Pressol Pneumatic grease pump 50:1 User manual

03 591 A411 GB
Pneumatic grease pump 50:1
and grease supply system

2
GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
Contents
General Information1. __________________________________________________________________2
Usage Stipulations1.1 ___________________________________________________________________2
Construction & Functional Description1.2 ___________________________________________________2
Technical Data1.3 ______________________________________________________________________3
Application Range1.4 ___________________________________________________________________3
Operational Area Requirements1.5 ________________________________________________________3
General Safety Advice2. ________________________________________________________________4
Signs and symbols used in the safety instructions2.1 __________________________________________4
Information on safety at work2.2 __________________________________________________________4
Risks when Working with the grease pump2.3 _______________________________________________5
Assembly3. ___________________________________________________________________________5
Preparing for Operation4. _______________________________________________________________6
Operation5. __________________________________________________________________________6
Replacement of container5.1 _____________________________________________________________7
Maintenance6. ________________________________________________________________________7
Accessories7. _________________________________________________________________________8
Troubleshooting8. _____________________________________________________________________8
Repairs/Service9. ______________________________________________________________________9
EC Declaration of Conformity10. __________________________________________________________9
Exploded view11. _____________________________________________________________________10
1. General Information
1.1 Usage Stipulations
This pump is to be used for feeding lubrication greases and multi function greases from NLGI 0 to NLGI 2
from original barrels. It is both designed for use in conjunction with distribution lines or directly on the
container.
To ensure that usage stipulations are met, read through the operating instructions completely before
using the pump and observe all stipulations.
Any departure from the usage stipulations (other uid media, use of force) or user modications (changes,
use of non-original parts) can be dangerous and are considered as non-stipulated usage.
The user is liable for any damage resulting from non-stipulated use.
Before commencing any repair or maintenance work, release the pressure from the installation.
Repairs and maintenance are only to be carried out by qualied specialists.
Only original replacement parts are to be used for any repairs, otherwise the warranty will be invalidated.
1.2 Construction & Functional Description
The grease pump can be tted with a variety of PRESSOL accessories.
The Pump casing is manufactured from die-cast zinc with a hardened stainless steel piston rod and high
quality durable synthetic control components.
The polyurethane or Buna N o-rings and washers are designed to meet the operating requirements of the
pump.

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Operating instructions for Pneumatic grease pump 50:1 G
1.3 Technical Data
Typ 50:1
Transmission ratio 50:1
Maximum air pressure bar 10
Minimum air pressure bar 2
Recommended air Pressure bar 8
Motor Displacement cm3220
Pump Displacement cm38
Number of strokes at 8 bar * Strokes/min 220
Pump performance at 8 bar * g/min 1100
Pump pressure at 8 bar compressed air bar 400
Air consumption at 8 bar compressed air l/min 400
Airline connection G ¼” i
Grease supply connection from the suction side Ø/mm 35
Grease supply connection from the pressure side G ¼” a
Noise level on no load, according to ISO 9614-2 (2 m distance) db (A) 78
Noise level on load, according to ISO 9614-2 (2 m distance) db (A) 77
Weight kg 8,4
* under free discharge
Tab. 1-3: Technical Data
1.4 Application Range
This pump is to be used for feeding lubrication greases and multi function greases from NLGI 0 to NLGI 2
from original barrels.
1.5 Operational Area Requirements
The grease pump is intended for use within a building. The installation area must be selected such that
correct operation is ensured.
To avoid unnecessary damage and to prolong the life expectancy of the pump we recommend that an air
line combination lter, regulator and lubricator is utilised to ensure that the compressed air supply is not
contaminated and is regulated at the recommended pressure.
New installation lines should be cleaned to avoid any residual metal lings damaging individual
components within the pump. When changing containers protect the suction tube properly to make sure
that the suction tube will not be contaminated by dirt particles, such as metal parts, splinters etc. which
will additionally contaminate the lubricant in a new container.
The operator of such an installation is, according to § 19i WHG (Germany) responsible for continuous
monitoring to ensure compliance with the above stated requirements at the installation.

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GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
2. General Safety Advice
2.1 Signs and symbols used in the safety instructions
The safety instructions used in these operating instructions are divided into various levels of hazard.
Various levels of hazard are indicated in the instructions with the following keywords and pictograms:
Pictogram Keyword Consequences of failure to comply with the
safety instructions
Warning Possible death or serious injury
Caution Possible slight or not serious injury or material damage
In addition, a further instruction is used which gives general tips for handling the product.
Pictogram Keyword Meaning
Tip Background information or tips about how to use the product
2.2 Information on safety at work
The grease pump has been designed and manufactured according to the health and safety requirements
of the relevant EC guidelines.
Nevertheless, there can still be risks if the product is not set up or operated as stipulated.
Therefore, before using the grease pump, read these operating instructions and pass them on to other
users of the pump.
When operating the grease pump, the local safety and accident prevention rules and regulations always
apply, as well as the safety advice in the operating instructions.
Only approved PRESSOL maintenance personnel should open or repair pumps within the guarantee
period.
Attention! The compressed air line must be disconnected and the discharge pistol actuated to ensure
so the pump is depressurised before the pump unit is opened or inspected. For safety reasons the
compressed air line should be disconnected when the pump is not in use otherwise the pump will remain
pressurised.
Caution!
If the grease pump is incorrectly installed, or used for a purpose other than that
originally intended for, it can result in personal injury or damage to equipment!
Before starting to use the grease pump, read through these operating instructions carefully and
completely.

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Operating instructions for Pneumatic grease pump 50:1 G
2.3 Risks when Working with the grease Pump
Warning!
Damaged attachments and accessories can lead to personal injury and material damage!
Suction and pressure pipes must not be kinked, twisted or stretched.

Attachments and accessories must be checked for wear, splits or other damage at all times.

Defective accessories are to be replaced immediately only by Original-PRESSOL-Spareparts.

With reference to the period of use, please note the details in ZH 1/A45.4.2 or DIN 20066

Part 5.3.2.
Caution!
Spilled fuel can result in environmental damage!
Local and country rules and regulations relating to domestic water supplies and fuel

storage must be obeyed.
Caution!
Overpressure may cause damages of grease gun head and its accessories!
Do not exceed the working pressure stated in chapter 1.3.

We recommend the use of original accessories according to DIN 1283 only.

Caution!
Overpressure at the point of lubrication may destroy the grease nipple and perhaps
even the bearings or the machine itself!
Do not exceed the working pressure stated in chapter 1.3.

Please pay attention to the maintenance and service advices of the manufacturer of your

machine.
3. Assembly
The grease pump will be delivered completely assembled.
Accessories will have to be mounted depending on the version used.

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GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
Tip
Please care about a tidy environment while assembling the pump please and make sure that
there is a tight connection of the accessories to the pump.
Please use suitable sealing material (e.g. Teon lm), only.
Remove the dust cover from the container and insert the follower plate (Pos. 1) slightly tilted. Then
push the follower plate against the grease until the grease gets out from the central opening.
Fix the stabilising xing brackets (Pos. 3) on the grease container (Pos. 1) and adjust the stabilising
xing brackets above the central opening of the follower plate (Pos. 2).
Push the dust cover (Pos. 4) onto the pipe of the grease pump (Pos. 5) and insert the pipe through the
stabilising xing brackets (Pos. 3) and through the follower plate (Pos. 2) to the grease container
(Pos. 1).
Fix the grease hose with all its corresponding accessories (swivel joint, high pressure grease control
gun, etc.) onto the pump exit (Pos. 5.1).
The grease pump is now ready for operation.
4. Preparing for Operation
Caution!
Never work on a pump that is running!
Mount or remove attachments and accessories only when the pump is switched o.

Connect the compressed air connection (Pos. 5.2) of the grease pump with the air supply line. The pump
now starts to run.
Operate the high pressure grease control gun until the grease ows out without air bubbles.
Stop operating the high pressure grease control gun. The pump stops automatically when having
obtained the set working pressure.
The grease pump is now ready for operation.
5. Operation
Warning!
The pump supplies a working pressure of 400 bar!
While working with the pump please do wear suitable safety equipments (leather gloves,

protective glasses).
Never point the high pressure grease control gun on parts of your own body or on other

persons standing nearby.
Caution!
Do not pump contaminated materials!
Please make sure that there are no contaminations in the grease that you will pump.


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Operating instructions for Pneumatic grease pump 50:1 G
Press the hydraulic coupler onto the grease nipple in axial direction. (ill. 5-1)
Operate the high pressure grease control gun to supply the greasing part until the wished amount of
grease has been reached.
Disconnect the hydraulic coupler from the grease nipple by moving the hydraulic coupler in circles.
(ill.. 5-2)
Tip
Disconnect the quick coupler of the grease gun from the compressed air supply if the greasing
procedure has been achieved or if the pneumatic grease gun is not to be used for a while to
avoid an unintentional discharge of the grease cartridge or to prevent leakage.
5.1 Replacement of container
Caution!
Never work on a pump that is running!
Replace the container only when the pump is switched o and only when there is no more

air pressure in the system.
Disconnect the quick coupler of the grease gun from the compressed air supply.
Operate the high pressure grease control gun until grease ow stops.
When using 200 l container the follower plate (Pos. 2) can be removed from the bottom of the container
while using compressed air supply. In order to achieve this blow compressed air above the hose under the
follower plate by means of an air insuate pistol.
Uninstall the grease pump, the dustcover, the stabilizing xing brackets and the follower plate in contrary
sequence as described under step 3 (assembly).
Tip
Do not place the pump with its pipe directly onto the oor. Protecting the pump from the dust
will avoid possible damages on the system as well as maintenance time and after sales service
costs.
6. Maintenance
The muer and air inlet lter should be cleaned regularly to maintain the trouble free performance of
the pump. If an air line lubricator has not been installed frequently lubricate the pump by inserting 2 to 3
drops of quality oil through the air inlet connector at regular intervals.
The grease pump is very easy to maintain and service.
Due to the operator responsibilities according to § 19i WHG (German rules), the following components
must be regularly checked and replaced as necessary, to minimise the possibility of environmental or
equipment damage, or personal injury:
Pump housing

Delivery hose

Nozzle valve

Connection lines

ill. 5-1 ill. 5-2

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GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
7. Accessories
See catalogue Garage equipment or www.pressol.com
Tip
Only with original-PRESSOL spare parts is perfect operation of your grease pump guaranteed! To
avoid faulty operation and danger, please use only original spare parts.
8. Troubleshooting
Problem Cause Solution
The air motor runs slowly or
not at all.
The air pressure is too low. Regulate the air supply at a minimum
pressure of 3 bar.
The muer (pos. 20) or the lter
(pos. 11) is obstructed or dirty.
Clean the muer and lter.
The air motor is running but
the pump is operating too
slow or not at all.
Sieve (Pos.41) foul. Sieve must be cleaned up.
Grease container dented. Shove the follower plate underneath
the dent.
Airbubbles in the grease. Remove the pump from the container.
Push the container several times on
the oor.Press down the follower
plate and replace the pump into the
container. Operate the high pressure
grease control gun and connect the
compressed air.
Grease too sti. Use only grease until consistency
grade NLGI 2. Do not use grease below
temperature of 15°C.
Friction loss in the delivery hose. Select if possible only short hoses and
insert the pump centrally.
The pump is running but no
pressure is generated.
The o-rings, washers or valves of
the pump are damaged or dirty.
Clean or replace the relevant
components.
Air escapes from the muer
when the pump is not
operating.
The plunger (pos. 5) is damaged. Replace the plunger (Art.-Nr. 03 324).
The o-rings or the distributor
seal (pos. 19.6) are damaged.
Replace the components utilising the
complete repair kit (Art.-Nr. 87 351)
Tab. 8-1: Fault Finding
If the solutions given in Tab. 8-1 for solving faults do not solve the problem, please contact our customer
service (Address, See Chap. 9).

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Operating instructions for Pneumatic grease pump 50:1 G
9. Repairs/Service
The oil pump was developed and produced according to the highest quality standards.
Should a problem develop, despite all quality controls, please contact our customer service:
PRESSOL Schmiergeräte GmbH
Tel [phone]
Fax [phone]
[email protected]
10. EC declaration of conformity
We hereby state that the appliance described below, in the model which we have made commercially
available, complies in its design and construction with the EU directives. If a change has been made to the
appliance, and this has not been agreed with us, this statement loses its validity.
Designation of the appliance: Pneumatic grease pump 50:1
Appliance type: Pneumatic pump
Year built: See identication plate
Applicable EC-Directives:: EU-Directive Machines annex 1
89/392 EEC-Directive dated September, 14th. 1989
91/368 EEC-Directive dated June, 6th. 1991
93/68 EEC-Directive dated August, 30th. 1993
Applicable national standards: DIN EN 292, part 1, part 2
DIN EN 45014
24.10.2012 PRESSOL Schmiergeräte GmbH
Dipl.-Ing. Rudolf Schlenker

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GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
11. Exploded view
No. Description Prod. no.
1 Upper casing 03 268
2 O-ring 03 316
3 Locking nut 03 311
4 Washer 87 116
5 Plunger 03 324
6 Compensating washer 03 250
7 Screw 87 221
8 Washer 87 212
9 O-ring 02 380
10 Intermediate casing 87 211
11 Filter 87 228
12 Reducing connector 03 319
13 Control lever 87 210
14 Sleeve 87 209
15 Compression spring 87 215
16 O-ring 87 223
17 Insert 87 206
18 Screw 87 220
19 Distributor repair kit 87 351
19.1 Clamp 87 214
19.2 Sliding disc 87 213
19.3 O-ring 87 225
19.4 O-ring 87 224
19.5 O-ring 87 223
19.6 Distributor 87 204
20 Muer 87 227
21 Retainer 87 207
22 Piston rod repair kit 87 352
22.1 O-ring 03 262
22.2 Piston rod 87 205
22.3 Slider 87 208
22.4 Piston rod 02 840
23 O-ring 87 226
24 Connecting ange repair kit 87 355
24.1 Connecting ange 87 216
24.2 Bearing 03 307
24.3 O-ring 02 380
24.4 Washer 87 262
24.5 Support washer 03 292

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Operating instructions for Pneumatic grease pump 50:1 G
No. Description Prod. no.
24.6 Lip washer 03 387
24.7 Circlip 03 264
25 Screw 87 222
26 Locking pin 03 260
27 Compression rod
Length 176 mm 87 515
Length 238 mm 87 516
Length 376 mm 87 517
Length 476 mm 87 518
Length 776 mm 87 519
28 Ball bearing 03 304
29 Pressure piston 87 508
30 Locking nut 00 808
31 Threaded rod 87 509
32 O-ring 87 521
33 Suction tube
Length 229 mm 87 510
Length 291 mm 87 511
Length 429 mm 87 512
Length 529 mm 87 513
Length 829 mm 87 514
34 Adapter 87 507
35 Lip washer 87 522
36 Upper casing 87 506
37 Circlip 03 501
38 Lip washer 00 152
39 Valve cone 03 477
40 Valve body 87 505
41 Sieve 03 503
42 Circlip 03 328
43 Washer 87 528
44 Locking nut 01 085
45 Suction sleeve 87 504
Tab. 11-1: Index to illustration 11-1

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GOperating instructions for Pneumatic grease pump 50:1
Operating instructions for Pneumatic grease pump 50:1 G
24
ill. 11-1: Exploded View of the Pneumatic grease pump

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Operating instructions for Pneumatic grease pump 50:1 G

Pressol Schmiergeräte GmbH
Parkstraße 7
93167 Falkenstein | Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.pressol.com