Groz GP1, GP3, GP2 Instruction Manual

INSTRUCTION MANUAL S1230, Rev D

Air Operated Grease Ratio Pumps 50:1 GP1, GP2, GP3

Congratulations on purchase of this World Class Air Operated Grease Ratio Pump !

• World-class Industrial High Pressure Grease pump with guaranteed performance & hassle free operation

• Pump dispenses Grease at pressures upto 50 times the Air inlet pressure

• Designed to work in tough conditions- Ideal for use in Industry, workshop, farm, construction or as part of the Mobile Grease system

• All metal construction, fully CNC machined with hardened wear resistant moving parts

• Reciprocating piston operated 2.5” (63 mm) dia. Air Motor

• Fitted with strainer at suction tube inlet for clean grease to the bearing

• Supplied in two choices :-

- Pump Only

- Pump with Drum Cover, Rubber Lined Follower Plate, High Pressure Grease Hose, Z swivel & Professional Grease Control Valve

Z Swivel

High Pressure Rubber Hose

Grease Control Valve

Suction Tube

Fig.1

Air Motor Assembly

Drum Cover

Nozzle Holder

Cover Screws

Follower Plate

Contents Page No.

PUMP CONSTITUENTS ..................................................................................................

PUMP CONSTRUCTION .................................................................................................

WORKING OF PUMP .....................................................................................................

INSTALLATION ...............................................................................................................

PUMP OPERATION .........................................................................................................

MAINTENANCE & REPAIR .............................................................................................

• Pumping Section Kit Replacement ............................................................................

• Drive Section Kit Replacement. ................................................................................

EXPLODED VIEW ............................................................................................................

7-11

7-8

9-11

PARTS LIST .....................................................................................................................

TROUBLESHOOTING ........................................................................................................

REPLACEMENT & SERVICE PARTS PROGRAM FOR GREASE RATIO PUMP .................

• Replacement Parts Program .....................................................................................

• Service Parts Program (Pumping Section Kit - KIT/BTM/RP-G) ...............................

• Service Parts Program (Drive Section Kit - KIT/TP/RP-G) .........................................

SPECIFICATIONS ............................................................................................................

WARNINGS ....................................................................................................................

13-14

16-18

PUMP CONSTITUENTS

1. Grease Pump Assembly

2. Drum Cover with Thumb Screws

3. Rubber Lined Follower Plate

4. High pressure Rubber Hose

5. Professional Grease Control Valve with Z Swivel

Fig. 2

PUMP CONSTRUCTION

Fig. 3

Drive Section

The pump is made up of two sections as given below :-

• Drive section :- It consists of an Air Motor Assembly driven

• Pumping Section :- It consists of a pump in which a piston

by compressed air. The piston diameter of the air motor is

2.5” / 63 mm. The motor consists of an air cylinder with

piston and one reciprocal valve with a nylon slider. The valve

directs the compressed air alternately to the top or bottom

of the piston, thus producing a reciprocating motion of the

piston rod.

lifts the grease through Non Return Valves by reciprocating

inside the pump cylinder. The grease is discharged with

pressure (from the outlet located at bottom of Air Motor) into

the delivery hose.

Pumping Section

NOTE

AIR MOTOR of these pumps starts automatically when the

Grease Control Valve is opened. When the valve is closed, Air

Motor builds up a back-pressure and stops operating the pumping

section.

PRESSURE RATIO of the pump states the ratio of the output

grease pressure to the incoming air pressure. When the pressure

ratio is 50:1, we achieve an output grease pressure up to 7500 PSI

(500 BAR) when the incoming air pressure is 150 PSI (10 BAR ).

WORKING OF PUMP

UPSTROKE DOWNSTROKE

Fig. 4 Fig. 5

UPSTROKE -

When Grease Control Valve is opened, compressed air enters

at arrow A and passes through passage B to the underside of

the Piston C, driving the Piston C and Piston Rod D upwards.

The air above the Piston is evacuated through passage E,

past the Slider Valve F and out at arrow G.

The Piston approaches top dead centre and Piston Rod D

makes contact with the Slider Rod H. Now the Slider Rod H

starts moving up with the Piston Rod D.

The air motor repeats Upstroke & Downstroke in continuous cycle to produce a reciprocating motion, driven

by compressed air. This motion is transferred via a connecting rod to the piston in the Pumping Section.

During every upstroke, non return valves (with spring & ball check) get opened & the piston lifts the grease.

During every downstroke, non return valves get closed & the piston discharges grease from the outlet valve.

Closing the Grease Control Valve shuts off the air motor & pump stops dispensing grease.

DOWNSTROKE -

The incoming air is now led via passage E to the upper side

of Piston C, driving it and the Piston Rod D downwards.

The air under the Piston C is evacuated through passage B,

past the Slider Valve F and out at arrow G.

The Piston approaches bottom dead centre and Piston rod

D makes contact with the Slider Rod H. When Slider Rod H

passes its centre position, the Pusher Spring I and Pusher

Button J snap it over to its lower position.

INSTALLATION

NOTE

An FRL (Filter-Regulator-Lubricator) unit must be used in the Air supply, before it is connected to the pump. Set the regulator to 6 BAR

(90 PSI) or any required inlet pressure, but never more than 150 PSI (10 BAR) or less than 30 PSI (2 BAR).

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.

Lift Handle

4. Tighten the drum cover

with the pump suction

tube with the help of

thumb screws.

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.

Hose

Extension

& Coupler

Z Swivel

Thumb

Screw

Air Line

PUMP OPERATION

1. Partially open the on/off air valve (It helps in creating initial vacuum when filling a totally dry pump). Pump will start operating

automatically until it gets primed. Pump is said to be Primed when grease is available at the pump outlet, making the pump ready to use.

Once primed, the air motor will stop. Open the on/off air valve fully.

2. Hold the grease control valve near a container & press the trigger. Pump will start

operating with continuous grease discharge as long as the trigger is pressed. Release

the trigger & this will stop the pump. Check for any leaks from any of the connections &

Tighten again if required.

3. Connect coupler fitted onto the control valve extension with the grease nipple & press trigger. Be careful not to over-lubricate as the pump

will keep dispensing grease as long as the trigger is pressed. Once the trigger is released, pump will stop dispensing grease & the air

motor will stop.

4. When not in use & at the end of each day, air supply to the pump must be switched off.

+ 14 hidden pages

Groz GP1, GP3, GP2 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual