Air Operated Grease Pump

Installation

1. Fill the drum with Grease leaving empty space of about 2” from the top rim. Shake the drum after it is filled to remove air pockets. Place the follower plate in the grease drum with the lift handle facing upwards. Push the follower plate down, until some grease is forced through the centre hole on the plate.
2. Place the drum cover on the drum.  Lift the pump assembly  & slide the suction tube through the drum cover & centre hole in the follower plate.
3. Push the pump assembly down till the bottom of the pump touches the base of the drum. Adjust the drum cover and tighten it with the thumb screws provided along with the drum cover.
4. Tighten the drum cover with the pump suction tube with the help of thumb screws.
5. Use a wrench to tighten high pressure hose to the pump outlet.
6. Use a wrench to tighten the other end of the hose to Z Swivel of grease control valve. Tighten the outlet extension & coupler to the control valve outlet. Use thread sealant on all connections to ensure leak-proof working.
7. With the air supply turned off, connect the Air line into the air inlet on the pump.

Troubleshooting

PROBLEM	POSSIBLE CAUSE	SOLUTION
Pump operates, but does not dispense any grease	Grease is too thick / too cold	Store grease in a warm place
	Air pockets in grease	Shake the Grease Bucket & manually force down  the Follower Plate to remove air pockets
	Dent in the Grease Bucket restricting movement of Follower Plate leading to formation of air pockets in the bucket and inefficient working	Get the dent removed to ensure proper movement of Follower Plate
Pump not working / less discharge	Inlet pressure is too less	Increase inlet pressure. It must be at least 30 PSI (2 BAR)
	Nylon Slider is jammed / overtight	1.    Loosen both Screws & remove Clip. Check for any build-up edge on Clip & tighten it again. Make sure the movement  of Nylon Slider is neither very loose nor very tight 2.    If needed,  replace Nylon Slider. Also replace the Paper Seal, Seat, Slider Guide & Clip to ensure the best fitting
	Piston / Piston Rod / Plunger jammed. NOTE Especially check Extension Rod, Cylinder, Top Coupler, Slide Bush & Piston Rod as shown in PARTS DRAWING	1.    Remove suction tube. Disconnect Air Motor Assembly from Pumping Section by removing the upper two Slotted Spring Pins from Connector 2.    Supply input air to Air Motor.  If it works properly without the barrel assembly, then the problem lies with the pumping section. Otherwise check the Air Motor for smooth movement 3.    After locating the faulty section, check the respective Piston / Plunger  & the associated washers & seals for any overlap or wear & tear. Replace the defective parts from Repair Kit 4.    Ensure to replace the moving parts having close tolerances (such as Piston  & Cylinder along with  Non Return Springs  & balls) as a SET to ensure the best fitting
Pump continues to operate even after the trigger of Grease Control Valve (69) has been released	Leakage in the assembly	Check all the connections to ensure they are air tight. Use thread sealant Check O rings & seals for damage. Replace the defective parts from Repair Kit
Grease comes through the air Exhaust  Valve (23)	Grease leaks into the Air Motor	Check Slider Guide, O Ring, lower O Ring, Seals & Seal Support  for wear & tear. Replace the damaged parts from Repair Kit
Air passes directly from inlet to the outlet & pump does not work	Nylon Slider is jammed / overtight	1.    Loosen both Screws & remove  Clip. Check for any build-up edge on Clip & tighten  it again. Make sure the movement  of Nylon Slider is neither very loose nor very tight 2.    If needed,  replace Nylon Slider. Also replace the Paper Seal, Seat, Slider Guide & Clip to ensure the best fitting
Discharge suddenly stoppped while the pump was running	Seals / O Rings Damage	Check all seals / O Rings & replace  the damaged parts from Repair  Kit
	Chip / Other foreign particles get clogged at discharge coupler	Open the coupler, remove all foreign particles / chips  & reassemble properly
	Clogging of Filter Tube	Open Filter Tube, clean it & reassemble it properly