ATD Tools ATD5217 - User Manual

ATD5217 MADE IN MEXICO FOR 120 LB. DRUMS
RETAIN THIS MANUAL FOR FUTURE REFERENCE TO IMPORTANT WARNINGS AND
OPERATING AND MAINTENANCE INSTRUCTIONS.
PROPER USE AND MAINTENANCE OF THIS EQUIPMENT IS THE RESPONSIBILITY OF THE
OWNER AND/OR OPERATOR.
DO NOT USE THIS EQUIPMENT UNLESS YOU HAVE CAREFULLY READ AND
UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THIS MANUAL.
! WARNING !
NEVER exceed the stated maximum working pressure of the pump or of the lowest rated component in your
system.
NEVER modify any part of this equipment.
NEVER use combustible gas with this equipment.
NEVER attempt repairs while the system is under pressure.
NEVER attempt to disassemble the equipment while the system is under pressure.
ALWAYS tighten fluid connections before using this equipment
ALWAYS read/follow the fluid manufacturer’s recommendations regarding fluid compatibility.
ALWAYS read/follow the fluid manufacturer’s recommendations regarding the use of protective clothing
and equipment.
ALWAYS use an air line filter/moisture eliminator at the air inlet for the pump.
ALWAYS use air line lubrication.
REGULARLY check all equipment and repair/replace worn or damaged parts immediately.
FAILURE TO HEED THESE WARNINGS INCLUDING OVERPRESSURIZING,
ALTERING PARTS, USE OF INCOMPATIBLE FLUIDS, MISUSE, OR USE OF
DAMAGED/WORN PARTS MAY RESULT IN EQUIPMENT DAMAGE,
PROPERTY DAMAGE, FIRE, EXPLOSION AND/OR SERIOUS PERSONAL
INJURY.
SAFETY INSTRUCTIONS
Extreme caution should be used when operating this equipment as it generates very high fluid pressure.
Leaks from loose or ruptured components or material from dispensing valve can inject fluid through the skin
causing serious bodily injury and possible need for amputation. Always wear protection to prevent material
splashing onto skin or into eyes.
IMPORTANT:
GET EMERGENCY MEDICAL CARE IMMEDIATELY IF ANY FLUID APPEARS TO
PENETRATE THE SKIN! INFORM PHYSICIAN OF EXACTLY WHAT WAS INJECTED. PLEASE
DO NOT TREAT THIS INJURY AS A SIMPLE CUT.
AIR OPERATED CHASSIS PUMP
50:1 RATIO, OUTPUT – 80 CU. IN./MIN.
MIN. AIR PRESSURE – 30 PSI
MAX. AIR PRESSURE – 120 PSI
MAX. OUTPUT PRESSURE – 7500 PSI
RECOMMENDED OPERATING PRESSURE 80-100 PSI
GREASE TYPE: NLGI #2
(maximum for effective
p
erformance)
OWNERS MANUAL

Summary

Owners Manual and Safety Warnings

General Safety Warnings

Crucial safety warnings covering pressure limits, modifications, combustible gas, and repair procedures.

Safety Instructions for High Pressure

Emphasizes extreme caution with high fluid pressure and immediate medical attention for injection injuries.

Pressure Relief and Inspection Procedures

Relief Procedure Warnings

Critical warnings about never pointing the valve, stopping leaks with body parts, and checking equipment.

Pressure Relief Procedure

Detailed steps to safely relieve pressure before servicing, installing, or cleaning the system.

Inspection and Service Guidance

Instructions on when to contact service for inspection or repair, and warranty contact information.

Installation Recommendation

Recommends using an air line filter/regulator/lubricator to remove contaminants.

Assembly Instructions

Drum Cover and Pump Assembly

Step-by-step guide to assemble the drum cover to the pump body.

Caster and Base Assembly

Instructions for assembling the casters onto the roll-around base.

Follower Plate and Tube Installation

Guide for inserting the follower plate and lowering the pump tube into the drum.

Muffler and Hose Connections

Steps for installing the muffler and connecting the lubricant hose.

Air Inlet and Coupler Assembly

Instructions for installing the air inlet extension and air coupler.

Pump Operation and Testing

Initiating Air Motor and Pump Operation

Detailed instructions on how to start and operate the air motor and pump.

Initial Pump Operation and Flushing

Procedure for operating the pump initially and flushing the hose with grease.

System Testing Procedure

Steps to test the system by pulling the trigger and checking grease ejection.

Troubleshooting and Maintenance Notes

Plastic Liner Issues

Addresses blockages from plastic liners and provides solutions for reseating or using a strainer.

Air Motor Lubrication and Life

Recommendations for lubricating the air motor to ensure efficiency and longevity.

Trouble Shooting Guide

Pump Does Not Operate

Troubleshooting steps for a pump that does not operate, checking air pressure and motor.

Air Leaks and Muffler Issues

Diagnosing air leaks at the nipple, coupler, or muffler installation.

Filter;Regulator Importance

Emphasizes the necessity of a Filter/Regulator to prevent water damage and ensure pump life.

No Material Pumped or Shut-off Issues

Troubleshooting for no material output, not reaching stall pressure, or not shutting off.

Air Motor Operates, No Material

Checks for follower plate issues, air pockets, and proper hose/valve connections.

Troubleshooting Specific Scenarios

Air Motor Operation Without Grease

Troubleshooting steps for the air motor when detached from the grease.

Blockage Diagnosis (Hose, Valve, Coupler)

Isolating blockages in the hose, control valve, or coupler for proper grease flow.

Preventing Contamination

Suggestion to use a foot valve strainer to prevent grease contamination.

Water Ingress Impact

Explains how water can damage the air motor and flush out grease.

Air System Components Recommendation

Recommends Air Lubricator, Moisture Evaporator, and Regulator for optimal pump operation.

Warning: Working on Live System

Critical warning about disconnecting air and relieving pressure before maintenance.

Pump Assembly Diagram and Lubrication

Air Valve Lubrication Procedure

Instructions on how to lubricate the air valve mechanism using specific grease.

Air Motor and Pump Specifications

Diagram showing the 2-1/2" air motor chassis pump assembly with specifications.

Pump Dimensions and Repair Kits

Pump Dimensional Overview

Diagram showing the 2-1/2" air motor pump assembly with key dimensions.

Available Repair Kits

List of available repair kits for servicing the air motor high pressure pumps.

Repair Kit Listings

Complex and Simple Repair Kits

Detailed lists of parts included in complex and simple repair kits for the pump.

Air Motor and Downtube Repair Kits

Lists of parts for air motor repair kits and downtube repair kits.

Service Instructions and Parts List

Lower Pump Tube Assembly Service

Instructions for servicing the lower pump tube assembly and checking ball checks.

Complete Pump Parts List

Comprehensive list of all part numbers and descriptions for the pump assembly.

Lubrigun Assembly Overview

Lubrigun Component Diagram

Diagram showing the components of the portable lubrigun, including pump assembly and base.

Product Description and Specifications

Grease Pump Assembly Details

Description of the 120 Drum Grease Pump Assembly, including components and specifications.

Optional Accessories and Kits

List of optional accessories like hoses and grease strainers, and available repair kits.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

This document describes the ATD5217 Air Operated Chassis Pump, a portable lubrigun designed for dispensing grease.

Function Description

The ATD5217 is an air-operated chassis pump, also referred to as a portable lubrigun, designed for high-pressure grease delivery. It operates using compressed air to pump grease from a drum. The system includes a pump assembly, a high-pressure grease delivery hose, a grease delivery control valve, and a rapid disconnect coupler. It is intended for professional and industrial use, particularly for lubricating chassis and other components requiring high-pressure grease. The pump is designed to be mounted on a 120 lb drum, which is then placed on a roll-around base for portability.

Important Technical Specifications

• Model Number: ATD5217 (Pump Assembly ATD5217-1)
• Drum Size: 120 LB.
• Ratio: 50:1 (Air Motor Operated Pumps)
• Output: 80 CU. IN./MIN. (Grease at 100 PSI NLGI#2 at 70 Degrees ambient temperature, 0.35 cu in/cycle)
• Minimum Air Pressure: 30 PSI
• Maximum Air Pressure: 120 PSI
• Maximum Output Pressure: 7500 PSI
• Recommended Operating Pressure: 80-100 PSI
• Recommended Grease Type: NLGI #2 (maximum for effective performance)
• Air Inlet: 1/8" NPT (f)
• Lube Outlet: 1/4" NPT (f)
• Pump Tube Length: Made for 120 lb Drum & 1.0" Diameter
• Air Motor Design: 20 cu. in.
• Weight: 48 LBS (21.8 KG)
• Box Dimensions: Length: 39.0" (100cm) X Width: 19-1/2" (49.5cm) X Height: 8.0" (20.32cm)
• Hose: Includes a 6 ft (1.85mts) High Pressure Grease Delivery Hose (ATD5361). Optional hose lengths are available: 10 ft (ATD5362), 20 ft (ATD5363), 30 ft (ATD5364), 40 ft (ATD5365), and 50 ft (ATD5366).
• Components: Includes a 50:1 Double Acting High Pressure Pump (ATD5217-1), Grease Delivery Control Valve (ATD5218), Rapid Disconnect Coupler (LT815ME), Muffler (ATD5317), Follower Plate (ATD5325) with outer rubber wiping ring on the drum and inner rubber wiping ring on the pump tube (Diameter 1.0"), Air Motor Cover (91407ME), Steel Drum Cover (45733ME) with screw downs for 120 LB Drum, and a Roll-a-Around Base (ATD5372) with 4 casters. Steel Drum is not included.

Usage Features

The ATD5217 is designed for ease of assembly and operation.

• Assembly: The drum cover (45733) is inserted onto the pump tube (ATD5217-1) and secured with screws (50060) to the pump body. Casters (66060ME) are attached to the roll-around base (ATD5372). A fresh drum of lubricant is placed centrally on the base and clamped rigidly. The follower plate (ATD5325) is slid onto the pump tube, which is then lowered into the lubricant until the drum cover rests on the drum's top bead. Adjusting screws (50415) secure the pump to the drum. The muffler (ATD5317) is installed in the exhaust port of the air motor head. The lubricant hose (ATD5361) is connected to the pump outlet body, ensuring leakproof connections. The extension tube (10181) is installed into the air inlet port of the air motor, and the air motor (91407) is placed on the pump head and secured with a washer (33034) and cover nut (11478). The air coupler (815ME) and nipple (11660) are threaded into the extension and pump head opening, respectively, using Teflon tape to prevent air leakage.
• Initiating Operation: Before connecting the control valve (ATD5218), the pump should be started slowly by turning on air from the air regulator. This allows approximately 1/3 cup of grease to flow out of the hose, priming the system and purging contaminants. The pump will reach prime at a stall pressure, which may initially require 60-70 PSI, then activate at 15-20 PSI under normal conditions (recommended 80 PSI). After priming, the control valve (ATD5218) and optional Z-swivel (ATD5253) can be installed.
• Safety: Extreme caution is advised due to high fluid pressure. Users must wear protective clothing to prevent material splashing and skin injection. Never point the dispensing valve at others or attempt to stop leaks with hands or body. Always ensure safety devices are in place and working. Do not modify the equipment. When flushing with solvents, hold the dispensing valve firmly to a grounded metal pail and operate at the lowest possible fluid pressure.
• Pressure Relief Procedure: This procedure must always be followed to reduce the risk of injury. Disconnect the air supply, aim the dispensing valve away from yourself and others, and open it into an appropriate container until all pressure is relieved. If clogging is suspected, slowly loosen the hose end coupling to gradually relieve pressure.
• Pressure Calculation: To determine lubricant pressure, multiply the air pressure by 50. For example, 100 psi of air pressure results in 5000 psi of grease pressure.
• Troubleshooting: A comprehensive troubleshooting guide is provided for common issues such as the pump not operating, leaking air, blowing air through the muffler, not pumping material, or not shutting off. Solutions include checking air pressure, connections, blockages, follower plate position, and ensuring proper air motor lubrication.

Maintenance Features

• Regular Checks: Regularly check all equipment and immediately repair or replace worn or damaged parts.
• Air Line Filtration and Lubrication: Always use an air line filter/moisture eliminator at the air inlet for the pump to remove harmful dirt and moisture. The filter should have an automatic dump mechanism. Always use air line lubrication. This is crucial as water in the compressed air system is a major cause of corrosion and damage to air-operated equipment.
• Corrosion Prevention: To prevent corrosion, never leave the pump filled with water or air. After normal flushing, flush the pump once more with mineral spirits or an oil-based solvent, relieve pressure, and leave the mineral spirits in the pump.
• Air Motor Lubrication: The air motor is factory-packed with grease, and 4-8 fl oz of common lubricating motor oil is injected into the air inlet port. To maintain efficiency and prolong life, inject at least 2 fl oz of common lubricating motor oil into the inlet port every week. Do not use synthetic oils like Marvel Mystery Oil, as they can swell Buna-N packings and cause irreparable damage.
• Preventing Blockages: To prevent blockages from contaminated grease, or to prevent contaminated grease from entering bearings, the use of a Grease Strainer (ATD5356) is suggested.
• Periodic Inspection: Periodic inspection of parts is advisable at least once each year.
• Repair Kits: Complete repair kits are available:
  • ATD5320 Simple Overall Repair Kit for Pump
  • R83054ME Complex Overall Repair Kit for Pump
  • ATD5322 Air Motor Repair Kit
  • ATD5323 Down Tube Repair Kit
• Warranty: The product comes with a two-year warranty against materials, workmanship, and labor.
• Service: For adjustments or repairs, contact an Authorized Distributor or Service Center. ATD Warranty & Service Center can be reached at 1-800-328-2897.

ATD Tools ATD5217 Specifications

General

Brand	ATD Tools
Model	ATD5217
Category	Water Pump
Language	English