INSTRUCTIONS

FOR USE

Pump 777
DROPSA SpA
In accordance with para. 1.7.4, of I, Dir CEE 89/392

Sections:

0.0 INTRODUCTION
1.0 DESCRIPTION OF THE PUMP
2.0 TECHNICAL SPECIFICATIONS
3.0 CORRECT USE
4.0 INSTRUCTIONS FOR ORDERING AND LIST OF
DISTRIBUTORS.

DECLARATION OF CONFORMITY

Catalogue P/N C2018IE - Wk 17/99

Registered name DROPSA SpA
Address via Croce 1, 20090 Vimodrone (MI), Italy
Model Pump 777
Year of manufacture 1999
Marking CE
0.0 INTRODUCTION

This users and maintenance manual refers to pump 777, for use in lubrication systems for oil and grease, including
high pressure systems (up to 500 bar).
The use of this pump permits the distribution of oil and grease in lubrication systems at pressures up to 500 bar.
It is recommended that this manual is carefully kept in good condition and is always available to persons requiring to
consult it.
To request further copies, updates or clarifications with respect to this manual contact the Engineering Department at
Dropsa SpA.
The use of the pump referred to in this manual must be entrusted to qualified personnel with a knowledge of
hydraulics and electrical systems.
The manufacturer reserves the right to update the product and/or the users manual without the obligation to revise
previous versions. It is however, possible to contact the Engineering Department for the latest revision in use.
The pump, and any accessories mounted on it, should be carefully checked immediately on receipt and in the event
of any discrepancy or complaint the Dropsa SpA Sales department should be contacted without delay.

DROPSA S.p.A. declines to accept any responsibility for injuries to persons or damage to property in the event of
the non-observance of the information presented in this manual.
Any modification to component parts of the system or the different destination of use of this system or its parts
without prior written authorisation from DROPSA S.p.A. will absolve the latter from any responsibility for injury or
damage to persons and/or property and will release them from all obligations arising from the guarantee.

Instructions for the correct ordering of the required model, and a list of importers, is shown in Section 4.

1.0 DESCRIPTION OF THE PUMP

The 777 series lubrication pumps can be adapted to meet many requirements without mechanical modifications, even
where the pump is already installed. By choosing from among a range of perfectly compatible and easily assembled
components, variations can be made to the pressure, the quantities of lubricant delivered, the type of lubricant or the
type of distribution.
This construction technique is based essentially on the following modules:
Motor and reduction unit
Dual element pump
Tank
Valves and output assembly (reverser, etc.)
The supporting structure is common to all versions, with the dual pumping element constituting the essential module.
From one pump assembly there are provided two separate outlets for the lubricant, protected by double non-return
valves. The two ways can be connected together to double the quantity of lubricant on one line only or they can be
employed separately on two independently controlled single line circuits.
On the same support structure it is possible to mount types of tank with different volumes suitable for oil or grease
with paddle units and level indicators.
The control of the motor is obtained by use of normal electrical equipment which provides for the reversing of the
direction of rotation and the execution of the programmed cycles.
The motor-driven pump 777 is totally protected from the external environment and can operate without difficulties
in the severest environmental conditions.

The pump is composed of a series of components with the following characteristics:

CHARACTERISTICS PUMP 777

Pump capacity max. 130

cc/min
Maximum pressure in bars 500 (7350 psi)
Tank capacity in litres 10 - 30 - 100

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 2

 By-pass rating
300 bar (4410 psi)
(with internal regulating screw)
Minimum operating time 24
(sec) (minimum pause time 96 sec)
Mineral lubricant characteristics at CSt 15 - 1500 (oil)
working temperature max NLGI 2 (grease)
Working temperature - 5 C + 40 C (+23F +104F)
Motor Three phase 220 380 V
50 Hz 4 pole
1500 rpm
Absorbed 370 W
Power On request 750 W
Grade of protection IP55
Insulation Class F

It is also possible to supply the pump with a mechanical or hydraulic reverser.

1.1 Pump assembly (Code 291415)

The assembly is made up of two identical pump units, each one having two identically sized pistons. The pistons are
in ground and lapped hardened steel; one of these acts as the pump and the other as the control valve. The pump
housing is in steel; the ports are bored and lapped; the drive shaft is in hardened and ground steel.
1.2 Reduction unit

The reduction unit casing is in aluminium. The drive shaft with worm screw is hardened and ground. The worm
wheel is in hardened steel.
Both the drive shaft and the worm wheel shaft are fitted with ball bearings.
The free wheels used on this pump are among the best brands on the market.
Attention: lubrication of the reduction unit in dual line grease systems is ensured by the return of grease into the
pump via port (F). Where the pump is utilised for grease on a single line system (where there is no return to the
pump) it would be advisable to provide a point for lubrication of the reduction unit through port (F).
Obviously, in an oil system this precaution is not necessary as all parts of the reduction gears are effectively in an oil
bath.

1.3 Reverser

1.3.1 Electro-mechanical reverser

When the pump is installed in a dual line system it is necessary to utilise this reverser.
The mounting is already prepared with fixing holes to accept this device, whose functioning is tied to the
use of the reverser and lubrication cycle electrical control equipment.

The main parts of the device are:

the reverser in steel with a hardened, ground and lapped piston;
cam assembly and freewheel in hardened steel;
two watertight micro-switches which control the reversing and the exact positioning of the piston.
The front of the reverser is prepared with a hole for connecting a manometer.

OPERATION AND ADJUSTMENT OF THE CONTACTS

One of the original features of this motor-driven pump is that of utilising the motor both for the movement
of the pistons of the pump unit and for the reversing of the line.
The motor, after the required pause between one lubrication and the next, is started by turning the worm
screw, the worm wheel and the pump assembly.
The worm wheel has an external appendix on which is mounted a cam for the reversing of the line.
When the motor drives the pump, the worm wheel shaft rotates anticlockwise for as long as the cam, for

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 3

 the effect of the free wheel, remains stationary.
The pump feeds line 1 and, after having filled the tubing and the valves, will act on the contact of the end
of line pressure switch which, through the electrical equipment, provokes the inversion of the motor
direction. This reversing will result in the reversing of the rotation of the cam shaft, while the pump will
stop instantaneously; also the pump drive shaft is attached with the free wheel.
The line reversing cam will rotate rapidly to the closure of the microswitch (32) contact, the motor will
reverse direction returning to drive the pump to feed line 2.
The closing of the line 2 pressure switch contact will provoke a further inversion of the initial rotation by
actuating the second microswitch closing contact. (32).
The closing of this contact will reverse the rotation of the motor for a period of approx. one second; this
will conclude the lubrication cycle.

1.3.2 Hydraulic reverser

The lubricant which comes from the pump through the central part of piston A (Fig.1) is distributed into
chamber C, entering into line 1 and tending to position piston B toward the left.
When the set pressure of spring M1 is reached, the small piston S1 of the sequence valve lifts and permits
the lubricant to enter into chamber D.
Piston A is moved toward the left; lubricant is sent into chamber E, the small piston B is moved to the
right (Fig.2) and the lubricant enters into line 2 while line 1 discharges (return).
When the set pressure of spring M2 is reached, lubricant is sent into chambers C and F; pistons A and B
invert their positions and the delivery is again directed to line 1.
The necessary reversing pressures are attained by regulating the loading of springs M1 M2.

1.4 Pressure Control Valve

Code Description
291162 Pressure 50 500 bar (735 7350 psi)
291391 Pressure 20 250 bar (294 3675 psi)

Also these valves can be easily disassembled for inspections.

They are adjustable and have the function of regulating the pressure.
It is important to keep in mind that the inversion of the lines is controlled by the closing of the pressure switch
contacts.
The regulation of the pressure switch must involve an operating pressure which is always less than the maximum
pressure controlled by this valve.

1.5 Flow regulator (Code 3293060)

The flow regulator serves to regulate the quantity of lubricant delivered at each pump cycle.
It can easily be set between * 14.5 - 65 cc./1 by turning the rear nuts code 3235097 clockwise or anticlockwise.
It is also applicable to a single pump element.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 4

1.6 Minimum and maximum level indicators

1.6.1 Indicator for grease

Minimum level

Code Description
291244 For 10 kg tank. (22 lb)
291220 For 30 kg tank. (66.1 lb)
291210 For 100 kg tank. (220.4 lb)

This device is used when it is wished to control the minimum level of the tank where the use of a paddle
unit is provided for grease.
The operation of the minimum level contact occurs through the reaction of the blade with the shaft (7)
opposing the grease moved by the arm of the moving paddle.
The minimum level contact serves to illuminate the warning lamp on the electrical panel and additionally
for any command signal to an automatic tank refilling pump.

Maximum level
This indicator must always be provided when it is wished to incorporate automatic tank refilling.
The refilling pump is automatically set in operation when the grease in the tank falls below the minimum
level actuating the respective electrical contact.
To avoid the refilling pump continuing to deliver lubricant beyond the capacity limit of the tank it is
essential to incorporate a maximum level microswitch with which to stop the pump.

1.6.2 Minimum and maximum level indicators for oil

Code Description
291155 Maximum level indicator
291275 Minimum level indicator for 30 l tanks.
291276 Minimum level indicator for 10 l tanks.
291291 Minimum level indicator for 100 l tanks.

Two magnetic contact indicators are incorporated for the control of the minimum and maximum oil levels.
The cover is suitably prepared for receiving these devices; the output cables can be run through a single
sheathing for connecting to the electrical control equipment.

1.7 Paddle unit for grease

Tanks are provided in three different capacities: 10, 30 and 100 kg. (22, 66.1 , 220.4 lb).
There is a paddle unit for grease assembly for each capacity.
The pump mounting, which also supports the tank, is prepared for receiving this assembly.

To install the paddle unit when the pump is already mounted, it is sufficient to remove the tank.

In addition to the perforated disk, which supports the paddle unit assembly, there is also provided, on the upper part,
a steel mesh filter disk with 0.5 mm holes. In this way the pump is protected from any foreign bodies that could be
encountered even in grease from sealed drums or which may inadvertently fall into the tank during refilling from
above.

Where the blade is not able to push very thick (above grade 3) grease through the holes in the filter mesh, or when
working at very low temperatures, the filter disk can be removed. However, care must then be taken to ensure that
refilling is carried out using a suitable manual or pneumatic pump and a filter, code 3130009.
Refilling of the tank by hand is not recommended.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 5

1.8 Manometer

Code Description
20550
Only one version is provided
1000 bar (14700 psi)

1.9 Operating control

The pump 777 can be supplied with an electrical control panel with indicators for on/off, minimum and maximum
lubricant levels, pressurisation of the two lines, alarms, lubrication cycle not respected and power on.
In addition there is a selector for continuous operation or timed by the system, and two timers for regulating the
pause and lubrication times.

1.10 Electrical equipment

DROPSA electrical equipment has been designed with the aim of supplying a system complete with all the
controls necessary for automatic operation and controlled by centralised lubrication system safety signalling.

1.10.1 Equipment for dual line systems

This equipment is enclosed in a robust metal cabinet with IP 55 grade protection, and is available in
different versions for the command and control of the 777 Series pumps with electromechanical or
hydraulic reversers.
It is equipped with two yellow warning lamps (B and G) for signalling minimum and maximum lubricant
levels, two white lamps (C and D) which signal the pressurisation of respectively lines 1 and 2 and a red
alarm warning lamp (F) which illuminates when the lubrication cycle is not effected in the time set on the
cycle control timer.
A green lamp (A) indicates power on, while a blue lamp (E) indicates the functioning of the pump.
A reset button (H) resets the system after an alarm and a selector (I) permits the selecting of either
continuous operation or timed by the system.
Two multi-scale electromechanical timers facilitate the simple and rapid setting of the pause and lubrication
times (working time of the pump).
The minimum and maximum work and pause times and the variations depend on the type of scale set.
The pause timer is equipped with a mechanical lock device which, in the event of a power off during the
pause, locks the timer in the position reached.

Code Description
1641295 For 777 pumps with electromechanical reverser
1638489 For 777 pumps with hydraulic reverser
1638488 As the 1638489 but c/w acoustic alarm signal
1638540 As the 1638489 but in a flameproof version

1.10.2 Equipment for progressive systems

This equipment is enclosed in a robust metal cabinet with IP 55 grade protection, and is equipped with an
electronic timer for the setting of the pause time and an electromechanical timer for setting the lubrication
time (working time).
The maximum standard pause time is 1 hour with variations of 2.5 min. By specifying when placing the
order or by acting on the electrical jumper situated in the timer it is possible to obtain a maximum pause
time of 8 hours (20 min. variations) or 24 hours (1 hour variations).
The working time can be regulated from 0 to 12 minutes with variations of 12 seconds.
It is equipped with alarm warning lights for lack of lubricant and minimum level in the tank.
A reset button resets the system after an alarm and a further button is used as a lubrication cycle manual
control.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 6

2.0 TECHNICAL CHARACTERISTICS

2.1 Fixing and overall dimensions

2.2 Electrical system Technical Data

Electrical power supply: 380 - 220 V 50/60 Hz

Absorbed power: Approx. 370 W

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 7

2.3 Hydraulic system Technical Data

Connections from the gear pump to the valve body by means of nylon tubing with external 4 mm (see attachment
7);

2.4 Other data

Class of protection F
Grade of mechanical protection IP55
Operating temperature -5 +40C (+23F +104F)
Operating humidity 90% relative humidity
Conservation temperature -20 +50C (-4F +122F)
Level of continuous sound pressure < 70 dB(A)

3.0 CORRECT USE

3.1 Putting into service

Damage to the power supply cable and housing could result in contact with high voltage live parts and hence be a
danger to life:
carefully check the integrity of the power supply cable and the unit before use;
In the event of there being damage to the power supply cable or the unit, DO NOT put the system into service!;
Replace the damaged power supply cable with a new one;
The unit can be opened and repaired ONLY by qualified personnel;
In order to prevent dangers of electric shock due to direct or indirect contact with live parts it is necessary that
the electrical power supply line is adequately protected by a suitable differential magnetothermal circuit breaker
with an intervention threshold of 0.03 Ampere and a max. operating time of 1 second.
The breaking capacity of the circuit breaker must be 10 kA and the nominal current In = 6 A.
The submersed pump MUST NOT be utilised in fluids or environments which are particularly aggressive or
explosive/inflammable if not prepared for this purpose beforehand by the supplier.
For correct fixing verify the distance between centres shown in the diagram in Section 2.
Use gloves and safety glasses as required in the lubrication oil safety chart;
DO NOT use aggressive lubricants with NBR gaskets and seals; if in doubt consult the Engineering Department
of Dropsa SpA, who will provide a chart with the details of recommended oils;
DO NOT ignore dangers to health and observe all hygiene standards;
WARNING! All electrical components must be grounded. This refers to both electrical components and control
devices. In this regard ensure that the ground cable is correctly connected. For reasons of safety the ground cable
must be approx. 100 mm longer than the phase cables. In the event of accidental detachment of the cable, the
ground terminal must be the last to be removed.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 8

action to be taken prior to start up
Verify the integrity of the pump;
Fill the tank with suitable lubricant;
Verify that the pump is at operating temperature and the tubing free from air bubbles;
Check that the electrical connections have been effected correctly (UNI 64/8, IEC );
The pump is supplied with a maximum and minimum level switch

3.2 Use

1. verify the settings made;

2. press the start button of the machine to which the 777 pump is connected;
3. verify the starting up of the pump;
4. verify the adequate lubrication of the machine (if doubt exists as to the correct functioning consult the
Engineering Department of Dropsa SpA to request test procedures).

3.3 Transport and storage

Transport and storage is effected in a wooden package.

No particular precautions are required except as noted on the package itself.
Handling must be effected utilising suitable lifting devices.
! After having removed the packaging, lift the pump utilising the appropriate brackets provided on the sides
of the base.
! The machine components can withstand temperatures, during storage, from -20 to +50C (-4F +122F);
however, in order to avoid damage, starting of the machine should occur at a minimum temperature of -5C
(23F).

3.4 Assembly/Disassembly

No pump assembly operations are envisaged.

For the fixing of the unit the holes provided in the inside of the base must be used. Adequate space is provided (as
shown in the installation diagram) to avoid abnormal postures and the possibility of impacts (see Section 2)
Subsequently it will be necessary, as previously described, to connect the pump to the machine hydraulically and
then to connect the control panel.

Remove the countersunk screws (9) and the locating pins (17) from both plates.
Remove the retaining rings (6 and 7) and the key (2).
Using screws in the M8 threaded holes, withdraw the plate (15) with the ball bearing (4) from the central shaft (11).
Remove the shim (12) and remove the lateral blocks (19) with the pistons (21).
Remove the springs and the cams withdrawing them from the shaft (11). Unhook the springs (18).

! before withdrawing the pistons from the blocks (19) mark them (they must be reassembled in the same
seating).

Remove the washer (12) and the shaft (11), utilising a press or an extractor.
The bearings (4 and 5) must be removed with care from their seatings.
It is now possible to proceed with disassembling the parts of the pumping element blocks (22) after having
withdrawn the pistons, removing the dowel (1), the ball (8), the plug (10) and the taper plug (20).

! the plugs (20) are slightly tapered; therefore it is advisable to replace them on reassembly.

During the disassembly the tank emptied.

Disconnect the electrical and hydraulic parts.
Where the machine is to be scrapped, do not dispose of potentially polluting parts in the environment, following
local regulations for their correct disposal.
At the time of the machine being scrapped it is necessary to remove and destroy the identification plate and all other
relative documents.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 9

3.5 Regulation

pressure
The working pressure can be regulated by rotating the by-pass screw clockwise to increase the pressure and
anticlockwise to decrease it. During this operation pay attention to the rotary joint.

Flow rate regulation

Serves to regulate the quantity of lubricant delivered during each cycle of the pump.
This accessory is installed on one or both pump elements.

3.6 Maintenance

! Locate the machine in conditions which facilitate easy access.

Utilise individual protection to avoid contact with mineral oil or grease.
Periodic inspection
Periodically it is necessary to check:

VERIFICATION WORK CYCLE

The state of lubrication 1000
Cleanliness of the filling filter and the suction filter 4000

The machine does not require any special tools to carry out checks or maintenance tasks, However, it is
recommended that only tools suitable for the tasks and in good condition should be utilised (DPR 547/55) to avoid
injury to persons or damage to machine parts.
Take due care when effecting cleaning of the tank (machine stopped and unable to be accidentally restarted).
Remember to reseal the tank at the end of the operation.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 10

3.7 Repairs

INDICATION CAUSE REMEDY

The motor driven pump does not The electric motor does not function Check the electrical connections
deliver lubricant between the motor and the power
supply line.

Check the motor windings.

Check that the connection links of the

motor terminal block are positioned
in accordance with the supply current

Refill the tank.

The tank is empty Attention: If the tank were to empty
without a minimum level warning
signal being given, the minimum
level contact must be checked

Take off the tank cover and check

The motor is rotating in the reverse that the paddle unit rotates and is
direction moving the lubricant; if this is not the
case invert two of the three motor
phases

See above
The pump is not actioned due to:
- the motor rotating in the reverse
direction Check the paddle unit control cams
- the motor rotating in the correct
direction but the paddle unit is
not turning Detach the pump delivery tube to
- presence of air bubbles in the bleed the lubricant until free of air
lubricant bubbles.

Adjust the valve (see Technical

The pressure regulating valve (by- Manual 777000)
pass) has been set at a very low value
Clean or replace the valve (see
Presence of foreign bodies in the Technical Manual 777000)
non-return valve
Disassemble the pump and carry out
Mechanical defect in the pump the checks described in Technical
Manual 777000

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 11

 INDICATION
On start up (first lubrication cycle) of
the system the pump delivers
lubricant, but on reaching pressure in
line 1 the reversing does not occur
and the line remains with pressure
No minimum level warning signal Incorrect minimum level adjustment
when there is no lubricant in the tank
Minimum level warning signal given Incorrect adjustment of the minimum Remove the tank cover, move
with lubricant above the minimum level
and the pump functioning
C2018IE - Pump 777 - Rev. 0
CAUSE REMEDY
Incorrect connection of the motor Invert the connections of two of the
phases: the motor rotates in the three motor phases
correct direction for pumping but in
the control panel the remote control
switch T1 (Reversing command) is
excited instead of switch TL
(Delivery command)
Incorrect electrical connections Invert the connections of the
between the electromechanical microswitches and check that the
reverser microswitches and the pump delivers lubricant. Where it
control and command panel does not, invert two of the three
motor phases
Incorrect connections of the control Invert the electrical connections to
pressure switch the control and command panel
Remove the tank cover, move
horizontally, in both directions, shaft
8, which actuates the microswitch.
This can present the following 2
cases:
- the command panel warning light
illuminates: adjust the contact by
turning screw 9 clockwise
- the command panel warning light
does not illuminate: check the
electrical connections and, if
necessary, replace the microswitch
horizontally, in both directions, shaft
8, which actuates the microswitch
(see Technical Manual 777000). This
can present the following 2 cases:
- the command panel warning
light goes out: adjust the contact
by turning screw 9 anticlockwise
(see Technical Manual 777000)
- the command panel warning
light remains on: check the
electrical connections and, if
necessary, replace the
microswitch
Jan. 1999 Page 12
 INDICATION CAUSE REMEDY
No maximum level warning signal Incorrect connection of the float with Remove the tank cover and lift the
when tank is full the microswitch float up until the microswitch is
actuated (see Technical manual
777000). This can present the
following 2 cases:
- the command panel warning
light illuminates: check that the
float rod is able to move freely.
If not, eliminate the cause to
permit the free movement of the
float
- the command panel warning
light does not illuminate: check
that, when the float is lifted up
the microswitch is actuated. If it
is not, move the microswitch
using the securing screws. Check
the electrical connections and, if
necessary, replace the
microswitch.

The maximum level warning light Incorrect connection of the float with Remove the tank cover and push the
illuminates when the tank is not full the microswitch float down (see Technical manual
777000). This can present the
following 2 cases:
- the command panel warning
lights goes out: check that the
float rod is able to move freely.
If not, eliminate the cause to
permit the free movement of the
float.
- the command panel warning
light does not go out: check that
when moving the float
downwards the microswitch is
actuated.. If it is not, move the
microswitch using the securing
screws. Check the electrical
connections and, if necessary,
replace the microswitch..

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 13

 INDICATION CAUSE REMEDY
AG6 DOSING UNITS

Alarm signalled for lack of lubricant The dosing unit piston is seized. Replace the dosing unit with another
delivery. The rods visible inside the having the same characteristics.
dosing unit turret must move Anyway ensure that the unit is
sequentially up and down and actuate correctly assembled, particularly as
the control microswitches when the regards the fixing. Overtightening of
pump is operating. Where this is not the securing screws could damage the
the case the two outlets or the single dosing unit and cause a seizing of the
outlet of that dosing unit will not piston.
deliver lubricant.

Tubing between the dosing unit Detach the tubing and ensure free
outlet and the lubrication point is passage for the lubricant.
obstructed.

Pressure in the line is too low Adjust the pressure regulating valve
(lubricant is not delivered to some (by-pass) or the control pressure
points) switch (end of line).

Dosing unit is prepared for two Check that, when only one outlet is
outlets but only one is utilised. used, the correct pad is assembled
and that the other outlet is plugged.
See the AG6 Dosing Unit Instruction
Leaflet.

INDICATION CAUSE REMEDY

END OF LINE PRESSURE
SWITCH

The pressure switch does not send a Incorrect electrical connections Check the electrical connections
signal to the electrical command and
control panel Incorrect adjustment of the control Reduce the pressure set on the
pressure switch. The pressure value pressure switch until an electrical
set is too high and the pressure contact is obtained
regulating valve (by-pass) intervenes
before the pressure switch can be
actuated

The pressure switch sends a signal Incorrect setting of the control Increase the set value of the pressure
before the end of the lubrication pressure switch. The pressure value switch. The optimum set value is that
cycle set is too low which permits a pressure of 50-70
bar at the end of the lubrication line.

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 14

 INDICATION CAUSE REMEDY
RIGID AND FLEXIBLE TUBING

Loss of lubricant Fracture of the tubing due to Replace the damaged section and
excessive pressure or material wear. ensure correct assembly.

Insufficient lubricant delivery. Loosening of connections due to Reassemble, using Teflon tape on the
incorrect assembly or vibration. threads if necessary, and adequately
tighten the connections.

Tubing flattened. Replace the damaged section,

correctly reassemble and install
external protection if necessary.

Dimensions of the tubing reduced by Replace the damaged section and

excessive bending. correctly reassemble.

3.8 Dangers present in use

The verification of conformity with the essential safety requirements and regulations of the Machine Directive is
effected by means of the compilation of a check list which has been pre-prepared and is contained in the technical
file.
the lists which are utilised are of three types:
list of dangers (as in EN 414 referring to EN 292)
application of essential safety requirements (Machine Dir. - att. 1, part 1)
electrical safety requirements (EN 60204-1)

the following is a list of dangers which have not been fully eliminated but which are considered acceptable:
during assembly/maintenance phases it is possible that there could be oil squirts or splashes (for this
reason appropriate protective clothing must be worn and appropriate protective measures must be taken
during these operations)
difficulty in handling: installation of suitable side brackets
exceptionally contact with split rings in rotation
contact with oil -> see the requirements for the use of suitable individual protective measures
use of unsuitable lubricant -> the characteristics of the fluid are shown on the pump and in the manual
(in case of doubt contact the Eng. Dept of Dropsa Spa )
protection against direct and indirect contact must be provided by the user
every time the tank cover is opened the catch must be correctly resealed immediately afterwards
given the purpose of the lubrication system, the pump must always be functioning; for this reason it is
necessary to pay attention to the electrical connections which, in the case of a power failure, the
customers machine is restarted only by means of a reset, while the lubrication pump is able to restart
automatically

INADMISSIBLE FLUIDS
Fluid Danger
Lubricants with abrasive additives High wear rate of contacted parts
Lubricants with silicon based additives Seizure of the pump
Petrol solvents inflammable liquids Fire explosion damage to seals
Corrosive products Corrosion of the pump injury to persons
Water Oxidation of the pump
Food substances Contamination of the substances themselves

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 15

4.0 INSTRUCTIONS FOR ORDERING

VERSIONS

Motor driven pump complete with mechanical line reverser with 0.37 kW 4 pole electric motor
Tank
Description
10 30 100
777005 777010 777020 With paddle unit for grease min. and max. levels

777393 - - With follower plate for soft grease

777510 777521 777535 For oil with min. and max. levels

Motor driven pump complete with hydraulic line reverser with 0.37 kW 4 pole electric motor
Tank
Description
10 30 100
777060 777040 777083 With paddle unit for grease min. level

777311 - - With follower plate for soft grease

777560 777572 777584 For oil with min. and max. levels

Motor driven pump for single line progressive system with 0.37 kW 4 pole electric motor
Tank
Description
10 30 100
777110 777030 777131 With paddle unit for grease

777312 - - With follower plate for soft grease

777613 777624 777635 For oil with min. and max. levels

REPLACEMENT PARTS

Pump assembly 291415

Reduction unit 291410
Electric Motor 0.37 kW gr71 3301110
Electric Motor 0.75 kW gr8 3301053
Electromechanical reverser 291380
Unidirectional valve 291355
Non-return valve 291413
By-pass valve 50 - 500 bar (735 7350 psi) 291162
By-pass valve 20 - 250 bar (294 3675 psi) 291391
Flow regulator 3293060
Minimum level indicator Tank 10 kg (22 lb) 291244
Tank 30 kg (66.1 lb) 291220
Tank 100 kg (220.4 lb) 291210
Maximum level indicator 291145
Paddle unit for grease Tank 10 kg (22 lb) 291245
Tank 30 kg (66.1 lb) 291247
Tank 100 kg (220.4 lb) 291246
Filling filter 3130009

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 16

 CE Declaration Of Conformity
Manufacturer :
DROPSA SpA
Company
Via Croce 1, - 20090 Vimodrone (MI), Italy
Address
+39 02 250 791
Telephone

It is certified that:
the machine: Pump 777 Ver. 01-06

is manufactured in conformity with the DIRECTIVE OF THE COUNCIL OF THE EUROPEAN COMMUNITY
concerning the harmonisation of member states legislation relative to machines (89/392/CEE + 91/368/CEE),
EMC (89/336/CEE) and BT (73/23/CEE) and relative amendments.
is manufactured in accordance with the following standards and harmonised technical specifications:
EN 292/1, EN 292/2, EN 50081-2, EN 50082-2, CEI EN 60204-1, EN 1050.

Technical Manager Ing. Walter Divisi

Product Manager Name

DROPSA SpA - Vimodrone (MI) - Italy

Company

January 1999
Signature Date

DROPSA

ITALY U.S.A. BRAZIL AUSTRALIA

Dropsa SpA Dropsa Corporation Dropsa Dropsa Australia Ltd.
t.(+39) 02-250791 t.(+1) 586-566-1540 t.(+55) 011-563-10007 t.(+61) 02-9938-6644
f.(+39) 02-25079767 f.(+1) 586-566-1541 f.(+55) 011-563-19408 f.(+61) 02-9938-6611

SPAIN U.K. GERMANY FRANCE

Polydrop, S.A. Dropsa (UK) Ltd Dropsa Gmbh Dropsa Ame
t.(+34) 93-260-22-50 t.(+44) 01784-431177 t.(+49) 0211-394-011 t.(+33) 01-3993-0033
f.(+34) 93-260-22-51 f.(+44) 01784-438598 f.(+49) 0211-394-013 f.(+33) 01-3986-2636

C2018IE - Pump 777 - Rev. 0 Jan. 1999 Page 17

 0083300-5
0083307-9
LINE 02 - INVERTORS
Pneumatic and electro-pneumatic invertors
for dual supply line plant 500 bar (7250 psi)

Description Electro-Pneumatic Invertor

These invertors have been designed for the
control of dual supply line plant(System 02)
using either oil or grease up to a maximum
pressure of 500 bar (7250 psi).
The function of these invertors Is to
alternatively transfer the pump to one of the
two Lines so that the redundant line pressure
is released. Part N Voltage Thread
On electro-pneumatic invertors a four way 0083300 110 V 50/60 Hz
solenoid valve is energized by the plants end 0083304 230 V 50/60 Hz
BSP
line pressure-switch and actuated by 0083308 24 V 50/60 Hz
compressed air which transfers the 0083309 24 V DC
pressurized lubricant, supplied to the 0083303 110 V 50/60 Hz
invertor, from one line to the other 0083305 230 V 50/60 Hz NPT
alternatively. 0083307 24 V 50/60 Hz
The solenoid valve is therefore energised
(electrically) directly by the control system of Pneumatic Invertor
the plant thus permitting automatic
lubricating cycle control.
Pneumatic invertors operate with two distinct
compressed air lines that are alternatively
inverted to create the reversing action. In
this case the pressure of the two
Part N Thread
compressed air lines is not controlled by the
lubricating plant or auxiliary equipment but by 0083301 BSP
means of a control appliance (i.e. solenoid 0083302 NPT
valve) provided by the user.
5) Wire the electro-pneumatic valve to the
control system via the solenoid connector
Installation
(6) using the relative wiring diagram.
Proceed as described below bearing in mind 6) Connect the compressed air supply to the
that the lubricant inlet is threaded as follows: fitting 28.
3/8" BSP for coded products 83300, 83304,
83301 and 83308. 3/8" NPT for coded
products 83302, 83303, 83305 and 83307. Pneumatic operated Invertor
All other connections are: 1/4" BSP for Refer to figure 3 to identify the parts (see
coded products 83300, 83304, 83301 and page 4).
83308. 1/4" NPT for coded products 83302, 1) Proceed as described in points 1 to 4 for
83303, 83305 and 83307. the electro-pneumatic operated invertor.
2) Connect fittings 1 and 2 to the
Electro-Pneumatic operated Invertor compressed
Refer to figure 2 to identify the parts (see air supply.
page 3). In the event of electrical or compressed air
1) Mount the invertor as required using the circuit malfunction all invertors shown can be
two 8.5 mm (0.335 in.) diameter fixing operated manually by pulling or pushing the
holes situated on the top of the invertor. manual override knob 10. Manual override
2) Connect the lube pipe to the connection operation is as follows: knob position out, air
marked inlet on the invertor. to line 2, knob position in, air to line 1.
3) Connect the two outlet pipes to the
fittings marked line 1 and line 2 on the
invertor.
4) Connector the lubricant return line to the
fitting marked return on the invertor.
www.dropsa.com

Centralised lubrication systems 1

WK 44/04
7177683

LINE 02 - INVERTORS
PNEUMATIC AND ELECTRO-PNEUMATIC INVERTORS
Maintenance
Periodic cleaning of the invertor is
necessary In order to guarantee gasket/seal
efficiency and ensure that all worn parts are
replaced.
Electro-Pneumatic operated Invertor
Refer to figure 2 to identify the parts.
1. Disconnect solenoid valve electric
contact by unscrewing the screw and
pulling off the connector.
2. Unscrew both pipe compression
fittings and remove the air pipe.
3. Unscrew fixing screws 23 and remove
the solenoid valve.
4. Unscrew the cylinder 22and remove
the cylinder gasket 17.
5. Unscrew the plunger 21 and remove
gaskets 18, 20 and seal disc.
6. Unscrew the control rod guide 9.
7. Pull the knob out 11 and remove the
pump assembly.
8. Disassemble the pump.
9. Remove the elastic ring 16 and extract
the spacer 5, seal 7, the two grub
screws 13 and two gaskets 12.
10. Check the gaskets and clean all parts.
Replace all damaged parts as
required.
11. Proceed with reassembling
invertor starting from point 11 and
working back to point 1.
Technical Data
Maximum lubricant pressure 500 bar (7250
psi).
Pipe bore 40 mm2 (.062 sq.in.).
Compressed air supply pressure from 3 to
10 bar (44 to 147 psi).
Air connection BSP - NPT.
Lubricant Inlet, outlet and return connections
3/8 BSP 3/8 NPT.
2
0083300-5
0083307-9
Pneumatic Invertor
Refer to figure 3 to identify the parts.
1. Disconnect the compressed air lines.
2. Both these fittings do not disconnecting
to service the invertor, they do however
required resealing before being
reconnected.
3. Unscrew the three fixing screws 1 and
remove the block.
4. Unscrew the cylinder 21 and remove the
cylinder gasket 16.
5. Unscrew the plunger 20 and remove
gaskets 17, 19 and seal disc 18.
6. Unscrew the control rod guide 8.
7. Pull the manual override knob out 10 and
remove the pump assembly.
8. Disassemble the pump.
9. Remove the elastic ring 15 and extract
the spacer 14, seal 6, the two grub
screws 12 and two gaskets 11.
10. Check the seals and clean all parts.
Replace all damaged parts as required.
11. Proceed with reassembling the invertor
starting from point 10 and working back
to point 1.
General Notes on Safety
Do not use damaged or excessively worn
parts.
the Check all pipework and fittings before using
the plant.
Always ensure that the electro-pneumatic
invertor power requirements match the power
supply before use.
OPERATING PRINCIPLE
 0083300-5
0083307-9
LINE 02 - INVERTORS
PNEUMATIC AND ELECTRO-PNEUMATIC INVERTORS

ELECTRO-PNEUMATIC INVERTORS

Pos. Description Part. No. Q.ty Pos. Description Part. No. Q.ty
1 Connector 3084566 1 14 Gasket 3190060 1
2 Pipe 5717301 1 15 Spacer sleeve 3011092 1
3 Connector 3084566 1 16 Spring washer 0018666 1
4 Tie-rod 3009118 1 17 Gasket 0018863 1
5 Spacer sleeve 3011073 1 18 Gasket 0234016 1
6 Gasket 0018806 1 19 Disk 0234004 1
7 Gasket 3190266 1 20 Gasket 0234034 1
8 Invertor piston 3101151 1 21 Pin 0234005 1
9 Control rod guide 0083913 2 22 Cylinder 0234002 1
10 Control rod 3002164 2 23 Screw TC M3x30 0014058 3
11 Hand knob 3023107 1 24 Washer 0016004 3
12 Gasket 3190111 2 Solenoid valve 110V-50/60 Hz 1
13 Grub screw 0622006 2 Solenoid valve 230V-50/60 Hz 1

3
 0083300-5
0083307-9
LINE02 - INVERTORS
PNEUMATIC AND ELECTRO-PNEUMATIC INVERTORS
PNEUMATIC INVERTORS

Pos. Description Part. No. Q.ty Pos. Description Part. No. Q.ty
1 Screw 0014058 3 12 Grub screw 0622006 2
2 Washer 0016004 3 13 Gasket 3190060 1
3 Tie-rod 3009118 1 14 Spacer sleeve 3011092 1
4 Spacer sleeve 3011073 1 15 Spring washer 0018666 1
5 Gasket 0018806 1 16 Gasket 0018863 1
6 Gasket 3190266 1 17 Gasket 0234016 1
7 Invertor piston 3101151 1 18 Disk 0234004 2
8 Control rod guide 0083913 1 19 Gasket 0234034 1
9 Control rod 3002164 1 20 Pin 0234005 1
10 Hand-knob 3023107 1 21 Cylinder 0234002 1
11 Gasket 3190111 2

DROPSA Spa
ITALY U.S.A.
Dropsa SpA Dropsa Corporation
t.(+39) 02-250791 t.(+1) 586-566-1540
f.(+39) 02-25079767 f.(+1) 586-566-1541
BRAZIL AUSTRALIA
Dropsa Dropsa Australia Ltd.
t.(+55) 011-563-10007 t.(+61) 02-9938-6644
f.(+55) 011-563-19408 f.(+61) 02-9938-6611

SPAIN U.K. GERMANY FRANCE

Polydrop, S.A. Dropsa (UK) Ltd Dropsa Gmbh Dropsa Ame
t.(+34) 93-260-22-50 t.(+44) 01784-431177 t.(+49) 0211-394-011 t.(+33) 01-3993-0033
4 f.(+34) 93-260-22-51 f.(+44) 01784-438598 f.(+49) 0211-394-013 f.(+33) 01-3986-2636
 FILTER WITH STEEL BODY FOR HIGHT 1113200

PRESSURE (MAXIMUM 500 BAR 7200 PSI) 1113259

Filtering Thread Filter Cartridge The maximum operating pressure indicated refers
degree BSP Part N. Part N. to the sealing of the system.
(micron)
25 1/4 1113235 If the difference of pressure between inlet and
25 3/8 1113245 1113265 outlet port is greater than 20 bar (290 psi) the filter
25 1/2 1113255 breaks, for this reason it is advisable to check
40 1/4 1113236 periodically the filter to avoid clogging.
40 3/8 1113246 1113266
During the installation of the lubrication system, it
40 1/2 1113256
is possible than foreign materials remain into the
40* 1/4 1113259 1113219
tube.
60 1/4 1113237
The use of the filter is recommended to avoid this
60 3/8 1113247 1113267 contamination to enter the lubrication system
60 1/2 1113257 damaging the machine and the lubrication plant.
125 1/4 1113238
125 3/8 1113248 1113268 Note: Standard thread of inlet and outlet port is
125 1/2 1113258 1/2"BSP.
150 1/4 1113230 For the other type of threads, the following
150 3/8 1113240 1113231 reducers are fitted on filter body:
150 1/2 1113250
300 1/4 1113200 Part N. 3077106 reducer from 1/2"BSP to
300 3/8 1113210 1113205 1/4"BSP
300 1/2 1113220 Part N. 3077117 reducer from 1/2"BSP to
3/8"BSP.

* Filter with holes for wall mounting

717 24/02 7176903

ITALY U.S.A. BRAZIL AUSTRALIA
Dropsa SpA Dropsa Corporation Dropsa Dropsa Australia Ltd.
t.(+39) 02-250791 t.(+1) 586-566-1540 t.(+55) 011-563-10007 t.(+61) 02-9938-6644
f.(+39) 02-25079767 f.(+1) 586-566-1541 f.(+55) 011-563-19408 f.(+61) 02-9938-6611

SPAIN U.K. GERMANY FRANCE

Polydrop, S.A. Dropsa (UK) Ltd Dropsa Gmbh Dropsa Ame
t.(+34) 93-260-22-50 t.(+44) 01784-431177 t.(+49) 0211-394-011 t.(+33) 01-3993-0033
http://www.dropsa.com f.(+34) 93-260-22-51 f.(+44) 01784-438598 f.(+49) 0211-394-013 f.(+33) 01-3986-2636
 END OF LINE PRESSURE SWITCH 1124402
1124415
Dual Line System. 1124440
1124447

PRODUCT DATA SHEET ENGLISH

DESCRIPTION:
This end of line pressure switch guarantees the correct
operating pressure and the line inversion in dual line
installations.
When lubricant pressure in the line reaches the pre-set
value, the pressure switch controls, through the electric
or electronic equipment, the lighting of a lamp and, if
the installation is equipped with an electric controlled
line pressure inverter, it drives the line inversion.

The end of line pressure switch comprises of:

1 sturdy block with 2 BSP inlet ports.

2 micro-switches.

2 pressure adjustment valves.

Pressure switch Part No. 1124447;
Particularly suitable for installations with many lubricant
2 pressure gauges feeders and with many secondary lines.
This switch must be fitted at the end of the main line or
2 air bleed valves. at the end of a particularly important secondary line
And is electrically connected to another pressure switch
Types of Pressure Switch: mounted on the other end of the line. If one of the two
pressure switches is not activated by lubricant pressure,
Pressure switch Part No. 1124440; the electric equipment signals an alarm to stop the
Fitted at the end of the main line, checks the correct machine. Only if both pressure switches are acted
operating pressure and, for installation with hydraulic upon by the correct lubricant pressure, the electric
inverter, controls the inversion from Line 1 to Line 2 and equipment signals the line inversion.
vice-versa.

Pressure switch Part No. 1124415; INSTALLATION/OPERATION:

Same as Part No. 1124440 but mounted in a
waterproof box. Protection degree IP 55.
Pressure switch Part No. 1124454;
Same as Part No. 1124415 but with explosion proof
switch.
Operation.
When lubricant pressure in the line connected to the
pump, reaches the pre-set value on the pressure
adjusting valve 1, piston 2, moves up to close the
contact of micro-switch 5 which signals, through the
lamp of the electric panel, the inversion of the line

ORDERING INFORMATION:
Ordering is by Part No. and description, please refer to the following table:

Part No. Electrical Pressure Operating Micro-switch features

connections adjustment range differential
pressure*
1124454 Terminal board 30 to 330 bar 16 to 20 bar 380V ac. 20A
1124415 Terminal board 30 to 330 bar 16 to 20 bar Life expectancy 10x106 cycles
1124440 Connector 3 poles 30 to 330 bar 16 to 20 bar Temperature range
+ earth -20oC to +85oC
1124447 Connector 6 poles 30 to 100 bar 12 to 14 bar
+ earth
* Operating differential pressure = difference of pressure necessary to obtain the change of micro-switch contacts.

-1- Sheet D2 C1083IE WK 26/05

under pressure. Ohmmeter the change of contacts in the micro-
For dual line installations with an electrically controlled switch).
inverter, micro-switch 5 also commands the inversion of 3. Tighten nut A.
pressurization of the lines. 4. Repeat the same operation on the valve that
Note: A red alarm lamp signals any malfunction of controls the other lubrication line.
the end of line pressure switch.
Note: by dismounting spring 4, maximum adjusting
The next lubrication cycle inversion will occur in the pressure will be 100 bar. In this case we advise the use
same way as described above. The lubricant pressure of pressure gauge Part No. 20606 (scale from 0 to 250
in the line now connected to the pump reaches the pre- bar).
set value on the other pressure adjusting valve. The
pressure in the previously pressurized line is released.
This release pressure must be equal to the operating
differential pressure in order to guarantee the correct Spare parts:
delivery of lubricant from the metering vlaves. Spare parts
Description Part No.
The operating differential pressure is the difference in 1. Adjusting valve assembly. 1124430
pressure necessary to open the contact of micro-switch 1. Adjusting valve assy. for 1124447. 1124446
5, and depends on distance X between piston 2 and 2. Piston 1124423
micro-switch 5, which must be 3,3 mm. 3. Spring. 3191222
4. Spring. 3191223
Adjusting valve setting: 5. Micro-switch. 38041
6. Pressure gauge (0 to 400 bar). 20604
1. Loosen nut A. 6. Pressure gauge (0 to 250 bar). 20606
2. Turn adjusting nut B until the desired setting
7. Air bleed screw. 3230103
value is obtained (check that the pump is
8. screws. 12707
operating at the correct pressure by means of
the pressure gauge and verify with an

NO C NC

B
X

2 1
3

4 A

100 300

0 400

7 6
8

-2- Sheet D2 C1083IE WK 26/05

Pressure Switch Part No. 1124440 Electrical connections.

9
Connector 9 10 8
Part No. 39976 2

10 3

Base 1
Part No. 39975
8 LINE 2 LINE 1

Pressure Switch Part No.s. 1124454 1124415 Electrical connections.

40 9 10 8 41

N.A. N.A.

C. C.

40 9 10 8 41 N.C. N.C.

LINE 2 LINE 1

Pressure Switch Part No. 1124447 Electrical connections block diagram.

1 2 3 4 5 5
Male
Part No. 3194002
4 3
5 2
Female 6 1
Part No. 3194001

LINE 2 LINE 1

LINE 1
LINE 2

LINE 2 IN PRESSURE: Electric signal.

TO INVERTER

LINE 1 IN PRESSURE: Electric signal.

-3- Sheet D2 C1083IE WK 26/05

 AN ISO 9001 APPROVED COMPANY

ITALY U.S.A. BRAZIL AUSTRALIA

Dropsa SpA Dropsa Corporation Dropsa Dropsa Australia Ltd.
t.(+39) 02-250791 t.(+1) 586-566-1540 t.(+55) 011-563-10007 t.(+61) 02-9938-6644
f.(+39) 02-25079767 f.(+1) 586-566-1541 f.(+55) 011-563-19408 f.(+61) 02-9938-6611

SPAIN U.K. GERMANY FRANCE

Polydrop, S.A. Dropsa (UK) Ltd Dropsa Gmbh Dropsa Ame
t.(+34) 93-260-22-50 t.(+44) 01784-431177 t.(+49) 0211-394-011 t.(+33) 01-3993-0033
f.(+34) 93-260-22-51 f.(+44) 01784-438598 f.(+49) 0211-394-013 f.(+33) 01-3986-2636

Copyright Dropsa - all rights reserved. Reproduction of any part of this document is strictly forbidden without prior consent from
Dropsa. Dropsa reserves the right to modify specifications without prior notice.

-4- Sheet D2 C1083IE WK 26/05