Ingersoll Rand Du All Control Handle 636103 Users Manual

636103 to the manual d110c235-03e8-4fa9-964d-a8211703e87e

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OPERATOR’S MANUAL
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
INCLUDE MANUAL: 636027 HYDRAULIC COUPLERS AND ADAPTERS (PN 97999Ć183)

636103
“DU-ALL” CONTROL HANDLE

636103
RELEASED:
8-7-85
REVISED:
11-20-00
(REV. L)

LIGHT WEIGHT PISTOL GRIP
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.

WARNING Whip Hose must not be used on this control hanĆ
dle in place of the tube and nozzle assembly. Pressures develĆ
oped are too great and may burst hose causing accidental
injection.

SERVICE KITS
• Use only genuine AROR replacement parts to assure compatible
pressure rating and longest service life.

• 71139 for repair of control handle.

636103

OPERATION
There are no complicated adjustments and it is easy to clean and serĆ
vice. It uses line pressure for normal lubrication, but for tough fittings,
operator merely squeezes (14) handle several times until fitting opens.
A maximum of 10,000 p.s.i. (689 bar) can be reached by squeezing the
(14) handle several times.
When removing the control handle from a grease fitting, do not pull the
hydraulic coupler straight off of the fitting. Move the control handle so
that the 636028 hydraulic coupler is at an angle of 30_ to 45_ from the
centerline of the fitting. Doing this will ease the removal of the coupler.

MAXIMUM INLET PRESSURE 7500 P.S.I. (517 BAR)
WARNING: HIGH PRESSURE DEVICE
IMPROPER USAGE OF EQUIPMENT COULD RESULT IN SERIOUS INJURY.
THE POSSIBILITY OF INJECTION INTO THE FLESH IS A POTENTIAL HAZARD.
NEVER ALLOW ANY PART OF THE HUMAN BODY TO COME IN FRONT OF OR IN
DIRECT CONTACT WITH THE MATERIAL OUTLET.
AN INJECTION INJURY CAN BE SERIOUS! IF INJECTION SHOULD OCCUR, CONTACT A
QUALIFIED PHYSICIAN FOR IMMEDIATE TREATMENT OF SUCH INJURIES.

INGERSOLL-RAND COMPANY

P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151

& (419) 636-4242 D FAX (419) 633-1674

E2000 D PRINTED IN U.S.A.

A

B

Filter (disc type or screen type)

C
17

Direction of lubricant flow.

SECTION 1
If little or no lubricant can be obtained from the control handle:
A. Check air line connection to pump to make certain there is air presĆ
sure to the pump.
B. Check lubricant container to make certain lubricant is not exĆ
hausted.
C. If above conditions are okay and no lubricant can be obtained from the
control handle, clean the filter in the bottom of the control handle.
1. Disconnect or shut off the air supply to the pump.
2. Pull (14) handle on the control handle to relieve pressure in the line
from pump to the control handle.
3. Remove control handle from swivel slowly. If filter is plugged, there
can still be some pressure retained in the line. Remove the control
handle slowly to allow pressure to bleed off slowly so that no injury
can be caused by grease injection.
SECTION 2
If lubricant leaks excessively around top of (5) piston:
A. Replace the two (26) packings. Also replace (5) piston if it is badly
scored on area that packing seals.
1. Follow instruction 1,2 and 3 as described in Section 1.
2. Remove the (1) nut and (2) pin that holds the two (28) links to the
(27) head. This will allow the (14) handle to be moved out of the way
from the (5) piston.
3. Place the flats of the (15) body in a vice.
SECTION 3
If control handle will not develop additional pressure:
A. If dirt got by the (17) filter in the bottom of the control handle, the (9)
outlet check may be fouled or the (19) balls in the (15) body may be
fouled.
1. Follow instruction 1,2 and 3 as described in Section 1.
2. Remove (8) valve body from (10) body.
3. Remove (11) retainer, (12) spring and (13) ball.
4. Clean ball seat of (10) body and (13) ball.
5. Examine ball seat of (10) body and (13) ball for nicks or score
marks. Replace damaged parts.
SECTION 4
If 636028 Hydraulic Coupler locks onto the grease fitting and cannot be
removed:
A. Unscrew the (6) needle one to two turns. This will relieve the grease
pressure out of the bleed hole beside the (6) needle.

PAGE 2 OF 4

4. Remove (16) adapter from control handle.
5. Remove (18) spring and (17) filter.
a. Clean exterior of filter in a solvent with a brush to remove most of
the foreign material and lubricant from the outside of the filter.
b. Blow air through the filter in the oposite direction of lubricant flow.
CAUTION: Be sure to wear eye protection, goggles or glasses
when doing this.
c. Repeat directions a" and b" until filter is clean.
6. If filter is damaged, replace it. (Deformed discs on old style filter or
broken screen on new style filter which would allow dirt to pass on
thru the filter).
7. Reassemble control handle and then assemble to swivel.

4. Use an end wrench or crescent wrench on the flats of the (27) head
and remove the head from the (15) body.
5. Remove (25) spring and (23) spring from the (27) head.
6. Remove the (5) piston by pulling it out of the top of the (27) head.
7. Remove the (25) washer and two (26) packings from the (27) head.
8. Install two new (26) packings and (25) washer in the (27) head.
9. Reassemble the control handle in the reverse sequence of disasĆ
sembly steps 6, 5, 4.
6. Remove (27) head from (15) body.
7. Remove (22) valve seat, two (19) balls, two (20) ball stops and (21)
spring from (15) body.
8. Clean ball seat in (15) body, ball seat in (22) valve seat and two (19)
balls.
9. Examine ball seats and balls for nicks or score marks. Replace
damaged parts.
10. Reassemble in the reverse sequence steps 8,7,6,5,3,2. See drawĆ
ing of control handle for correct placement of parts.

B. Remove control handle from the grease fitting and retighten the (6)
needle.

636103

PARTS LIST
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Description (size in inches)

Qty

Nut
Pin
Nut (1/4" Ć 28)
Set Screw
Piston
Needle
Tube
Valve Body
Outlet Check
Body
Retainer
Spring
Ball (.1250" dia.)
Handle
Body

Part No.

(2)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)

1
2

3

Item

72458
72258
Y11Ć104ĆC
2484
71111
F162Ć1
71303
3571
71122
71120
126
71121
Y16Ć204
71110
73485

Description (size in inches)

16
17
18
n19
n20
n21
n22
23
24
n25
n26
27
28
n

Adapter
Filter
Spring
Ball (.1562" dia.)
Spring Stop
Spring
Valve Seat
Spring
Spring
Packing Washer
Packing
Head
Link
Service Kit

Qty

Part No.

(1)
(1)
(1)
(2)
(2)
(1)
(1)
(1)
(1)
(1)
(2)
(1)
(2)

76493
76994
76494
Y16Ć205
71496
71115
71116
F51Ć50
71114
71113
71112
71118
70709
71139

4
5

21

6

7

H

28
27
26
25
24
23
22
19
20
21
20
19

8
10
11
12
13

H

H

H
636028 COUPLER

9

(See Manual 636027)

NOTE: All Threads are Right Hand.

z Torque to 60 Ć 70 ft lbs (81.3 Ć 94.9 Nm).
H Apply anaerobic pipe sealant to threads.

14

15 z

Place Wrench
on these Flats

18
17

H

Z" Swivel

Straight Swivel

15 Body

16 z

1/8'' N.P.T.F.

Remove at this point
636103

PAGE 3 OF 4

PN 97999Ć115
PAGE 4 OF 4

636103



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