DROPSA Rollo 888 User manual

INSTRUCTIONS
FOR USE
Pump 888 - Rollo
DROPSA SpA
In accordance with point 1.7.4, to I, Dir. 98/37 CE
Section:
0.0 INTRODUCTION
1.0 DESCRIPTION OF THE PUMP
2.0 TECHNICAL SPECIFICATIONS
3.0 CORRECT USE
4.0 INSTRUCTIONS FOR ORDERING
AND DISTRIBUTORS
DECLARATION OF CONFORMITY
Catalogue P/N C2020IE - Wk 23/02
Registered name DROPSA SpA
Address Via B. Croce 1, 20090 Vimodrone (MI), Italy
Model Pump 888 - Rollo
Year of manufacture 1999
Marking CE
0.0 INTRODUCTION
This user’s and maintenance manual refers to the pump 888 - Rollo, for use in progressive type lubrication systems
mounted on trucks, buses, refuse compactors and other types of machinery equipped with a 24 VDC electrical power
supply.
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, mechanical and electrical systems.
The manufacturer reserves the right to update the product and/or the user’s 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

C2020IE - Pump 888 - Rollo - Rev. 1 June 2002 Page 2 of 8
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.
The list of importers and instructions for ordering the required model are shown in Section 4.
1.0 DESCRIPTION OF THE PUMP
The Rollo is a range of motor driven pumps for mineral oil and grease.
The body of the Rollo is in aluminium coated with a special anticorrosion paint; the pump elements are in ground
and lapped steel. The pump is supplied as standard with one pump element assembly and with a capacity to deliver 6
cm3/min. On request it is possible to mount up to three pump element assemblies (note that the number of pump
element assemblies required must be stated at the time of ordering).
CHARACTERISTICS PUMP 888 - Rollo
Electrical piston pump
Max. pressure-bar
(psi)
250
(3625)
Flow rate 6 cm3/min
Tank capacity
Litres/Kg 2 or 4
Max. working time
(min) for 50 W version
5
(min. pause time/work time (lubrication) ratio
is 3:1)
Max. working time
(minimum for 120 W version) unlimited
Lubricant characteristics
at temperature of use
cSt
Oil Viscosity = min. 15 cSt
Max. grease consistency NLGI 2
Temperature of use; for situations
outside this range contact Dropsa
Engineering Dept
- 5 °C - + 40 °C
Motor
24 VDC
The motor can operate at voltages between 12
and 30 VDC
Absorbed power 50 W/120 W
Tank In transparent technopolymer - capacity 2 Kg
1.1 Auxiliary pump element (Part N° 888042)
The pumps are supplied with one only pump element, but are pre-prepared for the mounting of another one or two
pump elements.
This allows the feeding of more than one line independently or to combine the output of two or three pump elements
to double or treble the flow rate.
Pump element characteristics:
Piston Ø 6 mm
Useful piston stroke: 6 mm
Body capacity: 0.17 cm3 / stroke
1.2 Minimum level indicator
A permanent magnet located in a float (pump part N° 888120) or in the pressure disk (pump part N° 888110) actuate
a “reed” contact inside the float guide rod or the pressure disk piston.
Maximum commutable power: 26 VA. Max. voltage: 120 VDC. Max. current: 0.8 A.

C2020IE - Pump 888 - Rollo - Rev. 1 June 2002 Page 3 of 8
1.3 Operating control
The control of the pump functioning must respect the technical characteristics of the motor:
Max. functioning time 5 minutes/Unlimited
Min. pause time Three times the functioning time/Unlimited
2.0 TECHNICAL SPECIFICATIONS
2.1 Fixing and overall dimensions
2.2 Electrical system – Technical data
Motor driven piston pump
Electrical power supply: 24 VDC
Absorbed power: approx. 50 W – 120 W
DIMENSIONS
version with
electrical
minimum level
STANDARD
CONFIGURATION
CONFIGURATION WITH
QTY 3 PUMP ELEMENTS,
BY-PASS, PRESSURE
GAUGE AND DELIVERY
FILTER

C2020IE - Pump 888 - Rollo - Rev. 1 June 2002 Page 4 of 8
2.3 Other technical data
Class of protection F
Grade of mechanical protection IP55
Working temperature -5 - +40ºC
Working humidity 90 % relative humidity
Preservation temperature -20 - +50ºC
Level of continuous sound pressure < 70 dB(A)
3.0 CORRECT USE
3.1 Putting into service
♦ It is advisable to operate the pump while filling to facilitate the distribution of grease through the pumping area
and to avoid the formation of air bubbles.
♦ The unit should be opened and repaired ONLY by qualified personnel.
♦ The pump MUST NOT be submersed in fluids or utilised in environments which are particularly aggressive or
explosive/inflammable if not prepared for this purpose beforehand by the supplier.
♦ 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.
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;
♦ On starting the pump, check the direction of rotation of the electric motor: If rotating in the wrong
direction invert the cable connections.
☞ WARNING
For grease pumps it is essential that the paddle rotates in the direction of the arrow shown on the plate on
the tank (anticlockwise). Where the direction is incorrect, invert the two electrical power cables to the
motor.
3.2 Use
1. Verify the starting of the pump;
2. Check the rotation of the paddle (only for grease pumps);
3. 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 cardboard package.
No particular precautions are required except as noted on the package itself.
Handling can be effected manually.
!Lift the unit with taking account of the right way up indicated on the cardboard carton
!The machine components can withstand temperatures, during storage, from -20 to +50°C; however, in
order to avoid damage, starting of the machine should occur at a minimum temperature of -5°C.

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3.4 Assembly/Disassembly
No pump assembly operations are envisaged.
During the disassembly phase ensure the tank is empty.
Disconnect the electrical 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.
3.4.1 Disassembling the cover
Pumps Part N° 888100 and 888120
Screw a 3 mm screw into the hole of the nylon tube which secures the cover to the tank and, taking the head
of the screw with a pair of pliers, completely extract the nylon tube from its seating and remove the cover.
Pump Part N° 888110
This pump is equipped with a pressure disk with a seal which remains perfectly in contact with the internal
surface of the tank. When the pressure disk, following the level of the grease being pumped, descends down
the guide rod, an increase in pressure is created in the zone above the disk itself. After having removed the
nylon tube as described above, it is necessary to raise the cover and at the same time tilt it until the passage
of air is permitted eliminating the existing difference in pressure between the zones above and below the
pressure disk.
3.4.2 Removing the tank
Where it is necessary to remove the tank to clean or replace the pump, remove the nylon tube which secures
the tank to pump body as described for removing the cover.
3.5 Regulation
Pressure
It is possible to regulate the working pressure by inserting a regulating valve (Part No. 0888036) in the delivery line.
Pressure regulation: 0 - 25 MPa (0 - 250 bar).
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
The oil level 2000
Cleanliness of the filling and intake filter (where
fitted) 2500
Clean the tank of any deposits on the bottom 3000
The tank should only be filled with clean lubricant free from metallic particles or foreign bodies in order to ensure
the long life of the pump and to avoid damage to the machine being lubricated.
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

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3.7 Repairs
The following diagnostic table indicates the main anomalies which may be encountered, the probable causes and
possible solutions.
The anomalies shown are:
 the pump fails to deliver lubricant;
 irregular pressure;
 irregular flow rate;
 the lubricant does not arrive at the points to be lubricated.
In case of doubts and/or problems which cannot be resolved do not attempt to disassemble parts of the machine but
contact the Engineering Department of DROPSA S.p.A..
DIAGNOSTIC TABLE
INDICATION CAUSE REMEDY
The pump fails to
deliver lubricant
The tank is empty
The tank for grease has been
filled from the top and not by
using the appropriate side
connection
The pump element piston is
seized or the piston return
spring is broken
The pump is unable to operate
as the grease consistency
exceeds NLGI 2 (max.
recommended consistency).
The pump does not operate
because it has been running
with the tank empty creating
an air bubble within the pump
itself.
Refill the tank with clean lubricant, following the procedure in the section on
Maintenance.
Warning: if the tank has emptied without the electrical contact having signalled
the minimum level, check the minimum level contact.
Remove the connector cap for the supplementary pump element to purge the air
by running the pump until grease exits free from air bubbles. Replace cap B and
continue running the pump until grease exits between the threads and the cap
body, then fully tighten the cap.
Replace the pump element.
Remove the tank from the pump, remove the unsuitable grease and wash the
tank and filter with petrol.
Disassemble the pump and wash with petrol. Reassemble and refill the tank
(using the side connector equipped with a filter) with suitable grease and run the
pump, ensuring that the grease exits free from air bubbles. If necessary remove
the air vent cap B (See fig. on page 6) and purge as in the previous point.
Irregular pressure Pressure regulating valve (by-
pass) dirty.
Disassemble the parts shown in diagram A (see fig. on page 6) and wash them
with petrol. Also clean the valve seating. Check the condition of the components
and replace where necessary.
Before reassembling the valve, check that sealing ring 18818 is not damaged.
Irregular flow rate The flow is irregular due to
dirt in the system.
Remove the pump element from the pump body and completely disassemble it.
Check and clean all the pieces and reassemble.
Hold the pump element in wooden jaws to protect the lapped finish.
The lubricant does
not arrive at the
points to be
lubricated.
The lubricant has saponified in
the tubing and in the dosers.
Detach the feed tubing to determine that this is the problem.; where necessary,
use a high pressure (500 – 600 bar) hydraulic pump to purge the bearings of
saponified grease; the same operation must be carried out on all the connecting
tubing in the affected zone, then purge the dosers and, to finish, disconnect the
input tube to the dosers and, with the pump running, ensure that lubricant exits
from the tubing; where it does not, purge the tubing between the doser and the
pump and between the master doser and the secondary dosers. At the end of the
operation, check the working pressure of the system and set the maximum
pressure valve to 150 bar.
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

C2020IE - Pump 888 - Rollo - Rev. 1 June 2002 Page 7 of 8
file.
The lists which are utilised are of two types:
• list of dangers (as in EN 414 referring to EN 292)
• application of essential safety requirements (Machine Dir. - att. 1, part 1)
The following is a list of dangers which have not been fully eliminated but which are considered acceptable:
♦ in the version of the pump without a release it is possible to encounter squirts of oil (for this reason
appropriate protective clothing must be worn)
♦ contact with oil -> see the requirements for the use of suitable personal protective clothing
♦ 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)
INADMISSIBLE FLUIDS
Fluid Danger
Lubricants with abrasive additives High wear rate of contacted parts
Lubricants with silicone 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
4.0 INSTRUCTIONS FOR ORDERING
VERSIONS
MOTOR TANK
CAPACITY
FLOW
RATE
(cc/min)
at 40 rpm
PART N° DESCRIPTION
50W 2 kg 6 888100 Lubricant: grease – with paddle and agitator
50W 2 kg 6 888110 Lubricant: grease – with paddle, pres. disk, min. level.
50W 2 l 6 888120 Lubricant: oil – with min. level
120W 4 kg 6 888130 Lubricant: grease – with paddle and agitator
120W 4 kg 6 888140 Lubricant: grease – with paddle
120W 2 kg 6 888150 Lubricant: grease – with paddle and agitator
120W 2 kg 6 888170 Lubricant: grease – con paddle, press. disk, min. level
PRESSURE REGULATING VALVE
Pressure regulating valve, for mounting in the delivery line.
Valve Part N°: 299450
Pressure regulation: 0 - 25 MPa ( 0 - 250 bar)
It is recommended that this valve be fitted to ensure the correct functioning of the pump and to avoid any excess
pressure in the circuit.

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CE Declaration Of Conformity
Manufacturer:
DROPSA SpA
Company
Via Croce, 1 - 20090 Vimodrone (MI), Italy
Address
[phone]
Telephone
It is certified that:
The machine: Pump 888 - Rollo
∗ is manufactured in conformity with the DIRECTIVE OF THE COUNCIL OF THE EUROPEAN COMMUNITY
concerning the harmonisation of member states legislation relative to machines (98/37 CE + 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, EN 1050.
Technical Manager Ing. Walter Divisi
Product Manager Name
DROPSA SpA - Vimodrone (MI) - Italy
Company
January 1999
Signature Date
DROPSA
ITALY
Dropsa SpA
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Dropsa Corporation
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Dropsa
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Dropsa Australia Ltd.
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SPAIN
Polydrop, S.A.
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Dropsa (UK) Ltd
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Dropsa Gmbh
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Dropsa Ame
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