Corken Z Series, Z4200, Z2000, Z4500, Z3200 Installation, Operation & Maintenance Manual

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Page 1

ORIGINAL INSTRUCTIONS ID105K

Installation, Operation

& Maintenance Manual

Z-Series Sliding Vane Pumps

Truck and Stationary

Model Z2000 Truck Pump

Model Z3200 Truck Pump

Model Z3500 Truck and

Stationary Pump

Model Z4200 Truck Pump

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 qualied 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, ammable or explosive substances using Corken products is at user’s risk and equipment should be operated only by qualied personnel according to applicable laws and safety standards.

Model Z4500 Stationary Pump

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, Ok l a h o m a 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 tness 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, ammable 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 le containing all information on material specications and test data applying to your specic 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

APPLICABLE NOTICES FOR ATEX 94/9/EC CONFORMITY ...........................................4

PRINCIPLES OF THE Z-SERIES SLIDING VANE PUMP (CORO-VANE®) .................................5

EXCLUSIVE FEATURES OF THE Z-SERIES CORO-VANE® PUMP ......................................5

CHAPTER 1—INSTALLATION OF THE Z-SERIES CORO-VANE® TRUCK PUMP ..........................5

1.1 The Outlet Piping Should Include the Following ..................................................6

1.2 The Bypass System ........................................................................6

1.3 Power Take-off (PTO) Drive Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Hydraulic Drive Systems ....................................................................7

CHAPTER 2—OPERATION OF THE Z-SERIES CORO-VANE® TRUCK PUMP ............................7

2.1 How to Transfer From the Truck Tank at Full Capacity ..............................................7

CHAPTER 3—INSTALLATION OF THE Z-SERIES CORO-VANE® STATIONARY PUMP .....................8

3.1 The Inlet Piping Should Include the Following ....................................................8

3.2 The Outlet Piping Should Include the Following ..................................................8

3.3 The Bypass System Must Include the Following ..................................................9

3.4 A Vapor Equalizing System Should be Included ..................................................9

3.5 Driver Installation ..........................................................................9

CHAPTER 4—OPERATION OF THE Z-SERIES STATIONARY CORO-VANE® PUMP ......................10

CHAPTER 5—MAINTENANCE OF THE Z-SERIES CORO-VANE® PUMP ...............................11

5.1 Purpose ................................................................................11

5.2 Scope ..................................................................................11

5.3 Procedures .............................................................................. 11

CHAPTER 6—Z-SERIES CORO-VANE® SEAL REPLACEMENT INSTRUCTIONS ........................13

6.1 Repair/Rebuild Kits with Iron Seal Seat ........................................................16

6.2 Repair/Rebuild Kits with Silicon Carbide Seal Seat ...............................................17

6.3 Assembly Instructions For All Z-Series Repair and Rebuild Kits .....................................18

APPENDICES

A. Model Number Identication Code and Available Options ..........................................19

B. Specications ............................................................................21

C. Performance .............................................................................22

D. Outline Dimensions ........................................................................28

E. Parts Details .............................................................................38

F. V-Belt Selection ...........................................................................45

G. Troubleshooting Guide .....................................................................46

H. Extended Storage .........................................................................48

I. Hydraulic Motor Specications ................................................................48

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Applicable Notices for ATEX 94/9/EC Conformity

Product Type:

Sliding Vane Pump (Coro-Vane®)

Training Instructions:

Instructions for the safe application and use of this product are provided in this manual. Read this manual completely prior to installation and use of this product. Only qualied and properly trained personnel should be allowed to install, operate, and maintain this equipment.

Models Covered:

Z/ZH2000, ZX/ZXH2000, Z/ZH3200, Z3500, Z/ZH4200, and Z4500

Intended Application:

The pump models covered by this manual conform to the European Union ATEX 94/9/EC Directive for explosive gas atmospheres and transfer of liqueed gases such as Liqueed Petroleum Gas, anhydrous ammonia, freons, etc. Electric motors for these pumps in the assembly must comply with all applicable requirements for local, federal, and regional codes and regulations.

Possible Misuse Warning:

The designated pump models must only be installed in systems designed for its intended use, similar to the examples presented in this manual.

ATEX Classication:

Group II; Category 2; G; Temperature Class T4 – T5

These products are classied under the ATEX directive as Equipment – Group II – Category 2 – equipment is intended for use in areas where explosive atmospheres caused by gases or vapors (G) may be present. The surface Temperature Class rating is a range between T4 275°F (135°C) and T5 212°F (100°C).

Nameplate:

ATEX directive 94/9/EC marking

Explosive protection

Equipment classified as Group II— Catagory 2

Explosive gas atmosphere high level

Maximum surface temperature T4 275°F (135°C)

File number

ATE X a nd machinery directive

Mechanical Ignition Sources:

This equipment may be direct driven through a coupling by an electric motor or belt driven by an electric motor. Guards for the drive mechanism in the assembly intended for personal protection are to be supplied by the customer. The pump assembly including the drive system must be grounded to prevent possible electrostatic discharge. Internal parts of the pump require uid (product being pumped) or damage may occur. Do not run the pump dry (without liquid in the pump). The application of liquid level controls in the pump system is recommended. Preventive Maintenance guidelines are provided in this manual and are to be followed for the proper operation and performance of the pump.

Sound Levels:

When properly installed and operated, these pumps do not exceed 85 dBA noise levels at a distance of one meter (3.281 ft) from the surface of the pump. This value is highly dependent upon the installation and may vary from installation to installation.

Piping Forces and Moments: Maximum Allowable Pipe Torque

Z/ZH/ZX/ZXH2000

Inlet Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m)

Outlet Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m)

Z/ZH3200 and Z3500

Inlet Size 3 in. (80 mm)

Torque 1,800 in•lbs (203 N•m)

Outlet Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m) Auxiliary Inlet

Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m)

Z/ZH4200

Inlet Size 4 in. (100 mm)

Torque 1,900 in•lbs (215 N•m) Outlet Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m) Auxiliary Inlet

Size 2 in. (50 mm)

Torque 1,650 in•lbs (186 N•m)

Preventative Maintenance Pump Maintenance Schedule:

Daily Monthly 3 Months Lubricate bearings X Inspect drive couplings X Clean inlet strainer X Check for leaks X Inspect hose and ttings X

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Principles of the Z-Series Sliding

Chapter 1—Installation of the

Vane Pump (Coro-Vane®)

The Z-Series truck pump is a special type of rotary positive displacement pump, known as a sliding vane pump.

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. The Z-Series pumps are made with vanes produced from advanced polymers which exhibit extremely low coefficients of friction. The vanes are self-adjusting for wear which gives the pump long life.

Exclusive Features of the Z-Series Coro-Vane® Pump

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

Z-Series Coro-Vane® Truck Pump

Before installing of your pump, remove all temporary plastic plugs.

The installation of the Z-Series 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 are furnished to illustrate methods proved by hundreds of installations. Your own needs may require slight variations, but every effort should be made to follow the recommendations identied in this manual.

For the transfer of ammable 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:

• 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.).

• Qualication of the personnel.

• Type of liquid being transferred.

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

This model has 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 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. Sideplates may be reversed for extended service life.

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 in. pipe thread, are provided.

• Specic safety measures to be applied (e.g. gas detection, automatic shut-off valves, personal protection equipment, etc.).

See Appendix A for shipping weight and Appendix D for outline dimensions.

A rotation arrow is located on the side of the pump so check the Power Take-off (PTO) to determine its direction of rotation. The Z-Series pump will match either PTO rotation. Connect the drive shaft to the pump shaft that turns the pump in the direction of the arrow.

The PTO selection is important. The pump requires a PTO with an average output speed of 420 to 800 RPM when the truck engine is operating at the proper speed to maintain oil pressure and water circulation.

The DRIVESHAFT connecting the pump to the PTO should be of the “splined” or slip type. This type driveshaft permits the shaft to adjust for PTO movement and twisting of the truck frame. A xed driveshaft transfers the forces directly into the pump and PTO and will shorten the life of both considerably. The yokes of the driveshaft universal joints must be positioned as shown. Improper positioning will soon wear them out and potentially destroy the bearings in the pump and PTO.

The RELIEF VALVE is built-in and nonadjustable. The valve is preset at the factory.

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

INLET PIPING should be as short as possible with minimum restrictions so that the pressure drop is limited. Inlet piping is not generally required on the Z3200 or Z4200. These pumps are bolted directly to the tank internal valve and must be installed in accordance with the valve manufacturer’s instructions.

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Figure 1.1: Shaft Alignment

Correct assembly

Incorrect assembly

1.1 The Outlet Piping Should Include the Following

1. A liquid lled 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.

Figure 1.2: Universal Joint Alignment

3. If a meter with a vapor eliminator is installed, pipe the eliminator outlet to the top of your tank. Never pipe the eliminator into the pump inlet piping or into the liquid part of the system at any point.

4. The meter back-pressure valve may be piped into the tank top or into the pump inlet piping.

5. The discharge piping should be at least the same size as the meter.

1.2 The Bypass System

The internal safety relief valve is intended as a safety device and not as an operational bypass valve. The external bypass valve should be set at a differential pressure lower than the internal relief valve and may be connected to the tank at any convenient point, liquid or vapor. All Z-Series pumps (except ZX2000, which is set at 175 psid) are set near 150 psid.

ZH2000 Foot mounted hydraulic drive with NPT

connections

ZX2000 Foot mounted with NPT connections and high

pressure internal relief valve spring (175 psid rather than the standard 150 psid)

ZHX2000 Foot mounted hydraulic drive with NPT

connections and high pressure internal relief valve spring (175 psid rather than the standard 150 psid)

1.3 Power Take-off (PTO) Drive Systems

Proper pump operation and long life are directly dependent upon a good drive system. Many truck pumps utilize a power train consisting of shafts and universal joints from a power take-off shaft on the truck engine to the pump.

There are several basic principles that should be followed in laying out a PTO drive. These principles should not be violated. Following them will produce a workable power train that results in long pump life and reduced drive wear.

First, the driver shaft and the driven shaft must be parallel to one another within plus or minus one degree. Improper alignment will cause jerking and back and forth “whip” to the pump shaft, thereby imparting a surging pulsation to the liquid ow, which results in noise, vibration, and abnormal wear.

Second, the angle of the “oating” shaft should be within the limits for the particular equipment being used (usually a maximum of 15° at pump speeds up to 800 RPM). To ensure that shaft expansion or contraction does not distort the drive system, a splined slip joint should be placed between the two universal joints. The drive shaft should be of the “splined” or slip type to permit the shaft to adjust for PTO movement and twisting of the truck frame. A xed drive shaft transmits the forces directly to the pump and PTO which will shorten the life of both considerably.

Third, the yokes of the drive shaft universal joints must be in a parallel position. Figures one and two illustrate the proper arrangement.

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Improper installation of the U-joints will soon destroy them along with the bearings in the pump and PTO.

Properly mounted, the second universal gives uniform motion to the drive shaft by compensating for the rotational error introduced by the rst U-joint. An even number of universal joints (two, four, six, etc.) should always be used. An odd number of U-joints will cause unbalanced pump shaft rotation. This problem becomes greater with increased angularity.

Other points to consider include the proper sizing of the shaft components with a maximum horsepower load to be expected, good alignment of hanger bearings and proper pump coupling alignment. Improper PTO systems count for a high percentage of truck pump failures. Always remember to disengage the clutch before shifting the PTO into gear. Shifting the PTO into gear without disengaging the clutch imparts an enormous shock on the PTO, drive shaft, pump, and meter and will soon damage one or all of them.

performance charts in Appendix C. Information on the CharLynn hydraulic motor is found in Appendix I.

Chapter 2—Operation of the Z-Series Coro-Vane® Truck Pump

Performance curves and charts are provided in Appendix C.

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

1. Close the shutoff valve on the end of the delivery hose.

2. Follow the instruction s of the internal valve manufacturer for putting the valve into operation.

3. Start the pump and circulate liquid through the external bypass system.

For proper installation of pump drives, follow the rules listed below:

1. Driver shaft and pump shaft must be parallel, plus or minus one degree.

2. Operating angle of the “oating” shaft must be 15 degrees maximum.

3. Universal yokes must be in line and parallel.

4. Splined slip joints must be used where needed.

5. Use an even number of universal joints.

6. Always use the least practical number of shafts.

PTO selection and drive system design is extremely important. The PTO should have an average output speed of 420 to 800 RPM when the truck engine is operating at the recommended speed.

The designer of the drive system must select a PTO drive shaft capable of meeting the torque requirements of the pumping system.

4. If your system has a Corken bypass valve, adjust the valve by turning the adjusting screw counter clockwise until the pump discharge pressure gauge shows nearly the same pressure it did before you started the pump. Turn the adjusting screw clockwise until the gauge indicates about 90 to 115 psid above the tank pressure. If a bypass valve of another make is used, follow the instructions provided for adjusting the valve.

5. You may increase the speed of your pump as long as it increases the capacity of the pump and does not exceed the excess ow valve or external bypass valve setting. The one exception occurs when the pump is used to “Pump On” or to load the truck tank. In this case, the pump inlet conditions are poor at best so the pump should be operated at a slower RPM.

NOTE: IF PUMP SPEED IS INCREASED, BE CERTAIN THE METERING SYSTEM WILL HANDLE THE INCREASED FLOW.

WHEN PROPERLY INSTALLED AND OPERATED, Z-SERIES CORO-VANE® TRUCK PUMPS DO NOT EXCEED AN 88 dBA NOISE LEVEL AT A DISTANCE OF ONE METER (3.281 ft) FROM THE SURFACE OF THE PUMP.

1.4 Hydraulic Drive Systems

Truck pumps are also driven by hydraulic systems, consisting of an adaptor, motor, pump, cooler, and connecting hoses.

The truck pump’s shaft must be properly aligned with the hydraulic motor’s shaft to avoid excessive stress on the truck pump’s main and thrust absorbing bearings. See Appendix D for outline dimensions.

The sizing of the hydraulic motor, hydraulic pump, and hydraulic oil cooler must be done using the operational requirements of the truck pump (e.g. ow rate, differential pressure, pump speed, and required torque and power). These data are on the

2.1 How to Transfer From the Truck

Tank at Full Capacity

To move volatile liquids rapidly from a truck tank requires that a condition be maintained within the truck tank that keeps the liquid and the vapors above the liquid in equilibrium . As liquid is removed from the tank, some of the liquid boils to form vapor to ll the space created as the liquid leaves. If this action becomes too violent, the pump will begin to make noise, and the capacity will be reduced. Truck pumps can lower the truck tank pressure from 5 psi to 10 psi (below the starting tank pressure). If there is no means provided for equalizing, then the trouble starts! As the weather gets colder, the worse this condition will become.

Page 8

You can detect this “pull down” in pressure by observing your truck tank pressure gauge as the pump is operating.

To prevent this violent liquid boiling, pressure in some form must be introduced into the truck tank. The simple way to accomplish this is to “equalize” between the truck tank and the receiving tank. Equalizing takes the higher pressure vapors from the receiving tank and returns them to the truck tank. As a result, the void left by the receding liquid is lled. This in turn lessens the need for the liquid to boil excessively. The equalizing principle is necessary for volatile liquids.

1/2" x 8" anchor bolt

Pump base

Concrete

Fig u re 3 .1

• 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.).

NOTE: Z4500 baseplate should be filled with grout.

Metal shim

Large washer

NOTE: EQUALIZING BETWEEN TANKS OR THE ADDITION OF PRESSURE IS NOT A LEGAL

TRANSFER IN MOST STATES. IF EQUALIZING LINES ARE NOT PERMITTED REMEMBER THAT A QUIET PUMP IS AN EFFICIENT PUMP. A NOISY PUMP IS NOT EFFICIENT AND THE CONDITIONS THAT CAUSE THE NOISE ALSO CAUSE WEAR TO INTERNAL PARTS. OPERATE THE PUMP AT SPEEDS THAT RESULT IN A “QUIET” TRANSFER.

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

Chapter 3—Installation of the Z-Series Coro-Vane® Stationary Pump

NOTE: All pumps should be installed in a well ventilated area.

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 are furnished to illustrate methods proved by hundreds of installations. Your own needs may require slight variations, but every effort should be made to follow the recommendations identied 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 inadequate to supply the demand of the pump, you may expect trouble.

• The pump must be located as near the storage tank as

possible. For best results the pump inlet line including the vertical line from the tank should not exceed 12 feet (3.7 m) in length.

• The bottom of the tank should be at least two feet (0.6

m) above the pump center line. For best results four feet (1.2 m) is preferred.

• Qualication of the personnel.

• Type of liquid being transferred.

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

Appendix A shows the weight of the bare pump for each model. For handling a bare pump, lifting slings should be used. Web slings are preferred over metal slings to minimize damage to the paint. See Appendix D for outline dimensions.

3.1 The Inlet Piping Should Include

the Following

1. The tank excess ow valve (EFV) should have a ow

rate of 1-1/2 to 2 times the capacity of he pump. Do not use an EFV without knowing its ow capacity.

2. The tank shut-off valve should be a free-ow 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). A 10x pipe diameter before the pump is recommended.

4. Use a exible 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 (at side up).

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

3.2 The Outlet Piping Should

Include the Following

1. A liquid lled 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.

• The foundation for the pump is important. The foundation must be rm, level and preferably made of concrete. The suggestions in gure three should be observed.

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

Page 9

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

3.3 The Bypass System Must

Include the Following

1. If the pump discharge is shut off before the driver has stopped, a dangerously high pressure can develop; therefore, an external bypass valve must be installed. The installation of an external bypass valve permits the pump to discharge its full capacity back to the supply tank at a predetermined pressure. NOTE: Even though the pump may have an internal relief valve, it is not a substitute for an external bypass valve. The internal relief valve is a safety relief valve for the pump only and not the entire system.

2. Always install a Corken ZV200 or B177 external bypass valve in the discharge line of pump. The bypass valve may discharge into the supply tank at any convenient liquid or vapor opening; however, it should not connect to the pump inlet piping.

3.4 A Vapor Equalizing System

Should be Included

To obtain maximum performance from your 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 lled. 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 lled experiences a pressure increase as the rising uid 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 that a vapor equalizing line be installed.

Another way to consider this principle is to remember that 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.

3.5 Driver Installation

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.

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

Motor

phase

3 1 115 34.0 6 4 2

3 230 9.6 12 12 12

5 1 115 56.0 4 1 1/0

3 230 15. 2 12 12 10

7-1/2 1 230 40.0 8 6 4

3 230 22.0 10 10 8

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 10 0.0 2/0 2/0 2/0

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

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

Approximate

Volts

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

full load

amperes

Recommended

wire size, AWG

Length of run (ft)

0–100 to 200 to 300

Page 10

Chapter 4—Operation of the Z-Series Stationary Coro-Vane® Pump

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.

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.

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.

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

11. An ampmeter may be used by adjusting the bypass valve until the ampmeter indicates the full load motor amperage rating shown on the motor nameplate or maximum rated differential, whichever comes rst. 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 Important Instructions (IH102) and Installation, Operation and Maintenance (IOM) Manual (IH106) for more details on the use of the Corken bypass valves.

12. Your pump has an internal relief valve, it must be set higher than the external bypass setting. The internal relief valve is factory preset.

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

Fig u re 4 .1

Page 11

Chapter 5—Maintenance of the Z-Series Coro-Vane® Pump

5.1 Purpose

By following an effective 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.

Your Corken Z-Series 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.

Normal wear parts are the mechanical 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 Instructions. Use only genuine Corken replacement parts when repairing the Z-Series pump. Follow the instructions provided with the parts.

5.2 Scope

The Pump Maintenance Schedule table below 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.

Pump Maintenance Schedule

Daily Monthly 3 Months

Lubricate bearings X

Inspect drive coupling X

Clean inlet strainer X

Check for leaks X

Inspect hose and ttings X

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 result in “refrigerated” liquid being left 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.

NOTE: ONLY A PROPERLY TRAINED INDIVIDUAL SHOULD BE ALLOWED TO BLEED A PUMPING SYSTEM.

1. Visual Inspection:

This includes checking for leaks, corroded areas,

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

Maintenance must only be performed by a properly trained and qualied individual that follows all the applicable safety procedures.

5.3 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.

2. Clean Inlet Strainer Screen:

A clogged strainer screen will create too much ow

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:

There are two lubrication points on the Z-Series

pumps. A grease zerk is located on the top of each bearing cap. To prevent over greasing the bearings, a grease relief tting is located on the bottom of each

Page 12

bearing cap. Always clean each grease zerk and relief tting before lubricating the bearings. This practice helps prevent foreign material from reaching the bearings through the grease zerk and ensures the grease relief tting is not blocked. If the grease relief tting is blocked, the excessive grease that cannot be relieved may cause premature seal failure. If you use a hand grease gun, put the grease in slowly and stop as soon as the relief tting opens. Grease the U-joints and the spline of the drive shaft when greasing the pump.

NOTE: Always use ball bearing grease (MIL-G-10924C)

with a temperature rating of -65°F.

b. While transferring liquid with the pump, close the

discharge valve(s) so the full ow 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 ow 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.

5. Lubricate Motor Bearing:

If lubrication is required, 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.

7. Tighten all holddown bolts.

8. Inspect motor starter contact points.

This must be performed by an authorized and qualied

electrician, based on the electric motors manufacturer’s guidelines.

Page 13

Chapter 6—Z-Series Coro-Vane® Seal Replacement Instructions

Please Note: The photos listed below contain a Z2000; however, all Z-Series pumps use the same procedures for seal replacement.

To determine the parts needed for repair, refer to Appendix A—Model Number and Identication Code, and Appendix E—Parts Details.

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 hands clean while installing the seal. Never touch the smooth lapped faces of the carbon rotor or seal seat. For LP-Gas, anhydrous ammonia and similar liquids, you are trying to seal a uid that is 5 to 10 times thinner than water! Your new seal needs every chance it can get, so keep it clean.

Workmanship

Your Corken pump is a precision piece of equipment with very close clearances. Treat it as such. Never use force during assembly or disassembly (see steps 1 through 10).

Step 1

Depressurize and open the pump

Loosen the head bolts and remove one head with the bearing cap attached, while holding in on the shaft.

Step 2

Remove the seal seat and grease seal

the workbench as shown in the photo. When replacing the seal assembly, there is no need to remove the bearings. With a long screwdriver, reach through the opening of the bearing cap and lightly tap the seal seat until it falls out of the head. The seal seat is located at the bottom of the head. Next, remove the grease seal using same process. The old seal seat and grease seal will not be reused.

Step 3

Install the new grease seal

NOTE: The photo above is using a cutaway view for

better details.

After the head has been removed from the pump, remove the head O-ring and place to the side. Place the head on

NOTE: The photo above is using a cutaway view for better details.

Turn the head over as shown in the photo and install the new grease seal smooth side up by pressing into the bore next to the main bearing. To assist with the installation of the grease seal, place the old seal seat without the O-ring over the top of the grease seal and press into place as show in the photo. The grease seal should t ush with the shoulder of the bore (see Figure 6.1 for details).

Page 14

Sideplate

Step 4

Install the new seal seat

Carbon seal

Seal seat

Grease seal NOTE ORIENTATION: The grease seal is inserted with smooth side up, flush with the shoulder of the head, and directly beneath the seal seat as shown in this illustration.

Roller bearings

Retainer ring

Thrust bearing mounting ring

Thrust bearings

Bearing cap

Rotor shaft

Fig u re 6 .1

Step 5

Remove the old seal assembly (carbon seal and retainer)

Head

NOTE: The photo above is using a cutaway view for better details.

Be careful not to touch the smooth, shiny surfaces of the seal seat. The smooth shiny surfaces must stay clean at all times. Foreign material on these surfaces can cause seal failure. Before installing the new seal seat, spray or apply a generous amount of light oil to the new seal seat and O-ring. This will allow the O-ring on the outside of the seal seat to easily slide into place during installation. Before you press the seal seat in place, make sure you cover the seal seat with the protective cardboard disc as shown in the photo.

Remove the old seal assembly from the pump shaft while holding the sideplate against the pump casing. This will allow the seal retainer assembly to be removed without pulling the rotor-shaft out of the pump. Inspect the rotor shaft for burrs or scratches. If present remove with an emery or polishing cloth.

Page 15

Step 6

Install the new seal assembly (retainer and carbon)

Clean the pump shaft and apply a generous amount of light oil to the shaft and seal assembly.

Step 8

Completing installation

Torque the head bolts in a crossing pattern. There is no

need to disassemble or re-shim the bearing caps. Repeat all of the above steps when replacing the seal assembly on the opposite side.

Install the new seal assembly by aligning the seal retainer slot with the seal drive pin on the shaft.

Step 7

Mechanical seal installation

Install the new case O-ring onto the head.

Apply a generous amount of light oil to each seal face and carefully install the head assembly over the pump shaft.

Step 9

Lubrication and re-pressurizing

Note: Both sides of the pump are identical; duplicate procedure to change the seal on the opposite side.

Lubrication

There are two lubrication points on the Z-Series pumps. A grease zerk is located on each bearing cap. To prevent over greasing the bearings, a grease relief tting is located on the opposite side of each bearing cap. Always clean each grease zerk and relief tting before lubricating the bearings. This practice helps prevent foreign material from reaching the bearings through the grease zerk and ensures the grease relief tting is not blocked. If the grease relief tting is blocked, the excessive grease that cannot be relieved may cause premature seal failure.

If you use a hand grease gun, put the grease in slowly and stop as soon as the relief tting opens. Grease the U-joints and the spline of the drive shaft when greasing the pump.

NOTE: Always use ball bearing grease (MIL-G-10924C) with a temperature rating of -65°F.

Re-pressurize

For best results, slowly pressurize with vapor pressure.

Please Note: If you pressurize with liquid, it will sometimes refrigerate even though it enters the pump slowly. As a result, the seal elastomers will not seal properly thereby causing them to leak.

Page 16

6.1 Repair/Rebuild Kits with Iron Seal Seat

Repair Kit 3193-X1 (Z2000, ZH2000, ZX2000, ZXH2000)

2-224A O-ring, Buna-N 1 2-231A O-ring, Buna-N 2 275 4-X Roller bearing 2 426 2-X Vane driver 3 4428 Vane 6 4431-XA2 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3195-X1 (Z3200, ZH3200)

2-224A O-ring, Buna-N 1 2-234A O-ring, Buna-N 2 275 4-X Roller bearing 2 426 2-X Vane driver 3 4232 Va ne 6 4431-XA2 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3195-X2 (Z3500)

2-228A O-ring, Buna-N 2 275 4-X Roller bearing 2 5554-X Vane driver 6 3936 Vane 6 6660-XA2 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3197-X1 (Z4200, ZH4200, Z4500)

2-231A O-ring, Buna-N 2 2-234A O-ring, Buna-N 1 4460 -X Roller bearing 2 4449-X Vane driver 5 4448 Vane 6 4464-XA 2 Seal assembly 2 4453 Thrust bearing 2 4454 Thrust bearing mounting ring 2 4458 Bearing cap shim (0.002) 8 44 58-1 Bearing cap shim (0.010) 2 4458-2 Bearing cap shim (0.020) 2 4463 Grease seal 2 4459 Shaft key 1

Rebuild Kit 3194-X1 (Z2000, ZH2000, ZX2000, ZXH2000) Includes all items in the Repair Kit plus the following:

4414 Cam 1

4427 Sideplate 2

Rebuild Kit 3196-X1 (Z3200, ZH3200) Includes all items in the Repair Kit plus the following:

4242 Cam 1

4231 Sideplate 2

Rebuild Kit 3196-X2 (Z3500) Includes all items in the Repair Kit plus the following:

5539 Cam 1

3935 Sideplate 2

Rebuild Kit 3198-X1 (Z4200, ZH4200, Z4500) Includes all items in the Repair Kit plus the following:

4443 Cam 1

4446 Sideplate 2

Full Rebuild Kit 3194-X3 (Z2000, ZH2000, ZX2000, ZXH2000) Includes all items in the Repair Kit plus the following:

4414 Cam 1

4427 Sideplate 2

4430-X2R Rotor shaft assembly 1

Full Rebuild Kit 3196-X3 (Z3200, ZH3200) Includes all items in the Repair Kit plus the following:

4242 Cam 1

4231 Sideplate 2

4495-X2R Rotor shaft assembly 1

Full Rebuild Kit 3196-X4 (Z3500) Includes all items in the Repair Kit plus the following:

5539 Cam 1

3935 Sideplate 2

1208-1X6R Rotor shaft assembly 1

Full Rebuild Kit 3198-X3 (Z4200, ZH4200, Z4500) Includes all items in the Repair Kit plus the following:

4443 Cam 1

4446 Sideplate 2

4444-X2R Rotor shaft assembly 1

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

Page 17

6.2 Repair/Rebuild Kits with Silicon Carbide Seal Seat

Repair Kit 3193-X16 (Z2000, ZH2000, ZX2000, ZXH2000)

2-224A O-ring, Buna-N 1 2-231A O-ring, Buna-N 2 275 4-X Roller bearing 2 426 2-X Vane driver 3 4428 Vane 6 4431-XA6 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3195-X16 (Z3200, ZH3200)

2-224A O-ring, Buna-N 1 2-234A O-ring, Buna-N 2 275 4-X Roller bearing 2 426 2-X Vane driver 3 4232 Va ne 6 4431-XA6 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3195-X26 (Z3500)

2-228A O-ring, Buna-N 2 275 4-X Roller bearing 2 5554-X Vane driver 6 3936 Vane 6 6660-XA6 Seal assembly 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim (0.002) 8 44 39-1 Bearing cap shim (0.010) 2 4439-2 Bearing cap shim (0.020) 2 4441 Grease seal 2 2270 Shaft key 1

Repair Kit 3197-X16 (Z4200, ZH4200, Z4500)

2-231A O-ring, Buna-N 2 2-234A O-ring, Buna-N 1 4460 -X Roller bearing 2 4449-X Vane driver 5 4448 Vane 6 4464-XA6 Seal assembly 2 4453 Thrust bearing 2 4454 Thrust bearing mounting ring 2 4458 Bearing cap shim (0.002) 8 44 58-1 Bearing cap shim (0.010) 2 4458-2 Bearing cap shim (0.020) 2 4463 Grease seal 2 4459 Shaft key 1

Rebuild Kit 3194-X16 (Z2000, ZH2000, ZX2000, ZXH2000) Includes all items in the Repair Kit plus the following:

4414 Cam 1

4427 Sideplate 2

Rebuild Kit 3196-X16 (Z3200, ZH3200) Includes all items in the Repair Kit plus the following:

4242 Cam 1

4231 Sideplate 2

Rebuild Kit 3196-X26 (Z3500) Includes all items in the Repair Kit plus the following:

5539 Cam 1

3935 Sideplate 2

Rebuild Kit 3198-X16 (Z4200, ZH4200, Z4500) Includes all items in the Repair Kit plus the following:

4443 Cam 1

4446 Sideplate 2

Full Rebuild Kit 3194-X36 (Z2000, ZH2000, ZX2000, ZXH2000) Includes all items in the Repair Kit plus the following:

4414 Cam 1

4427 Sideplate 2

4430-X2R Rotor shaft assembly 1

Full Rebuild Kit 3196-X36 (Z3200, ZH3200) Includes all items in the Repair Kit plus the following:

4242 Cam 1

4231 Sideplate 2

4495-X2R Rotor shaft assembly 1

Full Rebuild Kit 3196-X46 (Z3500) Includes all items in the Repair Kit plus the following:

5539 Cam 1

3935 Sideplate 2

1208-1X6R Rotor shaft assembly 1

Full Rebuild Kit 3198-X36 Z4200, ZH4200, Z4500) Includes all items in the Repair Kit plus the following:

4443 Cam 1

4446 Sideplate 2

4444-X2R Rotor shaft assembly 1

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

Page 18

6.3 Assembly Instructions For All Z-Series Repair and Rebuild Kits

1. Place the pump head on a clean work surface with the bolting ange down.

2. Press the inner grease seal in through the main bearing cavity until ush with the bottom of the bore. Seal lips must be oriented down as shown in each parts detail drawing. (See Figure 6.1)

3. Press the main bearing into the head and install the retainer ring.

4. Install the relief tting into 1/8 in. NPT threaded hole and turn the head over.

5. After lubricating the mechanical seal seat with light oil, press the seal seat into the head using your ngers. Make sure the seal seat is fully seated and the shiny side faces up. Apply a generous amount of light oil to the seal seat to remove any remaining debris and ngerprints. Install the case O-ring around the pilot OD of the head.

6. Press the outer grease seals into each of the bearing caps.

7. Press the spring pins into each of the cam key holes.

8. Install the cam key into the pump case. Slide the cam into the pump case aligning the long inlet slots to the inlet portion of the case.

9. Install one sideplate and bolt one head into place with two bolts.

14. Carefully install the head over the pump shaft and seal assembly and torque the bolts in accordance with the appropriate bolt torque pattern drawing. This pattern ensures even bolting of the head into the case without deforming the cam inlet port. This is done by bolting those bolts over the solid portion of the cam port.

15. Turn the pump over and remove the rst head.

16. Install the seal retainer assembly and carbon as outlined in step 13 above.

17. Bolt head to case as described in step 14 above. Ensure the rotor shaft turns freely in either direction.

18. Slide the bearing race mounting ring onto one end of the shaft until contact with the main bearing inner race. Mount the thrust bearing assembly onto the bearing race mounting ring and install the bearing cap.

19. Lightly tighten the bearing cap with two opposed bolts until the rotor shaft cannot be freely turned. Measure the gap between the head and bearing cap at four points around the bearing cap. Adjustment may be necessary to contain the gap within .001 inch. Round up the average measurement to the nearest even number. This is the measured amount of bearing cap shims. Refer to parts pages for shim measurements.

20. Remove the two bearing cap bolts and install the measured amount of shims plus .006 inch. Install the four bearing cap bolts and torque in a crossing pattern.

10. Turn the pump onto the assembled head. Ensure there is enough room to allow the shaft to extend through the assembled head by six inches.

11. While holding the rotor-shaft vertical, install the vane drivers. Vertically install the rotor-shaft into the unit. Slide the vanes into each rotor slot ensuring the rounded tip contacts the cam and the vane slots face into the direction of rotation as shown in each parts detail drawing.

12. Install the remaining sideplate.

13. Lubricate the pump shaft and seal carbon with light oil. Install the seal retainer assembly by aligning the retainer slot onto the seal alignment pin. Carefully press the seal carbon into the retainer assembly with the polished face oriented outward by aligning the carbon notches to the retainer pins. Again, apply a generous amount of light oil to remove any remaining debris and ngerprints.

21. Install the remaining bearing race mounting ring and thrust bearing assembly on the opposite side of the pump.

22. Perform step 19 again on the opposite side and install the measured shims plus .002 inch. Install the four bearing cap bolts and torque in a crossing pattern.

23. Install the shaft key and ensure shaft rotates smoothly.

Page 19

Appendix A—Z-Series Truck Pumps Model Number and Identication Code

Base Model Z2000/ZH2000 ZX2000/ZXH2000 Z/ZH3200 Z/ZH4200 Inlet 2" NPT 2" NPT 3" ANSI 4" ANSI Outlet 2" NPT 2" NPT 2" ell Dual 2" NPT Auxiliary Inlet None None 2" NPT 2" NPT Internal Relief 150 psi 175 p si 150 psi 150 psi Weight Bare

Pump lb (kg)

Vane Type

Vanes GCB-50 Standard G

O-ring Material

Registered trademark of the DuPont company.

Seal Seat

Flange Options WF=Slip-on weld ange ell = Elbow All ANSI anges are 300# • indicates available ange connections

Inlet Flange

Standard

Extra Cost Options

6 Vanes with Vane Drivers

Buna-N Standard A Neoprene

Cast Iron No charge option — Silicon Carbide Standard 6

®1

2" NPT • • E 3" ANSI • P 4" ANSI • S

2" WF • • F

100 (45)

Standard H

No charge option B

140 (64)

275

(125)

Model Number

Base X X X X X X X

Outlet Flange

Standard

No Cost Options

Extra Cost Options

Auxiliary Flange

Standard

No Cost Options

Extra Cost Options

Part Number Test—Options

3000-X1 Hydrostatic test

2" NPT • • • E

2" NPT ell • G

1-1/2" NP T • C

2" NPT • E

1-1/2" WF • D

2" WF • • • • F

2" weld ell • H

2" NPT • • E

None • • U

1-1/2" NP T • C

Blind Flange • • T

1-1/2" WF • D

2" WF • • F 2" NPT ell • G 2" weld ell • H

Page 20

Appendix A—Z-Series Stationary Pump Model Number and Identication Code

Base Model Z3500 Z4500 Inlet 3" NPT (Standard) 4" 300# ANSI Outlet 3" NPT Elongated (Standard) 3" 300# ANSI Weight—bare

pump lb (kg)

Vane Type

Vanes GCB-50 Standard G

O-ring Material

Registered trademark of the DuPont company.

Seal Seat

Flange Options WF=Slip-on weld ange ell = Elbow All ANSI anges are 300# • indicates available ange connections

Inlet Flange

Standard

No Cost Option

Extra Cost Options

6 Vanes with Vane Drivers

Buna-N Standard A Neoprene

Cast Iron No charge option — Silicon Carbide Standard 6

®1

4" ANSI • S

3" NPT • M

4" NPT • Q

3" WF • N

4" WF • R

160 (73)

265

(120)

Standard H

No charge option B

Model Number

Base X X X X X X

Outlet Flange

3" ANSI • P

Standard

Extra Cost Options

Mounting Options

Description Model Part Number Maximum Driver (hp) Ship Weight (mounting only) lb

Mounting set up for V-belt drive. Includes steel baseplate, adjustable motor slid base, V-belt drive and enclosed belt guard

Part Number Test—Options

3000-X1 Hydrostatic test

3" NPT

Elongated

3" WF

Elongated

• T

• V

Z4500 103 -15 - 25 630

Z3500 103 -10- 20 560

Page 21

Appendix B—Specications

Equipment Type & Options

Truck sliding vane pump Multiple connection options Optional auxiliary inlet

Applications

Propane bulk transfer Auto-fuel pumping NH3 nurse tanks Carousel cylinder lling LPG cylinders

Features & Benets

Sliding vane: Positive displacement Heavy duty bearings: Long bearing life Single mechanical seal: Very easy seal replacement and maintenance Built in relief valve (NPT models only): Factory pre-set—added protection Pressure gauge connections: Suction and discharge to reduce piping needs Reversible side plates: Longer service life

Operating Specications

RPM range: 420–800 RPM Max. differential pressure: 125 psid (8.6 bar d)

for Z/ZH2000, Z/ZH3200, Z/ZH4200, and Z4500

150 psid (10.3 bar d) for ZX/ZXH2000 and Z3500 Maximum working pressure: 350 psig (24.1 bar) Temperature range: -25°F–225°F (-32°C–107°C) Flow range: 41–400 gpm (155–1,514 L/min) Internal relief valve: Yes

Material Specications

Part Model Standard Material Optional Material Case, head, rotor, reliefvalve cap, bearing cap Cam All Gray iron ASTM A48, Class 50 Sideplate All Gray iron ASTM A48, Class 30 Welding ange All Steel

Seal seat All Silicon carbide

Seal metal parts

All Ductile iron ASTM A536

Z/ZH/ZX/ZXH2000, Z/ZH3200, Z3500, Z/ZH4200, Z4500

Steel

Stainless steel, Ni-Resist, gray iron

Shaft All 8620 steel Vanes and vane drivers All Advanced polymers

Z/ZH3200 Steel, cadmium plated

Relief valve spring

Relief valve

Bearing All Steel Thrust bearing All Steel

O-rings All Buna-N

Retainer rings All Steel

Registered trademark of the DuPont company.

Z/ZH/ZX/ZXH2000, Z3500, Z/ZH4200, Z4500 Z/ZH3200, Z3500 Steel Z/ZH/ZX/ZXH2000, Z/ZH4200, Z4500

Stainless steel

Kalrez®1, Neoprene®1,

®1

Viton

Page 22

Appendix C—Z2000, ZH2000, ZX2000, and ZXH2000

150125

100755025

Differential Pressure (psid)

Capacity (gpm)

500 RPM

600 RPM

650 RPM

750 RPM

Performance Curves

The chart shows approximate deliver y rates as seen in vapor equalized propane systems at 70°F (21°C) with no pressure loss in pump suction piping. The following will cause increased vaporization of the liquid in the pump suction, adversely af fecting the deliver y:

1. Restrictions in the suction piping such as internal valves, excess flow valves, elbows, etc.

2. Restriction or lack of a vapor return line

3. Temperatures below 70°F (21°C) This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases. See the “GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT” (CP226) for additional information.

Page 23

Appendix C—Z3200 and ZH3200 Performance Curves

125

100

110

120

100755025

Differential Pressure (psid)

Capacity (gpm)

500 RPM

600 RPM

650 RPM

750 RPM

1. Restrictions in the suction piping such as internal valves, excess flow valves, elbows, etc.

2. Restriction or lack of a vapor return line

Page 24

Appendix C—Z4200 and ZH4200 Performance Curves

125

180

200

220

240

260

280

300

320

340

360

100755025

400

380

Differential Pressure (psid)

Capacity (gpm)

500 RPM

600 RPM

650 RPM

750 RPM

1. Restrictions in the suction piping such as internal valves, excess flow valves, elbows, etc.

2. Restriction or lack of a vapor return line

Page 25

Appendix C—Performance Charts

Z2000, ZH2000, ZX2000, and ZXH2000 Coro-Vane® Truck Pumps

Pump Speed

Differential

Pressure

Approximate Delivery of

Propane

Brake hp Required

Pump Torque

Required

RPM psid (kPa) gpm (L/min) bhp (kW) ft•lb (N•M)

750 50 (345) 82 (309) 2.9 (2.2) 2 0 .4 (27.7)

750 100 (689) 7 7 (2 91) 5.8 (4.3) 40.8 (55.3)

750 1502 (1,034) 75 (284) 8.9 (6.63) 62.2 (84.3)

650 50 (345) 69 (261) 2. 5 (1.9) 20.4 (27.7)

650 100 (689) 64 (242) 5.1 (3.8 ) 40.8 (55.3)

650 1502 (1,034) 63 (238) 7.7 (5.7) 62.2 (84.3)

600 50 (345) 63 (238) 2.3 (1.7) 2 0 . 4 ( 2 7.7 )

600 100 (689) 58 (219) 4.6 (3.5) 40.8 (55.3)

600 1502 (1,034) 56 (212) 7.1 (5.3) 62.2 (84.3)

500 50 (345) 52 (197 ) 1.9 (1.4) 20.4 (27.7)

500 100 (689) 4 6 (174) 3.9 (2.9) 40.8 (55.3)

500 1502 (1,034) 4 4 (166) 5.9 (4.4) 62.2 (84.3)

Z3200 and ZH3200 Coro-Vane® Truck Pumps

Pump Speed

RPM psid (kPa) gpm (L/min) bhp (kW) ft•lb (N•M)

750 50 (345) 112 (424) 6.2 (4.6) 43.4 (58.9)

750 100 (689) 99 (375) 9.9 (7.4) 69.3 (94.0)

650 50 (345) 95 (360) 5.2 (3.9) 42.0 (57.0)

650 100 (689) 84 (318) 8.2 (6.1) 66.3 (89.9)

600 50 (345) 86 (326) 5.0 (3.7) 41.3 (56.0)

600 100 (689) 76 (288) 7. 8 ( 5 . 9) 6 4.8 (87. 9 )

500 50 (345) 70 (265) 3.8 (2.8) 39. 9 (54.1)

500 100 (689) 62 (235) 5.8 (4.3) 60.9 (82.6)

Differential

Pressure

Approximate Delivery of

Propane

Brake hp Required

Pump Torque

Required

Z4200, ZH4200, and Z4500 Coro-Vane® Truck Pumps

Pump Speed

RPM psid (kPa) gpm (L/min) bhp (kW) ft•lb (N•M)

750 50 (345) 369 (1,397) 12.5 (9.3) 87 (118.0)

750 100 (689) 325 (1,230) 2 5 .1 (18.6) 175 (237.3)

650 50 (345) 316 (1,19 6) 10.8 (8.0) 87 (118.0)

650 100 (689) 278 (1,052) 21.7 (16.1) 175 (237.3)

600 50 (345) 289 (1,09 4) 9.9 (7.3) 8 7 (118 . 0)

600 100 (689) 254 (961) 20.0 (14.8) 175 (237. 3)

500 50 (345) 236 (893) 8.3 (6.2) 8 7 (118 . 0)

500 100 (689) 208 (787) 16.7 (12.4) 175 (237.3)

Delivery times are approximate—see note on page 22 for further explanation.

Applies to ZX/ZXH2000 models only.

Differential

Pressure

Approximate Delivery of

Propane

Brake hp Required

Pump Torque

Required

Page 26

Appendix C—Performance Curves

Z3500

Page 27

Appendix C—Performance Curves

Z4500

Page 28

Appendix D—Outline Dimensions for Model Z2000

1/4" x 1-9/16" square key

INTERNAL RELIEF VALVE

INSTALLER TO PROVIDE

NOT FOR RECIRCULATING

SET AT 125 P.S.I. MAXIMUM

CORKEN, INC.

A Unit Of IDEX Corp.

SET AT 150 P.S.I.

SEPARATE BY-PASS VALVE

3-1/4

(8.25)

(40.61)

1-1/8

(2.85)

2-1/8

(5.40)

2-1/8

(5.40)

3/4

(1.9)

Inltet: 2" NPT

1/2

(1.2 7)

7/16

(1.11)

5-15/16

(15.08)

2-1/ 2

(6.35)

(10 .16)

9-1 /4

(23.5)

2-3/8 (6.03)

2-1/ 2

(6.35)

4- 9/16 (11. 59)

(10 .16)

Outlet: 2" NPT

5-1/2

(13.97)

4- 9/16

(11. 59)

1/4" NPT

All dimensions are in inches (centimeters).

Page 29

Appendix D—Outline Dimensions for Model Z3200

Eight 7/8" (2.22) diameter holes

2" NPT auxillary inlet

2" NPT discharge

1/4" NPT

Internal

relief

valve

3" 300 lb ANSI flange inlet

1/4" square keyway

INTERNAL RELIEF VALVE

INSTALLER TO PROVIDE

NOT FOR RECIRCULATING

SET AT 125 P.S.I. MAXIMUM

CORKEN, INC.

A Unit Of IDEX Corp.

SET AT 150 P.S.I.

SEPARATE BY-PASS VALVE

8-3/4

(22.23)

6-3/4

(17.14)

(12.70)

3-7/8

(9.84)

14-15/16

(37.94)

10-15/16

(27.78)

4-15/16

(12.47)

1-1/8

(2.86)

17-1/2

(44.43)

1-5/8 (4.13)

3-7/16 (8.73)

5-11/32 (13.57)

2-7/16

(6.24)

1-1/8

(2.86)

8-1/4 D (20.95)

6-5/8 BC

(16.83)

All dimensions are in inches (centimeters).

Page 30

Appendix D—Outline Dimensions for Model Z3500

18.750 (47.6)

1.750 (4.4)

1.250 (3.2)

8.435 (21.4)

7.188

(18.3)

5.375 (13.7)

4.125

(10.5)

4.125 (10.5)

3.000 (7.6)

1.758 (4.5)

1.125 (2.9)

3" NPT

inlet

1/4"

keyway

5.500 (14.0)

7.188

(18.3)

6.813 (17.3)

6.046 (15.4)

3" NPT

outlet

3.25

(8.18)

7.688

(19.5)

All dimensions are in inches (centimeters).

Page 31

Appendix D—Outline Dimensions for Model Z4200

2-1/8

(5.40)

2" NPT

auxillary

inlet

Internal relief valve

1/4" NPT

INLET

OUTLET

Eight 7/8 (2.22)

diameter holes

Outlet: 2" NPT

5/16" square key

Inlet:

4" 300 lb ANSI

flange

13-13/16

(35.08)

(17.78)

7-3/4

(19.69)

(20.32)

3-1/4

(8.26)

16-31/32

(43.08)

2-5/8

(6.67)

1-3/16

(3.01)

(10.16)

19-1/2

(49.53)

1-1/4

(3.17)

10-1/8 D

(25.72)

7-7/8 BC

(20.00)

1-1/4 (3.18)

All dimensions are in inches (centimeters).

Page 32

Appendix D—Outline Dimensions for Model Z4500

8-Ø .875 (2.2) on a 6-5/8" B.C.

Outlet 3" R.F. 300# ANSI flange

21.121 (53.6)

2.875 (7.3)

Inlet 4" R.F. 300# ANSI flange

8-Ø .875 (2.2) on a 7-7/8" B.C.

5/16"

square key

10.75 (27.3)

1. 0

(2.5)

6.5

(16.5)

4-5/8 (1.587) mounting holes

8.469 (21.5)

4.688 (11.9)

1.875 (4.8)

4.688 (11.9)

6.125 (15.6)

All dimensions are in inches (centimeters).

Page 33

Appendix D—Outline Dimensions for Model ZH2000

Hydraulic motor

Hydraulic drive adapter assembly

1/4" square keyway

INTERNAL RELIEF VALVE

INSTALLER TO PROVIDE

NOT FOR RECIRCULATING

SET AT 125 P.S.I. MAXIMUM

CORKEN, INC.

A Unit Of IDEX Corp.

SET AT 150 P.S.I.

SEPARATE BY-PASS VALVE

4248

Char-Lynn Hydraulics, Inc.

A Division of EATON

6.2 Cubic Inch / Rev

Disc Valve Hydraulic Motor

Model No. 104-1002

(20.30)

1-1/8 D

(2.85)

17-11/16

(44.90)

10-1/2

(26.63)

3-1/4

(8.25)

13/16 (2.06)

2-1/8

(5.40)

Inltet: 2" NPT

3/4

(1.9)

5-15/16

(15.08)

1/2

(1.2 7)

7/16

(1.11)

All dimensions are in inches (centimeters).

(10 .16)

2-1/ 2

(6.35)

9-1 /4

(23.5)

2-3/8

(6.03)

2-1/ 2

(6.35)

4- 9/16 (11. 59)

(10 .16)

Outlet: 2" NPT

5-1/2

(13.97)

4- 9/16

(11. 59)

1/4" NPT

Page 34

Appendix D—Outline Dimensions for Model ZH3200

Char-Lynn Hydraulics, Inc.

A Division of EATON

6.2 Cubic Inch / Rev

Disc Valve Hydraulic Motor

Model No. 104-1002

INTERNAL RELIEF VALVE

INSTALLER TO PROVIDE

NOT FOR RECIRCULATING

SET AT 125 P.S.I. MAXIMUM

CORKEN, INC.

A Unit Of IDEX Corp.

SET AT 150 P.S.I.

SEPARATE BY-PASS VALVE

1/4" square keyway

3" 300 lb ANSI flange inlet

Hydraulic drive

adapter assembly

Hydraulic motor

1/4" NPT

2" NPT

discharge

Internal relief valve

1/4" NPT

Eight 8-7/8 (2.22)

diameter holes

1-1/8

(2.87)

6-3/4

(17.15)

5-5/16

(13.57)

14-15/16

(37.94)

(12.70)

1-5/8 (4.13)

10-15/16 (27.78)

4-15/16 (12.47)

8-3/4 (22.22)

18-1/8 (46.02)

10-15/16 (27.75)

3-7/15

(8.73)

8-1/4D

(20.96)

3-7/8

(9.84)

6-5/8 D B.C.

(16.83)

2-7/16

(6.24)

1-1/8 (2.86)

All dimensions are in inches (centimeters).

Page 35

Appendix D—Outline Dimensions for Model ZH4200

Hydraulic motor

2" NPT auxillary inlet

1/4" NPT

Inlet: 4" 300 lb

ANSI flange

5/16" square keyway

Eight 7/8 (2.22)

diameter holes

Outlet: 2" NPT Outlet: 2" NPT

Internal relief valve

Hydraulic drive

adapter assembly

19-9/16

(49.69)

9-3/4

(24.77)

12-3/8

(31.43)

(10.16)

(20.32)

3-1/4

(8.26)

10-1/8 D

(25.72)

7-7/8 B.C.

(20.00)

7-3/4 (19.69)

16-31/32 (43.08)

7 (17.78)

13-13/16

(35.08)

2-5/8

(6.67)

1-3/16

(3.01)

(10.16)

INLET

OUTLET

Char-Lynn Hydraulics, Inc.

A Division of EATON

6.2 Cubic Inch / Rev

Disc Valve Hydraulic Motor

Model No. 104-1002

MODEL

SERIAL

NO.

LISTED 656L

PAT. NOS. 3,072,066 AND 3,392,677

POWER OPERATED PUMP FOR LPG OR ANHYDROUS NH

READ CORKEN INSTRUCTION MANUAL BEFORE OPERATING

OKLAHOMA CITY,OKLAHOMA MADE IN U.S.A.

CORKEN,INC. A Unit Of IDEX Corp.

CORO-VANE

2-1/8

(5.40)

1-1/4 (3.18)

All dimensions are in inches (centimeters).

Page 36

Appendix D—Outline Dimensions for Z3500–103 Mounting

15 (38.1)

12 (30.5)

1-1/2 (3.8)

4-1/2

(11.4)

5-3/16

(13.2)

(7.62)

18-1/8

(46)

3" NPT inlet3" NPT outlet

34 (86)

7-1/2 (19)

7-3/16 (18)

31-1/2 (80)

1-1/4 (3)

7-3/16

(18)

8-1/2

(22)

1/4" pipe plug Electric motor

Adjustable motor slidebase

Use four 1/2" anchor bolts

All dimensions are in inches (centimeters).

Page 37

Appendix D—Outline Dimensions for Z4500–103 Mounting

20 (50.80)

17 (43.18)

12-1/4 (31.12)

4 (10.16)

5-5/8

(14.30)

8-1/2

(21.59)

10-3/4 (27.31)

10-1/2

(26.67)

9-1/2

(24.13)

1-1/4

(3.18)

1-7/8

(4.76)

1-1/2

(3.81)

Baseplate web

Discharge 3" - 300# ANSI

Adjustable motor slide base

Use for 1/2" anchor bolts

Electric motor

Beltguard

Inlet 4" - 300# ANSI

9-5/16 (23.65)

30-7/8 (78.44)

39-1/2 (100.33)

42 (106.68)

All dimensions are in inches (centimeters).

Page 38

Appendix E—Parts Details for Models Z/ZH/ZX/ZXH2000

36 (25 ft•lb)

Inlet

Outlet

37 (45 ft•lb)

35 (15 ft•lb)

36 (25 ft•lb)

O-ring Code

A Buna-N

B Neoprene

D Viton

E Tef l on

®a

Note: Hydraulic motor is not shown.

See pages 16 and 17 for repair/rebuild kits.

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

Ref.

Part No. Description Qty

No.

1. 4413 Case 1

2. 4414 Cam 1

3. 4416 Head 2

4. 4417 Bearing cap 2

5. 1174 - 3 Relief valve cap 1

6. 4282

7. 4424 Cam key 1

8. 4425 Relief valve 1

4426

1240

Shim (Z2000, ZH2000) 1 Shim (ZX2000, ZXH2000) 3

Relief valve spring (Z2000, ZH2000)

Relief valve spring (ZX2000, ZXH2000)

10. 4427 Sideplate 2

11. 4428

12. 4262-X Vane driver 3

13. 44 30-X 2R Rotor—shaft assembly 1

14.

15. 4432 Thrust bearing assembly 2

16. 4435 Bearing race mounting ring 2

4431-X_2 4431-X_6

Vane 6

Mech seal assy—cast iron 2 Mech seal assy—silicon carbide

17. 4438 Grease seal 2 4439 Bearing cap shim (.002) red

18.

443 9 -1 Bearing cap shim (.010) brown 4439-2 Bearing cap shim (.020) yellow

19. 275 4-X Roller bearing 2

20. 3253 Cam key pin 2

req.

Ref.

Part No. Description Qty

No.

21. 2760-244 Retainer ring 2

22. 4441 Grease seal 2

23. 2270 Shaft key—1/4" x 1-9/16" 2 4479-2 Flange–2" NPT 2

24. 4479-2S Flange–2" welded

25. 2649 Nameplate 1

4248

26. 4248-1

Relief valve nameplate (Z2000, ZH2000)

Relief valve nameplate (ZX2000, ZXH2000)

27. 1359 Lubrication instruction plate 2

28. 134 3 1/8" NPT relief tting 2

29. 2158 1/8" NPT grease zerk 2

30. 2159 Lubricap 2

31. 3442 1/4" NPT pipe plug 2

32. 2-231_

33. 2-224_

34. 2-261_

35. 7001-031-NC125A Bolt—hexagon head 4

O-ring—ange 2 O-ring—relief valve cap 1 O-ring—case 2

36. 7001- 037-NC150A Bolt—hexagon head 16

37. 7001-0 43- NC125A Bolt—hexagon head 16

38. 7012-006-SF025E Screw 8

39. 720 6 - 0 37A Lockwasher 8

40. 4985 Shaft protector 1

41. 7012-010SF050E Screw 2

Registered trademark of the DuPont company.

Slots in vanes must face TOWARDS the direction of rotation.

_ denotes O-ring code. See chart above.

Page 39

29 (15 ft•lb)

(25 f t•l b)

28 (60 ft•lb)

25 (25 ft•lb)

Inlet

Outlet

Appendix E—Parts Details for Models Z/ZH3200

O-ring Code

A Buna-N

B Neoprene

D Viton

E Tef l on

Ref.

Part No. Description Qty

No.

®a

1. 4495 -X2R Rotor shaft assembly 1

2. 4242 Cam 1

3. 4232

Vane 6

4. 4231 Sideplate 2

5. 4488 Head 2

6. 4239 Case 1

7. 4417 Bearing cap 2

8. 4438 Grease seal 2

9. 4435 Mounting ring 2 4439 Bearing shim (.002) red

10.

443 9 -1 Bearing shim (.010) brown 4439-2 Bearing shim (.020) yellow

11. 2270 Shaft key 2

12.

4431-X_2

4431-X_6

Mechanical seal assembly— cast iron

Mechanical seal assembly— silicon carbide

13. 2754 Bearing outer race 2

14. 4432 Thrust bearing assembly 2

15. 2760 -244 Retainer ring 2

16. 1174 - 2 Relief valve cap 1

17. 13 59 Lubrication instruction plate 2

18. 4441 Grease seal 2

19. 7012-0 06SF019E Screw 8

20. — Not shown –

21. — Not shown –

22. 2-262_

23. 2-224_

O-ring—case 2 O-ring—relief valve cap 1

24. 1240 Relief valve spring 1

Registered trademark of the DuPont company.

_ denotes O-ring code. See chart above.

Slots in vanes must face TOWARDS the direction of rotation

req.

Note: Hydraulic motor is not shown.

See pages 16 and 17 for repair/rebuild kits.

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

Ref.

Part No. Description Qty

No.

25. 7001-037NC150A Bolt—3/8-16 x 1-1/2" hex head 16

26. 2158 1/8" NPT grease zerk 2

27. 1343 1/8" NPT relief tting 2

28. 7001-050NC150A Bolt—1/2-13 x 1-1/2" hex head 16

29. 70 01- 031NC125A Bolt—5/16-16 x 1-1/4" hex head 4

30. 1241 Relief valve 1 1172-1.5 Outlet ange—1.5" NPT 1 1172-1.5 S Outlet ange—1.5" WF 1 117 2-2 Outlet ange—2" NPT 1

31.

117 2-2S Outlet ange—2" WF 1 1947 Outlet ange—1.5" NPT ell 1 4243 Outlet ange—2" NPT ell 1 5520 Outlet ange—2" steel WF

32. 4241 Cam key 1

33. 3253 Cam key pin 1

34. 3442 1/4" NPT pipe plug 1

35. 4262-X Vane driver 3

36. 2-234_

37. 2159 Lubricap 2 1172-1.5 Aux. inlet ange—1.5" NPT 1 1172-15S Aux. inlet ange—1.5" WF 1 117 2-2 Aux. inlet ange—2" NPT 1

38. 117 2-2S Aux. inlet ange—2" WF 1

1920-3 Aux. inlet ange—blind 1 4243 Aux. inlet ange—2" NPT ell 1

39. 2649 Nameplate 1

40. 4248 Relief valve nameplate 1

41. 4282 Relief valve shim

42. 72 0 6 - 037A 3/8" lockwasher 8

43. 4985 Shaft protector 1

44. 7012-010SF050E Screw 2

O-ring—ange 1

req.

Page 40

34 (25 ft•lb)

35 (45 ft•lb)

34 (25 ft•lb)

33 (25 ft•lb)

Appendix E—Parts Details for Models Z3500

O-ring Code

A Buna-N

B Neoprene

D Viton

E Tef l on

®a

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

Note: Hydraulic motor is not shown.

See pages 16 and 17 for repair/rebuild kits.

Ref.

Part No. Description Qty

No.

1. 2-228

2. 2-245

3. 2-259

4. 2-268

O-ring 1 O-ring 1 O-ring 1

O-ring 2 1206-3 Inlet flange—3" NPT 1 1206-4 Inlet flange—4" NPT 1

5. 1206-3S Inlet flange—3" WF 1

1206-4S Inlet flange—4" WF 1

6. 1207-2 Relief valve cap 1

7. 1208-1X6 R Rotor shaft assembly 1

8. 1224 Relief valve 1

9. 130 9 Cam key 1

10. 1343 Grease relief fitting 2

11. 1359 Lubrication plate 2

12. 2158 Grease zerk 2

13. 2159 Lubricap 2

14. 2270 S h a f t key—1/4 " 1

15. 2649 Nameplate 1

16. 2754-X Roller bearing 2

17. 2760-244 Retainer ring 2

18. 3253 Cam key pin 2

19. 3442 Pipe plug—1/4" NPT 2

20. 3935 Sideplate 2

21. 3936

22. 4248 Relief valve warning tag 1

Registered trademarks of the DuPont company.

_ denotes O-ring code. See chart above.

Slots in vanes must face TOWARDS the direction of rotation

Vane 6

Ref.

Part No. Description Qty

No.

23. 4417 Bearing cap 2

24. 4432 Thrust bearing assembly 2

25. 4435 Thrust bearing mounting ring 2

26. 4438 Grease seal / Oil seal 2

27. 4439 Bearing cap shim—0.002" 2

28. 4439 -1 Bearing cap shim—0.010" 2

29. 4439-2 Bearing cap shim—0.020" 2

30. 4441 Grease seal 2

31.

6660-X_2

6660-X_6

32. 4985 Shaft protector 1

33. 7001-037NC125A Hex head bolt 24

34. 7001-037NC150A Hex head bolt 16

35. 7001-043NC150A Hex head bolt 6

Mechanical seal assembly—cast iron

Mechanical seal assembly—silicon carbide

36. 7012-006SF019E Screw 9

37. 7012-010SF050E Screw 2

38. 7206-037A Lock washer—0.375" 8

39. 5534 Head 2

40. 5537 Case 1

41. 5539 Cam 1

42.

5538

5538-3S

Outlet flange—3" NPT Elongated

Outlet flange—3" WF Elongated

43. 5548 Spring 1

44. 5554-X Vane driver 6

Page 41

(75 f t•l b)

(25 f t•l b)

Appendix E—Parts Details for Models Z/ZH4200

Note: Hydraulic motor is not shown.

See pages 16 and 17 for repair/rebuild kits.

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

O-ring Code

A Buna-N

B Neoprene

D Viton

E Tef l on

®a

Ref.

Part No. Description Qty

No.

1. 4442

2. 4443

3. 4444-X2R

4. 4445

Case 1 Cam 1 Rotor-shaft assembly 1 Head 2

5. 4446 Sideplate 2

6. 4448

Vane 6

7. 4449-X Vane driver 5

8. 4450 Relief valve cap 1

9. 4451 Relief valve spring 1

10. 4452 Shim 1

11. 4453 Thrust bearing assembly 2

12. 4454 Bearing race mounting ring 2

13. 4455 Cam key 1

14. 4456 Bearing cap 2

15. 4457 Relief valve 1 4458 Bearing cap shim (.002) red

16.

445 8-1 Bearing cap shim (.010) brown 4458-2 Bearing cap shim (.020) yellow

17. 4459 Shaft key—5/16 x 1-3/4 1

18. 4460 -X Roller bearing 2

19. 2760-283 Retainer ring 2

20. 3253 Cam key pin 5

21. 4462 Grease seal 2

Registered trademark of the DuPont company.

_ denotes O-ring code. See chart above.

Slots in vanes must face TOWARDS the direction of rotation

Prior to January 1998.

req.

Ref.

Part No. Description Qty

No.

22. 4463 Grease seal 2

4464 -X_2

23. 4464 -X_6

117 2-2 Aux. inlet ange—2" NPT 1

24.

117 2-2S Aux. inlet ange—2" WF 1

Mechanical seal assembly—cast iron

Mechanical seal assembly—silicon carbide

1920-3 Aux. inlet ange—blind 1

4479-2

25. 4981-2 Discharge ange—2" NPT 2

Discharge ange—2" NPT 2

26. 2649 Nameplate 1

27. 4248 Relief valve nameplate 1

28. 1359 Lubrication instruction plate 2

29. 1343 1/8 NPT relief tting 2

30. 2158 1/8 NPT grease zerk 2

31. 2159

32. 3442 1/4 NPT pipe plug 2

33. 2-231_

34. 2-234_

35. 2-270_

Lubricap 2

O-ring—discharge ange 2 O-ring—auxiliary inlet ange 1 O-ring—case 2

36. 7001-037NC150A Bolt—hexagon head 24

37. 7001-0 62NC125A Bolt—hexagon head 16

38. 7012-006SF019E Screw 8

39. 720 6 - 0 37A Lockwasher 8

40. 4985 Shaft protector 1

41. 7012-010SF050E Screw 2

Page 42

Appendix E—Parts Details for Model Z4500

O-ring Code

A Buna-N

B Neoprene

D Viton

E Tef l on

Note: Hydraulic motor is not shown.

See pages 16 and 17 for repair/rebuild kits.

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

(25 f t• lb)

®a

(25 f t• lb)

(75 ft•lb)

Ref.

Part No. Description Qty

No.

1. 5522 Case 1

2. 4443 Cam 1

3. 4444-X2R Rotor-shaft assembly 1

4. 4445 Head 2

5. 4446 Sideplate 2

6. 4448

Vane 6

7. 4449-X Vane driver 5

8. 4450 Relief valve cap 1

9. 4451 Relief valve spring 1

10. 4452 Shim 1

11. 4453 Thrust bearing assembly 2

12. 4454 Bearing race mounting ring 2

13. 4455 Cam key 1

14. 4456 Bearing cap 2

15. 4457 Relief valve 1 4458 Bearing cap shim (.002) red

16.

445 8-1 Bearing cap shim (.010) brown 4458-2 Bearing cap shim (.020) yellow

17. 4459 Shaft key—5/16 x 1-3/4 1

18. 4460 -X Roller bearing 2

19. 2760-283 Retainer ring 2

Registered trademark of the DuPont company.

_ denotes O-ring code. See chart above.

Slots in vanes must face TOWARDS the direction of rotation

req.

Ref.

Part No. Description Qty

No.

20. 3253 Cam key pin 5

21. 4462 Grease seal 2

22. 4463 Grease seal 2 Mechanical seal

assembly—cast iron Mechanical seal

assembly—silicon carbide

23.

4464 -X_2

4464 -X_6

24. —— Inlet ange—4" ANSI 1

25. —— Outlet ange—3" ANSI 1

26. 2649 Nameplate 1

27. 4248 Relief valve nameplate 1

28. 1359 Lubrication instruction plate 2

29. 1343 1/8 NPT relief tting 2

30. 2158 1/8 NPT grease zerk 2

31. 2159 Lubricap 2

32. 3442 1/4 NPT pipe plug 2

33. 2-234_

34. 2-270_

O-ring—relief valve 1 O-ring—case 2

35. 7001-037NC150A Bolt—hexagon head 16

36. 7001-062NC125A Bolt—hexagon head 16

37. 7012-006SF019E Screw 8

38. 7206-037A Lockwasher 8

39. 4985 Shaft cover 1

40. 7012-010SF050E Screw 2

Page 43

Appendix E—Parts Details for Hydraulic Adapter (4496-X1)

Fits Models Z2000, Z3200, and Z3500 Only

Ref.

Part No. Description Qty

No.

1. 134 3 Grease relief tting 1

2. 1359 Lubrication plate 1

3. 2158 Grease zerk 1

4. 2159 Lubricap 1

5. 2270 Shaft key 1

6. 4439 Bearing cap shim—0.002" 1

7. 443 9 -1 Bearing cap shim—0.010" 1

8. 4439-2 Bearing cap shim—0.020" 1

9. 4441 Grease seal 1

10. 4487-1

Hydraulic drive solid coupling

11. 4496 Hydraulic drive bracket 1

12. 4497 Hydraulic drive bearing cap 1

13. 4499 Hydraulic drive name plate 1

14. 7001- 037NC150A Bolt—hexagon head 8

15. 7006-037NC037A Set screw 2

16. 7012-006SF019E Screw 6

72 0 6 - 037A Lock washer—0.375"

17.

Page 44

Appendix E—Parts Details for Hydraulic Adapter (4496-1X1)

Fits Models Z4200 and Z4500 Only

Ref.

Part No. Description Qty

No.

1. 134 3 Grease relief tting 1

2. 1359 Lubrication plate 1

3. 2158 Grease zerk 1

4. 2159 Lubricap 1

5. 2270 Shaft key 1

6. 4439 Bearing cap shim—0.002" 1

7. 443 9 -1 Bearing cap shim—0.010" 1

8. 4439-2 Bearing cap shim—0.020" 1

9. 4463 Grease seal 1

10. 44 87-2

Hydraulic drive solid coupling

11. 4 496 -1 Hydraulic drive bracket 1

12. 4939 Hydraulic drive bearing cap 1

13. 4499 Hydraulic drive name plate 1

14. 7001- 037NC150A Bolt—hexagon head 8

15. 7006-037NC037A Set screw 2

16. 7012-006SF019E Screw 6

72 0 6 - 037A Lock washer—0.375"

17.

Page 45

Appendix F—V-Belt Selection for Stationary Coro-Vane® Pumps

1,450 RPM Motor

Belt

Number

B64 B15.4 B7.4 2 420 1-3V14.0 1-3V3.35 3V600 B60 B13. 6 B4.2 470 1- 3V10.6 1-3V2.80 3V530 B60 B12.4 B4.2 520 1-3V10.6 1- 3V 3.15 3V530 B55 B 11. 0 B4.2 580 1-3V10.6 1-3V3.65 3V560 B56 B 11. 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 2A10 .6 2A3.6 520 1-3V14.0 1- 3V4.12 3V630 B55 2B11.0 2B4.2 580 1- 3V14.0 1-3V4.75 3V630 B60 B12.4 B5.4 640 2-3V8.0 2-3V3.00 3V500 B56 B 11. 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 B 7.4 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 2B11.0 2B4.2 580 2-3V10.6 2-3V3.65 3V560 B56 2B11. 0 2B4.8 640 3-3V8.0 3-3V3.00 3V500 B56 2B11. 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 2 B 7.4 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 3 B12.7 3B4.2 520 3-3V14.0 3-3V4 .12 3V630 B55 3B11. 0 3B4.2 580 2- 3V14.0 2-3V4.75 3V630 B56 3B 11. 0 3B4.8 640 2- 3V14.0 2-3V5.30 3V630 B56 3B 11. 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 - 3V 3.15 3V475 B51 3 B 7. 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 3-3V4 .12 3V630 B55 4B11.0 4B4.2 580 3-3V14.0 3 -3V4.50 3V630 B56 4B11. 0 4B4.8 640 2- 3V14.0 2-3V5.30 3V630 B62 3 B12.4 3B5.8 710 2-3V14.0 2-3V5.60 3V630 B56 3B 11. 0 3B5.8 780 2-B12.4 2-B5.6 B60 B62 3 B12.4 3 B 7.0 860 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 3V710 B71 3B18.4 3B5.8 470 4 -3V19.0 4-3V5.00 3V 710 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 5B11. 0 5B4.8 640 3 -3V14. 0 3-3V5.30 3V630 B56 5B11. 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 5 B 7.4 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

5VX680 4-5V15.00 4-5V5.50 25 520 4-B18.4 4-B5.2 BX76

5VX700 3- 5V14.0 3-5V6.30 640 4-B16.0 4-B5.6 BX70

5VX680 3-5V12.5 3-5V6.70 780 3 -B15.4 3 - B 7. 4 BX71 5VX660 3 - 5 V11.3 3-5V6.70 860 4-B15.4 4-B6.6 BX70

Sheave Pitch Diameter Sheave Pitch Diameter

Pump Motor Pump Motor

Motor

Nominal

Pump RPM

1,750 RPM Motor

Belt

Number

Page 46

Appendix F—V-Belt Selection for the Z4500

1,450 RPM Motor

Belt

Number 3VX690 QD 3/3V14.0 0 Q D3/3V4.12 7. 5 420 QD3/3V19.0 0 QD3/3V4.75 3/3V800

3VX710 QD3/3V14.00 QD3/3V4.50 470 QD2 /3V19.0 0 QD2/3V5.30 3VX800

3VX710 QD3/3V14.00 QD3/3V5.00 520 Q D3/3V14.00 QD3 /3V4.12 3VX690 3VX630 QD3/3V10.6 0 QD3 / 3V4.12 580 QD 3/3V14.0 0 QD3/3V4.50 3V X710 3VX650 QD 3/3V10.6 0 QD3 /3V4.75 640 QD2/3V14.00 QD2/3V5.30 3VX710

2/3VX 710 Q D2 /3V14.00 QD2/3V6.90 710 Q D3/3V10.60 QD3/3V4.50 3V650

3VX650 QD2/3V10.60 QD2/3V5.60 780 QD2/3V14.00 QD2/3V6.50 2/3VX710 3VX600 QD3/3V8.00 QD 3/ 3V4.75 860 QD2/3V10.60 QD2/3V5.30 3VX650 3VX580 QD3/3V6.90 Q D3/3V4 .5 0 950 QD 2/3V10.60 QD2/3V6.00 3VX670 3VX690 QD 3/3V14.0 0 Q D3/3V4.12 10 420 QD 3/ 3V14 .0 0 QD3/3V3.35 3VX690

3VX710 QD2/3V14.00 QD 2/3V4.75 470 QD3/ 3V14 .0 0 QD3/3V3.65 3VX690

3VX710 QD2/3V14.00 QD2/3V5.00 520 QD3/3V10.60 QD3 / 3V3 .15 3VX616

3VX710 QD2/3V14.00 QD2/3V5.60 580 QD2A15.6/B16.0 QD2A4.8/B5.2 2/B72 3VX650 QD2/3V10.60 Q D2 /3V4.75 640 QD2A15.0/ B15.4 QD2A5.0/B5.4 2/B71 3VX650 QD2/3V10.60 QD2/3V5.30 710 QD1A15.6/B16.0 QD1A6.0/B6.4 B74 3VX570 QD3/3V6.90 QD3/3V3.65 780 Q D2/3V10.60 QD2/ 3V4.75 3VX650 3VX600 QD2/3V8.00 QD 2/3V4.75 860 QD2/3V10.60 QD2/3V5.30 3VX650 3VX580 QD2/3V6.90 Q D2 /3V4.5 0 950 QD3/3V6.00 QD3/3V3.35 3VX550

3/3VX800 QD 3/3V19.00 QD3/3V5.60 15 420 QD3/3V25.00 QD3/3V6.00 3/3V900 3/3VX800 QD 3/3V19.00 QD3/3V6.00 470 QD3 /3V19.00 QD3/3V5.30 3VX800

3V830 QD3/3V19.00 QD3/3V6.90 520 QD3/ 3V19.00 QD3/3V5.60 3/3VX800

3VX710 QD3/3V14.00 QD3/3V5.60 580 QD3/ 3V19.00 QD3/3V6.50 3V810

3V730 QD3 /3V14.00 QD33/3V6.00 640 QD3 /3V14.00 QD3/3V5.30 3/3V710

3/3VX710 Q D3 /3V14. 00 QD3/3V6.90 710 Q D3/3V14.00 QD3/3V5.60 3V X710

3VX650 QD 3/3V10.6 0 QD3/3V5.60 780 QD3/3V10.6 0 Q D3 /3V4.75 3V X650

3/3VX670 QD 3/3V10.6 0 QD3/3V6.50 860 QD3/ 3V10.60 QD3/3V5.30 3VX650 3/3VX670 QD 3/3V10.6 0 QD3/3V6.90 950 Q D3/3V10.60 QD3/3V6.00 3VX670

B78 QD3A18.0/B18.4 QD3A6.0/B6.4 20 520 QD3A18.0/B18.4 QD3A5.0/B5.4 3/B77 B73 Q D3A15.0/ B15.4 QD3A6.2/B6.6 640 QD3A18.0/B18.4 QD3A6.0/B6.4 3/B78 B68 QD 3A12.0/B12.4 QD3A6.2/B6.6 780 QD3A15.0/B15.4 QD3A6.4/B6.8 3/B73 B65 QD3A10.6/B11.0 QD3A6.0/B6.4 860 QD 3A13. 2/B13.6 QDA6.2/B6.6 3/B70 B78 QD4A18.0/B18.4 QD4A6.0/B6.4 25 520 QD3/5V18.70 QD3/5V5.50 3/5VX800 B80 QD3A18.0/B18 .4 QD3A7.6/B8.0 640 QD3A18.0/B18.4 QD3A6.2/B6.6 3/B78 B75 Q D3A15.0/B15.4 QD3A7.6/B8.0 780 QD3/5V10.90 QD 3/ 5V4.90 5VX650 B72 QD3A13.2/B13 .6 QD3A7.6/B8.0 860 QD3A13.2/ B13. 6 QD3A6.2/B6.6 3/B70

Sheave Pitch Diameter Sheave Pitch Diameter

Pump Motor Pump Motor

Motor

Nominal

Pump RPM

1,750 RPM Motor

Belt

Number

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.

Problem Cause Solution Low capacity Pump speed too slow Check engine speed and PTO on pulley 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

Readjust, repair, or replace valve. open or set too low Clogged strainer Clean strainer.

4. Pressure in tank being lled.

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

6. Size and length of vapor equalizing line.

7. Pump speed if practical.

Page 47

Appendix G—Troubleshooting Guide (continued)

Problem Cause Solution Low capacity (continued)

Pump runs but no ow

Pump will not turn– locked up

Will not build pressure

Pump is noisy Cavitation from poor suction

Pump leaks around shaft

Suction pipe too small or restricted Worn vanes Replace. Pump without vapor return Without vapor equalization, a pump can remove only about 3%

Worn sideplates Reverse or replace sideplates. Check universal drive assembly

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

Valve closed Check valves. Make sure internal tank excess ow valve is

Excess ow valve slugged Stop pump until valve opens. If problem continues, slow pump

Broken shaft Disassemble and inspect pump. Repair if necessary. Defective meter Service meter. Foreign matter in pump Clean out the pump —check strainer in suction line. Vanes broken Clean out pump carefully and replace vanes. Has pump been

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

Moisture frozen in pump Let thaw and break loose carefully. Add methanol to tank (on

Poor suction conditions Clean inlet strainer. Increase pipe size. External bypass valve set too low Worn vanes and/or sideplates Disassemble, inspect and repair as necessary. Do not run dry!

conditions Vanes sticking As above. Bearings worn Replace—grease monthly. Meter screen clogged Clean Very high differential pressure Check for restriction in discharge line. Delivery hose too small

PTO shaft vibration Inspect and repair driveline component. Seal or O-rings failed Inspect seal assembly and replace if necessary. Keep new

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

of the truck tank capacity per minute without severe cavitation and capacity loss.

to make sure angularity is within limits, yokes are parallel and slip-joint is greased. Check bearings. Check pulley alignment on belt drive pumps.

Replace vanes if swollen.

open! Refer to manufacturer’s instructions.

down or install a new or larger excess ow valve.

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

grease manufactured for intended service.

LP-Gas). Check with product supplier about possibility of water in gas.

Set valve for higher pressure—see instructions. See IH102 and IH106 IOM manuals for more information.

As above.

and too long. Slow down pump! Check vapor release oat assembly on meter and meter differential valve.

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

Page 48

Appendix H—Storage of the Z-Series Coro-Vane® Pump

Appendix I—Hydraulic Motor Specications

If your Corken Z-Series 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 particles can destroy the pump’s seals almost immediately after startup.

1. Fill or thoroughly ush the pump with a light rust inhibiting oil. (If the pump is ushed 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. Refer to the “OPERATION OF YOUR PUMP” section of this manual.

Operating Specications for Char-Lynn Hydraulic Motor

Mounting ange 2 bolt SAE A

Input shaft

Port ‘A’ 7/8-14 O - ring Port ‘B’ 7/8-14 O - ring

Pilot diameter

Motor displacement

Maximum speed continuous duty 742 RPM Flow continuous duty 20 gpm (76 L/min)

Torque continuous duty

Case drain 7/16-20 O -ring

Recommended uids

Minimum viscosity 70 SSU (13 cSt) Maximum operating temperature 180°F (82°C)

Data applies to this particular motor only. Your application may vary, please consult factory for details.

1 in. diameter straight keyed

3.250/3.245 in. (57.15 /57.0 2 m m)

6.2 cubic in. per revolution

3,500 in•lb (395.5 N•M)

Premium quality anti-wear

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.

June 2016

Corken Z Series, Z4200, Z2000, Z4500, Z3200 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Applicable Notices for ATEX 94/9/EC Conformity

Exclusive Features of the Z-Series Coro-Vane® Pump

1.1 The Outlet Piping Should Include the Following

1.2 The Bypass System

1.3 Power Take-off (PTO) Drive Systems

Chapter 2—Operation of the Z-Series Coro-Vane® Truck Pump

1.4 Hydraulic Drive Systems

Chapter 3—Installation of the Z-Series Coro-Vane® Stationary Pump

3.5 Driver Installation

Chapter 4—Operation of the Z-Series Stationary Coro-Vane® Pump

Chapter 5—Maintenance of the Z-Series Coro-Vane® Pump

5.1 Purpose

5.2 Scope

5.3 Procedures

Chapter 6—Z-Series Coro-Vane® Seal Replacement Instructions

6.1 Repair/Rebuild Kits with Iron Seal Seat

6.2 Repair/Rebuild Kits with Silicon Carbide Seal Seat

6.3 Assembly Instructions For All Z-Series Repair and Rebuild Kits