Insert a tie bolt through the hole when multiple dispensers are to be connected.

Troubleshooting guide

Symptom Cause Countermeasure
Grease discharged from the nozzle end during standby
  • (1) If discharge is continuous, packing under the pilot plunger is worn out.
  • (2) If grease is dripping only, the air layer may be formed in the nozzle.
  • (3) The volume inside the piping between the dispenser and the work is too large. (It tends to be affected by residual pressure.).
  • (4) Hose or soft tube between the dispenser and the work is too soft (contracting or expanding).
  • (1) Remove the dispensing outlet fitting and replace the packing and backup rings.
  • (2) Operate the dispenser till the air layer is removed.
  • (3) Reduce the piping and the jig volume between dispenser and work.
  • (4) Do not use a hose between the dispenser and the work. Please use a hard tube.
Grease discharged from the grease drain port in the dispenser backside
  • (1) If discharge is continuous, packing above the pilot plunger is worn out.
  • (2) If grease is accumulated so much as to block the drain port,the grease adhering to plunger may be scraped and accumulated during pilot plunger operation.
  • (7) It is used with grease pressure exceeding the specification (MAX.14.7MPa).
  • (1) Remove two hexagon socket head cap screws fixing the air cylinder and pull out the pilot plunger together with the air cylinder upward. Remove the rod cover and replace the backup ring and packing. Clean the air cylinder inside with waste cloth.
  • (2) Pull out the pilot plunger together with the air cylinder according to the procedure same as the above described. Clean the rod cover inside with an air gun. Clean the air cylinder inside with waste cloth.
  • (7) Use grease pressure within the range of 5.9 to 14.7 MPa.
Grease discharged from the indicator rod of indicator rod case.
  • Packing worn out inside the indicator rod case.
  • (9) Same as (7) above.
  • Insert a spanner in the hexagonal section to remove the indicator rod case, and replace it with a new one. In this case, install the indicator rod case so that its window comes front.
  • (9) Same as (7) above.
Varying dispensing capacity
  • (1) Air layer formed in the piping between the dispenser and dispensing jig.
  • (2) Air collected in the dispenser or grease solidified.
  • (3) Too short tact time through the grease is hard.
  • (13) Same as (1)to(4) above.
  • (1) Operate the dispenser till the air layer is removed.
  • (2) Operate the dispenser to vent air.If grease is solidified, please disassemble and wash it by oil.
  • (3) Increase the air solenoid valve ON time period and OFF time period till the dispensing capacity becomes stable.
  • (13) Same as (1)to(4) above.

Contact

  • IHI Rotating Machinery Engineering Co.,Ltd.

  •  
  • 135-0062
  • 7-12,1Chome Shinonome Kotou-Ku Tokyo Japan KDX Toyosu GRAN SQUARE
  • TEL:+81-3-6703-0440 FAX:+81-3-6703-0443

Inquiries by phone

Inquiry by e-mail