Balcrank TIGER 500 Instruction Manual

Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
SERVICE BULLETIN SB1031
REV. B 6/03
TIGER®500
MODEL 1160-004
5:1 PUMP
STAINLESS STEEL
®

2
GENERAL SAFETY REQUIREMENTS
NOTE: THOROUGHLY READ AND UNDERSTAND
THIS MANUAL BEFORE INSTALLING, OPERATING
OR SERVICING THIS EQUIPMENT.
PRESSURE RELIEF
PROCEDURE:
Follow this procedure
whenever you shut off the
pump, when checking or servicing any part of
the system and when installing, cleaning or
changing any part of the system.
1 ) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
WARNING
!
DANGER: Not for use with
fluids that have a flash point
below 100°F (38°C). Examples:
gasoline, alcohol. Sparking could result in an
explosion which could result in death.
WARNING
!
THIS PUMP CONTAINS
ALUMINUM AND ZINC
PARTS. DO NOT use 1-1-1
Trichloroethane, methylene chloride or other
halogenated hydrocarbon solvents or uids
containing such solvents in this pump. Use of
these solvents/uids may result in a violent
chemical reaction, causing serious bodily
injury, property damage or death. All uids
used in this pump must be chemically
compatible with the wetted parts materials
shown on page three (3) of this manual.
Consult your chemical supplier to ensure
compatibility.
Because this pump can
be incorporated into
pressurized systems,
the following safety
precautions should be observed.
Check equipment regularly and repair or
replace worn and damaged parts.
Never alter or modify any parts of this pump,
doing so may cause damage to pump and/or
personal injury.
Under no circumstances should the dispensing
valve be aimed at any person at any time.
Personal injury may result.
Release pressures built up in the system
before any service or repair is begun. See the
pressure relief procedure below.
Do not operate this pump above 150 PSI
(10.3 BAR) air inlet pressure or 200 cycles
per minute.
Always read and follow the uid manufacturer’s
recommendations regarding the use of
protective eyewear, clothing and respirators.
IMPORTANT
!
Pump develops 750 PSI
(51 BAR) maximum working
pressure at 150 PSI (10.3
BAR) maximum inlet air
pressure. Be sure that any components or
accessories used in the system are rated to
withstand this pressure. To determine fluid
outlet pressure, multiply the ratio of the pump
by the air pressure being used.
EX: 5 (5:1 ratio) x 100 PSI = 500 PSI
uid pressure.
5 (5:1 ratio) x 6.8 BAR = 34 BAR
uid pressure.
WARNING
!
In the presence of explosive
vapors, take action to prevent
static sparking. Failure to
ground the pump, piping, valves, containers, or
other miscellaneous equipment can result in re or
explosion. A green grounding lug is provided on the
pump.
WARNING
!

3
The Stainless Steel Balcrank Tiger®500 pump is
a high quality, reliable pump for petroleum based
lubrication products. It is ideal for system distribution
of uids such as oil, automatic transmission uid and
pure antifreeze. It is rated for maximum air pressure
of 150 PSI (10.3 BAR) and an average working air
pressure of 100 PSI (6.8 BAR).
All air motor parts are lubricated at the factory with a
special synthetic grease (#826733) for improved life.
A lightly lubricated, ltered and regulated air supply
will prolong air motor maintenance intervals. DO NOT
OVER LUBRICATE. Set lubricator to a maximum of
2 drops per hour of operation and use a turbine oil of
150-170 SSU (at 100°F).
The internal air motor and a 360 degree internal
mufer provide efcient operation with low noise levels
conforming to 1994 OSHA requirements.
The Tiger®500 air motor is internally valved and very
simple, with few moving parts. It is constructed of
aluminum and steel with Buna-N seals for long life.
The uid section contains a stainless steel pump rod,
tube and uid piston for rugged duty and high quality
seals for long life. The uid section is also double
acting to provide consistent delivery. All of these
features make the Tiger 500 a top performing, long
life, easy to service lubrication pump.
Pressure Ratio........................................... 5:1
Air Motor Bore ...................4.25” (effective 3.25”)
Stroke ......................................................... 3.50"
Displacement.....................................9.2 in cycle
Cycles/gallon ...................................................25
Operating Air Pressure ..0-150 PSI (0-10.3 BAR)
Air Consumption..................................28 CFM *
Suction Lift.........................................20 in. Hg **
Air Inlet ................................................. 3/8" NPT
Fluid Inlet................................................. 1" NPT
Fluid Outlet ........................................... 3/4" NPT
Wetted Parts...............................Stainless Steel,
......................................... Viton, and Nylon
Shipping Weight ....................................23.5 Ibs.
* tested at 100 psi air pressure, 3.04 ft’ per gallon
** 15' vertical suction maximum
TECHNICAL DATA
GENERAL DESCRIPTION
After removing pump from carton, attach suction tube
or hose securely. NOTE: Performance will be affected
by a seal that is not air tight. If using the universal
bung adapter, thread bung adapter into bung bushing,
lower pump into bung adapter and tighten. If mounting
on a tank or wall bracket, place pump in tank or wall
bracket and tighten bolts securely. Always tighten pump
down securely to avoid damage to uid container,
pump and nearby equipment.
Blow out any foreign material from the air supply
line before connecting it to the pump. An air line
lter/regulator is recommended for all applications as
wet, dirty air will shorten the life of the air motor. This
pump has been designed and assembled to operate
on unlubricated air in regular duty installations. For
heavy duty operations, a lubricator may be used
with turbine oil of 150-170 SSU (at 100°F) set at a
maximum of 2 drops per hour of operation. The air
motor has been coated during assembly with a special
synthetic grease (#826733) so no additional air line
lubrication is normally necessary. This special grease
must be reapplied during each reassembly of the
air motor.
Be sure air supply is turned off before connecting to
the pump. Gradually open air regulator or air line valve
until pump begins to cycle. The pump should prime
within one to three cycles depending on the viscosity
of the pumped material. Pump a small amount of uid
at low air pressure to remove trapped air and foreign
materials from the line. Discard this waste material in
conformance with local and/or state regulations.
After the system is fully primed, open the air supply
regulator until desired ow and/or pressure is obtained.
Always use the lowest pressure needed to provide
the desired results, this reduces wear on all of the
system components.
INSTALLATION
WARNING: Attach a proper ground
wire to the Tiger’s grounding lug (item
38) before starting the pump.
!

4
Tools required for disassembly/assembly: 5/32" allen
wrench, 3/8", 7/16", 1/2" and 1-1/16" hex wrenches, 1-1/4"
to 3" spanner wrench and pipe wrench.
1) Using a soft jaw vice, clamp the pump horizontally on
the lower body (7). Remove four body screws (29) and
star washers (2), remove cap (6). Remove three air
valve nuts (3), washers (23), and screws (22). Remove
upper toggle plate (26). Remove three spacers (17)
and o-rings (19).
2) Clamp on adapter ats (15) and unscrew upper air
piston (14). Remove lower toggle plate (16), springs (10
& 36), and trip plate (18).
3) Remove foot valve (43) and pump tube (39). Using a
spanner wrench on the pump rod (41), remove the uid
piston (42). Remove adapter (40) by unscrewing the
four adapter screws (29) and lock washers (2).
4) Slide lower air piston (27)/pump rod (37,41) assembly
out the top of the pump body (7). Take care not to
scratch the pump rod, minor scratches can be polished
out with #320 grit, wet or dry paper.
5) Remove plate (38) by unscrewing the four adapter
screws (29). Place adapter (40) in a vice and remove
seal snap ring (33), backup ring (32), and rod seal
(5).
6) Replace all o-rings, the rod seal (5), the uid piston
quad-ring seal (31) and all springs (9, 10, & 36).
NOTE: The air motor is lubricated with a life-tested synthetic
grease (#826733) at the factory. This grease coats all parts
and repels air line moisture to prevent rusting. It is imperative
that any grease removed during routine maintenance be
replaced. Contact your Balcrank®service distributor, using
the above part number, for replacement grease.
1) Reassemble rod seal (5), backup ring (32), and snap
ring (33) in the seal pocket in the adapter.
2) Place mufer (25) and mufer screen (24) into pocket
inside lower end of the pump body (7). Place o-ring
(12) in groove in pump body (7). Bolt adapter (40) to
plate (38) with four adapter screws (29) and four lock
washers (2), make sure the lip on plate is facing snap
ring (33), tighten securely. Bolt adapter (40) to pump
body (7) with four adapter screws (29) and four lock
washers (2). Grease the rod seal (5). Slide air piston
(27)/rod assembly (37,41) into lower body (7) and
out through adapter (40). FROM THE TOP ONLY!
Any other assembly procedure will damage the
rod seal (5)!
3) Place lower pump body (7) horizontally in a suitable
xture. Assemble uid piston by placing ball (1) in piston
chamber (42), placing quad ring (31) on uid piston
(42). While holding the pump rod (41) with a spanner
wrench, thread the uid piston (42) onto the pump rod
(41) tighten securely. Place o-ring (4) below external
threads on the pump tube (39). Grease uid piston seal
(31) liberally, slide pump tube (39) over uid piston (42)
and thread into adapter (40) securely.
4) Assemble footvalve (43) by placing ball (1) in chamber
and placing retaining pin (34) into holes, place o-ring
(30) below external threads on footvalve. Thread
footvalve (43) into tube (39), tighten securely. Take
care that all o-rings are replaced correctly to
avoid leaks.
5) Place trip plate (18), then lower springs (10 & 36), then
lower toggle plate (16) onto air piston adapter (15).
Screw upper air piston (14), with o-ring (11) in groove,
onto air piston adapter (15), tighten securely. Place
three o-rings (19) between upper air piston (14) and
lower toggle plate (16), centering them between holes
in both plates. Place three spacers (17) into upper air
piston (14) holes, through o-rings (19) and centering
them over holes on lower toggle plate (16).
6) Place three air valve screws (22) through upper toggle
plate (26), spacers (17) and lower toggle plate (16).
Place washers (23) and nuts (3) on air valve screws
and tighten securely. Assure that all o-rings have
been placed correctly to avoid leaks.
7) Place o-ring (13) on lower body pump (7), around step.
Grease air piston o-ring (11) liberally. Carefully slide
air motor cap (6) down over air piston (14) taking care
not to pinch the o-ring (11). Bolt cap (6) to body with
four body screws (21) and four star washers (8), tighten
securely to prevent leaks. Install air line ttings into
air inlet hole in the cap. Install suction tube or hose
into footvalve and install uid outlet hose into uid
outlet in adapter (40).
PUMP DISASSEMBLY
PRESSURE RELIEF
PROCEDURE:
Follow this procedure
whenever you shut off the
pump, when checking or servicing any part of
the system and when installing, cleaning or
changing any part of the system.
1 ) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
PUMP R E AS SE MB LY

5
Trouble Probable Cause Corrective Action
Pump does not operate Inadequate air supply pressure or Increase or clear air supply (1)
restricted air line Assure air is on and valves are open
Clogged lines, hoses, valves, etc. Open; clear (1)
Damaged air motor Service air motor
Air motor is not tripping over Air motor seals are worn/damaged Service air motor
Air is leaking from exhaust Air motor seals are worn/damaged Service air motor
and or seal damage, etc.
Fluid is leaking from the exhaust Fluid seal (5) is worn/damaged Replace
Erratic pump operation Air entering suction line Check for loose connections
Fluid level too low Rell, reprime or ush
Air motor icing Run pump at lower pressure; run at lower
cycles per minute; clean mufer (25)
Pump runs continuously Empty uid supply Rell, reprime or ush
Blockage in pump tube or foot valve (43) Remove pump tube, clear blockage
Lower ball (1) is stuck in foot valve (43) Replace ball and reseat foot valve
Lower seal (31) is worn or damaged Replace
Fluid output on one stroke only or Upper ball (1) is stuck in uid piston (42) Replace ball and reseat
continues to operate when or one or both are damaged
dispensing valve is closed
Pump operates, but pump output Inadequate air supply pressure or Increase air supply; increase air supply size
on both strokes is low restricted air line
Closed or clogged solenoid valve, meter, Clear(1)
dispensing valve, etc.
Air inlet strainer/lter clogged Clear(1)
(1) Follow the Pressure Relief Procedure and disconnect the fluid line. If the pump starts when the air is turned on again,
the line, etc. is clogged.
TROUBLESHOOTING

6
Parts List
Tiger®500 5:1 Pump
Model 1160-004
* INCLUDED IN REPAIR KIT 826280
** INCLUDED IN REPAIR KIT 829298
ITEM PART DESCRIPTION QTY IN KIT
1 800971 Ball, 1” SS 2
2 805784 Lock Washer 8
3 814247 Air Valve Nut 3
4 826679 O-Ring, Viton 1 **
5 826072 Rod Seal, Viton 1 **
6 826201 Air Motor Cap 1
7 826202 Pump Body 1
8 826203 Star Washer, 5/16 4
9 826204 Upper Spring 1 *
10 826205 Lower Spring, Inner 1 *
11 826206 O-Ring, Buna-N 1 *
12 826207 O-Ring, Buna-N 1 *
13 826211 O-Ring, Buna-N 1 *
14 826212 Upper Air Piston 1
15 826213 Air Piston Adapter 1
16 826215 Lower Toggle Plate 1
17 826216 Air Motor Spacer 3 *
18 826217 Trip Plate 1
19 826218 O-Ring, Buna-N 3 *
20 826220 Spring Retainer 1
21 826221 Body Screw 4
22 826223 Air Valve Screw 3
ITEM PART DESCRIPTION QTY IN KIT
23 826224 Washer 3 *
24 826227 Mufer Screen 1
25 826228 Mufer 1 **
26 826242 Upper Toggle Plate 1 *
27 826253 Lower Air Piston 1
28 826665 Air Motor Screw 1
29 826666 Adapter Screw 8
30 826679 O-Ring, Viton 1 **
31 827065 Quad-Ring, Viton 1 **
32 827425 Backup Ring 1
33 827426 Snap Ring 1
34 827427 Ball Retainer 1 **
35 827441 O-Ring, Viton 1 **
36 827807 Lower Spring, Outer 1 *
37 828339 Rod Adapter 1
38 828340 Plate 1
39 831205 Pump Tube 1
40 828366 Adapter 1
41 828421 Pump Rod 1
42 828988 Fluid Piston 1
43 829027 Footvalve 1
44 831489 Grounding Lug (not shown) 1

7
Diagram
Tiger®500 5:1 Pump
Model 1160-004
Quality Checklist
Bill of Material checked for current content.
Pump was tested in water and met Balcrank®
performance standards.
I ________________________________________
certify that this product meets or exceeds Balcrank's
high quality standards.
Revision Log:
Rev. B - Added grounding lug (item 44)

PRODUCT EXTENDED WARRANTY
Tiger®500TM pumps are warranted to be free from defects in material and wokmanship for a period of Thirty
Years from the date installed in service by the original purchaser.
Balcrank®Corporation
Weaverville, NC 28787
800-747-5300
800-763-0840 Fax
www.balcrank.com
Distributed by:
SERVICE BULLETIN SB1031
Rev. B 6/03
829269
WARRANTY
All Balcrank®equipment sold by authorized Balcrank®distributors is warranted to their original customer to be free
from defects in materials and workmanship for a period of one year from the date the equipment was sold to the
original customer. Select equipment carries extended warranty terms as individually noted within the Balcrank®
Lubrication Equipment & Accessories User Price List. Any Balcrank®equipment carrying an extended warranty will
be warranted for the period indicated; those items carrying a “lifetime” warranty are warranted for a period of thirty
years. All Balcrank®equipment determined by Balcrank®to have defective materials or workmanship within the
one year warranty period will be repaired or replaced. For equipment carrying extended warranties Balcrank®will
repair or replace the product including parts and labor for the rst full year and will provide parts only for the
remaining period of the specied warranty.
This warranty only covers equipment installed and operated according to applicable Balcrank®Service Bulletins and
Installation Instructions. Any equipment claimed to be defective must be returned, freight prepaid, to an Authorized
Balcrank®Service Center. If the part(s) or equipment is found to be defective, it will be repaired or replaced, and
returned freight prepaid from the Authorized Service Center. If the claimed part(s) or equipment is found not to be
defective, the Authorized Balcrank®Service Center will, upon written authorization being received from the original
customer, repair them for a reasonable charge to the customer which will include all applicable parts, labor, and
return transportation costs. Any equipment returned to Balcrank®must have the Warranty Service Claim number
(WSC#) clearly marked on the outside of the carton. Balcrank’s sole responsibility is for defects in material and
workmanship, and Buyer’s sole and exclusive remedy hereunder, shall be limited to repair or replacement of
the defective part or equipment.
This warranty does not cover, nor shall Balcrank®be liable for repair or replacement of parts or equipment
resulting from general wear and tear through use, or damage or failure caused by improper installation, abuse,
misapplication, abrasion, corrosion, insufcient or improper maintenance, negligence, accident, alteration, or
substitution of non-Balcrank component parts. Furthermore the Balcrank®Warranty for Lubrication Equipment and
Accessories does not cover the following specic conditions:
 Failure or damage to equipment that is caused by dirt or debris in air and uid lines. This includes, but is not
limited to clogged inlet lters, strainers, or regulators; uid meters; control handles; uid tips; and valves.
Failure of normal wear parts including but not limited to: “o”-rings, packings, seals and valves unless originally
improperly installed by the factory.
Products placed in applications for which their use was not intended. Examples include but are not limited to: A
lubricant pump being used to pump solvents, or placing a piece of equipment intended strictly for indoor use in
an outdoor application.
Damage to equipment resulting from operation above and beyond Balcrank’s recommendations.
 Leaks at air and uid ttings and connections.
Damage caused by thermal expansion when adequate pressure relief was not included in the system.
Loose suction tubes on pumps.
Reel spring tension adjustment.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MER-
CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BALCRANK BE LIABLE
FOR ANY SPECIAL, CONSEQUENTIAL, OR OTHER DAMAGES OF SIMILAR NATURE, INCLUDING BUT NOT
LIMITED TO LOST PROFITS, LOST PRODUCTION, PROPERTY DAMAGE, PERSONAL INJURY, WHETHER
SUFFERED BY BUYER OR ANY THIRD PARTY, IRRESPECTIVE OF WHETHER CLAIMS OR ACTIONS, LEGAL
OR EQUITABLE, FOR SUCH DAMAGES ARE BASED UPON CONTRACTS, WARRANTY, NEGLIGENCE,
STRICT LIABILITY, OR OTHERWISE. ANY CLAIM OR ACTION FOR BREACH OF WARRANTY MUST BE
BROUGHT WITHIN TWO (2) YEARS FROM THE DATE OF SALE TO THE ORIGINAL CUSTOMER.