DP556 Pump 55:1, Air-operated, Grease General The DP556 Pump is a compressed air-operated reciprocating piston pump. This high capacity demand pump is compatible with mineral and synthetic grease and suitable for large installations with long length piping supplying several fluid outlets simultaneously. This pump is mounted directly on 120 lb and 400 lb drums. Operation This pump is self-priming. To prime it the first time, it is convenient to connect the air supply to the pump while keeping the outlet gun opened and slowly increase the air pressure by using a pressure regulator. Once grease starts flowing through all the outlets, the pump is primed. The pump starts to pump when an outlet valve is opened, for example a grease control gun. Technical Data Maximum Air Pressure Minimum Air Pressure 140 psi (10 bar) 42 psi (3 bar) Maximum Delivery 7.25 lbs (3.2 kg/min) Free delivery at 100psi air inlet pressure, using NLGI #2 grease @ 70 F Air Inlet Thread 1/2 NPT Grease Outlet Thread 3/8 NPT Air Piston Diameter 4.3 (110mm) Air Piston Stroke 4-1/4 (100mm) Installation Mounting with Reinforced Cover (Recommended) It is recommended to install this pump on a drum using a reinforced cover due to weight considerations, but it is possible to install two different ways. Mount with reinforced cover (part #F418026 for 400 lb drum and part #F418025 for 120 lb drum). Insert pump through the cover and fasten it with the enclosed screws. Insert the pump through the bung opening and fasten the cover onto the drum firmly. Mounting with Cover Adapter Mount with cover adapter (part #F360133) and bung bushing (part #F410001). Fasten the cover (part #F418026 for 400 lb drum and part #F418025 for 120 lb drum) onto the drum and screw the nut of the bung adapter securely into the 2 bung opening of the cover. Insert the pump through the nut and adjust it with the star nut to the desired height. 1 Always keep fingers and hands away from moving parts. Do not dent or damage the riser tube. Do not ever lay the pump on the floor or allow the grease covered pump tube to become contaminated in order to prevent damage to the internal seals of the pump.
Typical Layout The drawing below is a typical layout shown 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). The recommended pressure is 90 psi (6 bar). 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). Item Part Number Description A 39640 Air shut off valve B F985 Filter/Regulator/Lubricator C F822 Air hose D F940 Quick coupling E F945 Connection nipple F F622 (120lb) / F624 (400lb) Pump G F884 Grease hose H 37161 Grease shut off valve I F418025 (120ib) / F418026 (400lb) Cover J F964 (120lb) / F966 (400lb) Follower plate 2
Maintenance Separate the Air Motor from the Pump 1. Secure the pump in a vice in the horizontal position, unthread the suction tube (53) from the pump body (37) and pull out the tube until the pin (51) is visible. 2. Remove the pin (51) and unscrew the connecting rod (52) until it is loose. (See drawing on right.) Air Motor 1. Unscrew the lift ring (1) and the jam nuts (2) of the stroke end rod (3), remove the spacing sleeve (4) and the closing ring (5). 2. Unscrew the air cylinder assembly (6) from the air motor body (37). 3. Remove the circlips (29) and push the trip shoe spring (28) backwards. 4. Remove the spring seat (8), the inverter assembly and the trip shoes (26). 5. Unscrew the screws (13) and the nuts (17) and disassemble all the parts until the air gasket (23) becomes accessible. 6. Take out the air piston assembly and the seals (31, 34). 7. Clean all the parts and replace if necessary. Lubricate the components with grease and assemble the pump following the previous instructions, reversing each step. 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. Remove pin and unscrew connecting rod Replace the Packing Set 1. Follow steps 1 through 6 of the air motor maintenance procedure. 2. To unscrew the outlet adaptor (40); thread a 3/8 fitting completely into the adaptor and pull clockwise first to break the seal, then counter clockwise to loosen and remove it, or use a pipe wrench. 3. Unscrew and remove the packing set from the air motor body. 4. Replace the packing set with a new one. Mount the outlet adapter using Loctite Red sealer on its threads. 5. Clean and lubricate the air motor components carefully. Assemble the pump following the previous instructions, reversing each step. Clean or Replace the Upper Valve 1. Unscrew the suction tube from the foot valve tube (60), remove the pins (51) and unscrew the connection nut (54) from the piston (57). 2. Clean the balls (55, 56) and the housing carefully. 3. Verify the piston (57) and the high pressure cylinder (59) for scratches/scoring and the o-ring (58) for damage; replace if necessary. Assemble the pump following previous instructions, reversing each step. Clean or Replace the Foot Valve 1. Unscrew the nut (72) and remove the filter (71), unscrew the nut (70) from the priming rod (67) and remove the primer (69). 2. Push the rod (67) inwards and unscrew the priming tube (68) from the foot valve tube using the provided holes. 3. Take out the parts of the valve (62-65) and clean them carefully, replace if damaged. Assemble the pump following previous instructions, reversing each step. 3
Troubleshooting Symptom Possible Cause Remedy The pump is not working or there is no grease delivery. The pump begins to operate very fast. The pump runs on continuously after the grease outlet is closed. Grease is leaking through the air outlet muffler. Air is leaking through the air outlet muffler. Low air pressure or off. Some outlet line component is clogged or closed. The circlip (29) of the trip shoe guide is out of its place. There is an air pocket in the grease suction inlet area. The drum is empty or the grease level is beneath the suction tube inlet. There is a grease leak in some point of the outlet circuit. Contamination in the upper valve or in the foot valve. Grease has leaked to the air motor caused by worn or damaged seals (44). Slowly increase the air supply pressure. Clean or open the outlet circuit. Reset or replace the circlip (29). Stir and repack the grease. Replace the drum or lower the suction tube until the inlet reaches below the grease level. Verify and tighten or repair. Disassemble and clean. Replace damaged components. Replace the worn or damaged parts. The air piston rod (33) is scored. Inspect the air piston rod (33). Replace if damaged. The quad-rings (31, 35) are worn or damaged or scored piston assembly. The air gasket (23) of the inverter assembly is worn or damaged. Replace quad-rings (31, 35) and/or the piston assembly. Replace the air gasket (23). Refer to page 5 for parts reference. How to Order Name Drum Size Part # DP556 Pump 120 lb F622 400 lb F624 When ordering, specify by name, description and part number, e.g. DP556 Pump, 120 lb Drum, Part #F622. 4
Service Parts Item Description Part # 1 Lift ring F740503 2 Jam nut F941008 3 Stroke end rod F740513 6 Air cylinder assembly F740110 + F946180 + F740509 11 Spring support F740522 12 Spacer F740514 20 Valve disc F740518 22 Air gasket support F740508 31 Quad ring F946521 32 Air piston F740964 36 O-ring F946075 37 Air motor body F740112 38 Grease outlet F740516 39 Muffler F835400 40 Circlip F942730 42 Fixing nut (packing sleeve) F740563 Service parts continue on page 6. 45 Packing sleeve F740562 49 Packing sleeve holder F740517 52 Connection rod (for part #F624) F740545 Connection rod (for part #F622) F740560 53 Suction tube (for part #F624) F740544 Suction tube (for part #F622) F740559 54 Connection nut F740546 61 Connection tube F740557 68 Lower tube F740553 71 Inlet filter F840411 72 Filter fixing nut F740564 --- Reversing kit FPM6K-1 Spacing sleeve (4) --- Spring (7) --- Spring seat (8) --- Inverter support (9) --- Inverter body (10) --- Fixing nut (25) --- Trip shoe (26) --- Trip shoe seat (27) --- Trip shoe spring (28) --- Circlip (29) --- 5
Service Parts (Cont.) Item Description Part # --- Air seal kit FPM6K-2 Closing ring (5) --- Screw (13) --- Washer (14) --- O-ring (15) --- Guide sleeve (16) --- Nut (17) --- Closing seal protection (18) --- Closing seal (19) --- Washer (21) --- Air gasket (23) --- Closing valve (24) --- Spring sleeve (30) --- Air piston rod (33) --- Guide ring (34) --- Quad ring (35) --- --- Grease packing kit & lower end kit FPM6K-3 6 Scraper (41) --- O-ring (43) --- Stop seal (44) --- Guide ring (46) --- O-ring (47) --- O-ring (48) --- O-ring (50) --- Pin (51) --- Ball (55) --- Ball (56) --- HP Piston (57) --- O-ring (58) --- Piston sleeve (59) --- O-ring (60) --- Foot valve stop (62) --- Foot valve body (63) --- Step seal (64) --- Foot valve seat (65) --- Pin (66) --- Priming rod (67) --- Primer (69) --- Nut (70) --- See reference image on page 5.
Dimensional Schematics Measurements shown in millimeters. Part # A B C F622 1105mm 640mm 35mm (43.5 ) (25 ) (1.4 ) F624 1300mm (51 ) 835mm (33 ) 35mm (1.4 ) 7