PA62

0206
0007

P3 POWERLUBE / P6 MAXILUBE
AIR OPERATED GREASE PUMPS
INSTRUCTION MANUAL

INTRODUCTION
Thank you for purchasing either a P3 Power-Lube or
P6 Maxi-Lube air operated, high pressure grease pump.
Both the Power-Lube and the Maxi-Lube feature a
non-corroding 50:1 ratio air motor and are supplied with
drum lid, rubber edged follower plate, grease strainer,
4m high pressure grease hose, ‘Z’ type swivel and a B2
Booster Gun as standard equipment.

A full range of greasing accessories are available to suit

the Power-Lube or Maxi-Lube. Consult your local
Power-Lube distributor for more informatin

Please read and retain this instruction manual to assist

you in the operation and maintenance of this quality
product.

GENERAL INFORMATION
Weak, worn or damaged hoses are also a hazard. Before
This manual assists you in operating and maintaining your operation check hoses for signs of wear, leaks or loose
new Power-Lube or Maxi-Lube. The information contained fittings. Tighten all fluid connections regularly and replace
will help you ensure many years of dependable weak or damaged hose. Your personal safety and well
performance and trouble free operation. being are at stake.

If accidental injection should occur, seek immediate

Please take a few moments to read through this manual
emergency medical attention.
before installing and operating your Power-Lube or
Maxi-Lube. If you experience problems with the product, Do not use air pressure greater than 1035kPa /150psi /
refer to the Maintenance and Trouble Shooting sections of 10.3bar
this manual. If you require any further assistance please
Do not hit the unit if it fails to operate.
contact your local Power-Lube or Maxi-Lube distributor.

IMPORTANT INFORMATION CAUTION

Read this information carefully before use.Your safety Before attempting any maintenance or repairs of this
is important to us. Please read and follow all operating product, disconnect air supply then squeeze gun trigger
and safety instructions listed below.Make sure all to release pressure.
operators have adequate access to the following
instructions. ASSEMBLY
CAUTION This carton contains an Air Motor / Suction Tube assembly
(Pump unit), Lid, Follower, High Pressure Grease Hose,
This is a 50:1 ratio high pressure grease pump. Because B2 Booster Gun / Swivel assembly and a plastic bag
of the high pressures developed by this pump, the containing 3 slotted screws and an instruction sheet.
possibility of fluid injection into the flesh, or eyes, is a
1) Remove the components from the protective packaging.
potential hazard.
Reposition the 3 lid positioning screws so the threaded
Never allow any part of the human body to come in front ends are flush with the inside of the lid (Fig 1).
of, or in direct contact with a material outlet. Never point
the nozzle of the gun at yourself or anyone else. 2) Slide the suction tube through the lid. Line up the holes
in the lid with the threaded holes in the air motor base,
Most injections occur because of component rupture. Never so that the grease outlet of the pump faces one of the lid
exceed the pressure rating of any component in the handles (Fig4). This allows easy fitting and removal of
system. Remember, fluid pressure generated is fifty times the air -line. Secure the lid to the air motor with the 3
the air inlet pressure. slotted screws provided (Fig 2).
1
 8) Turn on your air supply and press the reset button
3) Remove the lid from the grease container. This grease (fig 1). Hold the B2 booster gun near a waste container
pump is recommended for use with grease up to and (to collect the test grease) and squeeze the gun trigger.
including NLGI No.2. Heavy grades of grease or cold The air motor will start to operate and the factory test
temperatures can result in operating difficulties. grease will appear followed by air (in high pressure
grease hose), followed by your grease. Tighten
4) Place the follower plate in the grease container with the connections as required.
follower handle and boss facing upwards (Fig 3). Push
the follower plate down onto the grease until some
grease is forced through the centre (boss) hole.
OPERATION
1) Before connecting the air supply check that all fittings
have been tightly fastened and all hoses are checked
Thumb Screw Lid for wear and or damage.

2) Fully depress the reset button (fig 1), add air cock and
recommended air filter (as described in item ‘2’ of
assembly section) then connect the air supply. The
Reset Button
optimum pressure range is 550 to 700 kPa (80-
100psi / 5.5–7 bar).

3) When air is connected to the pump and is turned on,

the air motor will start operating, this will allow grease
Remove plugs and 3 Slotted 1/4”
sleeves BSW Screws pressure to build, which pushes grease through the
pump and hose to the grease gun until ‘stall’ pressure
(Fig 1) (Fig 2) is reached,at this pressure the pump will stop.

5) Insert the suction tube through the follower boss and For grease delivery press the trigger on the booster
push the lid / pump assembly down until the lid sits gun. To stop grease delivery release the trigger on the
squarely on top of the grease container. Screw in the lid booster gun. When the trigger is released the grease
positioning the thumb screws equally, until finger tight. flow will stop and the pump will again build to ‘stall’
The lid must be centrally located on the grease container. pressure and stop.

Air-Line Pump outlet

4) To grease, connect the B2 booster gun coupler to the
grease nipple then squeeze the trigger. Normally, the
air motor will operate and grease will be pumped
through the nipple. If the grease nipple is blocked, the
air motor will stop (stall). If this happens do not
remove the gun from the nipple, just squeeze
the trigger on the B2 gun three or four times. The B2
Seal Condition booster gun has a boost facility which allows the
Hole (above
High Pressure grease pressure delivered to the grease nipple to be
pump outlet)
Follower Boss Grease Hose boosted and will clear most blocked nipples.
(Fig 3) (Fig 4)
Note: The B2 booster gun creates the extra pressure and
not the pump.
6) Apply thread tape or other thread sealant to both ends of
the high pressure grease hose. Pass the hose through
the lid assembly and screw the hose into the pump outlet
tightly ( fig 4). Screw the other end of the hose into the
ZSB swivel on the inlet of the B2 booster gun.

7) Before connecting the air supply the customer should

add a “stop” compressed air cock. The air cock must be
a ¼ turn type ( allowing quick closure) and should be
located close to the body of the pump and be easily
recognised. There is a wire mesh strainer located (Fig 5)
inside the brass air inlet. It is recommended that a
micro- fine (5 micron) in line air filter be fitted to ensure 5) Remove the coupler from the grease nipple by first
maximum efficiency of this pump. Then connect you tilting (to release any pressure) then a twist and pull
airline to the swivel type, brass air inlet. motion. Loosen the black coupler cap if difficult to
remove.

CAUTION
CAUTION
It is important to read all warnings and operating
instructions before use. Use the lid handles to move the greasing unit. Do not
move the pump by pulling the air or grease hose.

2
Note: At the end of the day or if the pump is not going to be Note: If piston rod is damaged, premature wear can occur
used for an extended period of time, disconnect the air to piston rod seal (18).
supply and release the grease pressure ( squeeze the
gun trigger till the grease ceases to flow). 11) Remove the strainer tube (53). there are spanner flats
on the bottom of this tube.
CAUTION
12) Remove the circlip (52), primer (51), valve seat (50)
and valve spacer (49).
Before carrying out any maintenance, disconnect the
air and release the grease pressure by pressing the 13) Use a pipe wrench or vice grips to remove the tube
trigger on the B2 Booster gun until the grease flow stops. link (48).

MAINTENANCE Note: Repair any damage caused to the tube link with a file
and emery paper.
1) Keep your pump, high pressure grease hose and
air-line clean. 14) Grip the high pressure suction tube (43), with a pipe
2) Inspect your pump, high pressure hose and air-line wrench, as close as possible to the top. Remove the
weekly for any signs of deterioration or damage. ie: hose high pressure suction tube.
seperation, hose distortion etc. (Replace any suspect or
Note: There is thread sealant on the insert / tube thread.
damaged components as required).

15) Pull out the primer (42) and piston rod assembly (13)
3) Every 2 weeks or sooner if the pump is used every day
from the base (21). Use this rod assembly to push the
apply a few drops of light oil, (sewing machine oil is
washer (44), Seal (45), and cylinder (46) out of the high
ideal), to the air inlet of the pump.
pressure suction tube (43).

4) Check the top seal condition hole (Fig 4). A small 16) Remove the gland nut (17), then the botton (short)
quantity of grease indicates seal lubrication is OK. A poppet valve assembly (27), including o’ring (1), (3)
continuous ‘worm’ of grease indicates a worn seal. from the cylinder base (21).
(Replace if required).
17) Use the primer / piston rod assembly to push the piston
PUMP UNIT DISASSEMBLY rod seal (18) from the cylinder base (21).

The following procedure should be followed for pump 18) Knock out the 2 roll pins (38) with a pin punch.
disassembly to carry out routine maintenance. Refer to Unscrew the primer / piston rod assembly and remove
the exploded parts diagram and listing on the following the steel balls (39) and suction spring (41).
pages.
PUMP RE-ASSEMBLY
1) Disconnect the air supply and release the grease
pressure by squeezing the B2 booster gun trigger. 1) Ensure that all parts have correct orientation. If the parts
are assembled upside down, the pump will not work.
2) Remove the high pressure hose and lid from the pump Check the parts diagram for the correct orientation.
unit.
Note: Assembly of the pump is a reversal of disassembly
3) Remove 4 screws (22) holding cylinder (7) to the base procedure.
(21). There’s a slot in the base near the valve body (30).
2) Apply thread sealant (loctite or similar) to insert (23)
4) Remove the cylinder (7) from the cylinder base (21).
and primer rod (42) threads.
5) Remove cover screw (6) and valve body cover (31).
3) Fill the strainer tube (530 with grease for initial prime.
6) Remove 6 screws (33) holding valve body (30) to Hand tighten the suction tube (43), tube link (48) and
cylinder (7) pull off valve body assembly and valve strainer tube. Use the spanner flats on the strainer
gasket (28). tube to tighten all three tubes.

7) Pull out 2 brass pins (32) from valve body. Lever out
4) Ensure that all o’rings, particularly in the valve body (30)
plugs (29) and (36).
and the poppet valve (2), (27) areas, sit square.
8) Gently push spool (34) out of valve body. Be careful
when removing “o” rings (3) and (14). 5) Apply Light grease eg. petroleum jelly to the o’rings (24),
(25) and piston seals (10) before fitting the cylinder
9) Remove top (long) poppet valve assembly 2,4,5 and (7) to the cylinder base (21).
‘o’rings (3).

10) Hold the hex section of insert (23) horizontally in a

vice, hold piston rod (13) as close as possible to the
piston (11) with multi-grips. Remove nut (8), piston
(11), washers (9) and ‘o’ ring (12).
3
PARTS DIAGRAM
1

2
29
3

3 4
28
31 6
30
5

8
37
9
32 27 38
34 1 39

33 35 38
3 11 40
14 12
26 10
36 25 4 9 41

14 13 39
3 42
15 17

18
16
24
43

22 21
44
20
15 22 19
45

23 46
48
47

49
50

51

52

53

54
55

56
58 57

4
PARTS LIST

OR D ER F OR R EPLA C EM EN T
I T EM PA R T N o . N o . o f f PA R T / SET KIT . R EF D ESC R I PT ION

P3 - 1K ( KI T A ) A I R M OT OR SER V I C E KI T
P3 - 5K ( KIT B ) incl 2 xB S117 LOW ER PU M P KIT
P3 - 3 K ( KIT 3 ) O' R IN G KIT

1 BS013 2 A &C O'RING

2 PA31 1 TOP POPPET BODY (LONG)
3 BS011 5 PA31s A &C O'RING
4 PA8 2 A &C POPPET SPRING
5 PA45 1 A POPPET PISTON ASSEM BLY
6 PA21 1 order PA44s COVER SCREW
7 PA68 1 PA68s AIR CYLINDER
8 N216 1 1/4" UNF NYLOCK NUT
9 N129 2 1/4" WASHER
10 PA25 2 PA4s CUP SEAL
11 PA3 1 AIR PISTON
12 BS010 1 A &C O'RING
13 PA19 1 PA19s PISTON ROD
14 BS012 2 A &C O'RING
15 PA36 2 PA48s A & B & C O'RING ( 90 IRHD )
16 BS022 1 A &C O'RING
17 PA48 1 GLAND NUT
18 PA23 1 PA23s A PISTON ROD SEAL
19 PF6 1 PF6 H.P. GREASE HOSE ASSEM BLY
20 PK94 1 PK94s HOSE ADAPTOR
21 PA46 1 PA46s CYLINDER BASE
22 N38 4 order PA2s incl 4xN38, 6xN37 HI-LO SCREW
23 PK95 1 PK95s incl 1xPA36 STEEL INSERT
24 BS231 2 A &C O'RING
25 BS006 2 A &C O'RING
26 PA32 1 PA33s incl 1xBS013, A POPPET PISTON ASSEM BLY
27 PA33 1 1xBS011, PA8 LOWER POPPET BODY (SHORT)
28 PA38 1 order PA39s A VALVE GASKET
29 PA93 1 order PA97s VALVE PLUG
30 PA39 1 PA39s incl PA38 VALVE BODY
1 ( For comp assy order PA30s)
31 PA44 1 PA44s incl PA21 VALVE BODY COVER
32 PA15 2 order PA97s END PLUG PIN
33 N37 6 order PA2s incl 6xN37, 4xN38 HI-LO SCREW
34 PA34 1 PA34s A VALVE SPOOL ASSEM BLY
35 PA95 1 PA97s incl BS012, A RESET BUTTON ASSEM BLY
36 PA16 1 1xBS011, 2xPA15, PA93 END PLUG
37 PK152 1 PK152 (P3 ONLY) P3 CONNECTING ROD
37 PK160 1 PK160 (P6 ONLY) P6 CONNECTING ROD
38 N325 2 B 3/ 32" X 1/2" ROLL PIN
39 N404 2 B 5/32" STEEL BALL
40 PK73 1 PK73s H.P. PISTON
41 PK84 1 B SUCTION SPRING
42 PK167 1 PK167s PRIM ER ROD
43 PK185 1 PK185 (P3 ONLY) P3 H.P. SUCTION TUBE
43 PK195 1 PK195 (P6 ONLY) P6 H.P. SUCTION TUBE
44 PK165 1 B SEAL SUPPORT WASHER
45 PK88 1 PK88s B H.P. PISTON SEAL
46 PK166 1 B H.P. PISTON CYLINDER
47 PA36 1 B &C O'RING ( 90 IRHD )
48 PK97 1 PK97s H.P. TUBE LINK
49 PK203 1 VALVE SPACER
50 PK78 1 PK78s VALVE SEAT
51 PK159 1 B PRIM ER
52 N373 1 B CIRCLIP
53 PK158 1 PK158s STRAINER TUBE
54 PK85 1 PK85s incl 3xN21 (P3 ONLY) P3 LID ASSEM BLY
54 PK101 1 PK101s incl 3xPK130 (P6 ONLY) P6 LID ASSEM BLY
55 N21 3 order PK100s incl 3xN21, 3xN52 5/16" BSW THUM B SCREW
55 PK130 1 order PK140s incl 3xPK130, 3xN52 5/16" BSW THUM B SCREW
56 BS216 1 B &C O'RING
57 PK86 1 PK86s incl 1xBS216 (P3 ONLY) P3 FOLLOWER ASSEM BLY
57 PK107 1 PK107s incl 1xBS216 (P6 ONLY) P6 FOLLOWER ASSEM BLY
58 N52 3 order PK100s (P3 ONLY) 1/4" BSW SLOTTED SCREW
order PK140s (P6 ONLY) 5
PARTS DIAGRAM 84
81

85 59

60

83 61
62 63 64 65 66 67 68

82

79

80 69

71 70

72

73
74

75

77
76

78
87

19
PARTS LIST 86

O R D ER F O R R EPLA C EM EN T
IT EM PA R T N o . N o . o f f N EW PA R T / SET KIT . R EF D ESC R IPT IO N

B 2 - 1K ( KIT A )

59 BJ1 1 PLUNGER GUIDE BUSH

60 BJ23 1 BJ1s A PLUNGER
61 BJ3 1 A BACK-UP WASHER
62 BS008 1 A O'RING
63 BJ4 1 BJ4s incl BJ6, KH5, N403 VALVE BODY
67 KH23 1 KH23 EXTENTION TUBE
68 KY 1 KY COUPLER ASSEM BLY
69 BJ8 1 BJ8s incl BJ20, BJ15, BJ17 GUN BODY
70 N4OO 1 A 1/4" STEEL BALL
71 BJ13 1 BJ9s BALL SUPPORT
72 BJ9 1 A BALL SPRING
73 BJ19 1 SPRING GUIDE
74 BJ6 1 VALVE INSERT
75 KH5 1 A VALVE SPRING
76 N403 1 BJ24s A 7/32" STEEL BALL
77 BS013 1 A O'RING
78 BJ24 1 INLET BODY
79 BJ15 2 TRIGGOR LINK
80 BJ17 2 LINK PIN
81 BJ20 2 BJ26s SCREW
82 N218 1 LOCK NUT
83 N29 1 ADJUSTING SCREW
84 BJ26 1 HIGH NUT
85 BJ25 1 BJ25s TRIGGER
86 SB6s 2 ZSB SWIVEL ADAPTOR ASSEM BLY
87 SB4s 1 SWIVEL BODY ASSEM BLY
6
TROUBLE SHOOTING GUIDE

PROBLEM CAUSE REMEDY

1) Air motor runs but does not pump a) The grease is too thick or too cold a) Use NLGI no 2 or thinner grease.
grease Store grease in a warm place
b) The grease container is damaged b) Repair or replace container.
causing the follower to stop Follower must be able to move
freely.

2) Air motor runs slower than a) The air pressure is too low a) Increase air pressure, Minimum is
normal 400 kPa/ 60 psi/ 4 bar, Maximum is
1000 kPa/ 150 psi/ 10 bar.

3) Air motor cycles intermittently a) Grease leaking at hose (19) and or a) Check all connections. Use
when not using the pump swivel (86/87) connections thread sealant and tighten leaking
connections.

b) Grease leaks at B2 Gun coupler (68) b) See ‘Problem 5’ below

c) Grease leaks at the seal condition hole c) See ‘Problem 4’ below

d) High pressure seal (45) worn or d) Replace high pressure seal (45)
damaged

4) Grease leaks out of the seal a) Small quantity of grease indicates seal a) No action required
condition hole lubrication is OK

b) Continuous ‘worm’ of grease indicates b) Replace Piston rod seal (18)

the seal is worn or damaged

5) Gun leaks continuously out of the a) Incorrect trigger adjustment a) Adjust the trigger to alow 3 to
coupler 6mm (1/8” to 1/4”) free movement

b) Bent or damaged plunger b) Replace plunger (60)

6) Air leaks continuously from the a) Replace worn air piston cup seals (10) a) replace cup seals and / or piston
valve body cover and / or piston (11)

7) Air motor does not operate, but a) The spool (34) is jammed in the valve a) i) Push the reset button
will cycle when the reset button is body (30)
ii) If the motor starts, disconnect
pressed
the air line and apply 3 or 4 drops
of light oil to the air inlet of the
pump
iii) If the motor does not start,
follow ‘Pump unit disassembly’
steps 1,2 and 4 through 7
iv) Replace spool (34) and clean
valve bore
v) When re-assembled, apply 3 or 4
drops of light oil to the air inlet
of the pump

b) Top poppet spring (4) is fatigued b) Replace the top poppet spring

8) Air motor does not operate or a) Lower poppet spring (4) is fatigued a) Replace the bottom poppet spring
cycle when the reset button is
pressed

7
 SPECIFICATIONS
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 ¼” (F) NPT (Swivel Type)
Pump Ratio 50:1 (Grease Pressure is 50 times the air pressure
B2 Booster Gun (Manual boost only) Up to 69.000 kPa / 10,000 psi / 690 bar
Hose Type/Threads 4m x 6mm I.D. SAE 100 R2 / ¼’ (M) NPT
Swivel Type/Threads High Pressure ‘Z’ type ¼” (F) NPT / 1/8” (M) NPT
Manufacture Date Week / Year located on the side of the cylinder base
Free flow output 563g/min @ 150psi applied air pressure (8000psi stall pressure)

WARRANTY POLICY
Macnaught Pty Ltd (“Macnaught”) warrants that all Products manufactured by Macnaught and
purchased after 1st of July 1999 will be free from any defects caused by faulty materials or
workmanship for a period of (5) years from the date of purchase of the product, provided that
during the Warranty period:
1) Macnaught receives notice setting out full details of any defect in any product and
details of the time and place of purchase.
2) The Purchaser, at their own cost returns the product to the nearest authorized Macnaught
service center.
For componentry contained in the product, (such as o’rings, seals, springs and hoses ) which
are subject to wear, the warranty period will be (12) months from the date of purchase of the
product.

Macnaught shall, at its option repair or replace any product found defective by its inspection.
This warranty does not cover failure of parts or components which, in the judgment of Macnaught,
arises from misuse, abrasion corrosion, negligence, accident, substitution of non-Macnaught
parts, faulty installation or tampering.

If Macnaught inspection discloses no defect in material or workmanship, repair or replacement

and return will be made at customary charges.
Macnaught’s liability and the purchaser’s rights under this Warranty shall be limited to such
repair or replacement and in particular, shall not extend to any direct, special, indirect or
consequential damage or losses of any nature.
The foregoing warranty supersedes, voids and is in lieu of all or any other warranties.

“Note: This warranty does not form part of, nor does it constitute, a contract between Macnaught
and the end-user or purchaser. It is additional to any warranty given by the seller of the products.
Macnaught Pty Ltd
PO Box 90 Arncliffe NSW 2205 Australia This warranty does not exclude, limit, restrict or modify the non-excludable rights or remedies
Telephone (02) 9567 0401 conferred upon the end-user or purchaser, or the non-excludable duties or liabilities imposed
Facsimile (02) 9597 7773 on the seller or Macnaught, by Part V, Divisions 2 and 2A of the Trade Practices act 1974
Email: sales@macnaught.com.au (Commonwealth) or other legislative provisions. Macnaught otherwise excludes, to the extent
Web: www.macnaught.com.au permitted by law, any rights conferred on the end-user or duties or liabilities imposed upon it.”