User Manual
Contents
1. Service Guide Grease pump Kit Description The Champion product grease kit is a manually operated spring powered grease kit that comes complete with a hand piece It is designed to fit a 2 5kg grease pail The hand piece for the product once loaded is capable of approximately 30 high pressure shots before needing to be reprimed The high pressure high volume option facilitates quick and easy greasing with grease pressures of 10 000psi and dispensing quantities of up to 1 25 grams per stroke possible Suitable for use with greases up to NLGI2 the light weight rugged and portable unit makes light work of arduous greasing applications The Champion product is the ideal greasing tool for people looking to minimize the time and effort required to grease their vehicles or machinery Specifications Uses Light and self collapsing grease Discharge Quantity Once loaded approximately 30 shots up to 1 25 grams of grease per shot Size 2 5kg grease pails Pressures Up to 10 000psi Important Please Note Our Champion product 2 5kg grease kit is designed for use with most greases however trouble free greasing is assured with the use of greases up to No 2 consistency That is the kit is recommended for use with light and self collapsing greases Preparing Your Champion 2 5kg Grease Kit 1 Remove follower plate from the pump tube 2 Insert follower plate into the grease container as shown with boss facing upwards Push down firmly onto2. as worked itself loose and is holding the outlet ball 3 off its seat The glyd ring 20 is worn a There is dirt under the delivery ball 18 or there is a damaged ball seat in the piston 19 b Seals are worn 25 26 and 27 c Valve inlet stem 17 has become loose or dislodged from the piston 19 setting and strike handle sharply If the coupler still leaks remove the rigid extension 9 spring keeper screw 21 spring 22 and outer ball 23 Clear the seat and partly replace the ball screw and spring keeper screw Prime the pump completely to ensure the maximum possible supply of grease to the hand piece and tighten up the spring keeper screw until the grease begins to stop leaking Then tighten the spring keeper in an extra two full turns Finally reassemble the rigid extension to the hand piece IMPORTANT Please note that if you tighten up the spring keeper screw too much the hand piece will become difficult to operate Too few turns will allow the hand piece to leak If the coupler still leaks replace the outlet body 4 When refitting the outlet body to the handle ensure that the handle is held in the closed position Doing so enables the back up washers 5 amp 7 and o ring seals to seat squarely on to the piston 19 b Remove the handle 23 by withdrawing the handle pin 22 Remove the piston 19 retighten the valve stem 17 or replace with Spare part Remove handle 22 by withd
3. l not pump grease Grease leaks at top of clamp nut 7 Grease leaks at bottom of strainer cover 11 Grease leaks from under clamp nut 7 a Dirt under clamp nut 7 b Damaged seal washer 8 a dirt trapped between inlet ball 26 and piston b piston O Ring 25 defective or worn a air lock in grease caused by dent in container stops follower damaged O Ring 21 in follower 20 b grease container empty c footvalve assy 19 faulty holding ball 18 off seat a grade of grease too heavy b strainer blocked Gland O Ring 96 and back up washer 5 are defective or worn a O Ring 14 damaged b Spot welds broken a unscrew clamp nut 7 and withdraw assembly Clean ball 26 and piston 10 thoroughly Reassemble b replace piston O Ring a remove dents or tilt follower plate 20 under dent Replace O Ring 21 in follower plate 20 Change over to new container or refill with grease Replace with new assy 17 18 19 do not attempt to rework this part a Use No 2 grade of grease or lighter Force out old grease b Unscrew clamp nut 7 and withdraw assembly Using a screwdriver lever off the strainer cover 11 Clean or replace the strainer 13 see general instructions below for cleaning technique Unscrew clamp nut 7 and withdraw assembly Hold piston 10 and loosen the nut 27 Remove the pin 9 and withdraw the piston 10 Ease spring tension on the n
4. n product from the container 3 Remove follower plate from the empty 2 5kg grease drum and repeat preparation steps 2 3 and 4 Before operating your product 2 5kg grease kit bleed any trapped air from the unit To remove trapped air Point gun in direction of an empty receptacle 1 Push pump plunger down a few times to start the grease flowing through the grease hose 2 Squeeze and hold gun handle in to automatically remove trapped air repeat 1 and 2 until all air is removed How to clean the strainer Should the strainer need cleaning refer trouble shooting guide page 3 item C b undo the nut at the base of the pump spring with a suitable spanner remove assembly lever off strainer cover and clean the appropriate parts as illustrated Parts and Drawing Breakdown For the Pump Kit Parts List ITEM a DESCRIPTION 1 Retainer Cap Washer SOS Bite up waster lamp mt Ball spring O Ball Ring ose ese Clamp Ring Clamp Not Sealing Washer Piston Rod and Cup Assembly Spiro Pin Strainer Cover O Strainer SO ante fERS Ring O id Base Thm Screw Pump Tube SOS Flower Ring all Retainer O o_O pe S Foo SOE Piston Rod and Cap Assembly Pep Spring Trouble Shooting For the pump Kit of the product PROBLEM CAUSE SOLUTION Rod cap rises slowly when the hand piece is not in use no visible external leakages Rod cap springs up and the unit will not pump grease Rod cap stays down The 2 5kg grease kit wil
5. ng control plunger 25 from the control body and replace with spare part kit Hand piece leaks at the grease swivel Worn seals 11 amp 12 Unscrew ball socket retainer 15 push the seals out and use spare part kit Be careful to replace the components in the following order O Ring 13 and washer 12 Locate O Ring 11 on to the hand piece casting 8 Reassemble ball When on the high volume setting the hand a Spring 16 may have weakened or collapsed a Replace spring 16 and use spare part kit piece is too slow and too hard to operate and are blocking the flow of grease and valve stem spare part kit b The grade of grease being used is too heavy b Change to an NLGI2 or lower viscosity grease c Too much comprehension on the outlet c Reset the spring keeper screw as noted in spring 2 the 2 5kg grease kits coupler leaks section If the problem persists you will need to replace the outlet body assembly GENERAL INSTRUCTIONS ALWAYS When the gun has been serviced and the trouble found to be caused by dirt in the valves the pump unit should also be cleaned out thoroughly to eliminate the dirt at its source CLEANLINESS Dirt and foreign matter lint etc can seriously affect operation and machinery Dismantling and reassembly of this unit should only be attempted in clean conditions
6. rawing handle pin 22 Remove the piston 19 and replace with the spare part IMPORTANT If any signs of wear are visible on the piston replace with the spare part will also be required to solve this problem a Change the setting to high volume and hit the handle 23 hard to shift the dirt off the seat If leaks are still occurring remove the handle 23 by withdrawing handle pin 22 spring 16 and ball 18 Clean the ball and seat if the problem continues order and install Spare part b Use spare part and b Use spare part and replace seals in the following order washer 5 O ring 6 and washer 7 c Refer to the 2 5kg grease kits coupler leaks section to referencing section b PROBLEM CAUSE SOLUTION The hand piece fails to deliver grease when on a There is dirt on the valve inlet seat 24 a IMPORTANT This problem will result in the high volume setting a decreased volume of grease being dispensed per shot Remove control body 26 and tap out valve inlet seat 24 O Ring 31 ball 30 and spring 27 Clean the ball and seat and replace in the following order spring ball O Ring valve seal and control body b Operating plunger control 25 sticking in b Replace the control body assembly 26 control body assembly 26 Control push rod in the control body leaks O Ring 31 is worn Remove control body assembly 26 from the hand piece Also remove the operati
7. the grease until grease emerges through the boss 3 Push the pump tube through the boss and down until the drum cover sits firmly on rim of grease container Hand tighten the 3 thumbscrews evenly under rim of the container 4 To achieve initial prime push rod cap down several times by using your hand or foot to start grease flowing through the grease hose When the hose is full of grease the rod cap will stay down 5 Squeeze gun handle and hold handle closed to bleed air out of the system When fully bled grease from out of the 2 5kg drum will appear at the coupler Note Grease must travel through entire length of hose to accomplish full bleeding and it may be necessary to repeat Step 4 a couple of times If unit fails to prime bump container base several times on a solid surface to settle the grease Important Please Note Your Champion product 2 5kg grease kit is now ready for operation While greasing the rod cap will rise slowly When it is fully up and the hand piece loses pressure push the rod cap down once or twice to reprime the system and to enable you to continue greasing Each pump prime will provide sufficient grease for up to 30 grease shots The hand piece is normally operated on the hi volume switch position Should high pressure be required to help clear a blocked or seized lube point simply move the button on the hi pressure position Changing over 2 5kg grease drums 1 Unscrew the 3 thumbscrews 2 Remove the Champio
8. ut 27 by pushing against spring 92 on clamp nut 7 and carefully undo nut 27 Replace O Ring 96 and back up washer 5 Order 5 When re assembling support piston 10 when driving pin 9 home please ensure that the flat end of spring 2 fits in the cap 1 a Unscrew clamp nut 7 and withdraw assembly Using screwdriver lever off strainer cover 11 replace O Ring Order 14 b Replace drum cover base 15 a Undo and clean surfaces b Replace seal washer Order 8 Parts and Drawing Breakdown For the Pump Hand piece SECTION A vn fe a rt g 22 1 2 3 S 6 7 AS TI J A I d G A n L v NE AR 8 Gy Q900 EI 1 en EE EEN ZB D i 16 17 18 19X20 21 A is clir a WT ES N J d RECHT gt o rae E gt SA D SECTION C GA Wee ZC d f ed Kai f Se h j v f a V CC a 27 58 K i A 30y _ SECTION D gt A ke Parts List The hand piece ITEM QTY 7 10 i 12 13 i4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3 Seal Body O ring 32 Trouble shooting for the product Hand Piece CAUSE a There is dirt under the seat of the outer ball 3 PROBLEM The 2 5kg grease kit coupler leaks SOLUTION a Set the hand piece to the high volume Hand piece leaks at the back end of the piston The hand piece fails to deliver grease when on the high pressure setting b The valve stem 17 h
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