ATD Tools ATD-30330 Fan User Manual
Contents
1. Troubleshooting Guide for Pum ATD5217 ATD5219 ATD5289 PROBLEM SOLUTION THINK SAFETY FIRST THINK SAFETY ALWAYS Your pump does not work There Air Motor Operates but Air Motor Operates Air Motor does not are Three Basic Problems nothing comes out Grease comes out but operate This is a less This is the most there is no pressure common occurrence common problem 2nd Common Prob We will deal with all 3 of these problems and step you through a troubleshooting sequence so you can solve the problem on your own without our intervention and be on your way All of the pumps undergo 2 types of stringent tests at the factory The first is a cycle test in grease with the pump pumping a certain amount of grease per cycle over a stated time period The second test is a pressure test with a meter to hold grease pressure at 5000 psi at 100 psi of air pressure for a stated period of time before they leave the factory This ensures that your pump will work out of the box If the Air is connected to the pump consider the pump to be live Do not attempt to work on the pump or the system without disconnecting the Air Inlet and relieving pressure in the system both air pressure and lube pressure Make sure there are no live air pockets in the air motor and all air has been bled from the Air Motor before working on the pump WA RNING Again Ensure that all of the Air Pressure and Lubrication Pressure has been bled z 7 out of the system2. High Pressure Grease 3 Go to Step 2 Downtube Blockage 4 If that does not solve the problem go to Step 4 Air Motor on Pump operates but no 1 Check the follower plate material comes out Make sure there are no air pockets in the grease underneath the follower plate Push down lightly on the follower plate to ensure a positive prime 2 Check that all hoses and control valves are fully connected 3 Check to see that there are no blockages in the lines hoses or control valves 4 Go to Step 2 Downtube Blockage below 5 If that does not solve the problem go to Step 4 below Air Motor still Operates but no Your pump has picked up some foreign debris or materials such as rocks stones Material comes out dirt sand plastic or metal Follow instructions for Lower Downtube Disassembly and Cleaning below Pump hoses and valves are See Trouble Shooting Sequence Below Question Answer Connected and pump does not Period Pump when pull the trigger on The control valve H i a If the Air is connected to the pump consider the pump to be live Do not Warning Again a attempt to work on the pump or the system without disconnecting the Air Inlet and relieving pressure in the system both air pressure and lube pressure Make sure there are no live air pockets in the air motor and all air has been bled from the Air Motor QUESTION YES NO Does the pump Air Motor operate Yes Then put the pump back in the No Then check Air Inlet for Press
3. all have to do with foreign Material such as Rocks Stones Metal Nuts Bolts Plastic Paper and other materials being picked up by the downtube and lodging themselves in the extension tube or the down tube To avoid this use a strainer for the downtube if in a difficult environment In rare cases with paper and bubble gum the material can work its way up into the bushing and plunger assembly 90554 and therefore this part needs to be disassembled and cleaned as well If sand or dirt is a constant problem you will find that the bushing and plunger assembly will wear excessively These two pieces are lapped and fitted together as one Constant Sand or Dirt passing through the part 90554 Bushing and Plunger can ruin the tight fit 11724 PLUNGER Procedure Fig A See Fig A Lay pump horizontal in vise and grip outlet body tightly in vise jaws Hold Extension Tube 61273 and unscrew Priming Tube 61275 B See Fig B Pull Plunger 11724 straight out until Plunger Rod 11723 is extended as far as possible out of the Extension Tube 61273 Hold bushing of Piston 90554 and unscrew Extension Tube 61273 Center Extension Tube 61273 between end of piston bushing and Plunger 11724 Insert any pointed tool in through hole at Base of Check Seat 11726 Note Plunger may unscrew from Plunger Rod 11723 or plunger rod may unscrew from Check Seat 11726 Extension Tube 61273 can be removed from free end of Plunger Ro
4. and there is no Residual Lube Pressure or Air Pressure in the System before you disassemble the pump VERY IMPORTANT WA RNING Do not stick your finger into the bottom of the Pump Downtube or 61275 Priming E Tube This could result in amputation WA RNING Do not stick any type of blunt instrument into the bottom of the Pump Downtube or j 61275 Priming Tube as this could ruin or bend the precision parts such as the 88223 Plunger RO Question Yes No Does the Air Motor Operate Next Section Check In Line Air Pressure to the pump Recommended Air Pressure is 80 PSI 100 PSI Check Air Compressor and FRL for obstructions or blockage Is the Air Motor is Leaking Air Check the Inlet Air Nipple Use Teflon tape to seal the threads at the Air Inlet Silicon is not recommended since it can escape into the interior of the Air Motor and cause damage to the valves Check the Quick Disconnect Coupler connection to the Air Hose Use Teflon tape to seal the threads at the Connection The Air Motor blows air through the Check to see that the Air Inlet Nipple is installed in the correct location Check that Muffler Exhaust Port the Brass Steel Plug is installed in the Air Motor head and is not leaking air If there are no air leaks and Air is fully engaged at least 80 psi then sometimes in RARE CASES the slide valve will stick in the neutral position take the rubber part of a mallet and lightly tap the top of the Air Motor or the cover of the
5. Air Motor 41202 with the rubber part only Did we say LIGHTLY TAP Yes we did Don t pound it and Don t beat it It is a casting and It will dent or Crack Sometimes and very rarely the slide Valve sticks in the neutral position and needs to be prodded off of the neutral position It also indicates that the Air Motor might have water damage or the damage is starting or there is water present in the air line Question Answer We strongly suggest the use of a Filter Regulator Lubricator FRL on Are you using a FRL the pump The Filter should be a moisture evaporator with an automatic dump on Filter Regulator Lubricator it so water is eliminated and purged from the air before entering the pump If you on the pump do not have a FRL on the pump chances are the pump head could be accumulating water and this will corrode the inside of the pump and moving parts thereby reducing the life of the pump Pump does not pump material Check to see if there are any blockages in the Lubricant lines If all lines are secure disconnect the Grease Hose from the pump Pump operates pumps material but Reason Pump is not reaching stall pressure does not shut off 1 Check that all hoses lubricant lines and controls valves are connected and the connections are tight There should be no leaks 2 Check that the hoses are SAE approved Grease Hoses and made for pumping High Pressure Grease Don t use Oil Hose or Garden Hose for pumping
6. Air Motor Air Motor Casing There should be Cover 41202 Go to Step 2 below NLGI 1 grease packed into the air motor casing If there is no grease Step 2 It is possible your pump has picked in the air motor casing the grease up some foreign materials or debris such as Step 3 Did this solve the problem Step 4 Pump not holding or building Pressure Step 5 Does it pump grease now when inserted in the drum Does the grease pump through the hose is white or the parts are corroded and rusted you have a moisture problem in your air line that needs to be corrected Try soaking the Air Motor Casing in SAE 30 Motor Oil to free up the moving parts If this does not solve the problem the pump needs to be rebuilt preferably by an Authorized ATD Service Center Yes Please think of using a Strainer ATD5356 See Note on the Strainer Below Yes The pump holds pressure fine Then you solved the problem Yes There is a blockage in the Hose or the Control Valve Remove the Control Valve from the hose and connect the hose to the pump Or Yes but it does not seem to hold or build pressure See note below on types of foreign materials Yes Then the blockage is in the Control Valve Attach the control valve to the hose Remove the coupler from the Control Valve Most likely the blockage is at the control valve rocks stones dirt sand plastic or metal This could block the down tube plunger 11724 from being
7. able to freely move up and down Follow instructions for Lower Down tube Disassembly Inspection and Cleaning No If this did not solve the problem with the pump then we have covered blockage in the downtube corroded or non function parts in the air motor blockage in the hose and control valve and air motor air leaks This covers approximately 99 of the problems Continue to Step 4 if the pump does not build or hold pressure or continue onto step 6 for unusual problems No It operates but does not hold or build pressure in the system or line Follow instruction for Lower Downtube Disassembly Inspection and Cleaning Chances are foreign material is lodged in the lower downtube In addition it is possible that the packing 35073 needs to be replaced in the Lower Downtube section This is a wear part and not covered by warranty Consult your service manual for the location of the 35073 and instructions for replacement are in the Downtube Disassembly instructions In some cases we have seen paper and bubble gum that get stuck up inside the plunger bushing 90554ME between the two check balls check seats and ball stop This part is a precision lapped part and if that is the case it will need to be cleaned out See note below on types of foreign materials No See Step 1 followed by Step 2 No Then the blockage is in the hose No There is a blockage in the main body of the Control Valve Control Valve needs to Do
8. d 11723 Fig C See Fig C When you remove the Extension Tube 61273 this exposes the Check Seat 11725 Priming Check 11721 Check Stop 11722 Support Bushing 11702 and Plunger Packing 35073 Note Unscrew Priming Check Seat 11721 from Check Stop 11722 to remove Support Bushing 11702 and Plunger Packing 35073 To do this you will have to put Check Seat 11721 in a vise and insert a point tool such as a punch through the holes in Check Stop 11722 to unthread Check Stop 11722 from Check Seat 11721 Plunger Packing 35073 incurs heavy wear and it is advisable to replace this part if worn Perform this only if you need to remove Cleaning Use Mineral Spirits and a Brush to Thoroughly Clean all Debris out of the Foot Valve 61275 and Extension Tube 61273 Thoroughly inspect all parts for wear or damage Clean all Parts Tentative Check List 1 Is the Plunger Rod 11723 bent 2 Is the Packing 35073 excessively worn Fig 3 Is the Check Seat 11725 worn or have abrasions or cuts Bushing and Plunger Assembly Otherwise Reassembly Pump Tube D See Fig D Removing Bushing and Plunger Assembly 90554ME Hold pump tube and unscrew bushing of Piston 90554 Bushing should slide off once unthreaded from the Pump Tube 4 Is the plunger 11724 bent or broken Fig E Grip two flats at top of piston plunger 5 95 of the problems with the pump not pumping material not holding pressure or not operatin
9. es the grease pump through the Yes there was blockage in the coupler of the control valve Clean the Coupler out with Mineral Spirits Is there Blockage in your Lubricant Lines Hoses Pumps and Control valve strainer ATD5356 Valves Common be disassembled and cleaned Step 6 Are there Dents in the Air Yes Look on the outside of the air No There are no dents or cracks on the Cylinder cylinder 61041 Are there any outside Go to step 7 dents The smallest dent will stop the operation of the pump You need to replace that part and order a repair kit as well Or Contact an Authorized ATD Service Center Also see warning note below on the use of Hammers Step 7 Any Synthetic Oil Has anyone injected marvel mystery oil or any synthetic oil into the air inlet of the pump Synthetic Oil will swell the Buna N Packings especially part 34090 The Air Motor will not operate and will need to be rebuilt Note Strainer ATD5356 To prevent Blockage in the pump hose lubricant lines or control valve with contaminated grease or to prevent contaminated grease from entering your bearings we suggest the use of a Grease Strainer ATD5356 Has your Pump been Outside in the Yes there is a possibility that water has accumulated inside the Air Motor Over elements Has water entered the Air time this can cause damage to the Air Motor All pumps are packed at the factory Motor with a water repellent NLGI 1 grease Over time with water accum
10. g have to do with foreign Material such as Rocks Stones Metal Nuts Bolts Plastic Paper Gum and other materials being picked up by the downtube and getting caught in the extension tube or the down tube When Changing Lube Containers Watch where you lay the pump and what the downtube touches Anything will stick to the grease on the end of the downtube with an end wrench and remove Check Seat 11726 Note Check Ball 66010 may remain in plunger after Check Seat 11726 is removed To remove check ball tilt pump in vise and gently tap top of plunger at location of two flats
11. ing dirt etc Also you will leave 1 2 of grease in the bottom when you change containers 3 Install a grease strainer ATD5356 on the downtube to prevent the liner from being picked up 4 In recent years manufactures have made their liners with a heavy plastic and this has not been an issue s If the air is connected to the pump consider the pump to be live Do not Final Warning on a attempt to work on the pump or the system without disconnecting the Air L ive Pump Inlet and relieving pressure in the system both air pressure and lube pressure Make sure there are no live air pockets in the air motor and all air has been bled from the Air Motor Revision January 23 2008 Lower Pump Tube Disassembly and Cleaning Instructions PIPE WRENCH PIPE WRENCH OUTLET B ny Extension Tube 61273 FOOT VALVE BUSHING OF 90554 PISTON 11726 CHECK SEAT 11723 PLUNGER ROD POINTED TOOL 61273 EXTENSION TUBE x FIG B N END WRENCH 4 p 11721 CHECK SEAT a 0 wO Mi TE 5i OL 11722 CHECK STOP 11702 SUPPORT BUSHING 11725 CHECK SEAT 11723 PLUNGER ROD ae 35073 PLUNGER PACKING FIG C PIPE WRENCH PUMP TUBE BUSHING OF 90554 PISTON END WRENCH 11726 CHECK SEAT a ey h PISTON PLUNGER J n fo gt N 31047 END WRENCH 66010 CHECK SEAT GASKET FIG E CHECK BALL 95 of the problems that occur with the pump not pumping material not holding pressure or not operating at
12. ulating inside the Air Motor the grease can be flushed out Note FRL To ensure the proper operation of your Pneumatic pump we suggest a Filter j Regulator Lubricator FRL on each Pump OR at the very least a Filter Regulator with an automatic dump mechanism on it to purge water out of the air z Don t Bang on the pump with a hammer or blunt instrument The pumps are Note Hammer Fix rugged and made for professional and industrial use but are made of Aluminum and if any parts are dented it will affect the operation of the pump Some foreign materials such as adhesives caulks anything w sugar bubble gum Note Types of abrasive materials can ruin or severely block part 90554ME This is a precision Fo re ign Materia Is lapped bushing and plunger assembly that can wear excessively when it is exposed to abrasive materials such as sugar dirt and sand If this does occur you will probably have to replace part 90554ME gt A If the Grease Drum Pail has a Plastic Liner and your pump operates but no grease Note Plastic Liner is delivered the downtube of the pump could be trying to pick up the plastic liner and the downtube is blocked Issues SOLUTION 1 You can try reseating the pump by lifting the pump approximately 6 12 inches above the drum pail and reseating it on top of the drum pail 2 You can try raise the pump up at least 1 2 out of the drum on blocks but might introduce contamination in the grease with blow
13. ure and when it is removed from the Grease grease Remove the hose from the check Air Motor for Leaks at the Air Nipple pump Muffler or Seals If there are no air leaks and Air is fully engaged at least 80 psi take the rubber part of a mallet and slightly tap the front cover of the Air Motor 41202 with the rubber part only Sometimes and very rarely the Toggle Valve sticks and needs to be prodded off of the neutral position Does the Air Motor have water in the If water is in the Air Motor Casing Casing 41245 The slide valve 45605 could be sticking because it is corroded or rusted Sometimes injecting 4 80z of SAE 30 Motor Oil into the air Inlet will lubricate the air motor parts enough to get the air motor operating This is a temporary fix Water Continued Oil Solution Do not use Marvel Mystery Oil or any synthetic oil as this will swell the Buna N Packings of the pump and render the pump useless Does the Air Motor Operate Now Yes check to see it will pump No This could be due to 2 problems We grease In the future keep the air will deal with each independently motor well oiled You need to See Step 1 below and then see Step 2 check the water and air quality in your air line Insert pump into grease and see below Step 5 Step 1 Water in the Air Motor Yes Remove Air Motor Cover No We did not find water in the Air Motor Step 2 Downtube Blockage 41202 and inspect the inside of the Casing when we removed the
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