Operating instructions

Pump FZ-A

INDEX
Page
1. General ................................................................................. 2
2. Safety .............................................................................. 2 – 4
A Pump type ............................................................................ 5
B Number of outlets ................................................................ 5
C Revision ................................................................................ 5
D Kinds of drive ................................................................. 6 – 9
E Position of drive .................................................................. 9
F Reservoir ............................................................................ 10
G Accessories ....................................................................... 10
3. Application ......................................................................... 11
4. Principle of operation ........................................................ 11
5. Rotational direction of drive ............................................. 12
6. Specifications .................................................................... 12
7. Start-up ............................................................................... 12
8. Maintenance ............................................................... 13 – 14
9. Plates .................................................................................. 14

Page 1 of 14 BA_2005_1_GB_FZA
1. General
Before installing and operating this equipment, we highly recommend that you become thoroughly familiar
with these instructions. DELIMON does not accept liability, expressed or implied, for any direct or
inconsequential injuries to personnel or damage to equipment, including process interruption, arising from
the misuse or misapplication of its products. Application and / or modification of product beyond its
intended purpose is strictly prohibited.
DELIMON reserves the right to make modifications, changes and/or amendments to both products and to
these instructions as may become necessary to assure ongoing technical clarity.
The content of this technical publication is the sole graphic and intellectual property of DELIMON and is
protected by local and International Copyright Law. As such, it may not be copied, reproduced or used for
any purpose other than that intended by the Company; i.e. as a guide to proper installation, maintenance
and operation of its equipment by qualified personnel and their supervisors. Use of this information for
any other purpose or intent requires the expressed written permission of DELIMON GmbH.

Contact Information: For assistance with product, replacement parts, service or training.
DELIMON GmbH Branch Office
Arminstraße 15 Am Bockwald 4
D-40277 Düsseldorf D-08344 Grünhain-Beierfeld
Phone : +49 211 77 74-0 E-mail : kontakt@bijurdelimon.com
Fax : +49 211 77 74-210 www.bijurdelimon.com

2. Safety
These instructions provide basic guidance which must be followed during installation, operation and
maintenance. It is assumed that personnel performing required tasks are skilled in the areas of electrical
and mechanical millwright trades plus all local and federal safety requirements. These instructions should
be kept near the point of use and made available for reference at all times.

2.1 Identification of safety warnings in the operating instructions

To minimize risk to people working with this equipment, safety warnings included within these instructions
must be observed. Potential safety issues are identified through use of the following general danger
symbols:

Safety Sign, per DIN 4844, provides warning of potential general danger.

Safety Sign, per DIN 4844, provides warning of potential electrical danger.

ATTENTION

Caution designation utilized to signify that damage to machinery and function may result if guidance is not
properly followed.
Instructions affixed directly to machines and equipment must always be observed and maintained to
ensure that they are fully legible. Examples of such instructions would be:
• Rotational direction arrows for shafts and couplings.
• Identification of fluid connections, direction of flow and substance contained in pipes.
Important Note: There is always increased risk of slipping or falling whenever spilled or leaking
lubricants are present. In all cases, they should be properly removed and disposed of.

Safety Sign, per DIN 4844, provides warning of an increased risk of slipping and falling
due to the presence of water, oil, grease or other foreign substances on pavements,
floors and walkways.

Page 2 of 14 BA_2005_1_GB_FZA
2. Safety (continuation)
2.2 Personnel qualification and training
Personnel performing work required to install, operate, maintain or inspect this equipment must be
adequately trained and qualified. In this regard, determination of competency, understanding and
supervision levels required for individual assignment is left to the purchaser of the equipment. However,
should assistance with on-site training be desired, please contact your local DELIMON office for
assistance.

2.3 Dangers in case of nonobservance of the safety instructions

Failure to properly follow all safety instructions may result in hazard to personnel, the environment or to
machinery and equipment. Failure to follow these instructions may also additionally void warranties and
nullify claims for damages. Examples of such instances follow:
• Failure of machinery or operating systems to function properly
• Failure to observe proper methods of maintenance and repair
• Unnecessary creation of hazards to personnel by means of electrical shock, mechanical injury or
exposure to potentially hazardous chemicals
• Unnecessary creation of environmental hazards through chemical leaks

2.4 Safety conscious working

All Safety Instructions resulting from National, Local or User mandated regulations, as well as those
contained within this instruction, must be observed at all times.

2.5 Safety instructions for the user/operator

• Users should always take care that only authorized and skilled personnel are allowed to perform
installation, maintenance and inspection work.
• Installation, maintenance and inspection of lubrication systems should only be performed while
machinery and equipment being serviced is in “Shut-Down Mode”.
• Protective covers and guards, provided to ensure that contact with moving parts is eliminated during
machine operation, (e.g. couplings, pulleys, gears, etc.), must be replaced following maintenance
and repair.
• Use “Common Sense”! When hot or cold machine parts can lead to potential dangers, those parts
must be handled in such manner so as to avoid human touch; i.e. shielding is required.
• Leaks from shaft seals, reservoirs, piping or fittings should be repaired so as to not cause potentially
hazardous materials from escaping to the work area. In instances where such leaks have occurred,
all local and National rules and regulations for their recovery and disposition must be followed.
• All potential hazards resulting from exposure to electrical sources must be eliminated. Please refer
to VDE and local power company rules and regulations for guidance.
• Before restarting system and equipment, refer to instruction in Section 7; Start-Up Procedure.

2.6 Safety instructions for maintenance, inspection and installation work

Before installing or servicing lubrication equipment and machinery, management should insure that only
persons who are fully trained, skilled and authorized to perform such work are assigned to such tasks.
Major installation or modification work should only be performed during shut-downs. It is also imperative
that shut-down procedures recommended by equipment manufacturers be followed. Pumps, lubricators
and distribution systems which deliver potentially hazardous materials to the environment must be
thoroughly cleaned. All safety devices and protective equipment, disabled or removed during cleaning,
must be immediately reinstalled and reactivated prior to machine use.

Safety Sign, per DIN 4844, Use Safety Glasses or Goggles.

Advice: Whenever working with compressed air, wear safety glasses

Safety Sign, per DIN 4844, Use Breathing Mask.

Advice: Observe EC-Safety Data Sheet for materials of consumption
and additives used and use personal protective equipment.

Page 3 of 14 BA_2005_1_GB_FZA
2. Safety (continuation)
Additional Cautions for Pump Type FZ-A
• Potential ‘pinch-point’ whenever closing the reservoir lid! When filling the reservoir while pump is
operational, DO NOT put your hand into the reservoir. Risk of personal injury may result from
contact with scraper blade and agitator.
• Whenever handling lubricants, take measures to avoid environmental pollution.
• DO NOT use high-pressure cleaning devices on outside of pump. Always use solvent free cleansers.

2.7 Unauthorized conversion and manufacture of spare parts

The modification and/or manufacturing of parts for use as spare or replacement parts in DELIMON
lubrication equipment, without the written consent and approval of DELIMON Engineering, is strictly
prohibited. Any such modification and/or manufacture of component parts shall immediately render any
and all warranties as null and void.

2.8 Unacceptable modes of operation

The operational integrity and reliability of all equipment supplied is warranted only when said equipment is
utilized in strict accordance with parameters established in Section 1; Introduction. Maximum operating
parameters outlined in Engineering Data Sheets must never be exceeded.

2.9 Guidelines & standards

1., 2. and 3. guideline (see data sheet: R&N_2009_1_GB)

3.0 Notes on environmental protection and waste disposal

During proper operation, various component parts of lubricating systems are subject to special
requirements as set forth by Environmental Legislation.
General requirements for handling lubricants are specified in their respective safety data sheets.
Used lubricants are hazardous forms of waste and therefore require special handling and supervision
with regard to § 41 paragraph 1, sentence 1 and paragraph 3 no. 1 of KrW-/AbfG (Closed-Loop Waste
Management Act).
Used oils must be handled in compliance with AltölV (Waste Oil Ordinance).
Any devices or components which become contaminated with lubricant must be disposed of by a certified
waste management company. Additionally, records indicating proper conformance to waste management
practice and law must be filed according to NachwV (Ordinance on Waste Recovery and Disposal
Records).

Page 4 of 14 BA_2005_1_GB_FZA
GENERAL PRODUCT CHARACTERISTICS
• Central piston technique
• Insert for anticlockwise and clockwise rotation
• Feed volume per outlet up to 60cm3/h
• Lubricants: oil, grease, liquid grease
• Surface signal grey RAL 7004

A PUMP TYPE FZA

B NUMBER OF OUTLETS
Outlets 1 - 6 are arranged in the upper row. Outlets placed one above the other can only be combined in
the order shown in the picture. Fusions begin at the outlets 1/7 and follow the direction of the arrow. Refer
to graphic for order of outlets.
The pump body is comprised of a control sleeve which guides the piston, and a setting spindle which
determines piston stroke; thus determining the delivery rate of each outlet (up to 6 outlets), or of two
outlets when placed on above the other (7 to 12 outlets).

Designation and position of outlets when being combined.

Whenever dealing with 2 outlets having half the total volumetric output, one outlet in the upper and lower
rows may be opened.

C REVISION
Stage A

Page 5 of 14 BA_2005_1_GB_FZA
D. KINDS OF DRIVE
Drive with oscillating lever
The assembly group constitutes an extension of the assembly group drive with free shaft end containing
those parts being necessary for the oscillating lever drive. The oscillating lever is reciprocated by a
suitable component part of the machine to be lubricated via an eccentric, a crank and rod, and at the
same time, the worm wheel is always turned – regardless of the rotational direction of the driving shaft -
in the same direction via the switch mechanism.

Drive with oscillating lever

Page 6 of 14 BA_2005_1_GB_FZA
D. KINDS OF DRIVE (continuation)
Drive with free shaft end
The drive assembly consists of a ball bearing supported drive shaft and worm gear. A filler plug is
provided to facilitate filling of the housing with oil. The filler plug must be removed prior to removal of the
shaft with a mandrel.

Rotary drive with free shaft end

Page 7 of 14 BA_2005_1_GB_FZA
D. KINDS OF DRIVE (continuation)
Drive with reduction gear or with reduction gear and motor
The assembly consists of the drive assembly with free shaft end, to which a second worm gear drive is
added.

Drive with reduction gear

Page 8 of 14 BA_2005_1_GB_FZA
D. KINDS OF DRIVE (continuation)

Drive with reduction gear and motor

E. POSITION OF DRIVE

Position 1 left
Position 5 right
without

Page 9 of 14 BA_2005_1_GB_FZA
F. RESERVOIR
The reservoir lid is hinged for ease of access. It can be secured with a padlock to prevent unauthorized
access or tampering. Reservoirs are equipped with a scraper and feed screw. The scraper removes
grease from the sidewall of the tank, while the feed screw assures slight pressurization of grease being
fed to the pump’s inlet chamber. A strainer is fitted in the bottom of the tank to protect the pump inlet
chamber against contamination.

G. ACCESSORIES

Level switch
A lubricant level switch is available for reservoir monitoringby ultrasonic means. When the minimum or
maximum level is reached, an electrical signal is generated. The signal may be used for the purpose of
providing visual indication of status by adding a signal lamp, or to activate an automated filling device.
When so equipped, operating instructions pertaining to P/N BA_2005_1_GB_76951_6001 are provided
with the unit.

Pressure control
When so equipped, operating instructions for pressure control PB_2005_1_GB_38132 are provided with
the unit.

Page 10 of 14 BA_2005_1_GB_FZA
3. Application
Pump FZ-A is designed as a single-piston pump with up to 12 outlets. It is predominantly intended for
multiline - centralized lubrication systems. The pump can be driven by the flange motor or by the machine
to be lubricated via an oscillating lever or a coupling.

4. Principle of operation (figures 1 and 2)

The top of the worm wheel (1) driven by a worm shaft is provided with 2 drivers with recesses in which a
crosspiece (2) engages. In two other grooves of the crosspiece the drivers of the eccentric disk (3)
engage and impart a rotary movement to the eccentric disk and the piston (4). The compression spring
(5) located between the crosspiece and the eccentric disk presses the eccentric disk upwards. On its top
surface the eccentric disk is provided with a cam which, due to its rotary movement, strikes the 6 setting
spindles (6) arranged on the circumference of the pump and therefore forces the piston to perform one
suction stroke each time.
The lubricant is supplied to the pump inlet chamber (S) by a feed unit.
The underside of the eccentric disk is provided with 6 cams. Due to the rotary movement the cams on the
eccentric disk strike against a pressure cam (7), causing the piston to make a compression stroke each
time. The piston has three vertical grooves (N), which terminate in an annular channel (R). On pumps
with up to 12 (2 x 6) outlets the piston has two sets of three vertical grooves each terminating in an
annular channel. During the suction stroke lubricant is drawn from the inlet chamber (S) into the vertical
grooves of the piston and from there delivered into the annular channels (R). During the compression
stroke the lubricant is delivered from the annular channel via a vertical groove into the pressure channel
(D).
In continuous operation the pump can overcome a backpressure of 200 bar. Transient pressures of up to
250 bars are permitted. Safety valves can be installed in the discharge line as protection against
overload.

Fig. 1 Section through the pump FZ-A (6 outlets) Fig. 2 Principle of operation (FZ-A, 12 outlets)

Page 11 of 14 BA_2005_1_GB_FZA
5. Rotational direction of drive
As required, all pumps can be set-up for clockwise or counter-clockwise operation without modifying the
method of drive.

6. Specifications
Permissible back pressure: .............................................................................................................. 200 bar
for a short time: ............................................................................................................. 250 bar
Permissible pump piston speed:
with running drive: .................................................................................................................. max. 10 r.p.m.
with oscillating drive: ............................................................................................................. max. 16 r.p.m.
Number of oscillating strokes: ............................................................................................. max. 300 min.-1
In case that higher speed or less then < 1 is requested and also when distributors ZPA or E 4 are
installed downstream, ask manufacturer.

In case of using the oscillating lever drive, the lever rod should be installed in such a way, that the
amplitude of the oscillating lever is same in both directions ∝ 1 = ∝ 2 = max. 50o
Lever amplitude max. : .......................................................................................................................... 100o
Lever amplitude min. : ............................................................................................................................ 10o

7. Start-up
Installing and connecting the lubricating pump
The pump should be installed and mounted vertically. Wiring connections of the motor to its control box
must be carried out according to the circuit diagram with full observance of the paragraph concerning
direction of drive. When utilizing mechanical drives, all moving parts must be properly enclosed. To
prevent injuries.
Filling the lubricant tank and piping
All piping must be properly descaled and carefully cleaned prior to use. Following cleaning, fill with clean,
fresh grease using a grease gun. For initial start-up, first fill the grease tank with oil up to the strainer;
then add grease. Failure to do so will result in longer start-up times by obstructing proper venting. Before
connecting piping, operate the pump at full capacity until grease emerges from each outlet, evenly and
without air. Next, connect the piping to the pump, taking care to use seal washers. Continue to operate
pump until air-free grease emerges from the ends of the pipe.

Once the bearings to be lubricated are also filled with grease, piping can be connected to the bearings.
The system can be then be started after all required settings and adjustments are completed.
Setting the delivery rate (figure 3)
Full discharge capacity, (equal to 0.1 cm3 lubricant per discharge per piston stroke), is indicated by an
arrow on the outlet pointing to the number 4 stamped on the head of the setting spindle (Figure 2.5).
Turning the spindle clockwise reduces delivery. Reduction below 1/4 of the max. delivery setting (above)
should be avoided. Where pumps have 7 to 12 outlets, the delivery rate of two vertically arranged outlets
is adjusted by means of an adjusting spindle. The second arrow on the outlet points to the outlet bore
related to the setting spindle.
Changing the drive speed or the internal gear ratio of the pump changes the output volume of all outlets
and thus, overall pump output volume is changed.

Page 12 of 14 BA_2005_1_GB_FZA
 Figure 3 Pump body FZ-A
* In case that the outlet bores are closed by item no. 2.17, item nos. 2.18 and 2.19 are to be removed
from the pertaining relieving bores.

8. Maintenance
Filling the grease tank
The grease tank should be refilled whenever ¾ of its capacity has been depleted. Never allow the tank to
empty to a point where the feed screw is exposed, as air may enter the distribution piping. When filling
the tank, use only clean grease and take precautions to ensure that no dirt enters into the system while
the tank lid is opened. Failure to prevent dirt from entering the tank may lead to system malfunction.
Whenever possible, utilization of an external filling valve and firmly installed plumbing is the preferred
method.
Changing the number of outlets (figure 3)
Pumps are furnished with the number of outlets configured according to the original factory order. Should
circumstances arise requiring changes to the outlets, make changes according to the following
procedure.

Outlets are blocked off by connecting the pressure channel to the pump inlet chamber. To facilitate this,
the top channels are joined to the pump inlet chamber by threaded connections. To block off an upper
outlet, remove the tank, then remove the M4 x 6 cap screw and seal from the threaded hole (Figure 2.19).
To open a blocked off outlet, insert a cap screw and new A4 x 8 seal (Figure 2.18) to assure a tight fit.
Associated outlets can generally be opened or closed by either inserting or removing a screw plug;
(Figure 2.17).

When working on pumps having two vertical outlets, the setting spindle, ball and compression spring,
(Figures 2.5, 2.6 and 2.7) must be removed in order to close off the lower outlet. Before removing the
spindle, unscrew the shank screw (Figure 2.9). Next, insert the plug (Figure 2.20) into the setting spindle
bore. For reconfiguration at a later time, successively reinsert the setting spindle, ball and compression
spring following removal of the shank screw and seal. Reinsertion of the locating screw will bring the
spring and ball to their correct position with relation to the setting spindle groove. Note: Always use a new
seal ring, and lubricate the ball and spring prior to insertion.

Whenever two outlets, arranged one over the other, are shut down for a short period of time, the setting
spindle must be set to 0 and the outlets must not be rigidly blocked. In such cases, use plastic plugs in
place of screw plugs to enable accidental grease discharges to escape without causing
overpressurization.

ATTENTION!
If the number of outlets is modified improperly, damage to the pump cannot be avoided.

Page 13 of 14 BA_2005_1_GB_FZA
8. Maintenance (continuation)
Removal of the drive shaft (see figure)
After removing the spring washer (3.11) and the cap, the circlip (3.13) should be removed. After
loosening the plug (3.20) the drive shaft (3.12) including the roller bearings (3.17) and the sleeve (3.16)
can be driven out using a copper dowel and a hammer.

Gearboxes:
Gearboxes are filled with liquid type grease; i.e. Gearmaster LX00 (Messrs. Lubritech) or equivalent.
Refilling should only be done following gearbox disassembly and cleaning.

Filler Plugs: Main Gearbox (Figure 3.9), Reduction Gear (Figure 3.20)

9. Plates
Name plate Type plate

Page 14 of 14 BA_2005_1_GB_FZA