Corken 51, D51, 521, 1021, F1521 Installation, Operation & Maintenance Manual

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ORIGINAL INSTRUCTIONS IC101H

Installation, Operation & Maintenance Manual

Sliding-Vane Stationary Pumps for LPG and NH

All Models 51, 521, and 1021

D51 Mo de l

1021 Model

Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products must be made only by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken products must comply with Corken instructions, applicable laws and safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.

Solutions beyond products...

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Warning

Install, use and maintain this equipment according to Corken’s instructions and all applicable federal, state, local laws and codes. Periodic inspection and maintenance is essential.

Corken One Year Warranty

CORKEN, INC. warrants that its products will be free from defects in material and workmanship for a period of one year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from the date of shipment from CORKEN. If a warranty dispute occurs, the DISTRIBUTOR may be required to provide CORKEN with proof of date of sale. The minimum requirement would be a copy of the DISTRIBUTOR’S invoice to the customer.

CORKEN products which fail within the warrant period due to defects in material or workmanship will be repaired or replaced at CORKEN’s option, when returned, freight prepaid to CORKEN, INC., 3805 N.W. 36th St., Oklahoma City, Oklahoma 73112.

Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves and packing, and other parts showing signs of abuse, neglect or failure to be properly maintained are not covered by this limited warranty. Also, equipment, parts and accessories not manufactured by CORKEN but furnished with CORKEN products are not covered by this limited warranty and the purchaser must look to the original manufacturer’s warranty, if any. This limited warranty is void if the CORKEN product has been altered or repaired without the consent of CORKEN.

All implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, are expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warrantee period.

CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR IMPLIED WARRANTY ON CORKEN PRODUCTS. Transfer of toxic, dangerous, flammable or explosive substances using CORKEN products is at the user’s risk. Experienced, trained personnel in compliance with governmental and industrial safety standards should handle such substances.

Important notes relating to the European Union (EU) Machinery Directive

Pumps delivered without electric motors are not considered as machines in the EU Machinery Directive. These pumps will be delivered with a Declaration of Incorporation. The fabricator of the machinery must assure and declare full compliance with this Directive before the machine in which the pump will be incorporated, or of which it is a part, is put into service.

Contacting the Factory

Before you contact the factory, note the model number and serial number of your pump. The serial number directs us to a file containing all information on material specifications and test data applying to your specific pump. When ordering parts, the Corken service manual or Operations, Installation and Maintenance (IOM) manual should be consulted for the proper part numbers. ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.

The model and serial numbers are shown on the nameplate of the unit. Record this information for future reference.

Model No.

Serial No.

Date Purchased

Date Installed

Purchased From

Installed By

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Table of Contents

Principles of a Sliding-Vane Pump ...............................................................4

Exclusive Features of the Coro-Vane® Pump ......................................................4

Chapter 1—Installation Procedures ..............................................................4

1.1 Location .................................................................................4

1.2 The Inlet Piping Should Include the Following: ...................................................6

1.3 The Outlet Piping Should Include the Following: ..................................................6

1.4 The Bypass System Must Include the Following: .................................................6

1.5 A Vapor Equalizing System Should be Included: ..................................................6

1.6 Driver Installation ..........................................................................6

Chapter 2—Operation Procedures ...............................................................7

Chapter 3—Maintenance Procedures ............................................................8

3.1 Preventative Maintenance Procedures .........................................................9

Chapter 4—Seal Replacement Instructions ......................................................10

4.1 Repair Kits and Spare Parts for Sliding-Vane Pumps .............................................13

Appendices

A. Model Number Identification Code and Available Options ..........................................14

B. Specifications ............................................................................16

C. Performance .............................................................................18

D. Outline Dimensions ........................................................................21

E. Parts Details .............................................................................28

F. V-Belt Selection ...........................................................................35

G. Troubleshooting Guide .....................................................................36

H. Extended Storage .........................................................................37

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Principles of a Sliding-Vane Pump

Corken’s Coro-Vane® pumps are a special type of rotary positive displacement pump, known as a sliding vane pump.

The PUMP NOZZLES on Models 521 and 1021 are equipped with flanges to simplify piping. It is not necessary to provide unions in the piping system near the pump because the flanges serve this purpose.

The sliding-vane pump has many of the positive displacement advantages of the gear pump, plus the ability to compensate for wear, and operate at a lower noise level.

The sliding-vane pump consists of a rotor turning in a cam (liner) machined eccentrically in relation to the rotor; thereby displacing the liquid trapped between the rotor, cam and vanes. Coro-Vane® pumps are made with vanes produced from advanced polymers which exhibit extremely low coefficients of friction. The vanes self-adjust for wear and extends the pump life.

Exclusive Features of the Coro-Vane® Pump

The pumping of volatile liquids is one of the most difficult of all pumping jobs, so more attention must be given to the design and manufacture of the pump and to its installation and operation.

In addition to being especially suited for handling volatile liquids, the Coro-Vane® pump has a number of features to help make it more easily operated and maintained.

Coro-Vane® pumps are manufactured in six models: the Models D51 and F51 small stationary and the Models 521, 1021, F1021 and F1521 stationary pumps. The Models F1021 and F1521 have ANSI flanged connections. All six models have been registered and listed by the UNDERWRITERS’ LABORATORIES, INC. for use in the handling of LP-Gas and Ammonia.

The CASE AND HEADS are made of ductile iron for extra strength and toughness.

The RELIEF VALVE is built-in as part of the pump on models 521 and 1021 and is adjustable under pressure.

NOTE: EVEN WITH THIS INTERNAL SAFETY VALVE, AN EXTERNAL BYPASS VALVE MUST BE INSTALLED.

Chapter 1—Installation Procedures

1.1 Location

The installation of the Coro-Vane® pump is simple; however, in order for the pump to deliver optimum performance, the principles discussed in this book should be followed. The piping details in figure 1.2 illustrate methods proved by hundreds of installations. Your own needs may require slight variations, but every effort should be made to follow the recommendations identified in this manual.

No pump can discharge more liquid than it receives, so the pump location and the inlet piping must be given careful attention. If the inlet piping is unable to supply the demand of the pump, you may expect trouble. The inlet sizes shown in figure 1.2 are the smallest piping size you can use with success.

For the transfer of flammable liquids like LPG, the pump must be installed according to the applicable local safety and health regulations. The installer and/or the user must take into account the following:

• The pump must be located as near the storage tank as possible. The complete inlet line, including the vertical line from the tank must not exceed twelve feet (3.7 m) in length.

The VANES are manufactured of advanced polymers to provide excellent life and quiet operation. After long service, the vanes are simply and inexpensively replaced.

Both the CAM and the SIDEPLATES are easily replaced should the need arise.

The MECHANICAL SEAL is designed for longer life under greater loads and may be inspected or replaced without disturbing the piping of the pump. No special tools are needed.

BEARINGS are heavy-duty roller type for long bearing life.

PRESSURE GAUGE connections, 1/4" pipe thread, are provided.

• The bottom of the tank must be no less than two feet (0.6 m) above the pump inlet nozzle, with four feet (1.2m) considered standard.

• The foundation for the pump is important. The foundation must be firm, level and preferably made of concrete. The suggestions in figure 1.1 should be observed.

1/2" x 8" anchor bolt

Pump base

Concrete

Fig u re 1.1

Metal shim

Large washer

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• Potential risk due to local conditions regarding the installation and operation (e.g. poor ventilation and additional risks due to other elements in the vicinity, etc.).

should be used. Web slings are preferred over metal slings to minimize damage to the paint. See Appendix D for outline dimensions.

• Qualification of the personnel.

• Type of liquid being transferred.

• Specific safety measures to be applied (e.g. gas detection, automatic shut-off valves, personal protective equipment, etc.).

The following table shows the weight of the bare pump for each model. For handling a bare pump, lifting slings

Model Shipping Weight: lb (kg)

D51 50 (22.7)

F51 25 (11.3)

521 132 (59.9)

1021 200 (90.7)

F1021 200 (90.7)

F1521 235 (10 6.6)

Figure 1.2: Typical Piping Diagram

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1.2 The Inlet Piping Should Include the Following:

1. The tank excess flow valve (EFV) should have a flow rate of 1-1/2 to 2 times the capacity of he pump. Do not use an EFV without knowing its flow capacity.

Model Maximum Differential Pressure

521, 1021, F1021 125 psi (8.8 kg/cm2)

F1521 100 psi (7.0 kg/cm2)

1.5 A Vapor Equalizing System

2. The tank shut-off valve must be a free-flow type and not a standard globe valve.

3. A strainer of the “Y” type, with 30 to 40 mesh screen, must be on the inlet line of the pump. (Mesh size indicates the number of openings per lineal inch).

4. Use a flexible connection in the pump inlet and outlet piping to compensate for piping strains.

5. Use an eccentric swage at the pump inlet nozzle to change the line size (flat side up).

6. Make the inlet line level or slope it downward to the pump.

7. The minium inlet piping sizes shown in figure 1.2 must be observed.

1.3 The Outlet Piping Should

Include the Following:

1. A pressure gauge should be installed in the pump outlet or near it. A pressure gauge is necessary to determine the efficiency of your pumping system.

2. A hydrostatic relief valve is required by most state laws and for your own safety.

3. If the outlet piping exceeds 50 feet (15.2 m) in length a check valve should be installed near the pump outlet.

4. The minimum outlet piping sizes shown in figure 1.2 should be observed.

1.4 The Bypass System Must

Should be Included:

To obtain maximum performance from the Coro-Vane® pump, a vapor equalizing system should be installed. This system is simply a pipe connecting the vapor sections of the tank being unloaded and the tank being filled. This equalizing line allows vapor to move freely between the two tanks (in either direction) and assures that both tanks remain at the same pressure.

As liquid is withdrawn from a tank, it must be replaced by an equal amount of vapor or the pressure in the tank will drop. If an equalizing line is not present, this vapor is formed by “boiling” of the liquid and a reduction of the tank’s pressure. Meanwhile, the tank being filled experiences a pressure increase as the rising fluid levels compresses the vapor space above it. A vapor equalizing line will eliminate both of these problems and will reduce pumping time, differential pressure, noise and wear on the entire system. Slow transfer rates will minimize these effects and reduce the need for a vapor equalizing line. However, today’s high transfer rates require the installation of a vapor equalization line.

Another way to consider this principle is to remember how it takes two holes in an oil can for oil to be poured smoothly from the can; one for the oil to exit and the other for the air to enter. The piping and hose sizes shown in figure 1.2 are minimum requirements.

1.6 Driver Installation

Model Maximum Speed

521, 1021, F1021 950 RPM

F1521 860 RPM

Include the Following:

1. A pump bypass system must be installed. If the pump discharge is shut off before the driver is stopped, dangerously high pressures can develop, unless a bypass valve is installed to permit the pump to discharge back to the supply tank, at a predetermined pressure.

2. The pump may have an internal relief valve, but it is intended as a safety relief valve device and not an operational bypass.

3. Always install an external bypass relief valve (such as the Corken B177) in the pump discharge line. The bypass valve may discharge into the tank at any convenient opening, either liquid or vapor; however, it should not connect into the pump inlet piping system.

The wiring of your electric motor is extremely important and must be done by a competent electrical contractor. The following wire sizing chart indicates the minimum standards for wire sizes.

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Motor Recommended wire size, AWG

Hp Motor

3 1 115 34.0 6 4 2

5 1 115 56.0 4 1 1/0

7-1/2 1 230 40.0 8 6 4

10 3 230 28.0 8 8 8

15 3 230 42.0 6 6 6

20 3 230 54.0 4 4 4

25 3 230 68.0 2 2 2

30 3 230 80.0 1 1 1

40 3 230 100.0 2/0 2/0 2/0

50 3 230 130.0 3/0 3/0 3/0

Based upon 3% voltag e loss copper wire type TW. Single phase motor calculations are based on two times distance.

Volts Approximate Full

Phase

3 230 9.6 12 12 12

3 230 15. 2 12 12 10

3 230 22.0 10 10 8

Load Amperes

220 17.0 12 8 8

460 4.8 12 12 12

230 28.0 10 6 4

460 7.6 12 12 12

450 11. 0 12 12 12

460 14.0 12 12 12

460 21.0 10 10 10

460 27.0 8 8 8

460 34.0 6 6 6

460 40.0 6 6 6

460 52.0 4 4 4

460 65.0 2 2 2

Length of Run (ft)

0–100 to 200 to 300

its power for every 1,000 feet (305 m) above sea level, so if your installation is at a higher altitude than normal, consult the factory.

Chapter 2—Operation Procedures

Performance curves and charts are provided in Appendix C.

The following steps should be performed for the initial pumping operation:

1. Verify the strainer screen is clean.

2. Rotate the pump by hand.

3. Check V-belt drive or direct drive coupling alignment. Misalignment will cause accelerated wear of the drive system, motor bearings and pump.

4. Check motor for proper wiring.

5. Review complete system to make certain the function of every valve and piece of equipment is clearly understood. Everyone operating this system must be properly trained in normal operating procedures and emergency procedures in event of a malfunction.

6. Close all hose valves.

Improper motor wiring will cause expensive motor difficulties from low voltage. If you suspect you have low voltage, call your power company. Connecting your motor for the voltage you have available is important too. The motors furnished with the stationary pumps are usually dual voltage, so you must be sure of the voltage your power company is supplying you. Your motor will be completely ruined if it is connected to the wrong voltage.

A humid climate can cause problems, particularly in explosion proof motor applications. The normal breathing of the motor, and alternating between being warm when running and cool when stopped, often will cause moist air to be drawn into the motor housing. This moist air will condense, and may eventually add enough free water to the inside of the motor to cause it to fail. To prevent this, make a practice of running the motor and pump at least once a week on a bright, dry day for an hour or so (pumping through the bypass system). In this period the motor will heat up and vaporize the condensed moisture, and drive it out of the motor. No motor manufacturer will guarantee an explosion proof or totally enclosed motor against damage from moisture.

Engine drivers pose a special consideration. The manufacturer’s instructions must be followed. When the stationary pump is equipped with an engine from the factory, the engine speed should normally not exceed 1,800 RPM. Excessive engine speed will overload the engine and cause early failure. The engine loses 3% of

7. Slowly open the storage tank bottom shut-off valve (suction line to the pump). Immediately check the system for leaks.

8. Open any shut-off valves between the bypass valve and the storage tank.

9. Make a note of all pressure gauge readings, especially the pressure gauge located at the discharge of the pump. Start the pump and circulate the liquid through the bypass system back to the storage tank.

10. Verify the proper pump rotation direction. There is an arrow cast in the pump case.

11. An ammeter may be used by adjusting the bypass valve until the ammeter indicates the full load motor amperage rating shown on the motor nameplate or maximum rated differential, whichever comes first. Permit the pump to circulate liquid for half an hour or more. If the motor overload protection device stops the motor in this period the bypass valve setting is too high and should be readjusted until the motor will run for half an hour. After a satisfactory setting is achieved, “seal” the valve adjusting stem to prevent tampering with the adjustment. See IH102 for more details on the use of the Corken bypass valves.

12. If your pump has an internal relief valve, it must be set higher than the external bypass setting. The internal relief valve may be adjusted while the pump

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is under pressure by removing the flush seal plug. Turning the adjusting screw clockwise will decreases the internal relief valve setting. Replace the flush seal plug after adjustment.

13. After initial operation, re-check the strainer screen.

Chapter 3—Maintenance Procedures

ALL REPAIRS TO THE PUMP MUST BE PERFORMED BY QUALIFIED PERSONNEL IN A SAFE MANNER, UTILIZING TOOLS AND/OR

EQUIPMENT THAT ARE FREE OF HAZARDS, AND FOLLOWS THE APPLICABLE SAFETY CODES OF PRACTICE SET BY THE LOCAL AUTHORITIES HAVING JURISDICTION. MAKE SURE THE SYSTEM PRESSURE HAS BEEN RELIEVED BEFORE ATTEMPTING ANY REPAIR TO THE PUMP.

A pump requires regular maintenance and care like all mechanical equipment. A neglected or improperly repaired pump will result in premature failure and cause unsafe conditions.

To promote product longevity and safety, maintenance must be performed by properly trained technicians. Make sure all safety systems are in place and the system pressure has been relieved before attempting ANY maintenance.

Make sure the transfer hoses are not “kinked” which can cause excessive pump discharge pressure. Always make sure your hoses are not out of date.

There are two lubrication points in which to grease the pump bearings; one zerk per bearing cap located at opposite ends of the pump. Four grease relief and seal ventilation fittings have been provided, two at each end of the pump, to prevent overgreasing the bearings. Overgreasing can cause seal failure if grease passageways are blocked in some way. Clean each fitting before lubricating the bearings. This practice helps to prevent foreign-material contamination of the bearings and accidental over-pressurization of the mechanical seals. Use only ball bearing grease (MIL-G-10924C) with a temperature rating of -50°F.

Normal wear par ts are the mechanical shaft seals, bearings, vanes and sideplates. All of these parts plus O-rings and grease seals are offered in the Corken “repair kit” listed in this manual directly after the Seal Replacement Instruction on page 10. Use only genuine Corken replacement parts when repairing the pump.

When it becomes necessary to repair your pump or remove it from the system, you must be absolutely certain that all propane, anhydrous ammonia or whatever product being pumped is bled from the pump and connecting piping. Once all the product has safely been bled from the pump and connecting piping, make certain no pressure is left in the system.

SPECIAL CARE MUST BE TAKEN DURING THE BLEED DOWN PROCESS TO AVOID DANGER TO PERSONNEL AND PROPERTY IN THE AREA.

Bleeding a system too fast is a common mistake and may leave “refrigerated” liquid in the pump and piping even though the pressure gauge shows no pressure. As the “refrigerated” liquid begins to warm, more gas will escape causing a dangerous condition. Take your time in bleeding your system and make proper provisions to vent or capture the gas in accordance with local regulations. ONLY A PROPERLY TRAINED

INDIVIDUAL SHOULD BE ALLOWED TO BLEED A PUMPING SYSTEM.

Pump Maintenance Schedule

Daily Monthly

Lubricate bearings X Inspect drive coupling X Clean inlet strainer X Check for leaks X Inspect hose and fittings X

Continuous duty applications may require monthly lubrication.

Figure 3

If the pump’s use is seasonal, then special care must be taken during the off season to protect your pump from corrosion. If it is feasible and safe to keep the pump pressurized with product during the off season, this will prevent the entrance of any moisture or air. This system should be checked periodically to make certain all of the gas has not bled out.

If the pump is to be removed from service for some time, the pump must be protected., as propane, butane and anhydrous ammonia all leave the metal “bare” and open to corrosion. Piping and tanks not in service should also be protected, as the rust that forms can destroy the pump’s seals almost immediately after start-up. To prevent these problems, complete the following:

1. Fill or thoroughly flush the pump with a light rust inhibiting oil. If the pump is flushed with oil, placing some desiccant packets inside the pump will provide added protection.

2. Plug all pump openings.

3. Store in a dry location.

4. Before placing the pump back into service, drain the oil and remove any desiccant packets.

5. Before operating the pump, refer to chapter 2 of this manual for operation procedures.

Three

Months

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3.1 Preventative Maintenance Procedures

Purpose

By following an effective preventive maintenance program, unscheduled downtime can be eliminated. This program should be used by the Operation Manager to get a maximum utilization of manpower and equipment as well as to prevent possible unsafe situations and/or production delays due to equipment breakdown.

5. Lubricate Motor Bearing:

Follow the recommendations of the electric motor

manufacturer for the type of grease to use and the lubrication frequency.

6. Performance Test:

a. While transferring liquid with the pump, check the

pressure at the pump’s inlet port. The pressure drop in the inlet piping should not be greater than 3 psi.

Scope

The maintenance chart in figure 3 includes the items to be regularly checked and inspected with a recommended time schedule. These are basic maintenance recommendations, and each company should develop their own comprehensive preventive maintenance program schedule, tailor-made to their individual operational procedures and requirements.

Maintenance must only be performed by a properly trained and qualified individual following all the applicable safety procedures.

Procedures

Every procedure herein recommended must be performed in a safe manner (utilizing tools and/or equipment which are free of hazards) and following the safety codes of practice set by the authorities having jurisdiction. These are general guidelines and are not intended to cover all the safety aspects that must be considered and followed while performing these procedures.

1. Visual Inspection:

This includes checking for leaks, corroded areas,

condition of hoses, piping and fittings, and any unsafe condition which may hinder the safety of the personnel and/or the facility.

b. While transferring liquid with the pump, close the

discharge valve(s) so the full flow will be directed back to the storage tank through the bypass valve. Then slowly close the valve downstream of the bypass valves. The discharge pressure of the pump should increase to the maximum differential pressure of the pump at no flow conditions (see Appendix C—Performance Curves).

c. If the maximum differential pressure is not obtained,

the pump must be serviced. See Appendix G— Troubleshooting Guide for additional help.

d. Replace vanes or sideplates if worn.

7. Tighten all hold-down bolts.

8. Inspect motor starter contact points. This procedure must be performed by an authorized and qualified electrician according to the electric motor manufacturer’s guidelines.

2. Clean Inlet Strainer Screen:

A clogged strainer screen will create too much flow

restriction and vapor will be formed causing the pump to cavitate. This reduces the pump’s capacity and accelerates the wear of the internal parts.

3. Inspect Drive Coupling and Driveline:

Check the coupling alignment and the condition of the

union for cuts, broken sections and wear.

4. Lubricate Pump Bearings:

Use only ball bearing grease, applied with a manual

lubrication pump or gun. Always clean the grease openings thoroughly before greasing.

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Chapter 4—Seal Replacement Instructions

For all models 521 and 1021.

Simple as A, B, C... but watch alignments A, B and C or your new seal will leak!

Caution: Bleed all pressure from the pump and piping before starting to install your seal assembly.

Cleanliness

Even the smallest amount of dirt on your new seal can cause early failure. Keep all parts, tools and your

Step 1

Depressurize and open the pump.

Remove the bearing cap and bearing housing. Should the bearing housing be rusted or frozen in place it may be necessary to remove the entire pump head. The housing can then be driven out gently with a block of wood.

hands clean while installing the seal. Never touch the smooth lapped faces of the carbon rotor or seal seat. With LP-Gas, anhydrous ammonia, and similar liquids, the fluid is 5 to 10 times thinner than water so the smooth/lapped surfaces of the new seal need to be as clean as possible.

Workmanship

This pump is a precision piece of equipment with very close clearances and should be treated with care. Never beat on it when inserting or removing parts.

Remove the old shaft O-ring and discard it. Never reuse an old O-ring except in an emergency. If you are also installing a new bearing or grease seal do so now.

Follow established safety regulations!

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Step 2

Remove the old seal.

The seat adapter plate can be removed using a bearing cap bolt as a puller. Disregard the old adapter plate O-ring, seat, and seat O-ring. Remove and discard the rest of the old seal. Thoroughly clean all surfaces that contact O-rings. Use fine emery or crocus cloth. The shaft under the seal O-ring should be shiny smooth. Lubricate all surfaces with a clean, light oil. Do not let dirt settle on the parts.

Caution: Mechanical seals are precision devices. Care must be used when handling and installing the seal seat to prevent chipping or cracking.

Step 3

Proper alignment of the new seal.

This is the most critical step of the seal installation. With clean hands unwrap the new seal without touching the seal faces.

A. Locate the notch on the back of the retainer assembly

and position over the shaft drive pin as shown in the illustration. If the shaft drive pin is not aligned with the notch, the seal will be improperly positioned and leak. It should not require any force to install the retainer assembly.

Hold the carbon rotor

without touching the lapped face; lubricate the rotor O-ring with a light oil and install both on the pump shaft. (For the optional PTFE CoroSeal installation, see the following paragraph.)

Rotor O-ring (or optional Coro-Seal)

Groove

Watch alignments A and B!

If you are using the optional PTFE Coro-Seal, make sure the shaft is very clean and smooth as the PTFE seal is not as tolerant of surface blemishes as rubber O-rings. After lubricating the Coro-Seal, install in the backside of carbon rotor with the spring toward you and slide the carbon rotor in position as previously described.

B. The two grooves in the carbon rotor must line up with

the drive indentations in the retainer assembly. If they do not, the seal will be improperly positioned and leak. Do not allow the carbon rotor to cock. This may chip the lapped face.

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Step 4

Completing the installation.

After applying some oil to the new adapter plate O-ring, insert it into the pump head. Without touching the lapped face, insert the new seat and oiled seat O-ring into the adapter plate. Install the adapter plate in the pump head. Install the shaft O-ring on the shaft.

C. Slide the bearing housing over the

shaft and install the bearing cap using a criss-cross method on the bolts and make sure the pump shaft turns freely.

Watch alignment C!

Step 5

Proper lubrication.

For proper lubrication, use MIL-G-10924C ball bearing grease only. Each pump is equipped with a grease zerk and relief fitting. Before greasing the bearing, the grease zerk and relief fitting must be cleaned thoroughly. If any dirt is forced through the grease zerk, early bearing failure will result.

Overgreasing will damage the pump bearings. To help prevent overgreasing, use a hand operated grease gun. Insert the grease slowly and stop as soon as the relief fitting opens. Excessive grease may drip out of the relief fitting for several hours after lubrication.

Do not overgrease!

NOTE: When lubricating truck pumps, grease the U-joints and the spline of the drive shaft as well.

Step 6

Repressurize the system.

For best results slowly pressurize the pump with vapor before introducing liquid to the pump. When liquid enters a unpressurized pump-even slowly-it can sometimes refrigerate enough to keep the O-rings/elastomers from sealing properly and cause a leak.

Vapor first, then liquid!

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4.1 Repair Kits and Spare Parts for Sliding-Vane Pumps

D51 and F51 Standard Repair Parts (no kit available) D51 and F51 Additional Spare Parts

2296-1X_6

Seal assembly

2451-2 Vane

2-15 4 _

Case O-ring

2491 Sideplate

521 Repair Kit 2904-X26

116 3 -2 Sideplate

116 8 -7 Vane

1358 Grease seal

176 9 -XRA6 Seal assembly (replacement)

2-112 A O-ring, Buna-N

2-224A O-ring, Buna-N

2- 227A O-ring, Buna-N

2-234A O-ring, Buna-N

2-261A O-ring, Buna-N

2010 Flange gasket

2014 Grease seal, thrust

2754-X Roller bearing

2492-X Rotor and shaft assembly

2471 Roller bearing

521 Additional Spare Parts

116 6 -1X1R Rotor and shaft assembly

116 2-2 Cam (liner)

1021 and F1021 Repair Kit 2906-X26

1209-1 Sideplate

1308-9 Vane

1358 Grease seal

176 9 -XRA6 Seal assembly (replacement)

2-112 A O-ring, Buna-N

2-228A O-ring, Buna-N

2-245A O-ring, Buna-N

2-249A O-ring, Buna-N

2-268A O-ring, Buna-N

2014 Grease seal, thrust

2754-X Roller bearing

For a complete list of parts and O-ring s, see parts details in Appendix E.

All repair kits have Buna-N O-rings which are suitable for both LPG and NH3 applications.

1021 and F1021 Additional Spare Parts

1208-1X1R Rotor and shaft assembly

1201-2 Cam (liner)

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Appendix A—Model Number Identification Code

Models D51 and F51

Product Description

D51 Bare pump with mounting bracket and flexible coupling to close couple the pump to any NEMA 56 or 66 C-face

motor (Note motor is not included).

F51 Frame mounted pump for baseplate mounting (bare pump only).

Base Model # D51 F51

Inlet 1" N PT 1" N PT

Outlet 3/4" NPT 3 /4" NPT

Weight bare pump lbs. (kg)

40 ( 18 .1) 2 5 (11.3 )

Specification Fields

Pump Iron Standard A

Vanes Carbon Standard D

O-ring Material

Seal Seat Material

Buna-N Standard A

Neoprene

Silicon carbide Standard 6

®1

No charge option B

Mounting Options

Part Number

101-12 F51 only 14 5T 25 (11.3)

Model

Reference

Maximum

Motor Frame

Size

Ship Weight

lb (kg)

Mounting Only

Mounting Option

Mounting for frame mounted pump (F51) mounting includes steel baseplate and direct drive through flexible coupling.

Model Number

Base X X X X

Registered trademark of the DuPont company.

Page 15

Appendix A—Model Number Identification Code and Available Options

Models 521, 1021, and F1021

Base Model # Inlet 2-1/2 " N PT 3" NPT 3" ANSI 300 lb Outlet 2" NPT 3" NPT 2-1/2" ANSI 300 lb Weight bare pump lb (kg)

521 1021 F 1021

132 (60) 200 (91) 200 (91)

Specification Fields

Blade Type 10 blades Standard E

Blade Material

O-ring Material

Seal Seat Material

Flange Options

Inlet Flange

Standard

No Cost

Extra Cost

Outlet Flange

Standard

No Cost

Extra Cost

GCB-50 Standard G

Buna-N Standard A

®1

Neoprene

Silicon carbide Standard 6

WF=Slip on weld flange All ANSI flanges are 300 lb. • = Available option “Blank” = Not available

2-1/2" NPT • J

3" NPT • M 3" ANSI • P 4" ANSI S

2" NPT • E

4" NPT • Q

2" WF • F

2-1/2" W F • K

3" WF • N 4" WF • R

2" NPT • E

3" NPT • M

2-1/2" A NSI • L

3" ANSI P

1-1/ 2" NP T • C 2-1/2" NPT • J

4" NPT • Q

1-1/ 2" WF • D

2" WF • F

2-1/2" W F • K

3" WF • N 4" WF • R

No charge option B

Model Number

Base X X X X X X

Mounting Options

Part Number

103-9- 521 245T 422 (191) Mounting set up for V-belt drive. Includes steel baseplate,

102- All Consult Factory

101GRB- All 254T Consult Factory

101GRC- All 324T Consult Factory

Registered trademark of the DuPont company.

Model

Reference

Maximum Motor

Frame Size

Ship Weight

lb (kg) Mounting Only

Mounting Option

adjustable motor slide base, V-belt drive, and enclosed belt guard.103-10- 1021 and F1021 284T 560 (254)

Mounting set up for use with engine driver through V-belt includes steel baseplate, flexible coupling and guard

Mounting set up for direct drive. Includes size B gear reducer, steel baseplate, reducer bracket, couplings, and coupling guard.

Mounting set up for direct drive. Includes size C gear reducer, steel baseplate, reducer bracket, couplings, and coupling guard.

Page 16

Appendix B—Specifications for Models D51 and F51

Operating Specifications

Minimum RPM: 145 0

Maximum RPM: 1750

Minimum temperature: -25°F (-32°C)

Maximum temperature: 225°F (107°C)

Maximum working pressure: 350 psig (24.1 bar g)

Maximum differential pressure: 125 psi (8.6 bar d)

Maximum driver size: 2 hp (1.5 kW)

Flow range: 1–6 gpm (4–23 L/min)

Material Specifications

Part Model Material

Case, head rotor All Ductile iron ASTM A536

Sideplate All Gray iron ASTM A48, Class 30

Seal seat All Silicon carbide

Seal rotor All Carbon

Seal metal parts All Steel

Vanes All Carbon

Relief valve springs All Steel, cadmium plated

Relief valve All Steel

Shaft All “Stressproof” steel

Mounting bracket D51 Gray iron ASTM A48, Class 30

Base F51 Steel

O-rings All Buna-N (standard), PTFE (optional), Viton

Neoprene

Relief valve adjusting stem seal All Buna-N

Retainer rings All Steel

Bearings All Cylindrical roller

Registered trademark of the DuPont company.

®1

(optional)

®1

(optional),

Page 17

Appendix B—Specifications for Models 521, 1021, and F1021

Operating Specifications

Model 521 1021 F1021

RPM range 420–950 420–950 420–950

Temperature range -25°F (-32°C) to 225°F (107°C)

Maximum working pressure psig (bar g)

Maximum differential pressure psid (bar d)

Maximum driver size hp (kW)

Flow range gpm 30–85 65 –19 5 65–195

Flange Options

Model Standard No Cost Option Extra Cost Option

521

1021

F1021

Inlet 2-1/2" NPT 2" NPT 2", 2-1/2" weld flange

Outlet 2" NPT 1-1/ 2", 1-1/1" NP T 1-1/2", 2", 2-1/2" weld flange

Inlet 3" NPT 4" NPT 3", 4" weld flange

Outlet 3" NPT 4" NPT 3", 4" weld flange

Inlet 3" 300# ANSI — —

Outlet 2-1/2" 300# ANSI — —

350 (24 .1) 35 0 ( 24.1) 350 (24 .1)

125 (8.6) 125 (8.6) 125 (8.6)

10 (7.5) 20 (15) 20 (15)

Material Specifications

Part Model Standard Material

Case, head, flange, rotor, seat adapter plate

Cam, sideplate, bearing cap All Gray iron ASTM A48, Class 30

Welding flange All Steel

Seal seat All Silicon carbide

Seal metal parts All Steel

Shaft 521, 1021 “Stressproof” steel

Vanes All Plastic

Relief valve spring 521, 1021 Steel, cadmium plated

Relief valve 521, 1021 Steel

Bearing All Cylinder roller

O-rings All

Retainer rings All Steel

Registered trademark of the DuPont company.

All Ductile iron ASTM A536, Class 30

Buna-N (standard), PTFE (optional), Viton Neoprene

®1

(optional)

®1

(optional),

Page 18

Appendix C—Performance Curves for Models D51 and F51

Page 19

Appendix C—Performance Curves for Model 521

gpm L/min

151.4

113.6

gpm

420 RPM

kW hp

7.5

75.7

37.9

gpm L/min

227.1

189.3

151.4

113.6

gpm L/min

264.9

227.1

189.3

151.4

gpm L/min

302.8

264.9

gpm

Differential Pressure psi (bar)

120 (8.27)100 (6.89)80 (5.52)60 (4.14)40 (2.76)20 (1.38)0 (0)

520 RPM

640 RPM

780 RPM

3.7

kW hp

7.5

3.7

kW hp

7.5

3.7

kW hp

7.5

227.1

189.3

gpm L/min

378.5100

340.7

302.8

264.9

227.1

gpm

Differential Pressure psi (bar)

120 (8.27)100 (6.89)80 (5.52)60 (4.14)40 (2.76)20 (1.38)0 (0)

950 RPM

3.7

kW hp

11.2 15

7.5

3.7

Page 20

Appendix C—Performance Curves for Model 1021

gpm L/min

378.5

100

302.8

gpm

420 RPM

kW hp

14.9

227.1

151.4

gpm L/min

454.2120

378.5

100

302.8

227.1

151.4

gpm L/min

529.9

140

454.2

120

378.5

100

gpm

Differential Pressure psi (bar)

120 (8.27)100 (6.89)80 (5.52)60 (4.14)40 (2.76)20 (1.38)0 (0)

520 RPM

640 RPM

7.5

kW hp

14.9

7.5

kW hp

14.9

7.5

302.8

gpm L/min

681.4

180

605.7

160

529.9

140

454.2

120

gpm L/min

832.8

220

757.1

200

681.4

180

605.7

160

gpm

Differential Pressure psi (bar)

120 (8.27)100 (6.89)80 (5.52)60 (4.14)40 (2.76)20 (1.38)0 (0)

780 RPM

950 RPM

kW hp

3022.4

14.9

7.5

kW hp

3022.4

14.9

7.5

Page 21

Appendix D—Outline Dimensions for Models D51 and F51

Model D51 (Direct Mount)

1-5 /16 (28.7)

4-5/8 (11.7 )

15/16

(2.38)

9/16

(1.43)

“E” keyway

Model F51 (Frame Mount)

3 -11/16

(9.36)

Relief valve outlet:

1/2" NPT

Inlet 1" NPT

Relief valve outlet:

1/2" NPT

1-7/16 (3.65)

(8.57)

1-7/16 (3.65)

3-3/8

(8.57)

3-3/8

3- 3/16

(8 .10)

1/4" pipe plug

Outlet 3/4" NPT

3- 3/16

(8 .10 )

“E” keyway

9/16

(1.43)

15/16

(2.38)

4-5/8 (11. 7)

7/16

(1.10)

7/16

(1.10)

6-1/8

(15.6)

3-1/8

(7.93 )

3 -11/16

(9.36)

All dimensions are in inches (centimeters).

Inlet 1" NPT

Four

9/16 " x 11/32"

(1.40 x 0.87)

slots

1-11/16

(5.08)2(5.08)

(4.29)

1-11/16

(4.29)

1/4" pipe plug

Outlet 3/4" NPT

1/8

(0.32)

Page 22

Appendix D—Outline Dimensions for Model F51-101 (Frame Mount)

A B C D E F G H J K L M N

(55.90)20(50.80)9(22.90)6(15. 20)10(25.40)4(10. 20)1(2.54)

All dimensions are in inches (centimeters).

(2.54)

3-1/2

(8.89)

1-7/16

(3.65)

2-1/ 2

(6.35)

3-3/8 (8.57)

3- 3/16

(8.10)

Page 23

Appendix D—Outline Dimensions for Models 521 and 1021

Model Inlet Outlet A B C D E F G H J K

521

1021

STD: 2-1/2" NPT OPT: 2" NPT 2", 2-1/2" Weld

STD: 3" NPT OPT: 4" NPT 3", 4" Weld

STD: 2" NPT OPT: 1-1/2", 2-1/2" NPT 1-1/2", 2", 2-1/2" Weld

STD: 3" NPT OPT: 4" NPT 3", 4" Weld

1-31/32

(5.00)

(5.08)

All dimensions are in inches (centimeters).

1-3/8 (3.49)

1-3/4 (4.45)

7-7/8

(20.00)

8-1/2

(21.59)

5-29/32

(15.00 )

6-7/ 16 (16.35)

6-1 /8

(15.56 )5(12.70)4(10.16 )

7-1/16

(1 7.94 )

5-1/2

(13.97)

4-1/8

(10.48)

6-1 /8

(15.56 )

7-1/16

(1 7.94 )

4-11/16

(11.91)

5-3/8

(13.65)

(1.27 )

1/2

Page 24

Appendix D—Outline Dimensions for Models F1021

Model A B C D E F G H J K L M N P Q

F1021 3 2-/12

7-3 /4

(19.70)

5-1/2

(14. 00)2(5 .10 )

1-3/4 (4.40)

All dimensions are in inches (centimeters).

2-5/8

(6.70)

3-1/2

(8.90)

8-1/2

(21.60)

6-1 /2

(16.50)

4-1/8

(10.50)

4-15/ 16

(12.50)

1/4

(0.64)

1-1/ 8

(2.90)

(1.27 )

1/2

Page 25

Appendix D—Outline Dimensions for Models 521 and 1021-103

Flange Dimensions

Model A (inlet) B (outlet)

521

1021

Standard: 2-1/2" NPT Standard: 2" NPT

Optional: 2" NPT Optional: 1-1/2", 2-1/2" NPT

Standard: 3" NPT Standard: 3" NPT

Optional: 4" NPT Optional: 4" NPT

521-103 Dimensions

Motor

Hp Frame

2 14 5T All 3-5/8 (9.21) 8 (20.30) 6-1/8 (15.60 ) 6-1/4 (15.9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

2 18 2T All 3-5/8 (9.21) 8 (20.30) 6 -1/8 (15.60 ) 6-1/4 (15.9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

3 18 2T All 3-5/8 (9.21) 8 (20.30) 6 -1/8 (15.60 ) 6-1/4 (15.9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

3 18 4T All 3-5/8 (9.21) 8 (20.30) 6 -1/8 (15.60 ) 6-1/4 (15.9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

5 18 4T All 3-5/8 (9.21) 8 (20.30) 6 -1/8 (15.60 ) 6-1/4 (15.9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

7-1/ 2 213 T All 3-5/8 (9.21) 8 (20.30) 6-1/8 (15 .6 0) 6 -1/ 4 (15. 90 ) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

10 215T 420–470 3-5/8 (9.21) 10 - 3/4 (27. 3 0) 6 -1/ 8 (15. 60) 9-1/4 (23.50) 39-1/2 (10 0. 30) 42 (106.70) 19-3/4 (50.20)

10 215T 520–950 3-5/8 (9.21) 8 (20.30) 6 -1/8 (15.60 ) 6-1/4 (15 .9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

Pump

Speed

C D E F G H J

1021-103 Dimensions

Motor

Hp Frame

3 18 2T All 4-1/ 2 ( 10.80) 8 -1/2 (21.60 ) 7-3/16 (18.30) 6 -1/4 (15.90 ) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

5 18 4T All 4-1/ 2 ( 10.80) 8 -1/2 (21.60 ) 7-3/16 (18.30) 6 -1/4 (15.90 ) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

7-1/ 2 213 T All 4-1/ 2 (10. 80) 8-1/2 (2 1.60) 7-3/16 (18.30) 6 -1/4 (15 .9 0) 31-1/2 (80.00) 34 (86.40) 16 -1/2 (41.9 0)

10 215T 420–470 4-1/2 (10. 80 ) 10-1/2 (26.70) 7-3/16 (18.30) 9-1/4 (23.50) 3 9-1/2 (100 .3 0) 42 (106.70) 19-3/4 (50.20)

10 215T 520–950 4-1/2 (10. 80 ) 8-1/2 (2 1.6 0) 7-3/16 (18.30) 6-1/4 (15 .9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

15 254T 420 –520 4-1/2 (10 .8 0) 10-1/2 (26.70) 7-3/16 (18.30) 9-1/4 (23.50) 3 9-1/2 (100 .3 0) 42 (106.70) 19-3/4 (50.20)

15 254T 580–950 4 -1/ 2 (10. 80) 8-1/2 (2 1.60) 7-3/16 (18.30) 6 -1/4 (15 .9 0) 31-1/2 (80.00) 34 (86.40) 16-1/2 (41.9 0)

20 256T 520 4-1/2 (10.8 0) 10-1/2 (26.70) 7-3/16 (18.30) 9-1/4 (23.50) 39-1/2 (10 0. 30) 42 (106.70) 19-3/4 (50.20)

20 256T 640–950 4 -1/ 2 ( 10.80) 8-1/2 (21.60 ) 7-3/16 (18.30) 6 -1/4 (15.90 ) 31-1/2 (80.00) 34 (86.40) 16 -1/ 2 (41.90)

All dimensions based on a motor speed of 1,750 RPM.

Pump

Speed

C D E F G H J

All dimensions are in inches (centimeters).

Page 26

Appendix D—Outline Dimensions for Models F1021

Flange Dimensions

Model A (inlet) B (outlet)

F1021 3" 300# ANSI 2-1/2" 300# ANSI

F1021-103 Dimensions

Motor

Hp Frame

3 18 2T All 4-1/4 (10 .8 0) 12 ( 30.50) 15 (3 8.10) 5 (12.70) 6 -1/4 (15 .9 0) 31-1/ 2 (80) 34 (86.40) 7-3/4 (19.70) 8-1/2 (2 1.60)

5 18 4T All 4-1/4 (10 .8 0) 12 ( 30.50) 15 (3 8.10) 5 (12.70) 6 -1/4 (15 .9 0) 31-1/ 2 (80) 34 (86.40) 7-3/4 (19.70) 8-1/2 (2 1.60)

7-1/ 2 2 13T All 4-1/4 (10.80) 12 (30.50) 15 (3 8.10) 5 (12.70) 6-1/4 (15 .9 0) 31-1/ 2 ( 80) 34 (86.40) 7-3/4 (19.70) 8 -1/2 (21. 60 )

10 215 T 420–470 4-1/4 ( 10.8 0) 12 (3 0. 50 ) 15 (38 .10 ) 5 (12.70) 9-1/4 (23.50) 39 -1/ 2 ( 100. 30 ) 42 (106.70) 7-3/4 (19.70) 10-1/2 (26.70)

10 215 T 520 –950 4-1/4 (10 .8 0) 12 (30.50) 15 (3 8.10) 5 (12.70) 6-1/4 (15 .9 0) 31-1/ 2 ( 80) 34 (86.40) 7-3/4 (19.70) 8 -1/2 (21. 60 )

15 254T 420–520 4-1/4 ( 10.80) 12 (3 0.50) 15 (38 .10 ) 5 (12.70) 9-1/4 (23.50) 39 -1/ 2 ( 100.30 ) 42 (106.70) 7-3/4 (19.70) 10-1/2 (26.70)

15 254T 580–950 4-1/4 ( 10.8 0) 12 (3 0. 50 ) 15 (38 .10 ) 5 (12.70) 6-1/4 ( 15. 90) 31-1/2 (80 ) 34 (86.40) 7-3/4 (19.70) 8-1/2 (21.6 0)

20 256T 520 4-1/4 (10.8 0) 12 (30. 50 ) 15 ( 38.10 ) 5 ( 12.7 0) 9-1/4 (23.50) 39-1/2 (10 0. 30) 42 (106.70) 7-3/4 (19.70) 10-1/2 (26.70)

20 256T 640–950 4-1/4 ( 10.8 0) 12 (3 0. 50 ) 15 ( 38.10 ) 5 (12.70) 6-1/4 ( 15.9 0) 31-1/ 2 (80 ) 34 (86.40) 7-3/4 (19.70) 8 -1/2 (21. 60 )

All dimensions based on a motor speed of 1,750 RPM.

Pump

Speed

C D E F G H J K L

All dimensions are in inches (centimeters).

Page 27

Appendix E—Parts Details for Seal Assembly (2296 Series)

Models D51 and F51

Ref

Part No. Description Qt y.

No.

1. 2471 Roller bearing 1

2. 5000-112 Retainer ring 1

3. 2595 Seat location pin 1

4. 2735 Drive band (with 2492-X) 1

5. 3471 Spring (with 2492-X) 1

6. 2492-X Rotor and shaft assembly 1 2296-X_6

7. 2296-1X_6

Not sold

8. separately

Not sold

9. separately

Not sold

10. separately

Not sold

11. separately

Not sold

12. separately

Not sold

13. separately

a, b

Seal 1 Seal Assembly 1

Silicon carbide seal seat 1

Seat O-ring 1

Rotor 1

O-ring 1

Disc 1

Retainer 1

Material Code

A Buna-N B Neoprene

_ denotes material code. See material code chart for details.

Seal assembly includes the seal and a 2-154_a case O-ring.

Not sold separately. These items are inc luded in both the seal and the seal assembly.

Registered trademark of the DuPont company.

®d

CAUTION: Always relieve pressure in the unit before attempting any repairs.

WARNING

Page 28

Appendix E—Parts Details for Model D51 (Direct Mount)

CAUTION: Always relieve pressure in the unit before attempting any repairs.

WARNING

Ref

Part No. Description Qt y.

No.

1. 2592 Key—1/8" sq. x 9/16" 1

2. 2510 Mounting bracket 1

3. 3442 Pipe plug—1/4" NPT 1

4. 246 8 Case 1

5. 2492-X Rotor and shaft assembly 1

6. 2491 Sideplate 2

7. 2296-1X_6 2604 Elbow grease zerk—1/8" NPT 2

8. 2159 Lubricap #2 (not shown) 2

Seal assembly 2

9. 2595 Seat location pin 2

10. 2472 Head 2

11. 2-154 _

12. 2471

Case O-ring 2 Roller bearing 2

13. 5000-112 Retainer ring 4

14. 2451-2 Carbon vane 8

15. 2590

Flush plug—1/8" NPT 1

16. 2760-53 Retainer ring 1

17. 2589 Stem seal 1

18. 2585 Relief valve plug 1

19. 2590 Flush plug—1/8" NPT 1

20. 2584-X Adjusting stem assembly 1

21. 2587

22. 2586

Outer relief valve spring 1 Inner relief valve spring 1

23. 2588 Relief valve 1

24. 2591 Nameplate 1 25 93 -1 Coupling with spider 1

25. 27 74 Coupling spider only 1

Material Code

A Buna-N B Neoprene

Ref

Part No. Description Qt y.

No.

26. 7002-025NC062A Bolt socket head 9

27. 7001-037NC100A Bolt hex head 4

28. 7012-006SF019E Nameplate screw 2

_ denotes material code. See material chart for details.

Registered trademark of the DuPont company.

The pump relief valve is installed at the factory to operate as an external bypass through the 1/2" NPT hole back to the storage tank. To change from this external configuration to an internal relief valve, remove relief valve plug 2585 and relief valve springs 2586 and 2587. Then remove flush sea l plug 2590 and plug the 1/2" NPT opening. Replace the relief valve plug and springs. In this case a separate external bypass valve must be used in the piping b etween the pump discharge and the storage tank. Set the internal valve at a pressure slightly above the setting on the ex ternal valve. Use only the outer relief valve spring 2587 for units with 1/3 hp motors. Use both springs for 1/2 hp motors and larger. Always replace the flush seal plug 2590 that screws into the relief valve plug 2585 after any relief valve adjustment.

Bearing replacement: Install roller bearing 2471 with open side of grease seals toward outside of pump as shown below.

®b

Page 29

Appendix E—Parts Details for Model F51 (Frame Mount)

CAUTION: Always relieve pressure in the unit before attempting any repairs.

WARNING

External bypass

opening—1/2" NPT

Ref

Part No. Description Qt y.

No.

1. 2592 Key—1/8" sq. x 9/16" 1

2. 3442 Pipe plug—1/4" NPT 1

3. 24 68-1 Case 1

4. 2492-X Rotor and shaft assembly 1

5. 2491 Sideplate 2

6. 2296-1X_6

Seal assembly 2

7. 2595 Seat location pin 2

8. 2472 Head 2

9. 2 -154 _

10. 2471

Case O-ring 2 Roller bearing 2

11. 5000-112 Retainer ring 4

12. 2451-2 Carbon vane 8

13. 2590

Flush plug—1/8" NPT 1

14. 2760-53 Retainer ring 1

15. 2589 Stem seal 1

16. 2585 Relief valve plug 1

17. 2590 Flush plug—1/8" NPT 1

18. 2584-X Adjusting stem assembly 1

19. 2587

20. 2586

Outer relief valve spring 1 Inner relief valve spring 1

21. 2588 Relief valve 1

22. 2591 Nameplate 1

23. 2594 Base 1 2158 Grease zerk—1/8" NPT 2

24. 2159 Lubricap #2 (not shown) 2

Material Code

A Buna-N B Neoprene

Ref

Part No. Description Qt y.

No.

25. 7002-025NC062A Bolt socket head 12

26. 7002-010NC050A Bolt socket head 3

27. 7012-006SF019E Nameplate screw 2

_ denotes material code. See material chart for details.

Registered trademark of the DuPont company.

Bearing replacement: Install roller bearing 2471 with open side of grease seals toward outside of pump as shown below.

®b

Page 30

Appendix E—Parts Details for Seal Assembly (1769 Series)

All Models 521 and 1021

CAUTION: Always relieve pressure in the unit before attempting any repairs.

WARNING

Sideplate

Head

Seal vent tting

O-ring used in 1769-X_6a, 1769-XR_6

Grease zerk

Ref

Part No. Description Qt y.

No.

1. 176 9 -X _ 6

Complete seal assembly 1

2. 2760-244 Retainer ring 1 2754-X Roller bearing, complete 1

2754 Bearing outer race 1 2755 Bearing inner race 1

4. 1769 Bearing housing 1

5. 2-128 _

7. 2- 227_

8. 182 2

9. 2-24 0_

10.

11. 2-223_

12.

13.

14. 176 9 -X R_6

Not sold separately

Shaft O-ring 1

Seal seat 1

Seat O-ring 1 Seat adapter plate 1 Adapter plate O-ring 1

Carbon seal 1

Rotor O-ring 1

Disc 1

Retainer assembly 1

Field replacement seal assembly 1

Material Code

A Buna-N B Neoprene

Lubrication nameplate

Bearing cap

Relief tting

Grease seal

Bearing cap bolt

_ denotes material code. See material code chart for details.

Registered trademark of the DuPont company.

Not included in field replacement seal assembly.

®b

Not sold separately. Available with 1769-X_6 a and 176 9- XR _6 a only.

Page 31

Appendix E—Parts Details for Models 521 and 1021

CAUTION: Always relieve pressure in the unit before attempting any repairs.

WARNING

21B

21A

Sideplate Replacement Instructions

Model 521 Model 1021

Smooth

side

Grooved

side

Grooved side must be against

the rotor.

Grooved

side

Smooth

side

Install with feeder channel

against rotor pointing

toward the outlet.

Outlet

Feeder

channel

Inlet

Page 32

Appendix E—Parts Details for Models 521 and 1021

Ref

Part No. Description Qt y.

No.

116 2-2 C am (521) 1

1. 1201- 2 Cam (1021) 1

2832 Case ( 521) 1

2. 28 41 Case (1021) 1

1172-2. 5 Flange—2-1/2" standard (521) 1 1172-2 Flange—2" standard (521) 1 1172-1.5 Flange—1/2" NPT, optional (521) 1 1172-15S Flange—1/2" Weld, optional (521) 1 1172-2 Flange—2" NPT, optional (521) 1 1172-2S Flange—2" Weld, optional (521) 1

3. 1172-2. 5 Flange—2-1/2" NPT, optional (521) 1

1172-2. 5 S Flange—2-1/2" Weld, optional (521) 1 1206- 34 Flange—3" standard (1021) 2 1206- 3S Flange—3" Weld, optional (1021) 2 1206- 4 Flange—4" NPT, optional (1021) 2 1206- 4S Flange—4" Weld, optional (1021) 2

2-234_

2-245 _ 2-249_

5. 2-112 _

Flange O-ring (521) 2 Flange O-ring-3" (1021) 2 Flange O-ring-4" (1021) 2 Adjusting screw O-ring 1

6. 2590 Flush plug—1/8" NPT 1

7. 2252 Relief valve adjusting screw 1 1174 Valve cap (521) 1

8. 1207 Valve cap (1021) 1

1242-X Relief valve spring and guide (521) 1

9. 1227 Relief valve spring guide (1021) 1

2-224 _

10.

11.

12.

13.

14.

15.

2-228_ 1241 Relief valve (521) 1 1224 Relief valve (1021) 1 1242 Relief valve spring (521) 1 1226 Relief valve spring (1021) 1 1170 Cam key (521) 1 130 9 Cam key (1021) 1 116 8 -7 Blade (521) 10 1308-9 Blade (1021) 10 116 6 -1X1R Rotor and shaft assembly (521) 1 120 8 -1X1R Rotor and shaft assembly (1021) 1

Relief valve cap O-ring (521) 1 Relief valve cap O-ring (1021) 1

16. 13 58 Grease seal 2

17. 1164-1 Bearing cap 2

18. 2158 Grease zerk—1/8" NPT 2

19. 1769 Bearing housing 2

20. 13 43 Seal vent relief fitting—1/8" NPT 2

Ref

Part No. Description Qt y.

No.

Complete seal assembly kit.

21A.

176 9-X _ 6

Includes bearing housing, seat adapter plate, bearings, retainer rings, seal, and O-rings.

21B.

176 9-XR_6

Seal assembly field replacement kit. Includes only the seal and O-rings.

116 3 -2

22.

23.

1209-1 1161- 4 H ea d (521) 2 1205- 4 Head (1021) 2

Sideplate (521) 2 Sideplate (1021) 2

2754-X Roller bearing—complete 2

24.

2755 Bearing inner race 2 2754 Bearing outer race 2

25. 2760 -244 Retainer ring 2

26. 1343 Grease relief fitting—1/8" NPT 2

27. 2-12 8A Shaft O-ring (Buna-N only) 2

28. 1882 Seat adapter plate 2

2-261_ 2-268 _

Adapter plate O-ring 2 Case O-ring (521) 2 Case O-ring (1021) 2

29. 2-240_

30.

31. 2270 Key —1/ 4" 2

32. 2949 Nameplate 1

33. 3442 Plug —1/4" N PT 1 7001-031NC125A Hex head bolt—5/16-18x1-1/4 (521) 4

34. 7001-037NC125A Hex head bolt—3/8-16x1-1/4 (1021) 4

7001-037NC125A Hex head bolt—3/8-16x1-1/4 (521) 28

35. 7001-037NC125A Hex head bolt—3/8-16x1-1/4 (1021) 32

36. 7001-037NC150A Hex he ad bol t—3 /8-16 x1-1/2 8 Not sold

37. separately

Not sold

38. separately

39. 2-227_

Retainer 2

Seal seat 2

Seal seat O-ring 2

40. 2159 Lubricap #2 2

41. 1359 Lubrication instruction tag 2

42. 7003-004DR0198

Material Code

A Buna-N B Neoprene D Viton

®c

Round head plated drive screw— 4 x 3/16

_ denotes material code. See material code chart for details.

Not sold separately. Available with 1769-X_6 a, and 1769-XR_6 a only.

Registered trademark of the DuPont company.

See sideplate replacement instructions.

E PTFE

Page 33

Appendix E—Parts Details for Model F1021

Outlet

CAUTION: Always relieve pressure in the unit b efore attempting any repairs.

WARNING

Inlet

Direction

Of rotation

Ref

Part No. Description Qt y.

No.

1. 2433 Case 1

2. 13 09 Cam key 1

3. 1201-2 Cam 1

4. 3442 Plug—1/8" NPT 2

5. 120 5-4 Head 2

6. 1209-1

Sideplate 2 Complete seal assembly kit.

Includes bearing housing, seat adapter plate, bearings, retainer rings, seal, and O-rings.

Seal assembly field replacement kit. Includes only the seal and

176 9-X _ 6

176 9-XR_6

O-rings.

8. 182 2 Seat adapter plate 2

9. 1769 Bearing house 1

10. 2158 Grease zerk—1/8" NPT 1

11. 1164-1 Bearing cap 2

12. 13 58 Grease seal 1

13. 2270 K e y—1/4" 1 2754-X Roller bearing—complete 2

14.

2755 Bearing inner race 2 2754 Bearing outer race 2

15. 2760-244 Retainer ring 1

16. 13 43 Grease relief fitting—1/8" NPT 2

17. 2-128A Shaft O-ring (Buna-N only) 1

18. 13 43 Seal vent relief fitting—1/8" NPT 1

19. 2-240_

20. 2-268_

Adapter plate O-ring 1 Case O-ring 2

25 10

24 11

12 13

17 18 19

Ref

Part No. Description Qt y.

No.

21. 1308-9 Va ne 10

22. 120 8 -1X1R

Rotor and shaft assembly with 2755

23. 2649 Nameplate 1

24. 7001-037NC125A Hex he ad bol t—3 /8 -16 x1-1/4" 32

25. 2159 Lubricap #2 2

26. 7012-006SF019E

Material Code

A Buna-N

B Neoprene

®b

Round head drive screw—6-32x3/16

_ denotes material code. See material code chart for details.

Registered trademark of the DuPont company.

See sideplate replacement instructions.

Sideplate Replacement Instructions

Outlet

Install with feeder channel

against rotor pointing

toward the outlet.

Inlet

Page 34

Appendix E—Parts Details for Rotor, Blade, Sideplate, and Cam

New Part Interface Dimensions

(max)

Cam

(nominal)

Sideplate

Model

(min)

(max)

Rotor and shaft

(max)

Blade

(min)

(max)

500 0.373 2.992 5.449 0.750 3.000 2.994 0.230 1. 323

1000 0.435 3.993 6.249 1.123 4.002 3.997 0.230 1.500

150 0 0.435 6.243 6.12 5 1.18 4 6.253 6.229 0.549 1.635

Page 35

Appendix F—V-Belt Selection for Sliding-Vane Pumps

1,450 RPM Motor

Belt

Number

B64 B15.4 B 7.4 2 420 1-3V14. 0 1-3V3.35 3V600 B60 B13.6 B4.2 470 1-3V10.6 1-3V 2.8 0 3V530 B60 B12.4 B4.2 520 1-3V10.6 1-3V 3.15 3V530 B55 B11.0 B4.2 580 1-3V10. 6 1-3V3.65 3V560 B56 B11.0 B4.8 640 1-3V8.0 1-3V3.00 3V500 B64 B15.4 B4.4 3 420 2-3V10.6 2-3V2.65 3V530 B64 B15.4 B4.8 470 2-3V10.6 2-3V2.80 3V530

A55 2 A10 .6 2A3.6 520 1- 3V14.0 1-3V4.12 3V630 B55 2 B11.0 2B4.2 580 1-3V14.0 1- 3V4.75 3V630 B60 B12.4 B5.4 640 2-3V8.0 2-3V3.00 3V500 B56 B11.0 B5.2 710 2-3V6.9 2-3V2.80 3V475 B53 B9.4 B4.8 780 1-3V8. 0 1-3V3.65 3V500 B53 B8.6 B5.0 860 2-3V5.3 2-3V2.65 3V450

B51 B7.4 B4.8 950 1-3V6.5 1-3V3.65 3V475 B64 2B15 .4 2B4.4 5 420 3 -A13. 2 3-A3.2 A60 B60 2B13 .6 2B4.2 470 2 -A13. 2 2-A3.6 A60 B60 2B12.4 2B4.2 520 2- A12. 0 2-A3.6 A56 B55 2 B11.0 2B4.2 580 2-3V10.6 2-3V3.65 3V560 B56 2 B11.0 2B4.8 640 3-3V8.0 3-3V3.00 3V500 B56 2 B11.0 2B5.2 710 2-3V8.0 2-3V3.35 3V500 B53 2B9.4 2B4.8 780 2-3V6.9 2-3V 3.15 3V475 B53 2B8.6 2B5.0 860 2-3V6.5 2 -3V 3 .15 3V475

B51 2B7. 4 2B4.8 950 2-3V6.0 2-3V3.35 3V475 B64 3B15 .4 3B4.4 7-1/2 420 4 -A13. 2 4-A3.2 A60 B64 2B15 .4 2B4.8 470 3 -A13. 2 3-A3.6 A60 B60 3B12.7 3B4.2 520 3-3V14. 0 3-3 V4 .12 3V630 B55 3 B11.0 3B4.2 580 2 -3 V14.0 2-3V4.75 3V630 B56 3 B11.0 3B4.8 640 2-3V14.0 2-3V5.30 3V630 B56 3 B11.0 3B5.2 710 2-3V10.6 2-3V4.50 3V560 B53 3B9.4 3B4.8 780 3-3V6.9 3 -3V 3.15 3V475 B53 3B8.6 3B5.0 860 3-3V6.5 3 - 3V3 .15 3V475

B51 3B7. 4 3B4.8 950 2- 3V8.0 2-3V4.50 3V530

B71 3B18.4 3B5.2 10 420 3-3V19.0 3-3V4.50 3V710

B71 2B18.4 2B5.8 470 3-3V19.0 3-3V5.00 3V 710 B60 4B12.4 4B4.2 520 3-3V14. 0 3-3 V4 .12 3V630 B55 4 B11.0 4B4.2 580 3 -3V14 .0 3 -3V4.50 3V630 B56 4 B11.0 4B4.8 640 2-3V14.0 2-3V5.30 3V630 B62 3B12.4 3B5.8 710 2- 3V14.0 2-3V5.60 3V630 B56 3 B11.0 3B5.8 780 2- B12. 4 2-B5.6 B60 B62 3B12.4 3B7. 0 860 2- 3V10.6 2-3V5.30 3V560 B60 3B9.4 3B6.0 950 2-3V10.6 2-3V5.60 3V560

B71 4B18.4 4B5.2 15 420 4-3V19.0 4-3V4.75 3V 710

B71 3B18.4 3B5.8 470 4-3V19.0 4-3V5.00 3V710 B62 5B13.6 5B4.8 520 3- 3V19.0 3-3V5.60 3V750 B60 5B12.4 5B4.8 580 4-3V14.0 4-3V4.75 3V630 B56 5 B11.0 5B4.8 640 3 -3V14 .0 3-3V5.30 3V630 B56 5 B11.0 5B5.2 710 3-3V14. 0 3-3V5.60 3V630 B53 5B9.4 5B4.8 780 3-B12.4 3-B5.6 B60 B53 5B8.6 5B5.0 860 2-B12.4 2-B6.0 B60

B51 5B7. 4 5B4.8 950 2- B11.0 2-B6.0 B56

B75 4B18.4 4B6.6 20 520 4-3V19.0 4-3V5.60 3V750 B68 4B15.4 4B6.8 640 4-3V14.0 4-3V5.30 3V630 B64 4B12.4 4B6.6 780 3-B13.6 3-B6.0 B62 B68 3B13 .6 3B8.0 860 4-3V10.6 4-3V5.30 3V560 B65 3B12.4 3B8.0 950 3 -B11. 0 3-B6.0 B56

Do not use a V-belt drive system on a Coro-Vane® pump with a driver greater than 25 horsepower. Consult factory if your application is outside this parameter.

Sheave Pitch Diameter Sheave Pitch Diameter

Pump Motor Pump Motor

Motor

Nominal

Pump RPM

1,750 RPM Motor

Belt

Number

Page 36

Appendix G—Troubleshooting Guide

In diagnosing pump and system troubles, record the following data during product transfers:

1. Pressure at pump suction.

2. Pressure at pump discharge.

3. Pressure in truck tank.

5. Pipe size and length of suction and discharge lines.

6. Size and length of vapor equalizing line.

7. Pump speed if practical.

4. Pressure in tank being filled.

Symptom Probable Cause Remedy

Low capacity Pump speed too slow Check engine speed and PTO ratio. Consult pump performance curve.

Use tachometer on pump if speed is questionable.

High differential pressure Restriction in discharge piping or hose too small. Vapor equalization lines

too small or not used.

External bypass valve stuck open or set too low

Clogged strainer Clean strainer.

Suction pipe too small or restricted

Worn vanes Replace.

Pump without vapor return Without vapor equalization, a pump can remove only about 3% of the truck

Worn sideplates Reverse or replace sideplates. Check universal drive assembly to make

Vanes sticking Remove vanes and clean out foreign matter (check strainer). Replace

Pump runs but no flow

Pump will not turn or is locked up

Will not build pressure

Pump is noisy Cavitation from poor suction

Pump leaks around shaft

Valve closed Check valves. Make sure internal tank excess flow valve is open! Refer to

Excess flow valve slugged Stop pump until valve opens. If problem continues, slow pump down or

Broken shaft Disassemble and inspect pump. Repair if necessary.

Defective meter Service meter.

Foreign matter in pump Clean out the pump and check strainer in suction line

Vanes broken Clean out pump carefully and replace vanes. Has pump been operated dry?

Bearing seized Replace pump bearings. Grease monthly. Use ball bearing grease

Moisture frozen in pump Let thaw and break loose carefully. Add alcohol to tank (on LP-Gas). Check

Poor suction conditions Clean inlet strainer. Increase pipe size.

External bypass valve set too low

Worn vanes and/or sideplates

conditions

Vanes sticking As above.

Bearings worn Replace if necessary and grease monthly.

Very high differential Check for restriction in discharge line. Delivery hose too small pressure

PTO shaft vibration Inspect and repair driveline component.

Seal or O-rings failed Inspect seal assembly and replace if necessary. Keep new seal very

Readjust, repair, or replace valve.

Indicated by pump inlet pressure dropping several pounds when pump is started. Remove restriction or modify piping.

tank capacity per minute without severe cavitation and capacity loss.

sure angularity is within limits, yokes are parallel and slip-joint is greased. Check bearings.

vanes if swollen.

manufacturer’s instructions.

install a new or larger excess flow valve.

Then, check for damage to cam and rotor shaft assembly.

manufactured for intended service.

with product supplier about the possibility of water in the gas.

Set valve for higher pressure—see instructions.

Disassemble, inspect and repair as necessary. Do not run pump dry!

As above.

and too long. Slow down pump!

Check vapor release float assembly on meter and meter differential valve.

clean when replacing seal. Recommend a light oil film on O-rings. Do not run pump dry!

Page 37

Appendix H—Extended Storage Procedures

If the pump is to be removed from service for some time, it must be protected as propane, butane, and anhydrous ammonia all leave the metal “bare” and open to corrosion. Piping and tanks not in service should also be protected, as the rust particles can destroy the pump’s seals almost immediately after startup.

1. Fill or thoroughly flush the pump with a light rust inhibiting oil. (If the pump is flushed with oil, place some desiccant packets inside the pump for added protection.)

2. Plug all pump openings.

3. Store in a dry location.

4. Before placing the pump back into service, drain the oil and remove any desiccant packets.

5. Refer to the “Operation Procedures” on page 7 of this Installation, Operation and Maintenance (IOM) manual.

373839

Page 38

Page 39

Page 40

Solutions beyond products...

CORKEN, INC. • A Unit of IDEX Corporation

3805 N.W. 36th St., Oklahoma City, OK 73112

Phone (405) 946-5576 • Fax (405) 948-7343

Visit our website at http://www.corken.com

or e-mail us at cocsalesdept@idexcorp.com

@CorkenInc

Printed in the U.S.A.

March 2017

Corken 51, D51, 521, 1021, F1521 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Principles of a Sliding-Vane Pump

Exclusive Features of the Coro-Vane® Pump

Chapter 1—Installation Procedures

1.1 Location

1.2 The Inlet Piping Should Include the Following:

1.6 Driver Installation

Chapter 2—Operation Procedures

Chapter 3—Maintenance Procedures

3.1 Preventative Maintenance Procedures

Chapter 4—Seal Replacement Instructions

4.1 Repair Kits and Spare Parts for Sliding-Vane Pumps