LockNLube X-Series Air Operated Grease Pumps
Service Manual
Introduction
This service manual provides instructions for the operation, maintenance, and repair of LockNLube X-Series air operated grease pumps. Please read this manual carefully and retain it for future reference.
Important Information & Safety
WARNINGS are listed throughout this manual to advise of actions that may cause damage to your equipment or personal injury. Please read this safety information carefully before use.
This is a 50:1 ratio high pressure grease pump. Due to the high pressures developed, there is a potential hazard of fluid injection into the flesh or eyes.
DO NOT allow the outlet nozzle to be in direct contact with hand or body.
Never point the nozzle of the gun at yourself or anyone else.
DO NOT exceed the pressure rating of any component fitted to the system.
Check hoses for any signs of wear, leaks, or loose fittings before operating. Tighten all fluid connections regularly and replace weak or damaged hoses.
If accidental injection should occur, seek immediate emergency medical attention.
Assembly Procedure
Follow these steps to assemble the grease pump unit:
- Assemble the collar and screw the collar to the lid.
- Slide the pump through the collar and tighten the cap screws.
- Slide the follower plate evenly to the top of the grease container.
- Slide the pump assembly through the follower, tighten the lid to the pail, and then tighten the collar screws.
- Apply thread tape or other thread sealant to both ends of the High Pressure grease hose.
- Attach an air line to the air inlet on the pump. Note: It is recommended that a 1/4 turn type "stop" compressed air valve is used close to the air inlet.
Maintenance
Before attempting any maintenance, disconnect the air supply and squeeze the gun trigger to release pressure.
- Inspect your pump, high pressure hose, and airline weekly for any signs of deterioration or damage. Replace any damaged components as required.
- Every 2 weeks, apply a few drops of light oil to the air inlet of the pump.
- Check the top seal condition hole at the base of the cylinder. A small quantity of grease indicates seal lubrication is OK. A continuous 'worm' of grease indicates a worn seal; replace if required.
Lift only with lid handles. Do not move the pump by pulling the air or grease hose.
Operation
Do not exceed the maximum working pressure of 1035 kPa / 150 psi / 10.3 bar.
- Before connecting the air supply, check that all fittings are tight and hoses are free from wear or damage.
- Fully depress the reset button. Install the air cock and recommended air filter (see assembly section), then connect the air supply. The optimum operating range is 550-700 kPa (80-100 psi / 5.5-7 bar).
- When air is connected and turned on, the air motor will operate and push grease through the pump and hose until "stall" pressure is reached. At this point, the pump will stop (stall).
- For grease delivery, press the trigger on the booster gun. To stop delivery, release the trigger. The pump will again build to stall pressure and stop.
- If the grease nipple is blocked, the air motor will stall. Do not remove the gun. Instead, squeeze the trigger on the booster gun three or four times. The booster gun's boost facility increases outlet pressure to clear most blockages. (Note: the booster gun, not the pump, creates this extra pressure.)
- When the grease drum is empty, turn off the air supply and disconnect the airline. Withdraw the pump from the container and place it on a clean surface.
- X6 only: Remove the lid and use the chain to reach the follower handle. This automatically opens the suction release valve, allowing easy withdrawal of the follower. Remove the follower plate, place it centrally in the new drum, then refit the lid and pump unit.
- Reconnect the air supply to commence priming.
- At the end of each day, disconnect the air supply and release grease line pressure by pressing the trigger on the booster gun.
Pump Unit Disassembly
Before attempting any maintenance, disconnect air supply and squeeze gun trigger to release pressure.
Air Motor Disassembly
- Remove exhaust screen and screw.
- Remove 6 x screws holding the valve body.
- Remove the valve body and gasket.
- Remove the top poppet valve assembly.
- Remove 4 x screws holding the cylinder.
- Carefully remove the cylinder.
- Remove the air piston from the shaft.
- Remove the bottom poppet valve assembly.
- Carefully remove the gland nut and piston rod seal.
- Remove the hose adapter.
Lower Pump Disassembly
- Carefully remove the strainer tube.
- Remove the circlip.
- Remove the primer.
- Remove the valve seat and valve spacer.
- Remove the valve seat and valve spacer.
- Remove the high pressure tube link.
- Unscrew and remove the high pressure suction tube. Use the internal rod assembly to push out the high pressure seal, piston cylinder, and washer.
- Use a suitable pin punch to remove the roll pin.
- Unscrew and remove the rod assembly from the piston rod.
- Unscrew the primer rod from the high pressure piston, and remove the suction spring and ball inside.
Assembly is a reversal of the disassembly procedure. Take care that the piston rod seal and all O-rings are fitted correctly and in the correct orientation. Apply light grease (e.g., petroleum jelly) to all O-rings and seals before assembly.
No special tools are required for assembly.
Air Motor Parts
The diagram below illustrates the components of the air motor assembly, with numbered parts corresponding to the list below.
Air Motor Parts Diagram
[Diagram showing numbered components of the air motor assembly]
Air Motor Parts List
| Item No. | No. Off | Description |
|---|---|---|
| 1 | 2 | BS013 - o'ring |
| 2 | 1 | Top poppet Body (Long) |
| 3 | 5 | BS011 - o'ring |
| 4 | 2 | Spring |
| 5 | 1 | Poppet Piston assy (incl 2 x o'rings) |
| 25 | 2 | BS006 -o'ring |
| 26 | 2 | BS006 -o'ring |
| 35 | 1 | BS006 -o'ring |
| 8 | 1 | nylock nut - 6mm |
| 9 | 1 | 1/4" Washer |
| 10 | 2 | Cup seal |
| 11 | 1 | Air piston |
| 12 | 1 | PA49 - o'ring |
| 14 | 2 | BS012 -o'ring |
| 15 | 2 | PA36 - o'ring |
| 16 | 1 | BS022 - o'ring |
| 17 | 1 | Gland Nut |
| 18 | 1 | PA23 - seal |
| 24 | 2 | BS231 - o'ring |
| 26 | 1 | Poppet Piston assy (incl 2 x o'rings) |
| 27 | 1 | Lower poppet body (Short) |
| 28 | 1 | Valve Gasket |
| 32 | 2 | End Plug Screw |
| 34 | 1 | PA34 - poppet valve assy |
| 35 | 1 | Reset Button Assembly |
O'Ring Reference size chart (not to scale): [Chart showing visual representations of O-ring sizes: BS231, BS022, PA36, BS013, BS012, BS011, PA49, BS006]
Lower Pump Parts
The diagram below illustrates the components of the lower pump assembly, with numbered parts corresponding to the list below.
Lower Pump Diagram
[Diagram showing numbered components of the lower pump assembly]
Lower Pump Parts List
| Item No. | No. Off | Description |
|---|---|---|
| 38 | 2 | 3/32"x 1/2"Roll Pin |
| 39 | 2 | 5/32"Ball |
| 40 | 1 | H.P Piston |
| 41 | 1 | Suction Spring |
| 44 | 1 | Seal Support Washer |
| 45 | 1 | H.P. Piston Seal |
| 46 | 1 | H.P. Piston Cylinder |
| 47 | 1 | PA36 - o'ring |
| 49 | 1 | Valve Spacer |
| 50 | 1 | Valve Seat |
| 51 | 1 | Primer |
| 52 | 1 | Circlip |
| 56 | 1 | BS216 - o'ring (follower plate o'ring) |
O'ring Kit
| Item No. | No. Off | Description |
|---|---|---|
| 1 | 2 | BS013 - o'ring |
| 3 | 5 | BS011 - o'ring |
| 4 | 2 | PA8 - Spring |
| 5 | 2 | BS006 -o'ring |
| 25 | 2 | BS006 -o'ring |
| 26 | 2 | BS006 -o'ring |
| 35 | 1 | BS006 -o'ring |
| 8 | 1 | 6mm - nylock nut |
| 10 | 2 | PA25 -Cup seal |
| 11 | 1 | PA3 - air piston |
| 12 | 1 | PA49 - o'ring |
| 14 | 2 | BS012 -o'ring |
| 15 | 2 | PA36 - o'ring |
| 47 | 1 | PA36 - o'ring |
| 16 | 1 | BS022 - o'ring |
| 18 | 1 | PA23 - seal |
| 24 | 2 | BS231 - o'ring |
| 34 | 1 | PA34 - poppet valve assy |
| 38 | 2 | N325 - 3/32"roll pin |
| 39 | 2 | N404 - 5/32" ball |
| 41 | 1 | PK84 - suction spring |
| 44 | 1 | PK165 - seal support w asher |
| 45 | 1 | PK88 - high pressure seal |
| 51 | 1 | PK159 - Primer |
| 52 | 1 | N373 - Circlip |
| 56 | 1 | BS216 - o'ring |
| 59 | 2 | BS216 - o'ring |
O'ring Reference size chart (not to scale): [Chart showing visual representations of O-ring sizes: BS231, BS216, BS022, PA36, BS013, BS012, BS011, PA49, BS006]
Troubleshooting Guide
| Issue | Possible Cause / Solution |
|---|---|
| Air motor DOES NOT operate when the reset button is pressed | a) Replace top poppet spring (4) b) Lubricate spool valve (drop of light oil) |
| Grease leaking | a) Replace seal (18) |
| Air motor cycles slowly when not using the pump | a) Replace HP seal (45) b) Leaking from hose connection or B2 gun, check connections and B2 gun |
| Air motor runs slower than normal | a) Increase air pressure above 400kPa/60psi/4 bar |
| Air leaking from exhaust screen | a) Replace cup seals (10) or piston (11) |
| Air motor ONLY cycles if reset button is pressed | a) Replace lower poppet spring (4) |
| Air motor runs but does not pump grease | a) Replace broken spring (41) b) Clean dirt from under seat (49) or ball (39) c) Check if grease is leaking from gun or air motor seal (18) |
Booster Gun Troubleshooting & Parts
The LockNLube X-Series Grease pumps come with a LockNLube Grease Coupler, flexible hose and swivel assembly.
Booster Gun Troubleshooting
| Issue | Possible Cause / Solution |
|---|---|
| Gun leaks continuously from the coupler | a) Adjust screw to allow ball (12) to seat b) Clean contaminant from under ball (12) |
| Grease leaks past the plunger | a) Replace damaged o'ring (4) |
| Fails to boost pressure | a) Clean contaminant under ball (6) b) Clean contaminant under ball (6) |
LNL81709 Booster Gun Parts Diagram
[Diagram showing numbered components of the LockNLube Booster Gun]
Booster Gun Parts List
| Item No. | Off | Part / set | Kit ref | Description | |||
|---|---|---|---|---|---|---|---|
| 10 | 1 | n/a | (KIT A) | A Plunger guide bush | |||
| 11 | 1 | n/a | (KIT A) | A Plunger | |||
| 21 | 1 | n/a | (KIT A) | A Backup w asher | |||
| 31 | 1 | n/a | (KIT A) | A O'ring (BS008) | |||
| 41 | 1 | n/a | (KIT A) | A Valve body | |||
| 51 | 1 | n/a | (KIT A) | Gun body | |||
| 12 | 1 | 1/4" Steel ball | A | A 1/4" Steel ball | |||
| 16 | 1 | A Ball support | A | A Ball support | |||
| 13 | 1 | A Ball spring | A | A Ball spring | |||
| 15 | 1 | A Spring guide | A | A Spring guide | |||
| 82 | 72 | 62 | 23 | 1 | A Valve insert | A | A Valve insert |
| 14 | 1 | for B2-01 model order PA44s | A | A Valve spring | |||
| 20 | 2 | A 7/32" Steel ball | A | A 7/32" Steel ball | |||
| 21 | 2 | for B2-SG model order B2-1SGK | A | A O'ring (BS013) | |||
| 19 | 2 | Inlet body | A | Inlet body | |||
| 17 | 1 | Trigger link | A | Trigger link | |||
| 18 | 1 | Link pin | A | Link pin | |||
| 24 | 1 | Screw | A | Screw | |||
| 22 | 1 | Lock nut | A | Lock nut | |||
| 25 | 2 | Adjusting screw | A | Adjusting screw | |||
| 26 | 1 | High nut | A | High nut | |||
| 26 | 1 | Trigger | A | Trigger | |||
| 1 | n/a | Swivel adapter assembly | A | Swivel adapter assembly | |||
| 2 | n/a | Swivel body assembly | A | Swivel body assembly |
Pump Assembly Diagram & Parts List
The diagram below shows the overall LockNLube grease pump assembly, including lid and follower components, with numbered parts corresponding to the list below.
Pump Diagram
[Overall diagram of the LockNLube grease pump assembly, including lid and follower components]
Parts List
| Item No. | Off | Order for replacement | Part / set | Kit. Ref | Description |
|---|---|---|---|---|---|
| 1 | 2 | (KIT A) | A &C | O'Ring (BS013) | |
| 2 | 1 | (KIT A) | A | Top poppet body (long) | |
| 3 | 5 | (KIT A) | A &C | O'ring (BS011) | |
| 4 | 2 | (KIT A) | A | Poppet spring | |
| 5 | 1 | (KIT A) | A | Poppet piston assy | |
| 6 | 1 | order PA44s | A | A &C | Cover screw |
| 7 | 1 | PA68s (incl 4 x N38) | A | A &C | Air cylinder |
| 8 | 1 | A &C | M6 Nylock nut | ||
| 9 | 2 | A &C | 1/4" Washer | ||
| 10 | 2 | A | Cup seal | ||
| 11 | 1 | A | Air piston | ||
| 12 | 1 | PA19s | A &C | O'ring Piston rod | |
| 13 | 1 | A &C | O'ring (BS012) | ||
| 14 | 2 | A & B & C | O'ring ( 90 IRHD ) | ||
| 15 | 2 | A & C | O'ring (BS022) | ||
| 16 | 1 | A | Gland nut | ||
| 17 | 1 | A & C | Piston rod seal | ||
| 18 | 1 | PF6 | A | H.P. Grease hose assy | |
| 19 | 1 | PA46s | A &C | P3 / P6 Hose adapter | |
| 20 | 1 | A &C | Cylinder base | ||
| 21 | 1 | A | HI-LO Screw | ||
| 22 | 4 | A | Screw | ||
| 23 | 1 | Steel insert | |||
| 24 | 2 | O'ring (BS231) | |||
| 25 | 2 | A &C | O'ring (BS006) | ||
| 26 | 1 | A | Poppet piston assy | ||
| 27 | 1 | A | Low er poppet body (short) | ||
| 28 | 1 | A | Valve Gasket | ||
| 29 | 1 | A | Valve plug | ||
| 30 | 1 | A | Valve body | ||
| 31 | 1 | PA44s | A &C | Exhaust screen | |
| 32 | 2 | PA30s | A | End plug screw | |
| 33 | 6 | A | HI-LO Screw | ||
| 34 | 1 | A | Valve spool assy | ||
| 35 | 1 | A | Reset button assy | ||
| 36 | 1 | A | End plug | ||
| 37 | 1 | PK152s | A | P3 Connecting rod | |
| 37 | 1 | PK160s | A | P6 Connecting rod | |
| 38 | 2 | P8 Connecting rod | B & C | 3/32" X 1/2" Roll pin | |
| 39 | 2 | B & C | 5/32" Steel ball | ||
| 40 | 1 | B | H.P. Piston | ||
| 41 | 1 | B & C | Suction spring | ||
| 42 | 1 | B & C | Primer rod | ||
| 43 | 1 | PK167s | B & C | P3 H.P. Suction tube | |
| 43 | 1 | PK195s | B & C | P6 H.P. Suction tube | |
| 43 | 1 | PK175s | B & C | P8 H.P. Suction tube | |
| 44 | 1 | B & C | Seal support w asher | ||
| 45 | 1 | B | H.P. Piston seal | ||
| 46 | 1 | B & C | H.P. Piston cylinder | ||
| 47 | 1 | B | O'ring ( 90 IRHD ) | ||
| 48 | 1 | use PK158s | B & C | H.P. Tube link | |
| 49 | 1 | B | Valve spacer | ||
| 50 | 1 | B | Valve seat | ||
| 51 | 1 | B | Primer | ||
| 52 | 1 | B & C | Circlip | ||
| 53 | 1 | PK158s incl PK97 | B & C | Strainer tube | |
| 54 | 1 | PA70s (w ith P3-01C only) | B & C | Lid Adaptor Set (not show n) | |
| 54 | 1 | PK85s | B & C | P3 Lid assy | |
| 54 | 1 | PK101s | B & C | P6 Lid assy | |
| 54 | 1 | PK151s | B & C | P8 Lid assy | |
| 55 | 3 | B & C | 5/16" BSW Thumb screw | ||
| 56 | 1 | B & C | O'ring (BS216) | ||
| 57 | 1 | PK86s | B & C | P3 Follow er assy | |
| 57 | 1 | PK107s | B & C | P6 Follow er assy | |
| 58 | 3 | B & C | 1/4" BSW Slotted screw |
Follower Assembly
| ITEM No. | Off | Order for replacement | KIT. REF | DESCRIPTION |
|---|---|---|---|---|
| 59 | 2 | PK138s | B & C | O'ring (BS216) |
| 60 | 1 | B & C | Follow er assembly | |
| 61 | 1 | B & C | 1/4" Nylock nut | |
| 62 | 1 | B & C | Washer | |
| 63 | 1 | B & C | Spring | |
| 64 | 1 | B & C | O'ring (BS113) | |
| 65 | 1 | B & C | Suction release valve | |
| 66 | 1 | B & C | Follower handle | |
| 67 | 1 | B & C | Handle chain |
Pump Specifications
| Specification | Value |
|---|---|
| Maximum Air Pressure | 1035 kPa / 150 psi / 10.3 bar |
| Minimum Air Pressure | 400kPa / 60 psi / 4 bar |
| Typical Air Consumption | 0.3m³ per minute (9 cfm) |
| Compressor Size | 0.08m³ per minute (3 cfm) |
| Noise Level | 85 Db @ 2 Meters |
| Air Inlet | 3/8" (F) NPT (Swivel Type) |
| Pump Ratio | 50:1 (Grease Pressure is 50 times the air pressure) |
| Maximum Grease Pressure (Manual boost only) | Up to 69,000 kPa / 10,000 psi / 690 bar |
| Hose Type/Threads | 4m x 6mm I.D. SAE 100 R2 / 1/4" (M) NPT |
| Swivel Type/Threads | High Pressure 'Z' type 3/8" (F) NPT / 1/8" (M) NPT |
| Manufacture Date | Week / Year located on the side of the cylinder base |
Disposal Information
This product should be disposed of according to all applicable local and national government environment regulations and guidelines.
Contact Information
LockNLube
24 Interchange Drive, West Lebanon NH 03784
Phone: (603) 795-2298
Fax: (603) 795-9307
Email: info@locknlube.com
For Warranty Terms and Conditions see: www.locknlube.com
