DP3 Pump. 3:1, Air-operated, Oil. General. Operation. Technical Data. Installation R0 10/09. 35a 35b 35c

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1 DP3 Pump 3:1, Air-operated, Oil General The DP3 Pump is a compressed air-operated piston reciprocating medium pressure pump. Suitable for medium flow transfer of high viscosity lubricants and for oil delivery through piped distribution systems, hose reels and meters. These pumps are supplied as separate components or as complete systems and optionally with all the accessories necessary for proper installation. These pumps may be mounted on mobile units, drums, tanks or walls, using the appropriate accessories. Operation This pump is self-priming. To prime it the first time, connect the air supply to the pump and slowly increase the air pressure from 0 to the desired pressure using a pressure regulator, while keeping the outlet valve opened. Once oil begins to flow through the oil gun/guns, the pump is primed. (Note: It is important that the foot valve of the pump does not come into contact with contaminated surfaces, such as a workshop floor, as it may become contaminated with dirt or foreign particles that can damage the seals.) Technical Data Maximum Air Pressure Minimum Air Pressure Air Consumption Maximum Delivery Air Inlet Thread Oil Outlet Thread Oil Inlet Thread Air Piston Bore Air Piston Stroke 140 psi (10 bar) 40 psi (3 bar) 5 CFM (150 l/min) 8 GPM (30 l/min) 1/4 NPT (F) 3/4 NPT (F) 3/4 NPT (F) 2 (50mm) 4 (100mm) Installation The pump can be mounted directly on a drum or on a wall bracket fitted with a 2 bung. Loosen the star nut (35a) of the bung adapter to remove the lower nut (35c) and screw this into the 2 bung opening of the drum or bracket. Place the star nut (35a) and the split collar (35b) on the suction tube. Lower the pump through the opening and fasten the assembly at the desired height by tightening the star nut (35a). 35a 35b 35c Always keep fingers and hands away from moving parts. Do not dent or damage the riser tube. Ensure that the mounting surface and attachments are strong enough to support the lift and pump assembly during operation. 1

2 Typical Layout See drawing below for typical layout with all the recommended accessories for the pump to operate correctly. The compressed air supply must be fixed between 40 and 140 psi (3 and 10 bar), 90 psi (6 bar) the recommended pressure. An air shut-off valve must be installed to be able to close the compressed air line at the end of the day (if the air inlet is not closed and there is leakage in some point of the grease outlet circuit, the pump will start automatically, emptying the container). A B F H I 1000mm E 1500mm G C D J TO OIL DRUM Item A B C D E F G H I J 2 Description Air ball valve (LP) Filter/Regulator Air hose Quick air coupler Quick air nipple 3:1 Pump (55 gallon drum) Pressure relief valve Oil hose Oil ball valve (MP) Bung adapter (included with pump)

3 Maintenance Separate the Air Motor from the Pump Secure the pump in a vice in the horizontal position, clamping it on the provided pads along the pump body (16). To unscrew the suction tube (30) from the pump body (16), use a 32mm wrench on the flats of the foot valve body (35) (See drawing). Pull clockwise first to break the seal, and then counter clockwise to loosen and remove the tube assembly, including the body base (29). Remove the upper roll pin (19) located in the upper part of the connecting rod (20) and unscrew the rod from the air piston (8). (See drawing on right.) Refer to page 5 for parts reference. Before starting any kind of maintenance or repair, disconnect the compressed air supply and open a downstream valve to relieve the oil pressure. Foot Valve 1. Gently attach the suction tube assembly to the vice and unscrew the foot valve body (34) from the suction tube (30). 2. Remove the roll pin (33) and clean the ball (24), the spring (32) and the ball seat, replace any damaged. Assemble the pump following the previous instructions, reversing each step. Fluid Valve Unscrew the valve seat (27) from the plunger body (22) and remove the washer (26), the oil plunger seal (25), the check ball (24) and the check spring (23). Clean these parts carefully. If any damage is found, replace the affected parts. Assemble the pump following the previous instructions, reversing each step. Use Loctite #242 sealer (or equivalent) on the threads of the valve seat (27). Inverting Set and Air Motor Secure the pump in a vice in the vertical position, clamping it on the provided pads along the pump body (16). Remove the four screws (13) and lift the air motor cylinder (1) clear. Check the upper spring (2) and the spring stop (3) inside the air motor cylinder (1). Replace if damaged. Remove the lower circlip (15) and muffler (14) and pull up the air motor assembly (4) until the hole in the air piston (8) becomes visible in the opening where the muffler was removed. Insert a steel rod (8mm) in the hole to lock the piston and prevent rotation. Use a prepared 17mm wrench to remove the air motor assembly (4). (See drawing on right.) Remove the air piston (8) and the upper snap-ring (9), the washers (10) and the air piston seal (11). Check the pump piston for scoring and replace all damaged parts. Assemble the pump following the previous instructions, reversing each step. Use Loctite #242 (or equivalent) sealer on the threads of the air motor assembly (4). Packing Set 1. Follow the procedure for the air motor until the air piston (8) has been removed from the air motor body. 2. Remove the lower snap-ring (18) and the packing set (17) from the pump body (16). Replace if damaged. (See drawing on right.) 3. Assemble the pump following the previous instructions, reversing each step. (Note: The packing set is directional and must be installed with the seals positioned as shown in drawing.) Unscrew suction tube, remove rod Remove inverting set with 17mm wrench Packing set installation 17 18

4 Troubleshooting Symptom Possible Cause Remedy The pump is not working or there is no oil delivery. The pump begins to operate very fast and no oil is being delivered at the gun. The pump runs on continuously after the oil outlet is closed. Oil is leaking through the exhaust muffler. Air is leaking through the exhaust muffler. The oil delivery has diminished or the flow is uneven. The pump operates only one cycle and then stops Not enough air supply pressure. Some outlet line component is clogged or closed. The drum is empty or the oil level is beneath the suction tube inlet. There is an oil leak in some point of the outlet circuit. Contamination in the upper valve (22-27) or in the foot valve (31-35). The lubricator is sending too much oil into the airline. Oil has by-passed to the air motor caused by worn or damaged packing set (17). The air piston seal (11) is worn or damaged. Slowly increase the air supply pressure. Clean or open the outlet circuit. Replace the drum or lower the suction tube until the inlet reaches below the oil level. Verify and tighten or repair. Disassemble and clean. Replace damaged components. Adjust the lubricator. Replace the packing set (17). Disassemble and clean. Replace damaged components. The air motor cylinder (1) is scored. Replace air motor cylinder (1). The air piston rod (8) is scored. Replace the air piston rod (8). The air motor assembly (4) is worn or damaged. Contamination in the upper valve (22-27) or in the foot valve (31-35). Replace the air motor assembly (4). Disassemble and clean. Replace damaged components. The upper spring (2) is damaged. Replace the upper spring (2). Refer to page 5 for parts reference. How to Order Name Drum Size Part # DP3 Pump Stub Pump F gallon F gallon F208 When ordering, specify by name, description and part number, e.g. DP3 Pump, 16 Gallon Drum, Part #F206. 4

5 Service Parts Service parts continue on page 6. Item Description Part # 1 Air motor cylinder F Air piston F Seal support washer F Air cylinder screw F Muffler F Lower circlip F Pump body NPT F Lower snap ring F Connecting rod F :1 Body base F :1 Suction tube F :1 Bung adapter F Air motor kit FAK-1 Upper spring (2) --- Spring stop (3) --- Air motor assembly (4) Lower spring (5) --- Spacer (6) Washer (7) Seal kit FAK Upper snap-ring (9) --- Air piston seal (11) --- Air cylinder O-ring (12) --- Packing set (17) --- Upper roll pin (19) --- Oil plunger seal (25) Body base O-ring (28) Oil plunger kit FAK Lower roll pin (21) --- 3:1 Plunger body (22) --- Check spring (23) --- 3:1 Check ball (24) --- Oil plunger seal (25) --- Washer (26) --- 3:1 Valve seal (27) --- Body base O-ring (28)

6 Service Parts (Cont.) Item Description Part # --- Foot valve kit FFV-31 3:1 Check ball (24) --- Foot valve O-ring (31) --- Foot valve spring (32) --- Foot valve roll pin (33) --- Foot valve body (34) --- See reference image on page 5. Measurements shown in millimeters. Dimensional Schematics AIR IN 1/4 A OIL OUT 3/4 B D C 6 Part # A B C D F200 F206 F mm (23.6 ) 1065mm (41.9 ) 1290mm (50.8 ) 365mm (14.3 ) 365mm (14.3 ) 365mm (14.3 ) 34mm (1.33 ) 34mm (1.33 ) 34mm (1.33 ) 235mm (9.25 ) 700mm (27.5 ) 925mm (36.4 )