ATD Tools ATD-5219, ATD-5289 User Manual

Troubleshooting Guide for Pumps

ATD5217 - ATD5219 - ATD5289

PROBLEM: SOLUTION:

WARNING:

Your pump does not work? There
are Three Basic Problems!

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.

WARNING:

WARNING: (Again!)
WARNING:

WARNING:

Question Yes No

Does the Air Motor Operate? Next Section Check In-Line Air Pressure to the pump.

Check Air Compressor and FRL for
Is the Air Motor is Leaking Air? Check the Inlet Air Nipple. Use Teflon tape to seal the threads at the Air Inlet.

The Air Motor blows air through the
Muffler / Exhaust Port

Question:

Are you using a FRL
(Filter / Regulator/Lubricator)
on the pump?

Pump does not pump material Check to see if there are any blockages in the Lubricant lines. If all lines are

Air Motor Operates but
nothing comes out.
This is the most
common problem.

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.
Ensure that all of the Air Pressure and Lubrication Pressure has been bled
out of the system and there is no Residual Lube Pressure or Air Pressure in
the System before you disassemble the pump!! (VERY IMPORTANT!!!!)

Do not stick your finger into the bottom of the Pump Downtube or 61275 Priming
Tube. This could result in amputation!!
Do not stick any type of blunt instrument into the bottom of the Pump Downtube or
61275 Priming Tube as this could ruin or bend the precision parts such a s the
11723 Plunger Rod.

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
Check to see that the Air Inlet Nipple is installed in the correct location. Check that
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
(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.
Answer: We strongly suggest the use of a Filter / Regulator/Lubricator (FRL) on
the pump. The Filter should be a moisture evaporator with an automatic dump on
it so water is eliminated and purged from the air before entering the pump. If you
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.

secure: disconnect the Grease Hose from the pump.

THINK SAFETY FIRST!!!!

THINK SAFETY ALWAYS!!!

Air Motor Operates;
Grease comes out but
there is no pressure.
2nd Common Prob.

Recommended Air Pressure is 80 PSI –
100 PSI.

obstructions or blockage

the top of the Air Motor or the cover of the Air Motor

Air Motor does not
operate. This is a less
common occurrence.

Pump operates, pumps material but
does not shut off.

Air Motor on Pump operates but no
material comes out

Air Motor still Operates but no
Material comes out.

Pump, hoses and valves are
Connected and pump does not
Pump when I pull the trigger on
The control valve

Warning: (Again!!!)

QUESTION??? YES!!! NO!!!

Does the pump Air Motor operate
when it is removed from the Grease?

Does the Air Motor have water in the
Casing?

Water Continued: Oil Solution Do not use Marvel Mystery Oil or

Does the Air Motor Operate Now? Yes: check to see it will pump

Step #1: Water in the Air Motor
Step #2: Downtube Blockage.

Reason: Pump is not reaching stall pressure.
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 High Pressure Grease.
3: Go to Step #2; Downtube Blockage.
4: If that does not solve the problem go to Step #4
1: Check the follower plate.
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
Your pump has picked up some foreign debris or materials such as rocks, stones,
dirt, sand, plastic or metal. Follow instructions for Lower Downtube Disassembly
and Cleaning below.

See Trouble Shooting Sequence Below: Question / Answer
Period.

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.

Yes: Then put the pump back in the

grease. Remove the hose from the
pump

If water is in the Air Motor Casing
(41245), The slide valve 45605
could be sticking because it is
corroded or rusted. Sometimes
injecting 4-8oz 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.

any synthetic oil as this will swell
the Buna N Packings of the pump
and render the pump useless.

grease. In the future keep the air
motor well oiled. You need to
check the water and air quality in
your air line. Insert pump into
grease and see below Step 5.
Yes: Remove Air Motor Cover
41202 and inspect the inside of the
Air Motor Casing. There should be
NLGI#1 grease packed into the air
motor casing. If there is no grease
in the air motor casing, the grease

No: Then check Air Inlet for Pressure, and
check Air Motor for Leaks at the Air Nipple,
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.

No: This could be due to 2 problems; We
will deal with each independently.

See Step #1 below and then see Step #2.

No: We did not find water in the Air Motor

Casing when we removed the Air Motor
Cover 41202. Go to Step #2 below.

Step #2: It is possible your pump has picked
up some foreign materials or debris such as