Ball cupling Page 1 REVISION STATUS Issuance/revisin date Revisin index dified pages 08/11/2016 0 -- Dcument issuance dificatin descriptin
Ball cupling Page 2 Smmari WARNINGS... 3 INSTRUCTIONS FOR STORAGE OF PRODUCTS IN STOCK... 4 PACKAGE CONTENTS... 4 GENERAL SYSTE DESCRIPTION... 4 ain cmpnents... 4 arking... 4 Available cdes... 4 INSTALLATION... 5 Hydraulic cnnectins... 5 Female cupling... 5 ale cupling... 5 INSTRUCTIONS FOR USE... 6 Setup prir t the first assembly... 6 Befre each cmmissining... 6 Befre each system strage... 6 Prtectin f the cuplings when discnnected... 6 Cnnectin sequence... 7 Discnnectin sequence... 8 CLEANING AND AINTENANCE... 8 Cleaning... 8 Rutine maintenance... 8 Extrardinary maintenance... 8 TROUBLESHOOTING... 9 AVAILABLE SPARE PARTS... 10 ale cupling valve seal replacement... 10 ACCESSORIES... 11 CONTACTS... 12 Appendix 1: Flat face male cupling seal replacement WARNINGS... 1/A RECOENDATIONS FOR STORAGE OF THE PRODUCTS... 1/A EXISTING SEALS TYPES AND THEIR REPLACEENT... 1/A TYPES OF SEALS COPOUNDS AND COPATIBLE GREASES... 1/A INSTRUCTIONS FOR SPARE KIT REPLACEENT... 2/A
Ball cupling Page 3 The fllwing instructins are a supplement and must be used as a single dcument tgether with the technical data sheet and the prduct drawing. A cpy f this dcument must be given t the staff respnsible fr the selectin and/r use f prduct. WARNINGS Read the fllwing instructins and the general instructins at http://www.stucchi.it/en/cntent/knwhw/instructins-and-warning carefully befre installing and using the prduct. isuse f ur prduct may cause malfunctins and risks related t safety. Use exclusively the type f fluid indicated n the technical data sheet. In case f using different fluids, first cntact Stucchi Technical Supprt. The prduct is required fr using pressure il, fr pressures indicated in the technical data sheet: in case f malfunctins, leakage r imprper use, there can be risks related t high pressure il leaks and/r ejectin f cmpnent parts. Befre installing be sure the prduct cde is crrect. Befre cntinuing with the installatin, verify that all structures n which prducts will be installed and that the surrunding areas are cleaned. The prduct must be installed, perated and serviced exclusively by qualified persnnel. Unqualified persnnel must be kept safe distance frm the abve peratins. It is recmmended t use the prduct n systems with a degree f cntrlled cntaminatin (19/17/14 accrding t ISO/DIS 4406 and 8 in accrdance with NAS 1638 r higher grade): dirt can wear/damage prduct cmpnents causing malfunctin and/r decrease in perfrmance. During installatin, adequately prtect prducts frm ptential cntaminants, such as metal debris, dirt, dust r paint residues. Remve the prtective caps n the quick cuplings nly befre installing the pipes. D nt use imprper tls, during installatin r maintenance, which may cause damages and/r malfunctins. Apprpriate security measures t prevent damage t persns r prperty as a result f any pressure drp in the circuit caused by the cupling must be prvided by the user. In case f damage t the seals r ther parts f the cupling, there is a risk f serius injuries by hydraulic il injectin and/r burns, as a result f il leakage under pressure and/r high temperature. In case f suspected il leakage, d nt perfrm inspectins with bare hands: always use a sheet f paper, able t highlight the leakage, withut risk fr the peratr s safety, and t adequately absrb any il jet (liquid r spray). In case f il leakage, d nt perate the system. Stp the system, releasing pressure and bringing it t rm temperature. D nt manually perate the valves f the quick cuplings t release the pressure inside the circuit, when discnnected. D nt perate the system when damage is visible n quick cuplings cmpnents. D nt disassemble, mdify r tamper with the cuplings. D nt insert freign bjects between the cuplings during the cnnectin, discnnectin r use in general. D nt use differently as shwn in this dcument. D nt use utside the perating parameters indicated in the prduct technical data sheet. D nt cnnect with the dynamic pressure in the circuit. Befre perfrming maintenance r cleaning the prduct, release the residual pressure in the circuit and bring the system t rm temperature. D nt direct high pressure jets n the cupling valves r n the seals (fr example during cleaning with a pressure washer). Fr cleaning the cuplings, d nt use aggressive r incmpatible fluids fr seals. Use nly riginal spare seals. In the event f malfunctins and sliding issues f the cupling parts, replace it. In case f replacement f ne f the tw parts damaged ( r F) which cnstitute the quick cupling, als replace the ther half crrespnding cupling.
Ball cupling INSTRUCTIONS FOR STORAGE OF PRODUCTS IN STOCK Page 4 Fr ptimal maintenance f prducts and t avid damages befre installatin, use the fllwing recmmendatins: the prduct must be kept in its riginal packaging t prtect the cmpnents (with special attentin t the seals) frm dirt, dust and ultravilet radiatin. the prduct must be kept in a dry place, away frm crrsive atmspheres and atmspheric agents, grease and/r il nt cmpatible with the installed seals, dirt, away frm heat and magnetic fields. keep away frm zne surces as extremely detrimental fr the seals. PACKAGE CONTENTS The prduct cde and its descriptin n the identificatin label are shwn. GENERAL SYSTE DESCRIPTION The FIRG and FIRG-QL series are quick cuplings series with flat faces and ball cnnectin, nt cnnectable with residual pressure, equipped with safety lcking ball. ain cmpnents ARKING FEALE SLEEVE-HOLDER FEALE COUPLING SAFETY LOCKING BALL ARKING LOCKING SLEEVE ALE COUPLING arking STUCCHI - - FIRG 100 V BSP anufacturer Cupling type (/F) Family Nminal size Special seal (ptinal) Cnnecting thread STUCCHI - - FIRG 100 Q V BSP anufacturer Cupling type (/F) Family Nminal size Versin Special seal (ptinal) Cnnecting thread Available cdes The list f cdes f prducts available can be fund in the data sheets f the FIRG series (cde 000100000) and FIRG-Q series (cde 000100005).
Ball cupling Page 5 INSTALLATION Befre installing the pipes, immediately remve the prtective caps frm the quick cuplings. Hydraulic cnnectins Female cupling Cnnect the pipe t the cupling with spanner and cunter spanner. DO NOT use pliers r ther tls which may affect the perfrmances f the cupling. Tighten the pipe fittings t the crrect trque indicated by the referenced standards/specificatins f the manufacturer f pipe fittings. ale cupling Cnnect the pipe t the cupling with spanner and cunter spanner. DO NOT use pliers r ther tls which may affect the perfrmances f the cupling. Tighten the pipe fittings t the crrect trque indicated by the referenced standards/specificatins f the manufacturer f pipe fittings. CAUTION: at least ne f the tw hydraulic cnnectins must be carried ut by using a flexible hse.
Ball cupling Page 6 INSTRUCTIONS FOR USE CAUTION: fr the risks related t use f the prduct, see WARNINGS f this dcument. Setup prir t the first assembly Befre the cmmissining f the cuplings the fllwing peratins must be perfrmed by qualified persnnel: tighten the pipe fittings t the crrect trque indicated by the referenced standards/specificatins f the manufacturer f the pipe fittings. clean, using nly nn-aggressive fluids and cmpatible with the seals, the flat faces f the quick cuplings, t avid the inclusin f cntaminants in the hydraulic circuit; cnnect the system up t end stp; verify that the quick cuplings perfrm a full strke; verify absence f damage n the quick cuplings; verify absence f il leakage; discnnect the system; repeat the attempt cnnecting and discnnecting a few times, t ensure it is prperly repeatable. The system is ready t be used at perating cnditins. Test the functinality in perating cnditins. Befre each cmmissining Befre each cnnectin, verify: absence f il leakage; that the system is clean, with special attentin t the quick cuplings, especially n the cnnecting surfaces; the quick cuplings fr damage. Befre each system strage After each discnnectin verify: absence f il leakage; that the system is clean, with special attentin t the quick cuplings; the quick cuplings fr damage. Prtectin f the cuplings when discnnected When the cupling is discnnected, prtect it, preferably using the apprpriate Stucchi caps (see the ACCESSORIES sectin f this dcument), frm the expsure t: dirt and/r crrsive envirnment; shcks which may damage the quick cuplings.
Service manual 000300011/E Ball cupling Page 7 Cnnectin sequence Befre cnnecting, clean, using nly nn-aggressive and cmpatible fluids fr the seals, the cupling faces, t prevent dirt entering the circuit. Insert the male cupling in the female cupling (fig. 1), until the lcking sleeve clicks: this guarantees the cmplete cnnectin (fig. 2). T prevent an accidental discnnectin, rtate the lcking sleeve, dephasing the security ball with respect t the tw husings machined in the lcking sleeve itself (fig. 3). Fig. 1 Fig. 2 HOUSING SAFETY LOCKING BALL Fig. 3
Discnnectin sequence Service manual 000300011/E Ball cupling Page 8 Rtate the lcking sleeve, dephasing the security ball with respect t ne f the tw husings machined in the lcking sleeve itself (fig. 1). Pull back the lcking sleeve, releasing the lcking balls, and extract the male cupling frm the female cupling (fig. 2). SAFETY LOCKING BALL AND HOUSING CLEANING AND AINTENANCE Fig. 1 Fig. 2 CAUTION: fr risks related t the prduct cleaning and maintenance, see WARNINGS f this dcument. Cleaning We recmmend, befre each cmmissining, t clean the system, t remve dirt which during use can be accumulated. D nt direct high pressure jets n the flat faces f the cuplings (fr example during pressure washer cleaning). Rutine maintenance nthly check: absence f il leakage; that the pipe fittings are tighten t the crrect trque indicated by the referenced standards/specificatins f the manufacturer f the pipe fittings. Extrardinary maintenance In the case f cupling failure, r leakage, see TROUBLESHOOTING in this dcument. In case f failure different frm that stated in the TROUBLESHOOTING f this dcument, r in case the prblem culd nt be slved using the trubleshting, prceed t the replacement f the crrespnding cuplings.
Ball cupling Page 9 TROUBLESHOOTING A A1 A2 A3 A4 B B1 B2 B3 B4 C C1 OIL LEAKAGE OF ALE COUPLING DISCONNECTED Lcate the rigin f the leakage. If the leakage was frm the pistn r pipe fitting, replace the male cupling and the crrespnding female cupling. Verify that the leakage is nt due t the pipe cnnectin. If the check in step A3 prves psitive, verify the prper clsing f the trque between the pipe and the male cupling. OIL LEAKAGE OF THE FEALE COUPLING DISCONNECTED Lcate the rigin f the leakage. If the leakage was frm the stem r frm pipe fitting, replace the female cupling and the crrespnding male cupling. Verify that the leakage is nt due t the pipe cnnectin. If the check in step B3 prves psitive, verify the prper clsing f the trque between the pipe and the female cupling. OIL LEAKAGE OF THE COUPLINGS CONNECTED Lcate the rigin f the leakage. C2 Discnnect the COUPLINGS and prceed as per pints A and B. C3 C4 D D1 D2 D3 E E1 E2 E3 F F1 F2 F3 G G1 G2 H H1 H2 In case the leakage persists nly with COUPLING cnnected, replace the seal f the cupling male. In case the leakage persists nly with COUPLING cnnected, replace the crrespnding cuplings. THE ALE COUPLING DOES NOT CONNECT WITH THE FEALE COUPLING Verify that the split pin has been remved frm the fixing ring nut. Verify that there are n freign bdies between the tw cuplings. Verify that there are n impediments n the cupling thread. THE LOCKING SLEEVE DOESN T OVE BACK Verify that the security ball is crrectly phased with ne f the tw husings machined in the lcking sleeve, befre pulling back the lcking sleeve itself. Verify that there are n freign bdies between the lcking sleeve and the female sleeve-hlder r in the ball hles f the female cupling. If the prblem persists, replace the crrespnding cuplings. THE LOCKING SLEEVE DOES NOT CLICK OR DOES NOT FULLY CLICK WITH CONNECTED COUPLINGS LETAENTE AD INNESTI ACCOPPIATI Verify that the male cupling has cmpleted the full cnnectin strke. Verify that there are n freign bdies between the lcking sleeve and the female sleeve-hlder r in the ball hles f the female cupling. If the prblem persists, replace the crrespnding cuplings. THE COUPLINGS DO NOT DISCONNECT Verify that the lcking sleeve has been cmpletely pulled back, befre the discnnectin. If the prblem persists, d nt frce the discnnectin and cntact Technical Supprt. THE FACES OF THE COUPLINGS ARE NOT COPLETELY FLAT AFTER THE DISCONNECTION Carry ut again the cnnectin and discnnectin and verify that, at this pint, the faces are flat. If the prblem persists, replace the crrespnding cuplings.
Ball cupling Page 10 AVAILABLE SPARE PARTS COUPLING DESCRIPTION FIRG14 VALVE SEAL KIT FIRG38 FIRG12 FIRG12A FIRG34 VALVE SEAL KIT VALVE SEAL KIT FIRG34B VALVE SEAL KIT FIRG34A FIRG100 VALVE SEAL KIT FIRG114 VALVE SEAL KIT FIRG112 VALVE SEAL KIT FIRG200 VALVE SEAL KIT ale cupling valve seal replacement In case f leakage frm the valve f the male cupling, it is pssible t replace the seal: fr ding this, please refer t the prper instructin Flat face male cupling seal replacement cde 000310000, available at the Appendix 1 f this manual.
Ball cupling Page 11 ACCESSORIES COUPLING DESCRIPTION ATERIAL FIRG14 FIRG38 FIRG12 FIRG12A FIRG34 FIRG34B FIRG34A FIRG100 FIRG114 FIRG112 FIRG200 F F F F F F ANODISED Aluminium ANODISED Aluminium ANODISED Aluminium Nyln ANODISED Aluminium Nyln ANODISED Aluminium Nyln ANODISED Aluminium Nyln Nyln Nyln ANODISED Aluminium Nyln ANODISED Aluminium Nyln ANODISED Aluminium ANODISED Aluminium F ANODISED Aluminium ANODISED Aluminium F ANODISED Aluminium ANODISED Aluminium
Ball cupling Page 12 CONTACTS Stucchi S.p.A. Via delle Arti e dei estieri, 17 24040 Pagazzan (BG) Italy assistenza@stucchi.it (+39) 0363 380100 The texts, data and illustratins, indicated in this dcument, may be changed by Stucchi S.p.A. at any time withut ntice.
Spare kit instructin 000310000/E Flat face male cupling seal replacement Page 1/A The fllwing instructins are a supplement and must be used tgether with the service manual f the quick cuplings. A cpy f this dcument shall be distributed t the persnnel respnsible fr the quick cuplings maintenance. WARNINGS aintenance peratins must be perfrmed by qualified persnnel nly. Befre perfrming maintenance peratins, read carefully the fllwing instructins. Befre perfrming maintenance peratins, check that the spare kit cde is crrect fr the prduct. aintenance peratins must be perfrmed in areas that are clean and prtected by ptential cntaminants. Befre perfrming maintenance peratins, make sure that the spare kits and the surrunding areas are clean. During maintenance peratins, avid using incrrect tls which culd cause damages and/r malfunctins. A misuse f the spare seals can cause malfunctins and safety risks. Befre perfrming maintenance peratins n the quick cupling, exhaust the residual pressure within the hydraulic system and let the system cl dwn. D nt perate manually the valve f the quick cupling t exhaust the pressure inside the circuit, when the system is discnnected. RECOENDATIONS FOR STORAGE OF THE PRODUCTS Fr an ptimal preservatin f the prducts and t avid damages befre installatin: the prduct must be kept in the riginal package t prtect the cmpnents frm dirt, dust and ultravilet radiatins; the prduct must be stred in a dry place, sheltered frm crrsive atmspheres, atmspheric agents, grease, il, dirt and far frm surces f heat and magnetic fields; keep away frm zne-generating surces, since they are very detrimental fr seals. EXISTING SEALS TYPES AND THEIR REPLACEENT OR + BACKUP RING OR + BACKUP RING OR + U-CUP RING PUR SEAL PUR SEAL TYPES OF SEALS COPOUNDS AND COPATIBLE GREASES SEAL COPOUND (DIN/ISO 1629) TYPE OF COPATIBLE GREASE RECOENDED GREASE NBR, HNBR, FP, VQ, FQ, PUR INERAL PAKER LI/2 EPD, CR SILICONE ROTOSFER GWF4
Spare kit instructin 000310000/E Flat face male cupling seal replacement Page 2/A INSTRUCTIONS FOR SPARE KIT REPLACEENT 1. Lck the cupling, by using the special wrench hexagn (r flats), in a vice with aluminum jaws, t avid damages t the hexagn surface. D nt apply an excessive frce n the vice, but enugh t keep the cupling in psitin, t avid defrmatins. 2. Open the valve, by pushing its tp with a blunt, nn-marring tl, aviding scratching its surface. Keep the valve in pening psitin, by interpsing a plastic stp (e.g. a cable tie, as shwn in figure) between the valve and the male bdy. Befre pening the valve, make sure there is n residual pressure inside the quick cupling. Use nly strng plastic tls as a stp (d nt use metallic r sharp tls). 3. Using a special tl (blunt and nn-marring, t avid scratches), extract the seal frm its husing. 4. Replace the seal: a) OR + BACKUP RING: insert the backup ring first (PTFE, white), arranging it at the tp f the husing, and then the O-Ring (rubber, black), slightly lubricating them with cmpatible grease. b) PUR SEAL: insert the seal, slightly lubricating it with cmpatible grease. Cmpatible greases are listed in the table at the previus paragraph TYPES OF SEALS COPOUNDS AND COPATIBLE GREASES. OR + BACKUP RING PUR SEAL 5. After seal replacement, restre the system: slightly pushing dwn the valve, remve the stp. Then, release the valve slwly, making it return in clsing psitin. During the stp remval, make sure that there are n remains inside the quick cupling (e.g. parts f the stp, metal residues r dirt). 6. Test the cnnectin/discnnectin f the quick cuplings withut pressure, t verify that the cnnectin wrks prperly and the mvement f the valves is crrect. 7. Pressurize the quick cuplings at lw pressure in discnnected psitin and verify that there are n leaks. 8. Cnnect the quick cuplings, pressurize them at lw pressure and verify that there are n leaks. 9. If the checks are psitive, it s pssible t cntinue the standard wrking cycle. In case f questins r maintenance prblems, please cntact Stucchi Custmer Service.