Roughneck 58079 User manual

READ & SAVE THESE INSTRUCTIONS
Air Operated 50:1 Grease Pump Kit
Fits Drums 110-132 Lb.
Owner’s Manual
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #58079

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Thank you very much for choosing a Roughneck™product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This pump kit is designed for certain applications only. Northern Tool and
Equipment is not responsible for issues arising from modification or
improper use of this product such as an application for which it was not
designed. We strongly recommend that this product not be modified
and/or used for any application other than that for which it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Packaging Contents..............................................................................................................................4
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................5
Specific Operation Warnings...............................................................................................................7
Main Parts of Product...........................................................................................................................9
Assembly Instructions........................................................................................................................12
Before Each Use..................................................................................................................................14
Operating Instructions........................................................................................................................14
Pressure Relief Procedure.................................................................................................................16
After Each Use.....................................................................................................................................16
Maintenance ........................................................................................................................................17
Troubleshooting..................................................................................................................................17
Parts Diagram......................................................................................................................................19
Parts List..............................................................................................................................................21
Replacement Parts..............................................................................................................................23
Limited Warranty.................................................................................................................................24

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Intended Use
The Roughneck Air Operated 50:1 Grease Pump Kit is designed for transferring grease. Compressed,
air-operated, reciprocating pumps are designed for high pressure greasing. The pump kit applies to all
types of grease (up to NLGI-2 consistency). The pumps can be supplied as separate components or as
a complete system with all the elements necessary for installation. The pump can be assembled on
mobile units as well as fixed positions.
Packaging Contents
Part No.
Description
Quantity
1701502
Grease pump
1
1708001
Drum trolley
1
1709004
Drum cover
1
1709014
Follower plate
2
1762213
1/4"x13' connection hose
1
1785702
Z-swivel
1
1785700
Grease control valve
1
Technical Specifications
Compression ratio
50:1
Operating pressure (psi)
70-115
Air inlet pressure (psi)
115
Max. fluid pressure (psi)
5800
Max. free flow rate (min)
1.76lbs
Air consumption(min)
@115psi/4.3CFM
Tube Diameter (inch)
1.18
Suction tube length (inch)
29-1/8”
Suitable for drum (lb.)
1/4'' quick plug/1/4'' NPT female
Air inlet connection (inch)
Male 1/4''
Oil delivery connection
1/4”Male
Noise level (dB)
82
Drum Cover and Follower Plate List
Drum Cover
Diameter (in.)
Flower Plate
Diameter (in.)
Drum
Application (lb.)
1709004
15.2”
1709014
14.6”
110-132

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Drum Trolley List
Item No.
Drum Capacity (lb.)
1708001
44-132
Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in serious injury or
property damage.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
Do not allow persons to operate or assemble the product until they have read this manual and have
developed a thorough understanding of how it works.
Do not modify this product in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the product. There are specific applications for which the product
was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. This
product will be safer and do a better job at the capacity for which it was intended. DO NOT use this
equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areas may
put you dangerously close to cutting tools and rotating parts.
Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence of
flammable liquids, gases, or dust. The product can create sparks, which may ignite the flammable
liquids, gases, or dust.
Do not allow the product to come into contact with an electrical source. The tool is not insulated and
contact will cause electrical shock.
Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the product.
Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your
work area. Some of these hazards may be hidden from your view and may cause personal injury
and/or property damage if contacted.

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⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use
the tool while you are tired or under the influence of drugs, alcohol, or medication. Amoment of
inattention while operating the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing and
gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
Air vents on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety
goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in
dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems,
and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
Remove keys or wrenches before connecting the tool to an air supply, power supply, or turning on
the tool. A wrench or key that is left attached to a rotating part of the tool may cause personal injury.
Secure the work with clamps or a vise instead of your hand when practical. This safety precaution
allows for proper tool operation using both hands.
⚠CAUTION
PUMP KIT USE AND CARE
Do not force the pump kit. Products are safer and do a better job when used in the manner for which
they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate the
product with a damaged part.
Do not use a product with a malfunctioning switch. Any power tool that cannot be controlled with the
power switch is dangerous and must be repaired by an authorized service representative before
using.
Disconnect the power/air supply from the product and place the switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Store the pump kit when it is not in use. Store it in a dry, secure place out of the reach of children.
Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with another
tool. Never use an accessory that has a lower operating speed or operating pressure than the tool
itself.
Keep guards in place and in working order. Never operate the product without the guards in place.
Do not leave the tool running unattended.

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Specific Operation Warnings
⚠WARNING
To prevent serious injury or property damage, read and understand owner's manual before
operating.
Wear ANSI Z87.1 compliant goggles and other protective gear while operating.
Wear an adiabatic glove when operating pump.
Do not exceed the maximum working air pressure of 115 PSI.
Never point the dispenser at people or animals.
Do not use the pump near open flames. Do not smoke during this operation.
When not in use, disconnect the air supply air to the pump.
Inspect before each use; check that all connections are tight and secure.
Never use if parts are damaged or broken; replace damaged or broken parts before operating.
Use only original parts when repairing the pump.
Always disconnect the air supply after use so that oil can't leak out in case one of the pump's
components should break.
The compressed air must be filtered to avoid dust and moisture into pump.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer's
warnings.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Disconnect air hose and relieve air pressure before servicing.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not lift or move pressurized equipment.
Always dispose of oil and other liquids according to local waste authority guidelines.
Not for use by or around children.
⚠WARNING
SKIN INJECTION HAZARD
Fluid from the dispensing valve, leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation or blood poisoning. Fluid splashed
in the eyes or on the skin can also cause serious injury. If a fluid injection injury occurs, GET
IMMEDIATE SURGICALTREATMENT. Do not treat as a simple cut.
Do not point the dispensing valve at anyone or at any part of the body.
Do not put your hand or fingers over the end of the dispensing valve.

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Do not stop or deflect leaks with your hand, body, glove, or rag.
Use only extensions and no-drip tips which are designed for use with your dispensing valve.
Do not use a low pressure flexible nozzle with this equipment.
Follow the Pressure Relief Procedure if the dispensing valve clogs before you clean, check or
service the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
⚠WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers.
Do not operate the pump with the air motor plates removed.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure to prevent the equipment from
starting unexpectedly.
⚠WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being lubricated.
If there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
dispensed.
Keep the dispensing area free of debris, including solvent, rags, and gasoline.
Do not smoke in the dispensing area.

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Main Parts of Product
50:1 SERIES GREASE PUMP EXPLODED VIEW

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Trolley

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Grease Control Valve Exploded View
Assembly Instructions
⚠WARNING
Do not exceed the maximum working air pressure of 115 PSI.
The compressed air must be filtered to avoid dust and moisture into pump.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
⚠WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being lubricated.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
dispensed.

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PUMP INSTALLATION
•When the pump is applied to a high viscosity grease, or used in low temperature, a grease
follower plate is recommended to avoid air pockets and to get the most out of your grease.
•The follower plate, which is pulled towards the bottom of the drum by suction pressure produced
by the air operated pump, compresses the grease, preventing the formation of air pockets which
may cause a blockage in delivery. The follower plate will always keep the grease clean to
preserve its characteristics and also enable the grease to be collected from the bottom of the
drum to avoid waste.
•Loosen the bung adaptor or wall bracket adaptor star nut. Slide the bung adaptor off of the suction
tube.
•Carefully slide the pump through the bung adaptor and the follower plate. Tighten the star nut
firmly in order to attach the pump.
CONNECTING THE AIR INLET LINE
•Air inlet connection is 1/4'' quick coupling (or 1/4'' NPT female) in all versions.
•Compressed air connection (to be supplied by the customer) should be done using the correct
tubes.
•Acompressed air treatment unit (filter and regulator) is recommended to be attached to the pump.
In order to improve the efficiency of the pump, the installation of a lubricator is also recommended.
CONNECTING THE REGULATOR
•The lubricator (I) must be placed as close as possible to the air inlet, followed by the pressure
regulator (II), and finally, the filter (III). In the case of pumps not installed on a wall support it is very
important to equip the pump's air inlet with an adaptor for quick coupling and the air inlet hose with
a quick connector.
CONNECTING THE GREASE DISCHARGE
1. The Grease discharge outlet is a 1/4'' G thread. Connect the outlet to the high pressure hose
(according to DIN-SAE norms) through the corresponding adapter and terminal.
2. Ensure the gun (or corresponding valve) is closed.
3. Slowly open the pump's compressed air inlet valve. The pump will start to function, filling the feed
circuit with grease. Maintain pressure on the gun until the grease start to flow out. The pump is now
ready for its usual function.

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PUMP OPERATION
•If the pump has already been primed and the compressed air feed is connected to the appropriate
work pressure level (70-115psi), the pump will start automatically when the nozzle or gun situated
at the end of the grease delivery circuit is opened.
•To stop the pump, simply close the nozzle or disconnect the air inlet line.
Before Each Use
⚠WARNING
Wear ANSI Z87.1 compliant goggles and other protective gear while operating.
Inspect before each use; check that all connections are tight and secure.
Never use if parts are damaged or broken; replace damaged or broken parts before operating.
DO NOT try to mend it with tape or any other device. Arepaired hose cannot safely contain the high
pressure fluid.
The compressed air must be filtered to avoid dust and moisture into pump.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer's
warnings.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Disconnect air hose and relieve air pressure before servicing.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
Operating Instructions
⚠WARNING
Wear ANSI Z87.1 compliant goggles and other protective gear while operating.
Wear an adiabatic glove when operating pump.
Do not exceed the maximum working air pressure of 115 PSI.
Never point the dispenser at people or animals.
Do not use the pump near open flames. Do not smoke during this operation.
When not in use, disconnect the air supply air to the pump.
The compressed air must be filtered to avoid dust and moisture into pump.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer's
warnings.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a

Page 15 of 25
chemical reaction, with the possibility of explosion.
Do not lift or move pressurized equipment.
⚠WARNING
SKIN INJECTION HAZARD
Fluid from the dispensing valve, leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation or blood poisoning. Fluid splashed
in the eyes or on the skin can also cause serious injury. If a fluid injection injury occurs, GET
IMMEDIATE SURGICALTREATMENT. Do not treat as a simple cut.
Do not point the dispensing valve at anyone or at any part of the body.
Do not put your hand or fingers over the end of the dispensing valve.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Use only extensions and no-drip tips which are designed for use with your dispensing valve.
Do not use a low pressure flexible nozzle with this equipment.
Follow the Pressure Relief Procedure if the dispensing valve clogs before you clean, check or
service the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
⚠WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers.
Do not operate the pump with the air motor plates removed.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure to prevent the equipment from
starting unexpectedly.
⚠WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being lubricated.
If there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
dispensed.

Page 16 of 25
Keep the dispensing area free of debris, including solvent, rags, and gasoline.
Do not smoke in the dispensing area.
PUMP OPERATION
If the pump has already been primed and the compressed air feed is connected to the appropriate
work pressure level (70-115 PSI), the pump will start automatically when the nozzle or gun situated at
the end of the grease delivery circuit is opened. To stop the pump, simply close the nozzle or
disconnect the air inlet line.
GREASE CONTROL VALVE OPERATION
1. Connect the control handle to the lubricant supply line (1/4 NPT male thread required).
2. Open the manual tip.
3. Squeeze control handle trigger. When the required amount of product has been dispensed, release
the trigger to stop delivery. Close the manual tip.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin,
or injury from moving parts, always follow this procedure whenever you shut off the pump, when
checking or servicing any part of the spray/dispensing system, when installing, cleaning, or changing
the spray tips/nozzles, or whenever you stop spraying/dispensing.
•Shut off the air to the pump.
•Point the outlet of grease gun to a container and trigger the grease gun to relieve pressure.
Grease Pump Control Valve Operation
⚠WARNING
Never point the dispenser at people or animals.
•Connect the control handle to the lubricant supply line (1/4 BSP or 1/4 NPT male thread required).
•Open the manual tip.
•Squeeze the control handle trigger. When the required amount of product has been dispensed,
release the trigger to stop delivery. Close the manual tip.
After Each Use
⚠WARNING
When not in use, disconnect the air supply air to the pump.
Always disconnect the air supply after use so that oil can't leak out in case one of the pump's
components should break.
Disconnect air hose and relieve air pressure before servicing.
Always dispose of oil and other liquids according to local waste authority guidelines.
•Let in 50 grams of Vaseline oil or other lubricator from the air inlet hole.
•Turn on the pump for several minutes until moving parts are fully lubricated. Do this weekly.

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•For the pumps that are attached with compressed air treatment equipment, empty the water
retained in the reservoir of the filter-purger frequently.
•For the pumps that are attached with a lubricator, pay close attention to the lubricator's grease
level and refill with NLGL-2 conditions when necessary.
Maintenance
⚠WARNING
Disconnect air hose and relieve air pressure before servicing.
Handling and storage of the pump do not require any special procedures. The dust in compressed air
can slow down or even block the motor cylinder. The following steps may prevent this from happening:
1) Add 50 grams of appropriate lubricating oil to the air inlet hole weekly; operate the pump for
several minutes after adding oil.
2) Turn on the pump for several minutes until the moving parts are fully lubricated. Repeat if
necessary. Do this on a weekly basis.
For the pumps that are attached with compressed air treatment equipment, empty the water retained in
the reservoir of the filter-purger frequently.
For the pumps that are attached with a lubricator, pay close attention to the lubricator's grease level
and refill with NLGL-2 conditions when necessary.
Keep the pump in a dry and cool place out of the reach of children.
Cleaning the Pump:
Operate the pump and drain off the oil, then the pump could be applied to other kind of oil.
Troubleshooting
Problem
Possible Cause
Solution
The pump
continues to
operate after the
gun trigger has
been released.
The pump continues to operate after
the gun trigger has been released.
1.Remove cover and take out
pump and follower plate.
Compact grease and fill the
drum or substitute it for a full
one.
2.Check and tighten
connections. Repair the leak.
3.Disassemble and clean
valves. Have them replaced if
damaged.
Reduction of the
grease delivery or
reduced pressure
in the grease
delivery.
1. Air pockets are trapped in the
grease drum.
2. Silencer (210) is dirtied.
3.There is a blockage at some point
in the grease circuit.
4.Ball valve (103) closes incorrectly
due to dirt or wearing.
5. Damaged O-ring (216).
1. Remove the cover and take
out the pump and the follower.
Plate. Compact the grease and
fill the drum.
2.Clean or recharge silencer.
3.Use clean grease.
4.Have damaged parts
replaced.

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Air loss through
the air exhaust.
1.The sliding valve (7) does not close
properly.
2.The press piece (36) is broken.
3.Damaged O-ring (208, 209, or 211).
4.Damaged piston (2).
5.Damaged washer(31).
6.Broken spring (33).
1.Disassemble and clean. Have
damaged parts replaced.
2. Have damaged parts
replaced.

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Parts Diagram
Kits List

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50:1 SERIES GREASE PUMP EXPLODED VIEW