series g model d - agri-inject.com · 1 frame and liquid end (d frame) code description sd2 max 0.7...
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Please record the following data for file referenceTag Number(s): _____________________________________Model Number: _____________________________________Serial Number: _____________________________________Installation Date: ____________________________________Installation Location: ________________________________
INSTALLATION,OPERATION, ANDMAINTENANCEMANUAL
Series G Model DMETERINGPUMP
339-0080-000ISSUED 07/02
TABLE OF CONTENTS
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SECTION DESCRIPTION PAGE
Series G Model D Pump Model Number and Options ................................................................................. 1
1.0 DESCRIPTION ............................................................................................................................................ 2
1.1 General Information ........................................................................................................................... 21.2 Principles of Operation ...................................................................................................................... 31.3 General Specifications ...................................................................................................................... 4
2.0 INSTALLATION........................................................................................................................................... 6
2.1 Unpacking ........................................................................................................................................... 62.2 Storage ................................................................................................................................................ 62.3 Safety Precautions ............................................................................................................................. 62.4 Mounting ............................................................................................................................................. 72.5 Drip Collection .................................................................................................................................... 72.6 Installation .......................................................................................................................................... 7
2.6.1 NPSH Considerations ............................................................................................................... 92.6.2 General Piping Considerations ............................................................................................... 92.6.3 Suction Piping Considerations ................................................................................................ 92.6.4 Discharge Piping Considerations .......................................................................................... 10
2.7 Valves ................................................................................................................................................ 102.8 Electrical Connections ..................................................................................................................... 11
3.0 OPERATION ............................................................................................................................................. 12
3.1 Start-Up Procedures and Checks .................................................................................................... 123.2 Checking the Electrical Connection of the Motor .......................................................................... 123.3 Start-Up .............................................................................................................................................. 123.4 Capacity Calibration ........................................................................................................................ 12
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4.0 MAINTENANCE......................................................................................................................................... 14
4.1 Preventative Maintenance............................................................................................................... 144.2 Returning Pumps to the Factory for Repair ................................................................................... 144.3 Routine Maintenance ....................................................................................................................... 144.4 Spare Parts ....................................................................................................................................... 15
4.4.1 Size SD2 and SD4 Liquid Ends - PVC and PVDF ................................................................. 154.4.2 Size SD2 and SD4 Liquid Ends - Stainless Steel ................................................................. 154.4.3 Size SD7 and SD8 - PVC, PVDF, and Liquid Ends ............................................................... 164.4.4 Size SD7 and SD8 - Stainless Steel Liquid Ends ................................................................. 16
4.5 Corrective Maintenance................................................................................................................... 164.5.1 Check Valve Assemblies Replacement: Liquid Ends SD2 and SD4 - PVC and PVDF ..... 174.5.2 Check Valves: Liquid End Sizes SD2 and SD4 - Metallic .................................................... 174.5.3 Replacement of Ball, Seat, and Seal: Liquid End SD7 and SD8 - PVC and PVDF ........... 174.5.4 Check Valve Replacement: Liquid End Size SD7 and SD8 - Stainless Steel .................. 18
4.6 Diaphragm and Oil Seal Bellows Replacement ........................................................................... 194.6.1 Diaphragm Replacement: Liquid End Size SD2 ................................................................. 194.6.2 Diaphragm Replacement: Liquid End Size SD4, SD7, and SD8 ....................................... 19
4.7 Oil Seal Bellows Replacement ....................................................................................................... 204.8 Restarting the Pump ........................................................................................................................ 21
5.0 PARTS LIST ............................................................................................................................................. 225.1 Parts List for Drive Side View .......................................................................................................... 245.2 Parts List for Drive End View ........................................................................................................... 265.3 Parts List for SD2 Plastic Liquid End PVC-NPT and PVC-Tubing ................................................. 285.4 Parts List for SD2 Metallic Liquid End Stainless Steel-NPT .......................................................... 295.5 Parts List for SD4 Metallic Liquid End Stainless Steel-NPT .......................................................... 305.6 Parts List for SD4 Plastic Liquid End PVC-NPT and PVC-Tubing ................................................. 325.7 Parts List for SD7 and SD8 Plastic Liquid End PVC-NPT and PVDF-NPT..................................... 345.8 Parts List for SD7 and SD8 316SS-NPT Liquid End ........................................................................ 36
6.0 TROUBLESHOOTING............................................................................................................................... 38
7.0 WARRANTY .............................................................................................................................................. 40
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Frame and Liquid End (D Frame)Code DescriptionSD2 Max 0.7 GPH / 175 PSISD4 Max 12.0 GPH / 150 PSISD7 Max 50 GPH / 100 PSISD8 Max 115 GPH / 75 PSI
Stroking SpeedCode Description
1 43 SPM2 86 SPM6 120 SPM3 173 SPM
MotorCode Description
X NEMA 56C Flange Less Motor8 115/230 VAC, 60 Hz,1 PH, 1800 RPM9 115/230 VAC, 50 Hz,1 PH, 1500 RPMJ 230/460 VAC, 60 Hz, 3 PH, 1800 RPML 220/380 VAC, 50 Hz, 3 PH, 1500 RPMP DC Variable Speed Drive
MACROY D PUMP MODEL NUMBER AND OPTIONS
Liquid End MaterialCode Description
2 PVDF7 316ss8 PVCP Polymer ServiceL Slurry ApplicationsN H2SO4 Applications
ConnectionsCode Description
P NPTT TubingB Outgassing Liquid Applications (NPT)C Outgassing Liquid Applications (Tubing)
Fram
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d Li
quid
End
Stro
king
Spe
ed
Mot
or
Liqu
id E
nd M
ater
ial
Conn
ectio
ns
SECTION 1DESCRIPTION
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1.1 GENERAL INFORMATION
The Series G Model D is a reciprocating, chemical dos-ing pump capable of producing flows up to 115 gallonsper hour (430 liters per hour) at pressures up to 175 psi(12 Bar). These pumps feature a mechanically actu-ated diaphragm liquid end, which eliminates the needfor flow-restricting contour plates, and a stroke adjust-ment mechanism based on the variable eccentric prin-ciple instead of the traditional lost-motion design. It isdesigned for industrial service and offers an accuracy of±2% of full rated flow between 10% and 100% of its flowrange.
The basic pump components as illustrated in Figure 1are:
� a drive device comprising a motor (1)
� a mechanical assembly (2)
� a liquid end (3).
An elastomeric bellows provides a leak-tight seal be-tween the mechanical assembly and the liquid end.
Capacity adjustment is manually controlled by a strokeadjustment knob (4).
Figure 1:Pump Assembly
1234
MotorMechanical AssemblyLiquid EndStroke Adjustment Knob
5678
Liquid End Mounting AssemblyCheck Valve Assembly (Suction)Check Valve Assembly (Discharge)Stroke Lock Knob
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1.2 PRINCIPLES OF OPERATION
Drive Assembly (See Figure 2)The pump consists of two major assemblies; the driveand the liquid end. Pump delivery is a function of thedrive's stroke rate, liquid end size and stroke length.Stroke length can be increased while the pump is run-ning by counterclockwise turning of the stroke adjust-ment knob. The drive assembly works on the principleof a variable eccentric. The rotational motion of the motoris transmitted by the worm (1) to the worm gear (2)which is linked to an eccentric system (3). The eccen-tric system then converts the rotary gear motion intolinear reciprocating motion of the connecting rod (4). At0% capacity setting, the connecting rod axis (B) isaligned with the gear axis (A) and no movement of theconnecting rod takes place. At 100% capacity setting,an eccentricity exists between the connecting rod axis(B) and the gear axis (A) which results in linear move-ment of the connecting rod and resulting pumpage.
Mechanically Actuated Diaphragm Liquid End(See Figure 2)The diaphragm assembly (5) is mechanically linked tothe connecting rod (4) and has the same reciprocatingmotion. As the diaphragm starts back on the suctionstroke, the pressure immediately drops inside the liq-uid end. When the pressure in the liquid end drops
below the suction line pressure, the suction ball checkis �pushed� upward and the process fluid in the suctionline flows into the liquid end chamber (diaphragm head).When the suction stroke ends, the diaphragm move-ment momentarily stops and the pressure in the liquidend equalizes with the pressure in the suction line caus-ing the suction ball check to reseat.
NOTE: It is important that the pressure in theliquid end remain above the vapor pressure ofthe process fluid during the suction stroke. Ifthe fluid pressure drops below the vapor pres-sure, cavitation will occur which will have a nega-tive impact on the performance of the pump.If you suspect the possibility of cavitation, con-tact your dealer for assistance.
As the diaphragm starts forward on the discharge strokethe pressure immediately rises inside the liquid end.When the liquid end pressure rises above the dischargeline pressure, the discharge ball check is �pushed� up-ward and the process fluid in the liquid end flows intothe discharge line. When the discharge stroke ends,the diaphragm momentarily stops again. The pressurein the liquid end equalizes with the discharge line pres-sure and the discharge ball check reseats. The cyclethen starts again.
Figure 2:Stroke Control OperatingPrinciple
(A) (B)
(A) (B)
(A) (B)
Zero Stroke Setting
Discharge PhaseSuction Phase
Setting to Maxmum Stroke
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WormWorm GearEccentricConnecting Rod
5678
DiaphragmStroke: two times the distance between (A) and (B)Position at rear neutral pointPosition at forward neutral point
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2
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1.3 GENERAL SPECIFICATIONS
FLOW RATE:
Up to 115 GPH (430 L/H)
PRESSURE:
Up to 175 PSIG (12 BAR)
LIQUID END TYPE:
Mechanically Actuated Diaphragm
DRIVE TYPE:
Variable Eccentric
STEADY STATE ACCURACY:±2% of pump full rated capacity between 10% and 100%of rated capacity.
CAPACITY ADJUSTMENT:Lockable stroke adjustment knob is adjustable from 0%to 100% while pump is running.
LUBRICATION:Drive is lubricated in an oil bath (Mobil SHC 629, 1 Quart).
TEMPERATURE:Ambient and Liquid:
122 0F (50 0C) Maximum
14 0F (-10 0C) Minimum
SUCTION LIFT:6.6 Ft (2 meters) of water column maximum
11.5 psia minimum internal pressure (3.2 psi maximumvacuum)
PAINT:Two part epoxy, yellow RAL 1018
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SECTION 2INSTALLATION
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2.1 UNPACKING
Pumps are shipped f.o.b. factory or representative ware-house and the title passes to the customer when thecarrier signs for receipt of the pump. In the event thatdamages occur during shipment, it is the responsibilityof the customer to notify the carrier immediately and tofile a damage claim. Carefully examine the shippingcrate upon receipt from the carrier to be sure there is noobvious damage to the contents. Open the crate care-fully so accessory items fastened to the inside of thecrate will not be damaged or lost. Examine all materialinside the crate and check against packing list to besure that all items are accounted for and intact.
2.2 STORAGE
Short Term Storage (Less than 6 Months)It is preferable to store the material under a shelter in itsoriginal package to protect it from adverse weather con-ditions. In condensing atmospheres, follow the long termstorage procedure.
Long Term Storage (Longer than 6 Months)The primary consideration in storage of pump equipmentis to prevent corrosion of external and internal compo-nents. This corrosion is caused by natural circulationof air as temperature of the surroundings change fromday to night, day to day, and from season to season. Itis not practical to prevent this circulation which carrieswater vapor and other corrosive gasses, so it is neces-sary to protect internal and external surfaces from theireffects to the greatest extent possible.
When the instructions given in this section are com-pleted, the equipment is to be stored in a shelter; pro-tected from direct exposure to weather. The preparedequipment should be covered with a plastic sheet or atarpaulin, but in a manner which will allow air circulationand prevent capture of moisture. Equipment should bestored 12 inches or more above the ground.
If equipment is to be shipped directly from the factoryinto long term storage, contact the factory to arrange forfactory preparation.
Pump Drive1. Remove motor and flood the gearbox compartment(Item 2 in Figure 1) with a high grade lubricating oil/rustpreventative such as Mobile Oil Corporation productMobilarma 524. Fill the compartment completely to mini-mize air space and water vapor condensation. After stor-age, drain this material and refill the equipment with therecommended lubricant for equipment commissioning.
2. Brush all unpainted metal surfaces with multipurposegrease (NLGI grade 2 or 3). Store these unattached.
Electrical Equipment1. Motors should be prepared in the manner prescribedby their manufacturer. If information is not available,dismount and store motors as indicated in step 3 be-low.
2. Dismount electrical equipment (including motors) fromthe pump.
3. For all electrical equipment, place packets of VaporPhase Corrosion Inhibitor (VPCI) inside of the enclo-sure, then place the entire enclosure, with additionalpackets, inside a plastic bag. Seal the bag tightly.
2.3 SAFETY PRECAUTIONS
WARNING
WHEN INSTALLING, OPERATING, ANDMAINTAINING THIS MACROY D PUMP, KEEPSAFETY CONSIDERATIONS FOREMOST.USE PROPER TOOLS, PROTECTIVE CLOTH-ING, AND EYE PROTECTION WHEN WORK-ING ON THE EQUIPMENT AND INSTALL THEEQUIPMENT WITH A VIEW TOWARD ENSUR-ING SAFE OPERATION. FOLLOW THE IN-STRUCTIONS IN THIS MANUAL AND TAKEADDITIONAL SAFETY MEASURES APPRO-PRIATE TO THE LIQUID BEING PUMPED. BEEXTREMELY CAREFUL IN THE PRESENCEOF HAZARDOUS SUBSTANCES (E.G., COR-ROSIVES, TOXINS, SOLVENTS, ACIDS,CAUSTICS, FLAMMABLES, ETC.).
CAUTION
THE PERSONNEL RESPONSIBLE FOR IN-STALLATION, OPERATION AND MAINTE-NANCE OF THIS EQUIPMENT MUST BECOMEFULLY ACQUAINTED WITH THE CONTENTSOF THIS MANUAL.ANY SERVICING OF THIS EQUIPMENT MUSTBE CARRIED OUT WHEN THE UNIT ISSTOPPED AND ALL PRESSURE HAS BEENBLED FROM THE LIQUID END. SHUT-OFFVALVES IN SUCTION AND DISCHARGESIDES OF THE LIQUID END SHOULD BECLOSED WHILE THE UNIT IS BEING SER-VICED. ACTIONS SHOULD BE TAKEN TOELIMINATE THE POSSIBILITY OF ACCIDEN-TAL START-UP WHILE SERVICING IS TAK-ING PLACE. A NOTICE SHOULD BE POSTED
BY THE POWER SWITCH TO WARN THATSERVICING IS BEING CARRIED OUT ON THEEQUIPMENT. SWITCH OFF THE POWERSUPPLY AS SOON AS ANY FAULT IS DE-TECTED DURING OPERATION (EXAMPLES:ABNORMALLY HIGH DRIVE TEMPERATURE,UNUSUAL NOISE, DIAPHRAGM FAILURE).
2.4 MOUNTING
Support the pump firmly in a level position on a solid,vibration-free foundation. The pump should preferablybe positioned with the base above floor level to protectthe pump from wash downs and to provide easier ac-cess for service. Be sure to allow enough space aroundthe pump for easy access during maintenance opera-tions and pump adjustments.
The pumps are provided with mounting holes to accom-modate anchor bolts. Refer to Figure 3 for mountinghole dimensions.
Pumps installed outdoors should be protected by a shel-ter.
2.5 DRIP COLLECTION
In the event of a failure of the diaphragm or oil seal bel-lows, provisions need to be made to contain the pro-cess fluid or pump oil. This is particularly importantwhen handling fluids which may be harmful to plant per-sonnel.
To collect fluid in the event of a diaphragm or oil sealrupture, (See Figure 1) position a tray under the plainhole located at the bottom of the liquid end mountingassembly (5). For SD7 or SD8 pumps, position trayunder tube fitting located at bottom of liquid end mount-ing assembly. Alternatively, a tube may be installedonto this tube fitting to drain any leakage to a suitablecontainer.
2.6 INSTALLATION
Figure 4 displays typical installations (both correct andincorrect). Figure 5 illustrates the recommended pipingand accessories in a metering pump installation.
As illustrated in the upper right portion of Figure 4, theremust be no swan-necks or stagnant volumes in the suc-tion line. In this illustration, the loop at the top of thetank forms an air trap. Eventually, air or gases will bubbleout of solution and accumulate in the trap leading to aloss of prime condition.
Figure 3:Series G Model DDimensional Outline
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8
12345
TankFoot Valve (with Filter)Metering PumpProcess PipingBleed Valve
6789-
Injection NozzleShut-off ValveFilterPulsation Damper-
Figure 4:Typical Installation
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1
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15
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6
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2.6.1 NPSH CONSIDERATIONS
Size piping to accommodate peak instantaneous flow.Because of the reciprocating motion of the pump dia-phragm, peak instantaneous flow is approximately equalto 5 times the average flow. For example, a pump ratedfor 16 gallons per hour (61 L/hr.) requires piping suffi-cient for 5 x 16 gph, or 80 gph (303 L/hr.).
To minimize viscous flow losses when handling viscousliquids, it may be necessary to use suction piping up tofour times larger than the size of the suction connectionon the pump. If in doubt, contact your dealer to deter-mine the necessary pipe size.
2.6.2 GENERAL PIPING CONSIDERATIONS
Use extreme care in piping to plastic liquid end pumpswith rigid pipe such as PVC. If excessive pipe stress orvibration is unavoidable, flexible connections are rec-ommended.
Use piping materials that will resist corrosion by theliquid being pumped. Use care in selecting materials toavoid galvanic corrosion at pump liquid end connections.
Use piping heavy enough to withstand maximum pres-sures. Remove burrs, sharp edges, and debris frominside piping. Blow out all pipelines before making finalconnections to pump.
Because vapor in the liquid end will cause inaccuratepump delivery, piping should be sloped up from pumpsuction check to the supply tank to prevent formation ofvapor pockets.
When pumping suspended solids (such as slurries), in-stall plugged crosses at all 90° line turns to permit linecleaning without dismantling piping.
See Figure 5 for a typical recommended pump installa-tion scheme.
2.6.3 SUCTION PIPING CONSIDERATIONS
It is preferable to have the suction of the pump floodedby locating the liquid end below the lowest level of theliquid in the supply tank.
To minimize the chances of a loss-of-prime condition,the pump should be installed as close as possible tothe supply vessel.
Avoid negative suction pressure conditions (suction lift),as such conditions adversely affect metering accuracy.A lift of 6.6 feet (2 meters) of water column is the maxi-mum permissible suction lift.
Series G pumps are designed to operate with processliquid supplied at or above atmospheric pressure. Al-though these pumps can move liquids supplied at lessthan atmospheric pressure (suction lift), in these nega-
Figure 5:General Piping
Supply Tank
CalibrationColumn
PulsationDampener
Strainer
SafetyValve
Vent
PulsationDampener
PressureGauge Back
PressureValve
To InjectionPoint
To Drain
MeteringPump
Prime/AirPurge Valve
Shut off Valve
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2.7 VALVES
Back Pressure ValvesAll metering pumps are prone to overpumping (exces-sive output) at low discharge pressures. To prevent thiscondition from occurring, it is necessary to maintainapproximately 10 psi (0.7 bar) back pressure againstthe pump. This can be accomplished through the in-stallation of a back pressure valve in the discharge line.Typically, the valve should be located near the pump.However, back pressure valves for large pumps with longand extremely small discharge lines may have to beinstalled near the point of discharge into the process (tominimize siphoning tendencies).
Pulsation DampenersAn accumulator, surge chamber, surge suppressor, orpulsation dampener should be used with the back pres-sure valve in the discharge line to absorb the flow peaksbetween the pump and the back pressure valve. With-out the pulsation dampener the valve mechanism willsnap open and closed with the surge from each pumpstroke. The pulsation dampener will allow the back pres-sure valve to oscillate about a partly-closed position,thus minimizing wear on the valve. Discharge line pul-sation dampeners offer the further advantage of limitingthe flow and pressure variations characteristic of thiskind of pump. Installing a properly sized pulsation damp-ener will improve pump performance and may reducesystem costs dramatically by permitting the substitu-tion of smaller piping. Please contact your dealer forfurther information on pulsation dampeners.
Safety Valves and Priming ValvesMotor-driven positive displacement pumps can developexcessive discharge pressures long before thermal over-load devices interrupt the motor electrical circuit. Toprevent a blocked discharge line from causing damageto the pump, piping, or process equipment, install asafety valve in the pump discharge line. This valve isdesigned and sized to handle system flow rates andpressures safely while resisting corrosion by the pro-cess liquid.
To aid in pump start-up, it is advisable to install a prim-ing valve on the discharge side of the liquid end.
Shut-off ValvesProvide shut-off valves in both suction and dischargelines next to the pump. Locate discharge line shut-offvalve downstream from the inlet connection of the safetyvalve. Figure 5 shows recommended valve locations.
tive pressure applications it is important that all con-nections be absolutely drip free and vacuum tight, andthat a foot valve be installed at the bottom of the suctionline (see upper left illustration of Figure 4).
When pumping a liquid near its boiling point, provideenough suction head to prevent the liquid from �flash-ing� into vapor when it enters the pump liquid end on thesuction stroke.
If possible, use metal or plastic tubing for the suctionline because tubing has a smooth inner surface andcan be formed into long, sweeping bends to minimizefrictional flow losses.
A strainer should be used in the suction line to preventforeign particles from entering the liquid end. This andany other measures which prevent debris from enteringand fouling the liquid end check valves will give increasedmaintenance-free service. Check strainer frequently toprevent blockage which could lead to cavitation. Keepsuction piping as short and straight as possible.
Piping size should be larger than the liquid end suctionfitting to prevent pump starvation.
If long suction lines are unavoidable, install a stand pipenear the pump in the suction line.
Suction piping must be absolutely airtight to ensure ac-curate pumping. After installation, test suction pipingfor leaks with air and soap solution.
2.6.4 DISCHARGE PIPING CONSIDERATIONS
Install pipe large enough to prevent excessive pressurelosses on the discharge stroke of the pump. Maximumpressure at the discharge fitting on the liquid end mustbe kept at or below the rated pressure (shown on thepump nameplate).
The pump will not deliver a controlled flow unless thedischarge line pressure is 10 psi greater than the suc-tion line pressure. One way to create an artificial pres-sure is the installation of a back pressure valve. (Pleasecontact your dealer for recommendations to increaseback pressure in slurry applications).
When pumping water treatment chemicals directly intoboiler drums, use one liquid end assembly for each boilerdrum. Discharging into a manifold having the slightestpressure difference between its several discharge con-nections can diminish metering accuracy as the outletwith the lowest pressure will receive more liquid thanthe other outlets.
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2.8 ELECTRICAL CONNECTIONS
CAUTION
OPERATION WITH THE WRONG MOTOR RO-TATION MAY DAMAGE THE PUMP AND MO-TOR AND VOID THE WARRANTY.DO NOT FORGET TO CONNECT THE EARTHTERMINAL ON THE MOTOR TO THE EQUIP-MENT EARTH CONDUCTOR.
Ensure that the electrical supply matches the pumpmotor nameplate characteristics. Connect the motorin accordance with the instructions and connection dia-grams on the motor (or in the motor terminal box).
Note: Before operating the pump, check thedirection of rotation of the motor to be sure itmatches the direction of the arrow on the motorfan cover (rotation should be counter clockwisewhen viewed from the top of the motor).
The electrical protection installed for the motor (fuse orthermal protection) must be suitable for the motor's ratedcurrent.
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SECTION 3OPERATION
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3.1 START-UP PROCEDURES AND CHECKS
Check that the pump is secured to its support.
If oil was previously removed for any reason, make surepump drive has the correct volume (1 quart) of oil (MobilSHC 629).
Make sure all isolation valves installed on the suctionand discharge lines are open. If the discharge line isequipped with an injection nozzle or a back-pressurevalve, open the priming valve for discharge (if there is nopriming valve, disconnect the discharge pipe). This al-lows for verification that liquid is present in the liquidend when the pump is installed in flooded suction con-dition. If the pump is installed in a suction lift condition,this allows for priming of the pump during start-up.
Make sure that pump is set at 0% capacity.
3.2 CHECKING THE ELECTRICAL CONNECTION OFTHE MOTOR
Start up the pump to check the motor's direction of rota-tion. It must comply with that indicated by the arrowmarked on the motor fan cover (counter clockwise asviewed from the top of the motor). If the rotation is in-correct, refer to Section 2.8 Electrical Connections.
3.3 START-UP
Once all the checks and procedures described abovehave been carried out, start the pump.
Conduct a visual and audio check of the pump (in par-ticular, listen for the presence of any �suspicious� noises).
Make sure that the stroke adjustment knob is unlocked.
Gradually increase the capacity until liquid can be seenflowing from the priming valve. If no priming valve is inplace, when the liquid end is primed, the dischargecheck valves can be heard to be operating (should heara clicking noise caused by movement of check valveballs). When liquid end is primed, stop the pump andclose the priming valve.
Adjust the pump to the desired capacity. Lock the strokeadjustment knob (Item 320 in Figure 8).
3.4 CAPACITY CALIBRATION
After the first 12 hours of operation, the pump may betested and calibrated to find the exact pump capacityunder specific operating conditions. Usually, calibrat-ing the pump at only 100, 50, and 10 percent capacitysettings is enough to indicate pump performance through-out the adjustment range.
The pump can be calibrated by measuring the decreasein liquid level pumped from a calibrated vessel. Thismethod is recommended for hazardous liquids becauseit eliminates operator contact with the liquid. Calibra-tion columns are available for convenient and accuratecalibration of the pump. Contact your dealer for moreinformation.
WARNING
THIS METHOD IS GENERALLY NOT RECOM-MENDED AS IT MAY EXPOSE OPERATINGPERSONNEL TO HAZARDOUS LIQUIDS.FURTHERMORE, IF NO BACK PRESSURE ISPRESENT ON THE DISCHARGE SIDE, THEPUMP MAY OVERPUMP DRAMATICALLY INWHICH CASE THE POSITION OF THE CA-PACITY ADJUSTMENT KNOB MAY HAVELITTLE EFFECT ON ACTUAL FLOW RATE.
WARNING
FOR SAFETY REASONS, A CHECK VALVEIS RECOMMENDED FOR USE IN THE DIS-CHARGE LINE NEAR THE POINT WHERETHE LINE ENTERS A HIGH-PRESSURE PRO-CESS VESSEL.
The pump can also be calibrated by collecting and mea-suring pumped liquid at the pump discharge port. Itmay be necessary to create backpressure at the col-lection point to allow for proper pump operation (seeSection 2.7 Back Pressure Valves for recommenda-tions).
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SECTION 4MAINTENANCE
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4.1 PREVENTATIVE MAINTENANCE
DriveInitially, change the oil in the pump drive assembly afterthe first 1000 hours of operation. Thereafter, changedrive oil on an annual basis or after every 5000 hours ofoperation.
The drive should be refilled with 1 quart of Mobil SHC629:
Viscosity @ 100 oF = 726 SSU
Viscosity Index = 149
ISO Grade = 150
Diaphragm AssemblyThe Series G Model D diaphragm should be replacedannually or every 5000 hours of operation to avoid thepossibility of failure. Refer to the instructions in Sec-tion 4.6 Diaphragm and Oil Seal Bellows Replacement.
Oil Seal BellowsThe Series G Model D oil seal bellows should also bereplaced annually. Oil seal bellows replacement requiresthe removal of the diaphragm assembly, so it is recom-mended that the oil seal and diaphragm assembly bereplaced at the same time. Refer to the instructions inSection 4.6 Diaphragm and Oil Seal Bellows Replace-ment.
Check ValvesAs in the case of the diaphragm, LMI/Milton Roy Com-pany recommends that check valve balls, seats, gas-kets, and O-rings be replaced on an annual basis orevery 5000 hours of operation. If highly corrosive mate-rial (acids, slurries, etc.) is being pumped, more fre-quent replacement may be required. Complete instruc-tions for replacement of worn check valves are given inSection 4.5 Corrective Maintenance.
4.2 RETURNING PUMPS TO THE FACTORY FORREPAIR
Pumps can not be accepted for repair without a ReturnMaterial Authorization. Pumps should be clearly labeledto indicate the liquid being pumped. Process liquidshould be flushed from the pump liquid end and oil shouldbe drained from the pump housing before the pump isshipped.
Note: United States of America Federal lawprohibits handling of equipment that is not ac-companied by an OSHA Material Safety DataSheet (MSDS). A completed MSDS must be
packed in the shipping crate with any pumpshipped for repair. These safety precautionswill aid the troubleshooting and repair proce-dure and preclude serious injury to repair per-sonnel from hazardous residue in pump liquidend. A Materials Safety Data Sheet must ac-company all returns.
All inquiries or parts orders should be addressed to yourlocal representative or distributor.
4.3 ROUTINE MAINTENANCE
LMI/Milton Roy Series G pumps are carefully designed,manufactured, assembled, and quality tested to givereliable service with minimal maintenance. However, aweekly maintenance check is recommended to confirmproper operation of the pump.
Visual Check of Seal Integrity of MechanicalAssemblyCheck for leaks in the following components. If leaksexist, contact the factory for assistance.
1. Motor flange: If leaking, replace motor flange sealinggasket (Item 11 in Figure 8).
2. Stroke adjustment knob: If leaking, replace strokeadjustment seal (Item 160 in Figure 8).
Checking the Pump CapacityAssuming the pump has been calibrated as describedin Section 3, the capacity can be checked by shuttingthe valve from the supply vessel and opening the valvefrom the calibration column to the suction side of theliquid end. Measure the volume of pumped liquid for agiven period of time at the various settings.
If a calibration column is not installed in the suctionpiping, place the foot valve (or suction line) in a calibrat-ing chamber (graduated reservoir). Measure the volumeof pumped liquid for a given period of time at the varioussettings.
Occurrence of Leak From Detection PortsDetermine whether the product collected at the detec-tion port in the liquid end mounting assembly is lubri-cating oil or the pumped fluid.
If the product is pumped fluid, the diaphragm has failed.If the product is lubricating oil, the oil seal bellows hasfailed. Proceed with its replacement (see Section 4.6Diaphragm and Oil Seal Bellows Replacement).
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4.4 SPARE PARTS
The following spare parts should be stocked for eachpump to prevent serious delays in repairs. (Refer toFigures 6 thru 14).
Parts orders must include the following:1. Quantity required
2. Part number
3. Part description
4. Pump serial number (found on nameplate)
5. Pump product code (found on nameplate)
Note: Always include the serial number andproduct code in all correspondence regardingthe unit.
4.4.1 SIZE SD2 AND SD4 LIQUID ENDS - PVC ANDPVDF
1 each, Diaphragm: Item 260 in Figure 6.
1 each, Oil Seal Bellows: Item 70 in Figure 7.
2 each, Cartridge Valve Assembly: Item 425 in Fig-ure 9.
4.4.2 SIZE SD2 AND SD4 LIQUID ENDS - STAIN-LESS STEEL
1 each, Diaphragm: Item 260 in Figure 6.
1 each, O-Ring: Item 253 in Figure 6 (SD4 only).
1 each, Oil Seal Bellows: Item 70 in Figure 7.
2 each, Check Valve Assembly: Item 425 in Fig-ures 10 & 11.
15
Figure 6:Diaphragm AssembliesBy Liquid End Size and Material
SD2 SD4 (Plastic)
SD7 and SD8 SD4 (316SS)
260252
260
240
274
271
250
270
260
274
271
250270
253
240
251
271
274
270
250
240
260
Note: Liquid end sizes SD2 and SD4 metalliccheck valves are precision assembled at thefactory. Do not attempt to disassemble thesecartridges.
4.4.3 SIZE SD7 AND SD8 - PVC AND PVDF LIQUIDENDS
1 each, Diaphragm: Item 260 in Figure 6.
1 each, Oil Seal Bellows: Item 70 in Figure 7.
2 each, Seat, O-Ring, Ball Set: Item 423 in Figure12.
Note: Item 423 (Kit) contains the following:
� 1 each, Ball: Item 422
� 1 each, Seat: Item 420
� 2 each, O-rings: Item 419
4.4.4 SIZE SD7 AND SD8 - STAINLESS STEELLIQUID ENDS
1 each, Diaphragm: Item 260 in Figure 6
1 each, Oil Seal Bellows: Item 70 in Figure 7
2 each, Check Valve Assembly: Item 425 in Figure14.
Note: The check valves for the size SD7 andSD8-PVC and PVDF liquid ends contain a re-movable seat, which permits the replacementof the seat, O-ring, and ball into a reusablevalve body. The liquid end size SD7 and SD8-Stainless Steel check valve has an integral ballseat, which necessitates replacement of theentire check valve assembly.
4.5 CORRECTIVE MAINTENANCE
WARNING
BEFORE CARRYING OUT ANY SERVICINGOPERATION ON THE PUMP OR PIPING, DIS-CONNECT ELECTRICAL POWER FROM THEPUMP, AND TAKE THE NECESSARY STEPSTO ENSURE THAT ANY HARMFUL LIQUIDCANNOT COME INTO CONTACT WITH PER-SONNEL. SUITABLE PROTECTIVE EQUIP-MENT MUST BE PROVIDED. BE SURE THATTHERE IS NO FLUID PRESSURE IN THEPUMP LIQUID END AND PIPING.
Cleaning Fouled Check ValvesCheck valve assemblies are designed to be self-clean-ing and should seldom need servicing. Fouled checkvalves can usually be cleaned by pumping a solution ofmild detergent and warm water (if compatible with liquidbeing pumped) for 15 minutes, followed by flushing withwater.
Check Valve ReplacementGeneralBefore beginning work on the valve assemblies, makesure the suction and discharge shut-off valves are closedand that pressure has been bled from the pump liquidend. When replacing the valves, be sure to replace thevalve O-rings. Pay close attention to the proper assem-bly and orientation of the check valves as shown in eachLiquid End figure. In the case of plastic check valves forliquid end size SD7 and SD8, be certain that the ball isplaced on the sharp edge of the valve seat.
CAUTION
BE SURE TO FOLLOW INSTRUCTIONSCAREFULLY AND REFER TO THE APPRO-PRIATE FIGURE WHEN REASSEMBLINGCHECK VALVES. IF CHECK VALVE CAR-TRIDGES ARE INSTALLED INCORRECTLY,ONE OF THE FOLLOWING WILL OCCUR:(A) IMMEDIATE AND SEVERE DAMAGE TO
PUMP MECHANISM.(B) NO PUMPING OF FLUIDS.(C) REVERSE PUMPING ACTION (FROM
DISCHARGE LINE INTO SUCTION LINE).
Preliminary Operations1. Set the pump capacity knob to 0%. If stroke lockingscrew (Item 320 in Figure 8) was previously tightened,slightly loosen the locking screw.
2. Disconnect power to pump motor. Check that theequipment cannot be accidentally started. Place a no-tice at the location of the power switch indicating thatthe pump is being serviced.
3. Disconnect the pump hydraulically by removing pipeor tubing connections to suction and discharge checkvalves.
16
4.5.1 CHECK VALVE ASSEMBLIES REPLACEMENT:LIQUID ENDS SD2 AND SD4 - PVC AND PVDF(SEE FIGURE 9 OR 12)
CAUTION
IMPROPER BALL AND SEAT INSTALLATIONCAN CAUSE DAMAGE TO THE PUMP. SEEFIGURE 9 OR 11 FOR PROPER BALL ANDSEAT ORIENTATION FOR BOTH THE SUC-TION AND DISCHARGE VALVES
CAUTION
DO NOT APPLY PTFE TAPE TO THETHREADS OF CHECK VALVE BODY THATSCREWS INTO THE HEAD (280), AS THISMAY PREVENT ADEQUATE SQUEEZE FROMBEING APPLIED TO THE VALVE O-RINGWHICH COULD RESULT IN LEAKAGE.
1. Unscrew the valve body (424) from the pump head(280).
2. Remove the cartridge valve assembly: cartridge in-cludes ball (422), seat (420), ball guide (426), O-ring(419), and washer (427).
3. Clean the valve body (424) and threaded port in thehead (280).
4. Press a new washer (427) into valve body (424).
5. Install new check valve assembly in orientation shown.
On discharge side, drop cartridge assembly (425) intothreaded port in head. The O-ring should be stretchedaround outside of cartridge on same end as ball seat.Screw valve body into discharge side of diaphragm headuntil valve is hand tight. DO NOT OVERTIGHTEN.
On suction side, drop the cartridge assembly into checkvalve body. The O-ring should be stretched around out-side of cartridge on opposite end of ball seat. Screwthe suction valve body with cartridge valve into suctionside of head. DO NOT OVERTIGHTEN.
4.5.2 CHECK VALVES: LIQUID END SIZES SD2AND SD4 - METALLIC (SEE FIGURE 10 OR 11)
The metallic check valves used on liquid end sizes SD2and SD4 are precision assembled at the factory. Donot attempt to disassemble these cartridges. If theybecome inoperative, flush them with solvent, wash themwith warm detergent and blow them out with compressedair to remove any foreign matter. If this treatment doesnot eliminate the trouble, the cartridge assembly shouldbe replaced.
DisassemblyRemove the check valves by unscrewing them from thepump head.
ReassemblyApply a small amount of thread sealing compound andPTFE pipe tape to check valve threads and install checkvalves by screwing them into the pump head with theflow arrows pointing up. DO NOT OVERTIGHTENCHECK VALVES.
CAUTION
PUMP DAMAGE WILL OCCUR IF CHECKVALVES ARE INSTALLED UPSIDE DOWN.INSTALL CHECK VALVES WITH THE FLOWARROW POINTING IN THE DIRECTION OFPROCESS FLOW (UP). TURN CHECK VALVEASSEMBLIES INTO LIQUID END ANDTIGHTEN BY HAND. DO NOT OVER-TIGHTEN, DAMAGE TO THE CHECK VALVESMAY OCCUR.
4.5.3 REPLACEMENT OF BALL, SEAT, & SEAL:LIQUID END SD7 AND SD8 - PVC AND PVDF (SEEFIGURE 13)
Disassembly1. Unscrew the union nut (435). The union end (445) isheld in place by the union nut and will separate easilyfrom the other liquid end parts.
2. Unscrew the check valve assembly (425) from thepump head (280).
3. Screw the union nut part way (one or two turns) ontothe end of the ball guide (424) that has the seat in it. Besure the union nut is on loosely. This will allow a gap forthe seat (420) to fall into as it is removed from the ballguide.
4. Set the ball guide/union nut on a flat surface with theunion nut down. Looking into the top of the ball guide,you will see four large holes surrounding one small hole.Insert a thin, blunt instrument such as a hex head screw-driver into the small center hole until it rests on the topof the ball (422).
5. Tap screwdriver gently with a hammer until the balland seat are released from the ball guide.
17
CAUTION
IF THE UNIT IS DISASSEMBLED FOR IN-SPECTION ONLY, BE SURE TO USE A BLUNTINSTRUMENT AND TAP GENTLY TO AVOIDDAMAGING THE BALL. IF THE BALL AND/OR SEAT ARE DAMAGED DURING DISAS-SEMBLY, THEY WILL HAVE TO BE RE-PLACED. IF AVAILABLE, TO AVOID DAM-AGE, IT IS ADVISABLE TO USE GENTLE AIRPRESSURE (APPLIED AT END OPPOSITETHE SEAT (420) FOR BALL AND SEAT RE-MOVAL.
6. Carefully remove the two O-rings (419) from the ballguide and seat.
7. Carefully clean any parts to be reused. If any chemi-cals are used in the cleaning process, ensure that theyare compatible with the process liquid.
Reassembly
CAUTION
THE ORDER OF ASSEMBLY AND ORIENTA-TION OF THE SUCTION AND DISCHARGECHECK VALVES IS DIFFERENT. REFER TOFIGURE 13 FOR PROPER ASSEMBLY OR-DER AND ORIENTATION. IF CHECK VALVECARTRIDGES ARE INSTALLED INCOR-RECTLY, ONE OF THE FOLLOWING WILLOCCUR:(A) IMMEDIATE SEVERE DAMAGE TO PUMP
MECHANISM(B) NO PUMPING(C) REVERSE PUMPING ACTION (FROM
DISCHARGE LINE INTO SUCTION LINE)
1. Drop the ball (422) into the curved inner chamber endof the body (424).
2. Set the body on a flat surface so that the end with theball faces upward. Position seat (420) on the body,with the beveled edge of the seat facing outward. Whenthe seat is pressed into the body, the ball should besitting on the side with sharp corners as shown in Fig-ure 13. The bevel should not face the inside of thecheck valve. Use a flat surface such as a board topress the seat into the body with firm, even pressure.
If the seat is improperly positioned, the ball will not cre-ate a tight seal and poor pumping performance will re-sult.
3. Fit new O-rings (419) into position on the body (424)and seat (420).
CAUTION
DO NOT APPLY PTFE TAPE TO THREADSOF CHECK VALVE BODY (424) AS THIS MAYPREVENT ADEQUATE SQUEEZE FROM BE-ING APPLIED TO THE VALVE O-RING WHICHWOULD RESULT IN LEAKAGE.
Note: To assure a tight, leak free seal, new O-rings should be used each time the checkvalves are disassembled.
4. Position the union end (445) onto the correct end ofthe body. Refer to Figure 12, as the correct end isdetermined by whether the valve is intended for the suc-tion or discharge port of the liquid end. Slip the unionnut (435) over the union end and screw tightly (handtight only) onto the body.
5. Screw the valve assembly into the pump head (handtight only). DO NOT OVERTIGHTEN.
4.5.4 CHECK VALVE REPLACEMENT: LIQUID ENDSIZE SD7 AND SD8 - STAINLESS STEEL (SEEFIGURE 14)
DisassemblyStainless steel check valves differ from the plastic ver-sions in that the ball seat is integral to the ball guide.The seats cannot easily be inspected for damage orwear. If you suspect that the check valve may be dam-aged or worn, replace the entire check valve assemblyas per the instructions below.
1. Unscrew the coupling (445).
2. Unscrew the check valve assembly (425) from theliquid end.
Reassembly
CAUTION
THE ORDER OF ASSEMBLY AND ORIENTA-TION OF THE SUCTION AND DISCHARGECHECK VALVES IS DIFFERENT. REFER TOFIGURE 14 FOR PROPER ASSEMBLY OR-DER AND ORIENTATION. IF CHECK VALVECARTRIDGES ARE INSTALLED INCOR-RECTLY, ONE OF THE FOLLOWING WILLOCCUR:(A) IMMEDIATE SEVERE DAMAGE TO PUMP
MECHANISM(B) NO PUMPING(C) REVERSE PUMPING ACTION (FROM
DISCHARGE LINE INTO SUCTION LINE)
18
1. Screw the correct end of the check valve assemblyinto the pump head, trapping a new O-ring between thepump head and the check valve assembly.
CAUTION
DO NOT APPLY PTFE TAPE TO THREADSOF CHECK VALVE BODY AS THIS MAY PRE-VENT ADEQUATE SQUEEZE FROM BEINGAPPLIED TO THE VALVE O-RING WHICHWOULD RESULT IN LEAKAGE.
Note: To assure a tight, leak free seal, new O-rings should be used each time the checkvalves are disassembled.
2. Screw the coupling (445) onto the check valve as-sembly, trapping a new O-ring (419) between the cou-pling and the check valve assembly.
4.6 DIAPHRAGM AND OIL SEAL BELLOWS RE-PLACEMENT
CAUTION
BEFORE BEGINNING DIAPHRAGM RE-PLACEMENT, MAKE SURE THAT ALL SHUT-OFF VALVES ARE CLOSED AND ALL PRES-SURE IS BLED FROM THE LIQUID END.
If failure of the oil seal bellows has occurred, it is rec-ommended that the diaphragm assembly and oil sealbellows be replaced at the same time.
4.6.1 DIAPHRAGM REPLACEMENT: LIQUID ENDSIZE SD2 (SEE FIGURES 6, 9, AND 10)
1. Loosen the head screws (Item 290 in Figure 9) andremove the diaphragm head (Item 280 in Figure 9). Markthe suction and discharge ports on the diaphragm headprior to removal.
2. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm (Item 260 in Figure 9) is in the full for-ward position (top dead center).
3. Hold the outer edge of the diaphragm and turn it coun-terclockwise to unscrew it from the pump drive.
4. Discard and replace with new diaphragm. Make surethat adaptor (Item 252 in Figure 9) is screwed in tightlyto connecting rod (Item 60. in Figure 7). Make sure thatseat ring (Item 230 in Figure 9) is in place. Apply a thinlayer of silicone grease to back (rubber side) of dia-phragm before installation. Holding the edges of the
diaphragm, screw the diaphragm assembly onto the malethread of the adaptor piece (Item 252 in Figure 9) until itreaches its mechanical stop.
5. With the capacity still set at 100% turn the motor fanuntil the new diaphragm is in the farthest rearward posi-tion (bottom dead center).
6. Reattach the diaphragm head with the suction anddischarge ports in the correct positions. Tighten thescrews in a crosswise pattern to a torque of 45 in-lb.
7. While turning the motor fan, set the stroke adjust-ment knob to the 0% position.
8. Reinstall motor fan cover.
4.6.2 DIAPHRAGM REPLACEMENT: LIQUID ENDSIZE SD4, SD7, AND SD8 (SEE FIGURES 6, 11 - 14)
1. Mark the suction and discharge ports on the dia-phragm head prior to removal. Loosen the head screws(290) and remove the diaphragm head (280).
2. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm cap (240) is in the full forward position(top dead center).
3. Hold the outer edge of the diaphragm (260) and turn itcounterclockwise to unscrew it from the pump drive.
4. While clamping on the hex on the diaphragm cap(240), disassemble diaphragm assembly by removingthe hex nut (271) on the back of the diaphragm supportnut (270).
5. Make sure that stainless steel support nut (270) isclean and free of corrosion. When cleaning the supportnut, take care not to scratch the smooth angled surfaceof the support nut. If corrosion cannot be removed with-out damaging the support nut, replace with a new one.
6. Install new diaphragm (260) onto diaphragm cap (240)with the convolution in correct orientation. As shown inFigure 6, the convolution in the Teflon diaphragm shouldbe facing down away from diaphragm cap (240) andagainst (or pointing towards) the stainless steel sup-port nut (270)
7. For Size SD4-stainless steel liquid ends, slide bolt(250), washer (251), and O-ring (253) through the dia-phragm cap and diaphragm as shown in Figure 6. Forall other liquid ends, install set screw (Item 250 in Fig-ure 6) into diaphragm cap (240), with hex hole in screwfacing outward, until it is bottomed out (hand tight only)in the diaphragm cap.
8. Slide support nut (270) onto set screw in correct ori-entation shown in Figure 6.
19
9. Install hex nut onto back of support nut and tighten tothe following torque values dependent on liquid end sizeand material. Torque diaphragm assembly as follows:
a) Liquid End Size SD7 and SD8 to 20 foot pounds.
b) Liquid End Size SD4-Plastic to 45 inch pounds.
c) Liquid End Size SD4-Stainless Steel tightenuntil washer (Item 251 in Figure 6) iscontacting diaphragm cap (Item 240 in Figure6).
10. Make sure that support ring (230) is in place andthen reinstall diaphragm assembly.
11. Apply thin layer of O-ring type grease to back of hexnut (271) and reinstall thin PTFE washer (274) to backof support nut.
12. Make sure that oil seal clamp ring (Item 210 in Fig-ure 12) is in place. Screw diaphragm assembly intoconnecting rod (Item 60 in Figure 7) until it reaches itsmechanical stop.
Note: Steps 11 and 12 are applicable to LiquidEnd Size SD4 (See Figure 6).
13. Apply a thin layer of grease to the back of hex nut(271).
14. Make sure that spring (Item 272 in Figure 13) is inplace and connecting rod is in full-forward position (at100% capacity setting). Screw diaphragm assemblyinto connecting rod cross piece (Item 61 in Figure 13)until it reaches its mechanical stop.
Note: Steps 13 and 14 are applicable to LiquidEnd Size SD7 and SD8 (See Figure 6).
15. With the capacity still set at 100% turn the motorfan until the diaphragm is pulled back to the rearwardposition (bottom dead center).
16. Reattach the diaphragm head with the suction anddischarge ports in the correct positions. Torque thehead assembly screws in a crosswise pattern as fol-lows:
a) Liquid End Size SD2 and SD4 to 45 inch pounds.
b) Liquid End Size SD7 and SD8 to 90 inch pounds.
17. While turning the motor fan, set the stroke adjust-ment knob to the 0% position.
18. Reinstall motor fan cover.
4.7 OIL SEAL BELLOWS REPLACEMENT (ITEM 70IN FIGURE 7)
CAUTION
BEFORE BEGINNING OIL SEAL REPLACE-MENT, MAKE SURE ALL SHUT-OFF VALVESARE CLOSED AND ALL PRESSURE HASBEEN BLED FROM THE LIQUID END (PUMPHEAD). WHEN REPLACING THE OIL SEAL,THE DIAPHRAGM ASSEMBLY MUST BE RE-MOVED FIRST. FOR EASE OF SERVICE, ITIS RECOMMENDED THAT THE OIL SEAL BEREPLACED IN CONJUNCTION WITH THE DIA-PHRAGM ASSEMBLY.
1. Disconnect connections to the pump motor terminalbox. Be sure to note the wiring layout before discon-necting from box.
2. Set the stroke adjusting knob to 100%.
3. Disconnect the suction and discharge connectionsto the pump head check valves.
4. Mark the suction and discharge ports on the dia-phragm head prior to removal. Loosen the head screws(Item 290 in Figure 12) and remove the diaphragm head(Item 280 in Figure 12).
5. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm assembly (Figure 6) is in the full forwardposition (top dead center).
6. Hold the outer edge of the diaphragm assembly (Item260 in Figure 6) and turn it counterclockwise to unscrewit from the pump drive.
7. Remove the diaphragm support ring (Item 230 in Fig-ure 12) from the spacer (225).
8. Drain the oil out of the pump drive by removing thedrain plug from the pump housing (Item 20 in Figure 8).
9. Remove oil seal bellows clamping components asfollows:
a) On Liquid End Size SD2 models (Figures 9 &10), remove adaptor piece (252), clamp ring(210), mounting screws (227), and spacer (225).
b) On Liquid End Size SD4 models (Figures 11 &12), remove oil seal clamp ring (210), mountingscrews (227), and spacer (225).
c) On Liquid End Size SD7 and SD8 models(Figure 13 & 14), remove spring (272), unscrewadapter (61), seal ring (210) mountingscrews (227& 228), and spacer (225).
20
24
10. Pull the oil seal (70) off the connecting rod (60).
11. Install a new oil seal onto connecting rod.
12. Apply a thin layer of O-ring type grease to top of oilseal (part adjacent to connecting rod).
13. Reinstall parts removed in step 9. For Liquid endsSD2, SD7, and SD8, install adaptor piece (252) or crosspiece (61) before mounting spacer.
14. Remove the motor and refill pump drive with oil (1quart of Mobil SHC 629).
15. Reinstall motor.
16. Reinstall liquid end components in accordance withthe procedures found in the following:
a) For Liquid End Size SD2 models, refer toparagraph 4.6.1, steps 4 thru 7.
b) For Liquid End Sizes SD4, SD7, and SD8models, refer to paragraph 4.6.2, steps 10 thru17.
17. Connect the motor in compliance with the direc-tions marked during the prior disconnection (see alsoSection 2: ELECTRICAL CONNECTIONS).
4.8 RESTARTING THE PUMP
1. Reconnect the pump to the piping system.
2. Check that capacity is set to 0%.
3. Open system suction and discharge shut-off valvesand restart pump.
4. Set the pump to 100% to obtain faster priming ofliquid end.
5. After priming, set the pump to the desired capacity.Retighten locking screw (320).
21
SECTION 5PARTS LIST
2522
GENERAL
1. This section gives information regardingreplaceable components.
ILLUSTRATED PARTS LIST
1. Figure and Item Number Column
(a) The item numbers shown in the detailed partslist correspond to the item numbersappearing on the exploded view illustration.To find an unknown part number, locate thepart on the illustration and note the itemnumber. Look for the item number on thedetailed parts list. The part number is on thesame line. A dash (-) precedes non-illustrateditem numbers.
2. Description Column
(a) The name of the item is in the descriptioncolumn.
3. Part Number Column
(a) The supplier�s part number is listed in the partnumber column.
4. Quantity Column
(a) The numbers appearing in the quantitycolumn are the total quantity of the listed partrequired in its immediate assembly.
5. Reference Code Column
(a) This column is used to denote assembly anddetail part variations among similarcomponents (models) covered by thispublication. When the symbol �A�, �B�, etc.is entered in this column, the part is usedonly in the model at which the symbolappears. If the column is blank, the part isused in all models.
23
Figure 7:Drive Side View
EIC MOTORONLY
70 10150
340
360
342
60
347
346
380
410
400
24
5.1 PARTS LIST FOR DRIVE SIDE VIEW
611097000360048
4040107231611166111361112611116111461115
405004303461122
4010003031435003852240500181194340009002
404764070324030
61076
106070
150340342342342346346347360380400400410
410-500600
1112111111113444
411
Drive HousingConnecting RodDrive Oil Seal BellowsRetaining RingBearingWorm, 43 spm �Model No. SD*1---� (see note 1)Worm, 86 spm �Model No. SD*2---� (see note 1)Worm, 173 spm �Model No. SD*3---� (see note 1)Worm w/Motor Coupling (IEC71, V1 Flange Motor)Worm w/Motor Coupling (NEMA 56C Flange Motor)Socket Set Screw CPT 1/4-20 X 5/16 STSet Screw, M8 X 12 (see note 2)Spring Pin (for IEC Motors Only)Motor Mounting Bolt (EIC Motors: M8 X 25)Motor Mounting Bolt (NEMA 56C Motors: 3/8-16 X 1)Motor Mount Washer (EIC Motors: Spring
Lockwasher 8mm)Motor Mount Washer (NEMA 56C Motors: 3/8 SAE)Gear Oil - 1 quartNameplate
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE
- Items not shown.
Note 1: Replacement of worm (342), only as assembly of items 342, 340, & 150.
Consult your dealer for this factory assembled collection of parts.
Note 2: When replacing set screw (347), consult factory for special assembly instructions.
7
FIGURENUMBER
25
Figure 8:Drive End View
170 150 140 120 111
11
102
100
121
600
101
50
110
1301901920206205320322
310
200
160
330
332
335
26
5.2 PARTS LIST FOR DRIVE END VIEW
225012109922501150994080068031
600865203094085N5203093085N5203092085N
611041600273192N1600273192N1600271192N
212914010005091
611051600260071N4310006455N3701310039N
611083701300039N
6006440999940004040107231
2502110067N21292
4380024051N7204400301N4350003375N4340009065N4370040050N5600400022N4380249031N
700667005460996
11111920505050
100100100100101102110110111120121121130140150160170190200205206310320322330332335
1111111111111111111122111133111121
Gasket Motor (IEC71, V1 Flange Motor)Gasket Motor (NEMA 56C Flange Motor)O-RingOil Drain PlugGear, 43 spm (Model No. SD*1---)Gear, 86 spm (Model No. SD*2---)Gear, 173 spm (Model No. SD*3---)Male Eccentric, Model No. �SD2----� (see note 1)Male Eccentric, Model No. �SD4----� (see note 1)Male Eccentric, Model No. �SD7----� (see note 1)Male Eccentric, Model No. �SD8----� (see note 1)Drive Shaft (see note 1)Spring Pin .187 X 1 STL (see note 1)Female Eccentric, Model No. �SD2----�Female Eccentric, Model No. �SD4, SD7, SD8----�Spring Pin 3mm Diameter 14mm LongStroke Adjust KeyGear Key, Model No. �SD2----�Gear Key, Model No. �SD4, SD7, SD8----�Retaining RingBearing (see note 1)Retaining RingSeal, Side CoverStroke Adjust ScrewO-Ring, Side CoverSide CoverSocket Head Screw M6 X 16, 304SSWasher M6 304SSStroke Locking BallStroke Locking ScrewO-RingStroke Adjust KnobPan Head Screw, M6 X 20Knob Sticker, MacRoy
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE
- Items not shown.
Note 1: Replacement of male eccentric (100) only as assembly which includes items 100,101,102,140,& 150.
Consult your dealer for part number for this factory assembled collection of parts.
8
FIGURENUMBER
27
Figure 9:SD2 Plastic LiquidEnd
426
227
252
424
425427422
420
430419
290
300
260
280
419
426
422
420425 427
225
ASSEMBLY
PLASTICLIQUID ENDONLY
ASSEMBLY
210
28
5.3 PARTS LIST FOR SD2 PLASTIC LIQUID END PVC-NPT AND PVC-TUBING
Model: Code:SD2_ _ 8P A
SD2_ _ 8T B
SD2_ _ 2P C
SD2_ _ 2T D
60043610357005461088610833091661089610906053461059
4040002053N/AN/AN/AN/A
6114161142
N/AN/AN/AN/A
210225227230252260280280-281290300
419* 420* 422* 424*425-425 426* 427*-435*-445*
114111111442222222222
A, BC, D
A, CB, D
B, DB, D
Oil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Seat RingAdapterDiaphragmDiaphragm HeadDiaphragm HeadDecalPan Head Screw, #10-24 X 3/4Flat Washer, #10 18.8SSO-RingBall Seat, HAST. C22Ball 9/32 CeramicValve Body 1/4� NPTCheck Valve Assembly - NPTCheck Valve Assembly - NPTBall CartridgeMolded WasherCoupling NutFerrule
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE
- Items not shown.
* Items included as part of item number 425.
9
FIGURENUMBER
29
Figure 10:SD2 Metallic Liquid End
425
290
260
280
425
252
225
210
ASSEMBLY
ASSEMBLY
230
227
5.4 PARTS LIST FOR SD2 METALLIC LIQUID END STAINLESS STEEL-NPT
Model: SD2 _ _ 7P
- Items not shown.
600436103570054610886108330916611066105961140
210225227230252260280290425
114111142
Oil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Seat RingAdapterDiaphragmDiaphragm HeadPan Head Screw, #10-24 X 3/4Check Valve Assembly - NPT
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE10
FIGURENUMBER
30
5.5 PARTS LIST FOR SD4 METALLIC LIQUID END STAINLESS STEEL-NPT
Model: SD4 _ _ 7P
Figure 11:SD4 Metallic Liquid End
ASSEMBLY
ASSEMBLY
230
227
225
271425
280
290
240
251
250
253
425 270 210
274
260
6004361035700546107561074619716107261073609956105161054610556107061059
CV202294
210225227230240250251253260270271274280290425
114111111111142
Oil Seal Clamp RingSpacerPan Head Screw, M6 X 20Supporting RingDiaphragm Cap, 316SSHex Head Screw, M8 X 50, 316SSWasher, 8M, 316SSO-Ring, VitonDiaphragmSupport Nut, 316SSHex Nut, M8 ThinPTFE WasherDiaphragm Head, 316SSPan Head Screw, #10-24 X 3/4Check Valve Assembly
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE11
FIGURENUMBER
- Items not shown.
31
Figure 12:SD4 Plastic Liquid End
424
ASSEMBLY
PLASTICLIQUID ENDDIAPHRAGMASSEMBLY
427422
420
419
290
300
250
240
280
219
426
422
420 425
425
426
427
260
274
270 210
230
227
225
271
PLASTICLIQUID ENDONLY
ASSEMBLY
32
5.6 PARTS LIST FOR SD4 PLASTIC LIQUID END PVC-NPT AND PVC-TUBING
Model: Code:SD4_ _ 8P A
SD4_ _ 8T B
SD4_ _ 2P C
SD4_ _ 2T D
600436103570054610756105261053610586099561051610546105561056610576053461059
4040002053N/AN/AN/AN/AN/A
3636636360
N/AN/A
210225227230240240250260270271274280280-281290300
419* 420* 422* 424* 424*425425
426* 427*
1141111111111144222222222
A, BC, D
A, BC, D
A, CB, DA, CB, D
Oil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Support RingDiaphragm Cap - PVCDiaphragm Cap - PVDFSocket Set Screw, M8 X 50DiaphragmSupport Nut, 316SSHex Nut, M8 X 50PTFE WasherDiaphragm HeadDiaphragm HeadDecalPan Head Screw, #10-24 X 3/4Flat Washer, #10 18.8SSO-RingBall Seat, HAST. C22Ball 9/32 CeramicValve Body - NPTValve Body - TUBECheck Valve Assembly - NPTCheck Valve Assembly - TUBEBall CartridgeMolded Washer
ITEMNUMBER DESCRIPTION PART
NUMBERQUANTITY
PUMPREFERENCE
CODE12
FIGURENUMBER
- Items not shown.
* Items included as part of item number 425.
33
Figure 13: SD7 & SD8 PlasticLiquid End
CHECK VALVEASSEMBLY 445
435 273
62
424
423
422
420
419
260
280
240
250270
419
425422
420
419
435 445
230
424272
61 225CHECK VALVE
ASSEMBLY
KIT
425419
271
448
423
KIT
290 300
302 305
302 305
227 228
34
5.7 PARTS LIST FOR SD7 AND SD8 PLASTIC LIQUID END PVC-NPT AND PVDF-NPT
Model: Code:SD7_ _ 8P or SD8_ _ 8P A
SD7_ _ 2P or SD8_ _ 2P B
611554350016075N
6115461156
4350003375N4350047395N
600356062860630
435007128460618610656106870081611536003360031
435000165543400050854340009005
6115243500000454080068075
403482240173078407001517130508795003050879700
60024305087000730508700084320236038
6011760119
470096073N
6162
-210225227228230240240250260270271272273280280290300302-304305
419* 419* 420* 422*423423
424*425425435445445448
11112211111111111666664422222222221
AB
AB
AB
AB
AB
AB
AdapterSocket Head Set Screw, M8 X 20PTFE Seal RingSpacerSocket Head Set Screw, M6 X 16, 304SSSocket Head Set Screw, M6 X 30, 304SSDiaphragm Support RingDiaphragm Cap - PVCDiaphragm Cap - PVDFSocket Set Screw, Dog PT M10 X 45DiaphragmSupport NutHex Nut, M10 Thin, 316SSSpringSpring CupHead PVCHead PVDFHex Head Screw, M8 X 110mm, LG 304SSFlat Washer, M8, Regular 304SSSplit Washer M8, 304SSNut SpacerHex Nut, M8, 304SSO-Ring, VitonO-Ring, PTFESeat, PVDFBall, 5/8 CeramicKit - Ball, Seat & O-RingsKit - Ball, Seat & O-RingsCartridge Body, PVDFCheck Valve AssemblyCheck Valve AssemblyUnion Nut, 1/2� PVCUnion End, 1/2� NPT PVDFUnion End, 1/2� NPT PVDFBlow-Off Nozzle
ITEMNO. DESCRIPTION SD7
PART NO.QTY.
PUMPREF.
CODE
- Items not shown.
* Items included as part of item number 425.
611554350016075N
6115461156
4350003375N4350047395N
600706063360635
435007128460624611466106870081611536114861147
435000165543400050854340009005
6115243500000454080068075
403482240173078407001517130508795003050879700
60024305087000730508700084320236038
6011760119
470096073N
SD8PART NO.
13
FIG.NO.
35
Figure 14: SD7 & SD8 316SSLiquid End
ASSEMBLY
290 300
304 305
302 305
445
227 228419
425
419
260
240
250280
270
302
61272
273
62
271 210
448 225
230445
419
425
ASSEMBLY
419
36
5.8 PARTS LIST FOR SD7 AND SD8 316SS-NPT LIQUID END
Model: SD6 _ _ 7P or SD8 _ _ 7P
611554350016075N
6115461156
4350003375N4350047395N
6106660631
43500712846061861065610687008161153
210760016435000165543400050854340009005
61152435000004540800680753050876602
60135470096073N
6162
210225227228230240250260270271272273280290300302304305419425445448
111122111111111666664221
AdapterSocket Head Set Screw, M8 X 20PTFE Seal RingSpacerSocket Head Set Screw, M6 X 16, 304SSSocket Head Set Screw, M6 X 30, 304SSSupport RingDiaphragm Cap - 316SSSocket Set Screw, Dog PT M10 X 45DiaphragmSupport NutHex Nut, M10 Thin, 316SSSpringSpring CupHead, 316SSHex Head Screw, M8 X 110mm, LG 304SSFlat Washer, M8, Regular 304SSSplit Washer M8, 304SSNut SpacerHex Nut, M8, 304SSO-Ring, VitonCheck Valve AssemblyCoupling, 1/2� NPTBlow-Off Nozzle
ITEMNO. DESCRIPTION SD7
PART NO.QTY.
PUMPREF.
CODE61155
4350016075N6115461156
4350003375N4350047395N
6106660631
43500712846062461146610687008161153
210760016435000165543400050854340009005
61152435000004540800680753050876602
60135470096073N
SD8PART NO.
14
FIG.NO.
- Items not shown.
40
THIS PAGE INTENTIONALLY BLANK
37
SECTION 6TROUBLESHOOTING
41
1. Pump motor won't operate.
2. Insufficient pump delivery.
SYMPTOMS POSSIBLE CAUSE REMEDY
a) Low process liquid level in thetank.
b) Worn or dirty check valves.
c) Blocked discharge line.
d) Frozen liquid.
e) Blown fuse.
f) Open thermal overload device inmotor starter.
g) Broken wire.
h) Low voltage.
i) Pump not primed.
j) Capacity adjustment set at zero.
a) Incorrect capacity adjustment.
b) Incorrect pump speed.
c) Starved suction.
d) Leaky suction piping.
e) High suction lift.
f) Liquid near boiling.
g) Leaky safety valve in dischargeline.
h) High liquid viscosity.
i) Worn or dirty check valve seats.
a) Add liquid.
b) Clean or replace.
c) Clear line.
d) Thaw liquid throughout pumpingsystem.
e) Replace fuse.
f) Reset device.
g) Locate and repair.
h) Investigate and correct (wiringmay be too tight).
i) Allow suction line and pumphead to fill with liquid beforepumping against pressure.
j) Readjust capacity.
a) Readjust capacity setting.
b) Match line voltage and frequencyto pump motor data plate.
c) Increase piping size or suctionhead.
d) Repair piping.
e) Rearrange equipment to de-crease lift and/or install foot valvein suction line.
f) Cool liquid or increase suctionhead.
g) Repair or replace valve.
h) Reduce viscosity (e.g., heat ordilute liquid), or consult thefactory for special check valveoptions.
i) Clean or replace.
38
42
3. Erratic pump delivery.
4. Motor and pump body hot.
5. Pump still pumps even at zerocapacity setting.
6. Gear noise.
7. Loud knock with each stroke.
8. Noisy operation in liquid end.
SYMPTOMS POSSIBLE CAUSE REMEDY
a) Leaky suction piping.
b) Leaky safety valve.
c) Insufficient suction head.
d) Liquid near boiling.
e) Worn or dirty check valves.
f) Clogged or dirty line strainer.
a) Normal operating temperature ofboth motor and pump body isfrequently uncomfortable to thetouch. However, neither shouldexceed 200°F (93°C).
b) Power supply does not matchelectrical requirement of motor.
c) Pump is being operated atgreater than rated performance.
d) Pump improperly lubricated.
a) Misadjusted capacity knob.
b) Insufficient discharge pressure.
a) Excessive backlash.
b) Worn bearings.
c) Wrong or insufficient lubricant.
a) Excessive gear set wear.
b) Worn bearings.
a) Noise in check valves.
a) Repair piping.
b) Repair or replace valve.
c) Raise suction tank level and/orinstall foot valve in suction line.
d) Cool liquid or increase suctionhead.
e) Clean or replace.
f) Clean strainer.
a) N/A
b) Insure proper matching of powersupply and motor.
c) Reduce pressure or strokespeed. If this is not practical,contact service facility.
d) Drain oil and refill with properamount of recommendedlubricant.
a) Readjust capacity setting.
b) Correct condition (e.g., install aback pressure valve).
a) Consult service facility.
b) Consult service facility.
c) Replace or replenish lubricant.
a) Consult service facility.
b) Consult service facility.
a) Ball checks move up and downwith some force. A distinct"clicking" noise is normal,especially in metal pipingsystems.
39
SECTION 7LIMITED WARRANTY
The LMI/Milton Roy Company (�Company�) warrants that its pumping products will be free from defects in title, andso far as of its own manufacture, will be free from defects in materials and workmanship for a period of twelvemonths from shipment by the Company. The Company additionally warrants that all of its other products, includ-ing actuators, will be free from defects in title, and so far as of its own manufacture, will be free from defects inmaterials and workmanship for a period of twelve months from shipment by the Company. The Company will, asits option, repair or replace its products provided the Company�s inspection reveals the products to have beendefective or nonconforming within the terms of this warranty. This warranty is expressly conditioned upon thefollowing: (a) proper installation, maintenance, and use under the Company specified service conditions, (b)prompt notice of nonconformance or defect, (c) the Company�s prior written authorization for return, (d) the prod-ucts being returned to the Company, or at the Company�s discretion, to a Factory Authorized Service Center, allat no cost to the Company. The Company will deliver repaired or replacement products Ex Works its factory orFactory Authorized Service Center. Products not of the Company�s manufacture are warranted only to the extentprovided by the original manufacturer. The company shall not be liable for damage of any kind resulting fromerosive, corrosive or other harmful action of any liquids, gases, or any other substance handled by the Company�sproducts.
THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, OBLIGATIONS, OR LIABILITIES, WHETHEREXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE.
UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL,OR SPECIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM THIS CONTRACT, ITS PERFORMANCE,OR IN CONNECTION WITH THE USE OF, OR INABILITY TO USE THE COMPANY�S PRODUCTS.
The liability of the Company in respect of all damages, losses, costs or expenses, whether suffered or incurred bythe Purchaser or any third party arising in any manner or incident related to this contract or the performancehereunder, shall be limited in the aggregate to the actual price paid by the Purchaser to the Company.
Revision A 17 March 1998
40
Sales & Marketing8 Post Office Square � Action, MA 01720 USA � (978) 263-9800 � Fax: (978) 264-9172 � www.lmipumps.com
Technical & Aftermarket201 Ivyland Road � Ivyland, PA 18974 USA � (215) 441-0800 � Fax: (215) 441-8620 � www.miltonroy.com
E-mail: [email protected]