DP1 Pump

1:1, Air-operated, Oil

General
The DP1 Pump is a compressed air-operated piston reciprocating medium pressure pump. Suitable for high flow transfer of high viscosity lubricants and other fluids. These pumps can be supplied as separate components or as complete systems with all the elements necessary for installation. These pumps may be mounted on mobile units, drums, tanks or walls, using the appropriate accessories. (Note: These pumps are designed and intended for transfer only and do not reliably stall under pressure when used as a demand pump. They must be controlled with a valve on the air inlet.)

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(s), 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 Maximum Delivery Air Inlet Thread Oil Outlet Thread Air Piston Diameter Air Piston Stroke 140 psi (10 bar) 40 psi (3 bar) 15 GPM (60 l/min) 1/4 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 (29a) of the bung adapter to remove the lower nut (29c) and screw this into the 2 bung opening of the drum or bracket. Place the star nut (29a) and the split collar (29b) on the suction tube. Lower the pump through the opening and fasten the assembly at the desired height by tightening the star nut (29a).
Always keep fingers and hands away from moving parts. Do not dent or damage the riser tube.

29a 29b 29c

Ensure that the mounting surface and attachments are strong enough to support the lift and pump assembly during operation.

BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560

35992 R0 10/09

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) is 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 1000mm E

G 3000mm

D I

Item A B C D E F G H I

Description Air shut-off valve Filter/Regulator Air hose Quick coupler Air nipple 1:1 Pump (200 liter drum) Oil hose High delivery control valve Bung bushing adapter BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560

35992 R0 10/09

Maintenance
Separate the Air Motor from the Pump
1. Secure the pump in a vice in the horizontal position, clamping it on the provided pads along the pump body (13). 2. To unscrew the suction tube (30) from the pump body (13), use a 46mm wrench on the milling of the foot valve body (34) for stub pump (see drawing on right), or a rod in the holes of the foot valve body (36) for long pump. 3. Remove the upper roll pin (21) 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: stub pump, 36: long pump) from the suction tube (30). 2. Unscrew the nut (35), remove and clean the screw (31), the washer (32) and the valve body, and replace if damaged. Assemble the pump following the previous instructions, reversing each step.

Upper Valve
1. Unscrew the nut (28) from the connecting rod (20) and remove the washer (27), the valve body (26) and O-ring (25), the washer (24) and the spring (23). 2. Clean these parts carefully. If any of them are damaged, replace them before reassembly. 3. Assemble the pump following the previous instructions, reversing each step.

Unscrew suction tube, remove rod

Reversing Set and Air Motor

1. Secure the air motor body (13) in the vise and loosen the four screws (14) to remove the air motor cylinder (1). 2. Check the upper spring (2) and the spring stop (3) inside the air motor cylinder (1). Replace if damaged. 3. Remove the lower circlip (15) and muffler (16) and pull up the air motor assembly (4) until the hole in air piston (8) is visible in the opening where the muffler was removed. Insert a steel rod (8 mm) in the hole to lock the piston. 4. Use a prepared 17mm wrench to disassemble the air motor assembly (4) (see drawing on right). 5. Remove the air piston (8) and disassemble the circlip (9), the washers (10) and the air piston seal (11). Check the piston for scratches and replace damaged parts. 6. Assemble the pump following the previous instructions, reversing each step.

Remove inverting set with 17mm wrench

17 18

Packing Set
1. Follow the above procedure for the air motor until the air piston (8) has been removed from the air motor body (13). 2. Remove the circlip (18) and the packing set (17) from the air motor body (13) (see drawing on right). Replace if damaged. 3. Assemble the pump following the previous instructions, reversing each step. (Note: The packing set is directional. It is not marked and must be installed correctly or it will leak. Look carefully at the inside diameter of the seal, you will see three components. The middle black ring that is split is a bearing. Above and below it are the brownish Turcite seals, these are made with a step, and the step faces the oil. Confirm this by looking into the seal from both directions, from one side you will not see the steps, and from the other you will; this is the side that faces the oil. See drawing on right.) 3

Packing set installation

BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560

35992 R0 10/09

Troubleshooting
Symptom The pump is not working or there is no oil delivery. Possible Cause 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 (23-28) or in the foot valve (31-35). Oil is leaking through the exhaust muffler. 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). Air is leaking through the exhaust muffler. The air piston seal (11) is worn or damaged. The air motor cylinder (1) is scored. The air piston rod (8) is scored. The air motor assembly (4) is worn or damaged. The oil delivery has diminished or the flow is uneven. The pump operates only one cycle and then stops Contamination in the upper valve (23-28) or in the foot valve (31-35). The upper spring (2) is damaged. Remedy 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.

Refer to page 5 for parts reference.

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.

Disassemble and clean. Replace damaged components. Replace air motor cylinder. Replace the air piston rod. Replace the reversing set. Disassemble and clean. Replace damaged components. Replace the upper spring.

How to Order
Name DP1 Pump Drum Size Stub Pump 16 gallon 55 gallon Part # F214 F216 F218

When ordering, specify by name, description and part number, e.g. DP1 Pump, 16 Gallon Drum, Part #F216.

BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560

35992 R0 10/09

Service Parts
Item 1 8 10 13 14 15 16 20 21 22 23 24 26 27 28 29 30 31 32 33 34 35 --Description Air motor cylinder Air piston Seal support washer Pump body NPT Air cylinder bolt Circlip Muffler Connecting rod (1:1) Upper roll pin Lower roll pin Check spring Check washer (1:1) Valve body (1:1) Washer (1:1) Plunger body nut Bung adapter (1:1) Suction tube (1:1) Foot valve screw Foot valve washer Foot valve O-ring Foot valve body (stub) Foot valve nut Air motor kit Upper spring (2) Spring stop (3) Air motor assembly (4) Lower spring (5) Spacer (6) Washer (7) Air cylinder O-ring (12) Square cut seal (19) --Packing set & seal kit Upper snap ring (9) Air piston seal (11) Air cylinder O-ring (12) Packing set (17) Circlip (18) Square cut seal (19) O-ring (25) Part # F735100 F735414 F735211 F735103 F940321 F942730 F835400 F735208 F943041 F943042 F835300 F735206 F735207 F735408 F941008 F2029 F735204 F735214 F835303 F946025 F735229 F941108 FAK-4 ----------------FAK-5 --------------BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560
14 15 16 30 31 32 33 34 35 8 9 10 11 10 12 13 14 5 6 7 19 20 23 24 25 26 27 28 4 2 3 1

29

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Dimensional Schematics

Measurements shown in millimeters.

AIR IN 1/4

AIR IN 1/4 B

OIL OUT 3/4

OIL OUT 3/4

C
Part # F214 F216 F218 A 590mm (23.25) 1060mm (41.7) 1285mm (50.6) B 365mm (14.5) 365mm (14.5) 365mm (14.5) C 52mm (2) 52mm (2) 52mm (2) D 215mm (8.5) 695mm (27.3) 910mm (35.8)

BIJUR DELIMON INTERNATIONAL (919) 465 4448 LOCAL (800) 631 0168 TOLL-FREE (919) 465 0516 FAX www.bijurdelimon.coM 2100 Gateway Centre Blvd., Suite 109 Morrisville, NC 27560

35992 R0 10/09