ATD Tools ATD5289 User Manual

ATD5289 MADE IN MEXICO FOR 25-50 LB. BUCKETS

AIR OPERATED CHASSIS PUMP

OWNERS MANUAL

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.

RECOMMENDED OPERATING PRESSURE 80-100 PSI

GREASE TYPE: NLGI #2

DO NOT USE THIS EQUIPMENT UNLESS YOU HAVE CAREFULLY READ AND
UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THIS MANUAL.

50:1 RATIO, OUTPUT – 80 CU. IN./MIN.

MIN. AIR PRESSURE – 30 PSI

MAX. AIR PRESSURE – 120 PSI

MAX. OUTPUT PRESSURE – 7500 PSI

(maximum for effective performance)

! 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:

PENETRATE THE SKIN! INFORM PHYSICIAN OF EXACTLY WHAT WAS INJECTED. PLEASE
DO NOT TREAT THIS INJURY AS A SIMPLE CUT.

GET EMERGENCY MEDICAL CARE IMMEDIATELY IF ANY FLUID APPEARS TO

! WARNING ! – RELIEF PROCEDURE

DO NOT EVER point the dispensing valve at another person.
DO NOT EVER attempt to stop material from the dispensing valve or a leaking connection with your hand

or body.
BEFORE EACH USE, check equipment for proper operation and to insure safety devices are in place and
working properly.
NEVER modify this equipment. Modification could cause equipment malfunction and result in serious
bodily injury.
When flushing the pump with solvents, ALWAYS hold a metal part of the dispensing valve firmly to the
side of a grounded metal pail and operate pump at the lowest possible fluid pressure to reduce the risk of
injury from splashing or static sparking.

WARNING: This pump can develop 7500 PSI working pressure at 120 PSI maximum incoming air
pressure. Be sure that all system equipment and accessories are rated to withstand the maximum working
pressure of this pump. NEVER exceed the maximum working pressure of the lowest rated component in the
system. IMPORTANT: “Whip” hoses for dispensing valve are fluid pressure rated at 4500 PIS. NEVER
exceed 90 PSI, air pressure to pump when using “whip” hoses.

WARNING: Water and even moist air can cause this pump to corrode. To aid in the prevention of this
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. BE

SURE TO CORRECTLY FOLLOW THE PRESSURE RELIEF PROCEDURE.

PRESSURE RELIEF PROCEDURE

ALWAYS FOLLOW THIS PROCEDURE to reduce the risk of serious bodily injury, including splashing
into the eyes. After shutting off the pump; checking/servicing any part of the system; installing/cleaning or
changing any part of the system, ALWAYS follow this procedure:

1. Disconnect the air supply to the pump.

2. Aim the dispensing valve away from yourself and others.

3. Aim the dispensing valve into an appropriate container and open until all pressure is relieved.
If you believe that the dispensing valve or hose is completely clogged or that pressure in the pump has not
been fully relieved after following the above procedure, VERY SLOWLY loosen the hose end coupling to
relieve the pressure gradually and then loosen completely. Then proceed to clear the valve or hose.

WARNING: ALWAYS follow the Pressure Relief Procedure after shutting off the pump.
WARNING: ALWAYS follow the Pressure Relief Procedure when checking/servicing any part of the

system and when installing, cleaning or changing any part of the system.

INSPECTION INSTRUCTIONS

If you believe that you have overpressurized the equipment, or if your equipment requires adjustments or
repair, contact your Authorized Distributor or Service Center for inspection of the pump.

INSTALLATION

It is recommended that you use an air line filter/regulator/lubricator to remove

harmful dirt and moisture from the compressed air supply and to provide automatic lubrication to the
air motor. Blow-dry the lines and hoses with air before connecting them to the system..

Instruction for Assembly of ATD5289 Lubrigun

Unpack ATD5289 Assembly from
Carton

Assemble Drum Cover to Pump

(For Coupler and Ferrule Assembly)

Assemble Drum Cover to Pump

(For Screw Mounted Cover Assembly)

Insert follower plate onto the bottom of the pump tube and slide the follower plate up the pump tube.
Lower pump tube into lubricant until drum cover rests on top bead of drum.
Insert the three (3) adjusting screws into the drum cover and tighten securely to hold the pump to the drum.

Assemble the lubricant hose to the pump outlet body. The connections must be leakproof. Do not connect the
ATD5218 Control Valve Yet. You want to prime the system and purge contaminants out of the Grease Hose.

Insert Air Nipple 11660 and thread into pump head opening. Use Teflon tape to seal threads to prevent air leakage if
necessary.

Assemble air coupler 815 to an air hose of sufficient length so that the lubrigun can be moved to cover the
entire lubrication area with the hose attached. When air coupler 815 is attached to air coupler nipple 11660,
lubrigun is ready for operation. To release air coupler 815, draw back on the coupler sleeve.

This should include the following pieces: Pump, Drum Cover (Red),
Follower Plate, Grease Control Valve, 6 Foot Grease Hose, Muffler, Air
Nipple and Rapid Disconnect Coupler
Place ferrule both top and bottom on either side of the drum cover and
insert end of pump tube through the respective holes.. Thread top and
bottom of ferrule together with the pump cover in between both pieces of
the ferrule. Do this as far up the pump tube as possible underneath the
bottom of the air motor.
Insert end of pump tube through hole in the drum cover. Line up holes in
drum cover with the pump outlet body. Place the screws in there
respective holes and tighten drum cover to the bottom of the pump body

.

NOTE: DO NOT INSTALL ATD5218 CONTROL VALVE YET!
DID YOU:

YES:
NO:

Purchase a Filter / Regulator for your pump? The Filter / Regulator should have an
automatic dump mechanism to purge the water out of the incoming air. Water in
the compressed air system is the biggest “Killer” of Air Operated Equipment.
Proceed

Think about it! It is cheap insurance to keep your pump running at maximum
efficiency and the pump will last longer.

Initiating Air Motor and Pump Operation

To Start Pump: Turn on air from Air Regulator slowly. You will hear the air enter the air motor. Pump will

start quickly and then reach prime at a stall pressure. It might take as much as 60-70 PSI to get the pump
started initially. Recommended Air Pressure to operate the pump under normal conditions is 80PSI. Pump
will activate as low as 15-20PSI. For first time operation, pump will start at 50-60 PSI. After that pump will
activate at the lower pressure.
Pump will start quickly and then reach prime at a stall pressure when the control valve is attached.
Allow pump to operate: Pumping Grease into the hose. Allow approximately 1/3 Cup of Grease to flow out
of the Hose. This is to insure that any particles or contaminants or residue inside the hose do not enter
the ATD5218 Control Valve. Stop Pump; Install the ATD5218 Control Valve on the hose; Make sure
connections are tight; Resume operation of the pump. The pump should reach stall pressure and stop.

Test the System

Never Put your Finger or Other Bodily parts near the valve control nozzle when pulling the trigger on
the control valve ATD5218.

To know the amount of lubricant pressure in your system or the hose, multiply the amount of air pressure by

50. For example, if there is 100 psi of air pressure indicated on the regulator (100 psi of air entering) then
there is 5000 psi of grease pressure in the lubricant line.

Revision: January, 2003 Version LT989B

Pull the Trigger slowly and Grease should be ejected from the nozzle.
Don’t point it at anyone!

Instruction for Assembly of ATD5289 Lubrigun
Additional Instruction Notes…

Ensure that the Muffler ATD5317 is inserted in the correct orifice.
The Air Coupler and Nipple are packed in a separate bag.
Thread the Nipple into the orifice on the side of the pump.
Once the Nipple is threaded into the pump orifice, the Rapid Disconnect Coupler can be inserted onto the nipple.
Connect Lube Hose 75072 to orifice at indicated in pump drawing.
Connect ATD5218 Control Valve to Hose.
Adhering the Drum Cover to the Pump and Pump Tube: Use the Knurl Fixture. Two pieces that thread together.

A: Unthread both sections.
B: Put the thicker piece on top of the Drum Cover and the thinner piece on the bottom of the Drum Cover.
C: Thread them together with the Drum Cover Hole Between them.
D: Slide the Assembly up the Pump Tube.
E: To slide the Knurl Fixture that adjusts the drum cover on the pump tube, grease or some type of
lubricant might have to be applied to the “O” ring on the inside of the Knurl Fixture. This fixture is for
adjustment of the drum cover on the Pump Tube and prevents the Drum Cover from sliding up and down
the pump tube when the pump is removed from the drum.

Slide the Follower Plate onto the Bottom of the Pump Tube.
Insert Pump, Cover and Follower Plate into Pail.
Use the 3 adjustment screws on the Drum Cover to ensure that the pump is securely attached to the Pail or Drum

Before Starting Pump ensure all connections are tight.
Read Caution and Warning Statements included with the Pump.
Start Pump slowly and gradually increase air pressure to desirable level. Normal Operating Air Pressure
is 80 to 100 PSI.

Have you thought of a Grease Strainer for the Pump Down Tube: 99% of Pump Repairs are due to Foreign
Particles caught in the Down Tube. Ask for Strainer ATD5356 (82103ME).

Revision: January, 2003 Version LT989B