Groz BGRP Series User manual

1
INSTRUCTION MANUAL S1350, Rev C
Air Operated Grease Ratio Pumps 50:1
BGRP
Congratulations on purchase of this World Class Air Operated Grease Ratio Pump!
Grease Control Valve
Grease Drum
Grease Pump
Z Swivel
Drum Cover
High Pressure
Rubber Hose
Wheels
Cover Screws
Pull Handle
Drum Capacity
30 Kg
Drum Capacity
50 Kg
Drum Capacity
15 Kg
• World-class Industrial High
Pressure Grease pump with
guaranteed performance &
hassle free operation
• Pump dispenses Grease at
pressures upto 50 times the Air
inlet pressure.
• Designed to work in tough
conditions- Ideal for use in
Industry, workshop, farm,
construction or as part of the
Mobile Grease system
• All metal construction, fully
CNC machined with hardened
wear resistant moving parts
• Reciprocating piston operated
2.5” (63 mm) dia. Air Motor
• Fitted with strainer at suction
tube inlet for clean grease to
the bearing
• Supplied complete with built-in
Steel Drum, wheels & pull
handle, Drum Cover, rubber
lined Follower Plate, 7’ (84”) of
high pressure Grease Hose, Z
swivel & professional Grease
Control Valve

2
PUMP CONSTITUENTS
PUMP CONSTRUCTION
Drive Section
1
6
2
5
3
4
The pump is made up of two sections as given below :-
• Drive section :- It consists of an Air Motor Assembly driven
by compressed air. The piston diameter of the air motor is
2.5” / 63 mm. The motor consists of an air cylinder with
piston and one reciprocal valve with a nylon slider. The valve
directs the compressed air alternately to the top or bottom
of the piston, thus producing a reciprocating motion of the
piston rod.
• Pumping Section :- It consists of a pump in which a piston
lifts the grease through Non Return Valves by reciprocating
inside the pump cylinder. The grease is discharged with
pressure (from the outlet located at bottom of Air Motor) into
the delivery hose.
1. Grease Pump Assembly
2. Drum Cover
3. Rubber Lined Follower Plate
4. Steel Bucket with Cover Screws, Wheels & Pull Handle
5. High pressure Rubber Hose
6. Professional Grease Control Valve with Z Swivel
NOTE
AIR MOTOR of these pumps starts automatically when the
Grease Control Valve is opened. When the valve is closed, Air
Motor builds up a back-pressure and stops operating the pumping
section.
PRESSURE RATIO of the pump states the ratio of the output
grease pressure to the incoming air pressure. When the pressure
ratio is 50:1, we achieve an output grease pressure up to 7500 PSI
(500 BAR) when the incoming air pressure is 150 PSI (10 BAR ).
Pumping Section

3
WORKING OF PUMP
UPSTROKE DOWNSTROKE
A
B
C
D
G
H
J
I
F
A
B
C
D
G
E
H
J
I
F
E
UPSTROKE -
When Grease Control Valve is opened, compressed air enters
at arrow A and passes through passage B to the underside of
the Piston C, driving the Piston C and Piston Rod D upwards.
The air above the Piston is evacuated through passage E, past
the Slider Valve F and out at arrow G.
The Piston approaches top dead centre and Piston Rod D
makes contact with the Slider Rod H. Now the Slider Rod H
starts moving up with the Piston Rod D.
DOWNSTROKE -
The incoming air is now led via passage E to the upper side
of Piston C, driving it and the Piston Rod D downwards. The
air under the Piston C is evacuated through passage B, past
the Slider Valve F and out at arrow G.
The Piston approaches bottom dead centre and Piston rod
D makes contact with the Slider Rod H. When Slider Rod H
passes its centre position, the Pusher Spring I and Pusher
Button J snap it over to its lower position.
The air motor repeats Upstroke & Downstroke in continuous cycle to produce a reciprocating motion, driven by compressed air. This
motion is transferred via a connecting rod to the piston in the Pumping Section. During every upstroke, non return valves (with spring
& ball check) get opened & the piston lifts the grease. During every downstroke, non return valves get closed & the piston discharges
grease from the outlet valve.
Closing the Grease Control Valve shuts off the air motor & pump stops dispensing grease.

4
INSTALLATION
1. Fill the drum with
Grease leaving empty
space of about 2” from
the top rim. Shake the
drum after it is filled
to remove air pockets.
Place the follower
plate in the grease
drum with the
lift handle facing
upwards. Push the
follower plate down,
until some grease is
forced through the
centre hole on the
plate.
2. Place the drum cover
on the drum. Lift the
pump assembly &
slide the suction tube
through the drum
cover & centre hole in
the follower plate.
3. Push the pump
assembly down till
the bottom of the
pump touches the
base of the drum.
Adjust the drum cover
and tighten it with
the thumb screws
provided along with
the drum cover.
An FRL (Filter-Regulator-Lubricator) unit must be used in the Air supply, before it is connected to the pump. Set the regulator to 6 BAR (90 PSI)
or any required inlet pressure, but never more than 150 PSI (10 BAR) or less than 30 PSI (2 BAR).
4. Tighten the drum cover
with the pump suction
tube with the help of
thumb screws.
5. Use a wrench to tighten
high pressure hose to the
pump outlet.
6. Use a wrench to tighten
the other end of the hose
to Z Swivel of grease
control valve. Tighten the
outlet extension & coupler
to the control valve outlet.
Use thread sealant on all
connections to ensure
leak-proof working.
7. With the air supply turned
off, connect the Air line
into the air inlet on the
pump.
NOTE
Air Line
Z Swivel
Thumb
Screw
Thumb Screws
Extension
& Coupler
Hose
Lift Handle

5
MAINTENANCE & REPAIR (Refer to Parts Drawing)
Service Precautions
• Before performing any service operation, always shut off the air supply and release the pressure of the medium, i.e. let the grease out so
that the pressure decreases. When storing the pump assembly without the bucket, cover the Filter Tube (57) with Filter Cap (62).
• Be careful not to damage any parts when dismantling. While removing shafts which do not have key flats, wrap a thick piece of cloth
around the shaft before removing it with a Pipe wrench, Polygrip wrench or the like. The easiest way to remove such a shaft is to grip it in
a vice with aluminium or copper jaws, clamp the shaft in a hand-drill chuck and then turn the chuck by hand.
• Be careful when fitting O-rings and seals. Always lubricate them with oil or grease before fitting. They must never be threaded over sharp
edges when being fitted. Lubricate all moving parts with oil or grease.
• When troubleshooting, be on a lookout for dirt in valves / ball seats, scratches in sealing surfaces & damaged O-rings / seals / gaskets.
• Pump Cylinder (51) has a pin-hole end that must face
upwards; towards Extension Rod (46).
• Slide Bush (53) has a slotted end that must always
face upwards; towards Top Coupler (52).
• When fitting Plunger Rod (9), Connecting Rod (43) &
Plunger Nut (7), apply locking fluid on the threads.
• Replace Component No. 51, 52, 53 & 55 as a SET.
Drive Section Disassembly & Reassembly
Pumping Section Disassembly & Reassembly
1. Hold the complete pump assembly in a vice & unscrew the
Filter Tube (57). Prevent the Piston Rod (55) from rotating by
inserting a rod through the side hole in Piston Rod. Remove
the Nyloc Nut (61) & Piston Washer (60).
2. Unscrew the Bottom Coupler (54) & remove Slide Bush (53).
Unscrew the Top Coupler (52) & remove lower Steel Ball (47),
Non Return Spring (48), Valve (49) & both O Rings (50).
3. Unscrew the Barrel (63). Drive out the lower Slotted Spring
Pin (44) taking care not to bend the Extension Rod (46).
4. Unscrew the Pump Cylinder (51) from Extension Rod (46).
Remove upper Steel Ball (47) & Non Return Spring (48).
5. Drive out the upper two Slotted Spring Pins (44), unscrew the
Extension Rod (46) and then Connector (45).
6. Assemble by following the steps 1-5 in reverse order taking
care of the points below:
1. Remove Bend Pipe (1) by opening both the Coupling Nuts (2).
Remove both Sealing Rings (3) & unscrew both Bends (4).
Unscrew the Cylinder Cover (5) and Cylinder (10).
2. Unscrew Inlet Cover (32) & dismantle the two Pushers (15)
with their Pusher Springs (17), Pusher Nuts (18) & Pusher
Buttons (19).
3. Remove Circlip (20), both Filters (21), O Ring (22) & Exhaust
Valve (23).
4. Unscrew the Plunger Nut (7) and remove Rubber Plunger (8).
5. Unscrew Plunger Rod (9) from Connecting Rod (43) and
remove Slider (30). Remove Slider Guide (38), its outer O Ring
(37), Seals (39), Seal Support (40) & its inside O Ring (11).
6. Open the two Screws (29) & remove Clip (28), Nylon Slider
(27), Slider Guide (26), Seat (25) & Paper Seal (24).
7. For reassembly of Air Motor, follow the above-mentioned
steps 1-6 in reverse order taking care of the points below:
• When fitting Pushers (15), open Inlet Cover (32) &
ensure correct installation of Pusher Buttons (19).
• Conical side of Seals (39) must face upwards.
Assemble Slider guide (38), its outer O Ring (37),
Seals (39), Seal Support (40) & its inside O Ring (11).
Hold them as a set & mount on Connecting Rod (43).
1. Partially open the on/off air valve ( It helps in creating initial vacuum when filling a totally dry pump ). Pump will start operating
automatically until it gets primed. Pump is said to be Primed when grease is available at the pump outlet, making the pump ready to use.
Once primed, the air motor will stop. Open the on/off air valve fully.
2. Hold the grease control valve near a container & press the trigger. Pump will start
operating with continuous grease discharge as long as the trigger is pressed. Release
the trigger & this will stop the pump. Check for any leaks from any of the connections &
Tighten again if required.
3. Connect coupler fitted onto the control valve extension with the grease nipple & press
trigger. Be careful not to over-lubricate as the pump will keep dispensing grease as long
as the trigger is pressed. Once the trigger is released, pump will stop dispensing grease
& the air motor will stop.
4. When not in use & at the end of each day, air supply to the pump must be switched off.
PUMP OPERATION

6
PARTS DRAWING FOR BGRP
69
68
66
67
PUMP ASSEMBLY GREASE BUCKET, DRUM COVER, FOLLOWER PLATE,
HOSE, Z SWIVEL & GREASE CONTROL VALVE
3
4
6
11 25 27
16
29
15
39
37
3
15
16
17
51
50
53
52
56
61
55
60
48
46
47
48
5
1
8
2
9
10
7
12
13
19
2
18
6
24
4
20
21
22 21
14
19
23
26
28
30
31 32
33 16
34
18
16
17
35 36
11
40
42
41
44
43
45
44
50
54
57
58
59
63
Replace Component No.
51, 52, 53 & 55
as a SET
49
Slotted side
must face
upwards
Pin Hole end
must face
upwards
51
53
38
47
62
Correct Fitment of
Slide Bush (53) &
Pump Cylinder (51)
Conical side of
Seals (39)
must face
upwards
Correct Fitment of
Seals (39)
38
40
39
65
64

7
REFERENCE NO. DESCRIPTION QUANTITY
1 Bend Pipe 1
2 Coupling Nut 1
3 Sealing Ring 2
4 Bend 2
5 Cylinder Cover 1
6 O Ring BS141 2
7 Plunger Nut 1
8 Rubber Plunger 1
9 Plunger Rod 1
10 Cylinder 1
11 O Ring BS614 2
12 Rod Guide 1
13 O Ring 1
14 Housing 1
15 Pusher 1
16 O Ring BS617 4
17 Pusher Spring 2
18 Pusher Nut 2
19 Pusher Button 2
20 Circlip 1
21 Filter (B) 2
22 O Ring BS121 1
23 Exhaust Valve 1
24 Paper Seal 1
25 Seat 1
26 Slider Guide 1
27 Nylon slider 1
28 Clip 1
29 Self Tapping Screw 2
30 Slider 1
31 O Ring BS129 1
32 Inlet Cover 1
33 Filter (B) 1
34 Air Inlet Adapter 1
35 Outlet Adapter 1
36 Adapter Cap 1
37 O Ring 1
38 Slider Guide 1
39 Seal 4
40 Seal Support 1
41 Spring 1
42 Washer 1
43 Connecting Rod 1
44 Slotted Spring Pin 3
PARTS LIST FOR PUMP ASSEMBLY

8
PARTS LIST FOR GREASE BUCKET, DRUM COVER, FOLLOWER PLATE,
HOSE, Z SWIVEL & GREASE CONTROL VALVE
REFERENCE NO. DESCRIPTION QUANTITY
64 Grease Bucket 15 kg
Grease Bucket 30 kg
Grease Bucket 50 kg
1
1
1
65 Follower Plate 1
66 Drum Cover 1
67 Hose 1
68 Z Swivel 1
69 Grease Control Valve 1
REFERENCE NO. DESCRIPTION QUANTITY
45 Connector 1
46 Extension Rod 1
47 Steel Ball (7/32”) 2
48 Non Return Spring 2
49 Valve 1
50 O ring (BS812) 2
51 Pump Cylinder 1
52 Top Coupler 1
53 Slide Bush 1
54 Bottom Coupler 1
55 Piston Rod 1
56 Guide Bush 1
57 Filter Tube 1
58 Filter Washer 1
59 Filter Circlip 1
60 Piston Washer 1
61 Nyloc Nut 1
62 Filter Cap 1
63 Barrel 1

9
PROBLEM POSSIBLE CAUSE SOLUTION
Pump operates, but does not
dispense any grease
Grease is too thick / too cold Store grease in a warm place
Air pockets in grease Shake the Grease Bucket (64) & manually force down the
Follower Plate (65) to remove air pockets
Dent in the Grease Bucket (64) restricting
movement of Follower Plate (65) leading to
formation of air pockets in the bucket and
inefficient working
Get the dent removed to ensure proper movement of
Follower Plate (65)
Pump not working / less
discharge
Inlet pressure is too less Increase inlet pressure. It must be at least 30 PSI (2 BAR)
Nylon Slider (27) is jammed / overtight
1. Loosen both Screws (29) & remove Clip (28) . Check
for any build-up edge on Clip (28) & tighten it again.
Make sure the movement of Nylon Slider (27) is neither
very loose nor very tight
2. If needed, replace Nylon Slider (27). Also replace the
Paper Seal (24), Seat (25), Slider Guide (26) & Clip (28)
to ensure the best fitting
Piston / Piston Rod / Plunger jammed.
NOTE
Especially check Extension Rod (46),
Cylinder (51), Top Coupler (52), Slide Bush
(53) & Piston Rod (55) as shown in PARTS
DRAWING
1. Remove suction tube. Disconnect Air Motor Assembly
from Pumping Section by removing the upper two
Slotted Spring Pins (44) from Connector (45)
2. Supply input air to Air Motor. If it works properly
without the barrel assembly, then the problem lies with
the pumping section. Otherwise check the Air Motor
for smooth movement
3. After locating the faulty section, check the respective
Piston / Plunger & the associated washers & seals for
any overlap or wear & tear. Replace the defective parts
from Repair Kit
4. Ensure to replace the moving parts having close
tolerances (such as Piston & Cylinder along with Non
Return Springs & balls) as a SET to ensure the best
fitting
Pump continues to operate
even after the trigger of Grease
Control Valve (69) has been
released
Leakage in the assembly
Check all the connections to ensure they are air tight. Use
thread sealant
Check O rings & seals for damage. Replace the defective
parts from Repair Kit
Grease comes through the air
Exhaust Valve (23) Grease leaks into the Air Motor
Check Slider Guide (38), O Ring (37), lower O Ring (11),
Seals (39) & Seal Support (40) for wear & tear. Replace the
damaged parts from Repair Kit
Air passes directly from inlet
to the outlet & pump does not
work
Nylon Slider (27) is jammed / overtight
1. Loosen both Screws (29) & remove Clip (28) . Check
for any build-up edge on Clip (28) & tighten it again.
Make sure the movement of Nylon Slider (27) is neither
very loose nor very tight
2. If needed, replace Nylon Slider (27). Also replace the
Paper Seal (24), Seat (25), Slider Guide (26) & Clip (28)
to ensure the best fitting
Discharge suddenly stopped
while the pump was running
Seals / O Rings Damage Check all seals / O Rings & replace the damaged parts from
Repair Kit
Chip / Other foreign particles get clogged at
discharge coupler
Open the coupler, remove all foreign particles / chips &
reassemble properly
Clogging of Filter Tube (57) Open Filter Tube (57), clean it & reassemble it properly
TROUBLESHOOTING
(Refer to Parts Drawing)

10
REPLACEMENT & SERVICE PARTS PROGRAM FOR BUCKET GREASE RATIO PUMP
REPLACEMENT PARTS PROGRAM
REFERENCE NO. PART NO. DESCRIPTION
64 FLP/195-22S/6
FLP/322-380/6
FLP/322-380/6
Follower Plate, BGRP15
Follower Plate, BGRP30
Follower Plate, BGRP50
65 DC/BGRP/15
DC/GP1/BL
DC/GP2/BL
Drum Cover, BGRP15
Drum Cover, BGRP30
Drum Cover, BGRP50
66 HOSE/GRP/84/B
HOSE/GRP/84/N
Hose, BSP Threads
Hose, NPT Threads
67 HFC/1-4F/1-4M/B
HFC/1-4F/1-4M/N
Z Swivel, BSPT Threads
Z Swivel, NPT Threads
68 APG/HD/Z/1-4F/B
APG/HD/Z/1-4F/N
Grease Control Valve, BSPT Threads
Grease Control Valve, NPT Threads

11
SERVICE PARTS PROGRAM
KIT PART NO. KIT
DESCRIPTION
CONSTITUENT
PART NO.
PART
DESCRIPTION
REFERENCE NO. FROM
PARTS DRAWING
QTY.
PER
KIT
KIT/TP/RP-G DRIVE SECTION KIT
SR/B/RP Sealing Ring 3 2
BEND/90/RP Bend 4 2
ORG/BS141 O Ring 6 2
ORG/BS614 O Ring 11 2
ORG/BS617 O Ring 16 4
ORG/BS121 O Ring 22 1
SEL/P/RP Paper Seal 24 1
SET/RP Seat 25 1
SLD/NY/RP Nylon Slider 27 1
CLP/RP Clip 28 1
SCR/M4/RP Self Tapping Screw 29 2
ORG/BS129 O Ring 31 1
ORG/BS614 O Ring 37 1
GUD/SEL/RP Slider Guide 38 1
SEAL/RP Seal 39 4
SU/SEL/RP Seal Support 40 1
ROD/CNR/S/RP Connecting Rod 43 1
SSP/3/0.6/15.3 Slotted Spring Pin 44 3
KIT/BTM/RP-G PUMPING SECTION KIT
SB/7-32 Steel Ball (7/32”) 47 2
SPR/NR/RP-G Non Return Spring 48 2
VLV/RP-G Valve 49 1
ORG/BS812 O Ring 50 2
CYL/RP-G Pump Cylinder 51 1
CPL/TOP/RP-G Top Coupler 52 1
BSH/SLD/RP-G Slide Bush 53 1
ROD/PST/RP-G Piston Rod 55 1
BSH/RP-G Guide Bush 56 1
WSR/PST/RP-G Piston Washer 60 1
NN/M6/RP-G Nyloc Nut 61 1
IC/FLT/RP-G Filter Cap 62 1

12
• Always wear protection gear like safety goggles, gloves,
apron, and ear plugs while operating the pump
• Never let any body part come in front of, or in contact with
the control outlet
• Always cut off air supply after use, so that media cannot leak
incase any of the pump component fails
• Before switching the air supply on, check hoses for sign of
wear, leak or loose fittings. Replace as necessary
• Do not smoke near the pump. Do not use the pump near a
source of spark / open flames
• When changing the working fluid, at least 1 litre of new fluid
should be discarded to avoid mixing of fluids
• Pump should NOT be operated for more than 4 hrs
continuously
• Pump must be supplied with CLEAN & DRY compressed air
via an FRL unit
• Before attempting any maintenance or repair of this product,
disconnect air supply and then squeeze control valve trigger
to release fluid pressure
• Use only genuine factory parts for repair
• In case of accident, immediately seek medical attention. Do
not try to treat the injury yourself
Groz Engineering Tools (P) Ltd.
Groz Net Industries
Village Kherki Daula, National Highway-8
Gurgaon-122001, Haryana, INDIA
TEL [phone]
FAX [phone]
FAX (USA) +1.509.271.7848
FAX (UK) +44.870.121.1854
E-MAIL [email protected]
URL www.groz-tools.com
The Groz name, Groz logo and the mark are
trademarks of Groz Engineering Tools (P) Ltd. India
MODEL BGRP/15 BGRP/30 BGRP/50
Bucket Capacity 15 Kg / 1.8 Gal / 33 lbs. 30 Kg / 3.5 Gal / 60 lbs. 50 Kg / 6 Gal / 110 lbs.
Suction Tube Length 17.32” (440 mm) 17.32” (440 mm) 28.74” (730 mm)
Suction Tube Dia. 1.18” (30 mm)
Flow Rate 1.10 Kg / min. (2.42 lbs / min)
Working Pressure 10 BAR (150 PSI)
Maximum Outlet Pressure 500 BAR (7500 PSI)
Air Inlet Connection ¼” (F)
Pump Outlet Connection ¼” (F)
Air Consumption 230 LPM (61 GPM)
Hose Length* 7’ (84”)
Noise Level 81 db
SPECIFICATIONS
WETTED COMPONENTS
Steel, Brass, Aluminium, & Polyurethane
RECOMMENDED USE
With light and self collapsing grease up to NLGI No. 2
* IT MAY VARY FROM ONE MODEL TO ANOTHER