PNEUMATIC PUMP

400000 SERIES
Instruction &
Maintenance Manual

Warranty

INDEX

1. INTRODUCTION
2. GENERAL DESCRIPTION
3. MACHINE IDENTIFICATION
4. THECNICAL DATA
5. PUMP COMPONENTS
6. UNPACKING AND INSTALLATION
7. OPERATING INSTRUCTIONS
8. PROBLEMS AND SOLUTIONS
9. MAINTENANCE PROCEDURES
10. DISPOSAL
11. ORDERING INFORMATION
12. DIMENSIONS
13. HANDLING AND TRANSPORT
14. PRECAUTIONS FOR USE
15. GUIDELINES FOR USE
16. WARRANTY
17. DECLARATION OF COMPLIACE
18. DISTRIBUTORS

www.dropsa.com The manual has been prepared in compliance with

Directive CE 06/42 C2011IE WK 01/12 1
1. INTRODUCTION

This operating and maintenance manual refers to the Pneumatic Pump 40000 series, use in oil and mineral grease
lubricant systems.

The latest version may be obtained from the Technical-Commercial Office, or by consulting our web site
http://www.dropsa.com.

The pump subject of this manual must be used by qualified personnel with basic hydraulic and electrical knowledge.
This user and maintenance manual contains important information about protecting the health and safety of the
personnel who intend to use this apparatus. You must read and look after it carefully, making sure that it is available at all
times for the operators who intend to consult it.

2. GENERAL DESCRIPTION

400000 series are sturdy and powerful pneumatic pumps, used primarily for standard barrel or large reservoir, as grease,
lubricating oils and non-corrosive fluids transfer pumps so for lubrication field to filling reservoir or feeding of centralized
systems.
These pumps are assembled by a pneumatic engine with a synthetic rubber, vertically moved by compressed air and by a
shaft with chrome steel piston that sucks the fluid from the bottom of the barrel and supply with a pressure whose value
is related to the compression ratio of the pump.

3. MACHINE IDENTIFICATION

Located on the side of the pump, a yellow identification label indicates the device model, part number, and other basic
characteristics.

4. THECNICAL DATA

CHARACTERISTICS
560 versions 75:1 and 40:1
Maximum pressure (bar) 280 version 25:1
63 version 6:1
5 Kg/min version 75:1
8 Kg/min version 40:1
Maximum delivery
16 liter/min version 25:1
28 liter/min version 6:1
7 version 75:1
Air driven maximum pressure (bar)
14 versions 40:1, 25:1, 6:1
Lubricant characteristics at temperature of use Max NLGI 2 (see table)
Temperature of use(C) +5 C +80 C (+41 F +176 F)
Air connection G 3/4" UNI ISO 228/1 (3/4 BSP)
Lubricant outlet G 1/2" UNI ISO 228/1 (1/2 BSP)
Working humidity 90% relative humidity
Level of continuous sound pressure >85 dB (A)
weight 28 kg (61 lb)

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5. PUMP COMPONENTS

AIR MOTOR PART NO. 400100

(FIG. A)

Air Inlet and outlet: G. 3/4" UNI ISO 228/1

AIR MOTOR PART NO. 400100 (FIG. C)
Lubricant outlet: G. 1/2" UNI ISO 228/1

AIR MOTOR PART NO. 400100 (FIG. B)

4
 spare parts kit

spare parts kit

spare parts kit + fig. B

spare parts kit

Spare parts kit + fig. B
spare parts kit
spare parts kit

5
6. UNPACKING AND INSTALLATION

6.1 UNPACKING
Once the suitable location for installation has been identified, open the package and remove the pump. Check that it was
not damaged during transport or storage. The packaging material does not require special disposal precautions as it is not
in any way dangerous or polluting. Refer to the local regulations for disposal.

6.2 INSTALLATION
Pump assembly operations are not required.
Identify a suitable space for installing the unit on the machine which is easily accessible. Do not install the unit in
particularly harsh or explosive/inflammable environments.

7. OPERATING INSTRUCTIONS

7.1 START-UP OF THE PUMP

Check the barrel integrity, dents may block the sliding of follower plate.
Open the barrel cover and level the grease surface.
Secure the pump to the barrel cover.
Then place the cover with the pump over the barrel, making sure to secure it with the wiring screws.
Connect hose to the pump; make sure the pressure and operating flow rate.
Finally connect the pump to the compressed air distribution network.

7.2 ADJUSTMENT PUMP OPERATION

You can adjust only the inlet air pressure and the flow rate. To modify the value is necessary to increase or decrease the
air pressure control.

7.3 DISPOSAL OF PUMP

The pump has been engineering to required minimal maintenance.

To disassemble the pump follows these steps:
1. Disconnect the pump both from the air supply and the lubricant outlet;
2. Empty pumping shaft, running the pump with free air and holding the shaft upward. Attention: do not keep
hands to the suction fitting while the pump is running!

6
 DIAGRAMM

Example
This an example to determine the discharge pressure
HIGH PRESSURE - RATIO 75:1 at delivery and the air consumption.
DISCHARGE PRESSURE - BAR

5 Kg/min desired from 40:1 pump, air 100 psi house

AIR CONSUMPTION - LT/1'

PUMPED MATERIAL: NLGI 2 TO 28C
FLOW AT STROKE: *22,5 c.c air pressure (Material NLGI 2)

a. To determine discharge pressure at delivery:

a. Select delivery per minute desired from
bottom scale (5 Kg/min).
b. Read upward to find point of intersection
on 100 psi air pressure curve (solid line).
c. Read left from this point on discharge
pressure scale which is approximately
FLOW RATE - KG/1' 2000 psi.

b. To determine air consumption:

a. Use same delivery per minute point on
bottom scale (5 Kg/min).
b. Read upward to find point of intersection
HIGH PRESSURE - RATIO 40:1 on 1000 psi air pressure curve (dotted
line).
DISCHARGE PRESSURE - BAR

PUMPED MATERIAL: NLGI 2 TO 28C

AIR CONSUMPTION - LT/1'

c. Read right from this point on air

FLOW AT STROKE: *40 c.c
consumption scale which is approximately
2000 litres/minute.

FLOW RATE - KG/1'

LOW PRESSURE - RATIO 6:1

MEDIA PRESSURE - RATIO 25:1
DISCHARGE PRESSURE - BAR
DISCHARGE PRESSURE - BAR

AIR CONSUMPTION - LT/1'

PUMPED MATERIAL:
PUMPED MATERIAL: SAE 140 TO 28C SAE 140 TO 28C
AIR CONSUMPTION - LT/1'

FLOW AT STROKE: *64 c.c

FLOW AT STROKE:
*160 c.c

FLOW RATE - KG/1'

FLOW RATE - KG/1'

7
8. PROBLEMS AND SOLUTIONS

A diagnostics table is provided below that indicates the main anomalies, the probable causes and the possible solutions.
If you were not able to solve the problem after consulting the diagnostics table, do not try to find the fault by
disassembling machine parts but contact the Dropsa technical office and report the anomalies that have been discovered,
with a detailed description.

DIAGNOSTIC TABLE

PROBLEMS PROBABLE CAUSE SOLUTION

Pneumatic motor doesnt work o Problems to supply line o Check the supply connections and the air treatment unit.

o Pumping shaft blocked

o Disconnect the shaft and check if it flows freely, otherwise
disassemble and clean it

o internal Broken
o Remove the shaft and check that motor is running,
otherwise provide to disassemble, clean and replace any
o No lubricant in the barrel damaged parts.

Pneumatic motor works but o impurities clog the suction

doesnt supply the product o Fill or replace the barrel
o valves or gaskets Weared

o Disassemble the shaft and clean it internally

Pump doesnt hold the pressure

9. MAINTENANCE PROCEDURE

Before assembling, the pump is subjected to severe test. It requires a minimum maintenance. It is recommended the use
of lubricants without impurities, in addition to a carefully cleaning of leaks parts. The machine doesnt require any type of
special equipment for no activity control and / or maintenance. However, it is recommended to use appropriate tools and
in good condition to avoid damage to persons or machine parts.
When cleaning the air motor before closing fill the box inverter with about 0.5 kg (1.1 lb) of fat type "BP GREASE LT2"
code 3225014.

10. DISPOSAL

During machine maintenance, or if it is demolished, do not dispose of the polluting parts in an improper manner. Refer to
the local regulations for their correct disposal. When demolishing the machine, the identification plate and all other
documents must be destroyed.

8
11. ORDERING INFORMATION

11.1 VERSIONS

Pump Air motor only Piston rod only Delivery

Ratio assembly Lubricant
Part no. Part No. Part No. (at 100 psi)
40:1 400200 400100 400170 Grasso NLGI 2 8 Kg (17 lb)/ min
75:1 400300 400100 400155 Grasso NLGI 2 5 Kg (11 lb)/ min
25:1 400205 400100 400165 Grasso / olio 1000 cSt 16 lt (4 gal.)/ min
6:1 400210 400100 400160 Olio 1000 cSt 28 lt (7 gal.)/ min

High-pressure pumps, with compression ratio of 75:1 and 40:1 are used to pumping hard grease, tough and fibrous, with
NLGI 2 consistency.
Medium pressure pumps, with compression ratio 25:1 are particularly suitable both for pumping soft grease (NLGI 0) and
very viscous fluids (max 140 SAE).
Low pressure pumps with a compression ratio of 6:1 are suitable for pumping highly viscous fluids only (max 140 SAE).
The ability of these pumps to deliver lubricant under high pressure makes them particularly suitable for supplying grease
lubrication system, operating in condition of low temperatures.

11.2 ACCESSORIES

PART NUMBER DESCRIPTION

2034950 Silencer for air discharge control
0400040 Cover for 180 kg barrel (396 lb)
1141617 Follower plate for 180 kg barrel (396 lb)

It is recommended to use the special silencer (code 2034950) because the pump is very noisy (> 85 db).

9
12. DIMENSIONS

PART A
NUMBER mm inch.
400200 872 34.33
400300 872 34,33
400205 866 34,09
400210 865 34,05

10
13. HANDLING AND TRANSPORT

The weight and dimension of the pumps are limited therefore its handling does not require the use of lifting equipment.
Before shipping, the pumps are carefully packed inside cardboard box. Upon receipt, check that the package has not
been damaged and store the equipment in a dry location.

14. PRECAUTIONS FOR USE

The warnings about the risks involved in using a pump for lubricants must be read carefully.
The operator must understand its operation and clearly understand the hazards connected to pumping pressurized grease.

Power supply
Any type of intervention must not be carried out before unplugging the machine from power supply. Make sure that no
one can start it up again during the intervention. All the installed electric and electronic equipment, reservoirs and basic
components must be grounded.
Flammability
The lubricant generally used in lubrication systems is not normally flammable. However, it is advised to avoid contact with
extremely hot substances or naked flames.
It is recommended to install fire extinguishers near the lubrication systems for prompt intervention in case of fire.

Pressure
Prior to any intervention, check the absence of residual pressure in any branch of the lubricant circuit as it may cause oil
sprays when disassembling components or fittings.
Noise
Oil pumps generally are noisy machines. This noise depends on kinds of pumps, and generally increases according to the
dimension, number of stroke and pressure.
Despite the various steps that can be adopted in the construction of central lubrication (antivibration, hoses, ...) can be generated
noises annoying for people.

15. GUIDELINES FOR USE

Compliance with the essential safety requirements and the provisions specified in the machine directive was checked by
filling out prepared check lists that are contained in the technical file.
Two types of lists were used:

Risk assessment (UNI EN ISO 14121-1).

Compliance with the essential safety requirements Machine Directive EC 06/42).
The risks that were not completely eliminated, but considered acceptable, are specified below:

Use of unsuitable lubricant: the types of fluids that are not compatible with correct pump operation are listed
below. *
Contact with harmful fluids.

FLUIDI NON AMMESSI

FLUIDS RISKS
Lubricants with abrasive additives wear rate of contacted parts
Lubricants with silicone based additives Pump seizure
Petrol solvents inflammable liquids Fire explosion damage to the gaskets
Corrosive products Pump corrosion damage to persons
Water Pump oxidation
Food substances they would be contaminated

* Per informazioni pi dettagliate in merito alla compatibilit del prodotto con fluidi particolari rivolgersi allUfficio
Tecnico della Dropsa S.p.A.

11
16. WARRANTY INFORMATION

All products manufactured and marketed by Dropsa are warranted to be free of defects in material or workmanship for a
period of at least 12 months from date of delivery. Extended warranty coverage applies as follows:

Complete system installation by Dropsa: 24 Months

All other components: 12 months from date of installation; if installed 6 months or more after ship date, warranty shall be
maximum of 18 months from ship date.

If a fault develops, notify us giving a complete description of the alleged:

malfunction

part number(s)

test record number where available (format 3905000xx-3905000xx)

date of delivery

date of installation

operating conditions of subject product(s)

We will subsequently review this information and, at our option, supply you with either servicing data or shipping
instruction and returned materials authorization (RMA) which will have instructions on how to prepare the product for
return.

Upon prepaid receipt of subject product to an authorized Dropsa Sales & Service location, we will then either repair or
replace such product(s), at out option, and if determined to be a warranted defect, we will perform such necessary
product repairs or replace such product(s) at our expense.

Dropsa S.p.A. reserves to right to charge an administration fee if the product(s) returned are found to be not defective.
This limited warranty does not cover any products, damages or injuries resulting from misuse, neglect, normal expected
wear, chemically caused corrosion, improper installation or operation contrary to factory recommendation. Nor does it
cover equipment that has been modified, tampered with or altered without authorization.

Consumables and perishable products are excluded from this or any other warranty.

No other extended liabilities are states or implied and this warranty in no event covers incidental or consequential
damages, injuries or costs resulting from any such defective product(s).

The use of Dropsa product(s) implies the acceptance of our warranty conditions. Modifications to our standard warranty
must be in made in writing and approved by Dropsa S.p.A.

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17. DECLARATION OF CONFORMITY

Dropsa Spa Tel.: (+39) 02. 250.79.1

Via Benedetto Croce, 1 Fax Sales: (+39) 02. 250.79.767
20090 Vimodrone (MI) E-mail: sales@dropsa.it
Italy Web site: http://www.dropsa.com

DICHIARAZIONE DI CONFORMIT/DECLARATION OF COMPLIANCE WITH STANDARDS/

DECLARATION DE CONFORMITE/ KONFORMITTSERKLRUNG DES STANDARDS /DECLARACIN DE
CONFORMIDAD/ DECLARAO DE CONFORMIDADE

La societ Dropsa S.p.A., con sede legale in Milano, Via Besana,5/ Dropsa S.p.A., registered office in Milan, Via
Besana,5 / Dropsa S.p.A. au Sige Social Milan, Via Besana,5/ Dropsa S.p.A., Sitz in Milano, Via Besana 5/ La
sociedad Dropsa S.p.a., con sede legal en Miln, Via Besana,5/ A Dropsa S.p.A, com sede em Milo, via Besana, n
5

DICHIARA /CERTIFIES / CERTIFIE/ ZERTIFIZIERT, DASS/ DECLARA/ CERTIFICA:

che il prodotto denominato/that the product called/ le produit appel/ das Produkt mit dem Namen/ el producto que
se llama/ o produto chamado:

Descrizione/ Description/ Description/ Beschreibung/ Pompa pneumatica

Descripcin/ Descrio: Pneumatic pump
Nome Commerciale/ Product Name/ Dnomination/
-
Handelsname/ Denominacin/ Denominao:
Versioni/ Versions/ Versions/ Versionen/ Versiones/
Tutte
Verses:
Codici/ Codes/ Cdigos/: Serie 400***

conforme alle condizioni previste dalle Direttive CEE /has been constructed in conformity with the Directives Of
The Council Of The European Community on the standardization of the legislations of member states/ a t
construite en conformit avec les Directives Du Conseil Des Communautes Europeennes/ Entsprechend den
Richtlinien des Rates Der Europischen Union, fr die Standarisierung der Legislative der Mitgliederstaaten,
konstruiert wurde/ cumple con las condiciones establecidas por las directivas comunitarias/ foi construdo em
conformidade com as diretivas do Conselho das Comunidades Europeias:

La persona autorizzata a costituire il Fascicolo Tecnico c/presso Dropsa S.P.A. Technical Director:
The person authorized to compile the Technical File care of Dropsa S.P.A. Maurizio Greco

....................................
.

Vimodrone (MI), Gennaio 2012 Legal representative

Milena Gavazzi

....................................
.
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18. DISTRIBUTORS
Dropsa S.p.A.
Via B. Croce,1
20090 Vimodrone (MI) Italy.
Tel: (+39) 02 - 250.79.1
Fax: (+39) 02 - 250.79.767
E-mail: sales@dropsa.it (Export)
E-mail: vendite@dropsa.it (National)
Dropsa (UK) Ltd
Unit 6, Egham Business Village,
Egham,Surrey,TW20 8RB
Tel: (+44) 01784 - 431177
Fax: (+44) 01784 - 438598
E-mail: salesuk@dropsa.com
Dropsa USA Inc.
6645 Burroughs Ave
48314-2132 Srerling Hts,Mi Us -USA
Tel: (+1) 586-566-1540
Fax: (+1) 586-566-1541
E-mail: salesusa@dropsa.com
Dropsa Gmbh
Volmerswerther Strasse 80
40221 Dusseldorf 1, Deutschland
Tel: (+49) 0211/39 4011
Fax:(+49) 0211/39 4013
E-mail: sales@dropsa.de
Web site: http://www.dropsa.com - E-mail: sales@dropsa.com
14
Dropsa Ame
23, Av.des.Morillons
Z.I. des Doucettes 91140
Garges Les Gonesse, France
Tel: (+33) 01 39 93 00 33
Fax: (+33) 01 39 86 26 36
E-mail: salesfr@dropsa.com
Dropsa do Brazil Ind. E Com. Ltda
Rua Sobralia 175,
Sao Paulo, Brazil
Tel: (+55) 011-5631-0007
Fax: (+55) 011-5631-9408
E-mail: salesbr@dropsa.com
Dropsa Lubrication Systems
Nr 8 Dongxing Road,
Songjiang Industrial Zone
(Shanghai) Co., Ltd
Tel: +86 (021) 67740275
Fax: +86 (021) 67740205
E-mail: china@dropsa.com
Dropsa Australia Pty.
C20/148 Old Pittwater Road
Brookvale, NSW 2100
Tel: +61 (02) 9938 6644
Fax: +61 (02) 99 386 611
E-mail: salesau@dropsa.com