Groz GP1 User 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

Grease Control Valve Air Motor Assembly

Z Swivel

Drum Cover

High Pressure Rubber Hose

Cover Screws

Suction Tube

Follower Plate

Nozzle Holder

Fig.1

Contents Page No.

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

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

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

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

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

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

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

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

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

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

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

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

7-11

13-14

16-18

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

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

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

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

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

7-8

9-11

PUMP CONSTITUENTS

PUMP CONSTRUCTION

Drive Section

Pumping Section

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

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

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.

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

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.

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 ).

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

Fig. 3

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.

WORKING OF PUMP

UPSTROKE DOWNSTROKE

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.

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.

Fig. 4 Fig. 5

INSTALLATION

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.

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).

4. Tighten the drum cover

with the pump suction

tube with the help of

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.

NOTE

Air Line

Z Swivel

Thumb

Screw

Thumb Screws

Extension

& Coupler

Hose

Lift Handle

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.

PUMP OPERATION

MAINTENANCE & REPAIR (Refer to Exploded View - Page 12)

Service Precautions

Recommended Tools

• Before performing any service operation, always shut off the air supply and release the pressure of the medium, i.e. let the grease out so

that the pressure decreases. When storing the pump assembly without the bucket, cover the Filter Tube (57) with Filter Cap (62).

• Be careful not to damage any parts when dismantling. While removing shafts which do not have key flats, use a Pipe wrench, Polygrip

wrench or the like. The easiest way to remove such a shaft is to grip it in a vice with aluminium or copper jaws, clamp the shaft in a

hand-drill chuck and then turn the chuck by hand.

• Be careful when fitting O-rings and seals. Always lubricate them with grease before fitting. They must never be threaded over sharp

edges when being fitted. Lubricate all moving parts with synthetic grease. Apply minor locking fluid on all threaded joints.

• When troubleshooting, be on a lookout for dirt in valves / ball seats, scratches in sealing surfaces & damaged O-rings / seals / gaskets.

Pumping Section Kit Replacement (Refer to Table 5 - Page 17)

1. Hold Barrel (63) in a soft-

jaw vice. Pull out Filter

Cap (62) by hand.

2. Unscrew Nyloc Nut (61)

using T-handle (size 10

mm) & also remove

Piston Washer (60) from

the end of Filter Tube

(57).

3. Unscrew Top Coupler (52)

using wrench (size 28

mm) on the given flats.

Remove lower coupler

assembly.

4. Remove the outlet adapter

(35) using wrench (size 25

mm).

Lower Coupler Assembly

Nyloc Nut Piston Washer

Combination Wrench

Size 10, 14, 21, 25, 28 & 32 mm

Adjustable Caliper Wrench

Ball Pein Hammer

Plastic Mallet

A Soft - Jaw vice

(Aluminum or Copper Jaws)

Pin Punch

2 mm

Tweezer

T- Handle

Size 10 mm

1/2” Male Threaded Pipe

Phillips Screwdriver

5. Tighten a 1/2” male

threaded pipe into the

outlet port & unscrew

Air Motor Assembly

anticlockwise. Carefully

remove Air Motor from

Barrel (63).

6. Support Pump Cylinder

(51) on a V block &

insert a pin punch

vertically into the hole

of Pump Cylinder (51).

Tap lightly with a hammer

to drive out lower Slotted

Spring Pin (44) taking

care not to bend the

Extension Rod (46).

7. Unscrew Pump Cylinder

(51) & remove upper

Steel Ball (47) & Non

Return Spring (48).

8. Hold Filter Tube (57) in

vice. Using two wrenches

(size 28 mm), hold Bottom

Coupler (54) & unscrew

Top Coupler (52). Remove

Slide Bush (53).

9. Unscrew Bottom Coupler

(54) with wrench (size 28

mm) & remove Guide Bush

(56).

• Pump Cylinder (51) has a pin-hole

end that must face upwards;

towards Extension Rod (46).

• Slide Bush (53) has a slotted end

that must always face upwards;

towards Top Coupler (52).

Non return

Spring

Steel Ball

10. Replace the Repair Kit (KIT/BTM/RPG) as mentioned in Table

5 - Page 17, by following the steps 1-9 in reverse order taking

care of the points below:

• Replace Part No. 51, 52, 53 & 55 TOGETHER as a set

even if there is a need to replace only one of these

parts. Apply minor grease on all the moving parts

before assembly. Also, ensure movement of part 51,

52 & part 53, 55 is smooth.

Guide Bush

Slide Bush

1. Hold Barrel (63) in a soft-

jaw vice. Pull out Filter

Cap (62) by hand.

2. Unscrew Nyloc Nut (61)

using T-handle (size 10

mm) & also remove

Piston Washer (60) from

the end of Filter Tube (57).

3. Remove the outlet

adapter (35) using

wrench (size 25 mm).

4. Tighten a 1/2” male

threaded pipe into the

outlet port & unscrew

Air Motor Assembly

anticlockwise. Carefully

remove Air Motor from

Barrel (63).

5. Support Extension

Rod (46) on a V block

& insert a pin punch

vertically into the hole

of Connector (45).

Tap lightly with a

hammer to drive out

upper Slotted Spring Pin

(44) taking care not to

bend Extension Rod (46).

6. Unscrew Connector

(45) with wrench (size

14 mm) & separate Air

Motor Assembly from

Extension Rod (46).

7. Hold Air Motor

Assembly in a soft-

jaw vice. Loosen both

Coupling Nuts (2) using

wrench (size 21 mm).

Drive Section Kit Replacement (Refer to Table 6 - Page 18)

8. Remove Bend Pipe (1)

along with both Coupling

Nuts (2) & Sealing Rings

(3). Unscrew Exhaust Valve

(23) with an adjustable

wrench.

9. Unscrew both Bends (4)

using wrench (size 13

mm).

10. Lightly tap Cylinder (10)

with a plastic hammer &

unscrew it .

11. Unscrew Inlet Cover

Adapter (34) using wrench

(size 25 mm).

12. Connect a caliper wrench

into the holes on inlet

Cover (32) & unscrew it.

13. Unscrew both Pushers

(15) using wrench (size

25 mm).

14. Remove both Pushers

(15), Springs (17), Pusher

Nuts (18) & Pusher

Buttons (19).

15. Using two wrenches

(size 10 mm), hold

Plunger Rod (9) &

turn Connecting Rod

(43) anticlockwise.

This will unscrew

Connecting Rod (43).

16. Remove Connecting

Rod (43) along with

Washer (42), Spring (41),

Seal Support (40), Seals

(39) & Slider Guide (38).

If Connecting Rod (43) is

still attached to the inner

rod of Slider (30), hold

the inner rod in a vice &

unscrew Connecting Rod

(43) with wrench (size 10

mm).

This manual suits for next models

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