Liquid Controls PT, PT30, PT25, PT20, PTH20 Maintenance Manual
...
ID108F
Installation, Operation
& Maintenance Manual
PT-Series Petroleum Pumps
For Refined Petroleum Products and Industrial Solvents
Model PT20
Model PT30
Warning: (1) Periodic inspection and maintenance of Liquid Controls Group products is essential. (2) Inspection, maintenance and
installation of Liquid Controls Group products must be made only by experienced, trained and qualified personnel. (3) Maintenance,
use and installation of Liquid Controls Group products must comply with Liquid Controls Group instructions, applicable laws and safety
standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous,
flammable or explosive substances using Liquid Controls Group products is at user’s risk and equipment should be operated only by
qualified personnel according to applicable laws and safety standards.
Model PT25 with optional air
operated valve (AOV) and strainer
LIQUID CONTROLS GROUP
Warning
Install, use and maintain this equipment according to Liquid Controls Group’s instructions and all applicable federal,
state, local laws and codes. Periodic inspection and maintenance is essential.
Liquid Controls Group One Year Limited Warranty
Liquid Controls Group 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 Liquid Controls Group. If a warranty dispute occurs, the distributor may be required to provide
Liquid Controls Group with proof of date of sale. The minimum requirement would be a copy of the distributor’s invoice
to the customer. Liquid Controls Group products which fail within the warranty period due to defects in material or
workmanship will be repaired or replaced at Liquid Controls Group’s option, when returned, freight prepaid to Corken,
Inc., 3805 N.W. 36th Street, Oklahoma City, OK. 73112.
Parts subject to wear or abuse, such as mechanical seals, vanes, piston rings, packing and other parts showing
signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not manufactured by
Liquid Controls Group but furnished with Liquid Controls Group products are not covered by this limited warranty and
purchaser must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Liquid Controls
Group product has been altered or repaired without the consent of Liquid Controls Group.
All implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, are expressly
negated to the extent permitted by law and shall in no event extend beyond the expressed warranty period.
Liquid Controls Group disclaims any liability for consequential damages due to breach of any written or implied warranty
on Liquid Controls Group products. Transfer of toxic, dangerous, flammable or explosive substances using Liquid
Controls Group products is at the user’s risk. Such substances should be handled by experienced, trained personnel
in compliance with governmental and industrial safety standards.
Important notes relating to the European Union (EU) Machinery Directive
Pumps delivered without electric motors are not considered as machines in the EU Machinery Directive. These pumps
will be delivered with a Declaration of Incorporation. The fabricator of the machinery must assure and declare full
compliance with this Directive before the machine in which the pump will be incorporated, or of which it is a part, is
put into service.
Contacting the Factory
Before you contact the factory, note the model number and serial number of your pump. The serial number directs
us to a file containing all information on material specifications and test data applying to your specific pump.
When ordering parts, the Liquid Controls Group Installation, Operation 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
2
Table of Contents
Principles of the PT-Series Pumps ................................................................................................................................. 4
Exclusive Features of the PT-Series Pumps ................................................................................................................... 4
Installation of the PT-Series Truck Pump ........................................................................................................................ 5
Power Take-Off Drive Systems .................................................................................................................................... 5
Hydraulic Drive Installation .......................................................................................................................................... 6
Pump Rotation ............................................................................................................................................................. 6
To Change Pump Rotation ........................................................................................................................................... 6
Operation of the PT-Series Truck Pump ......................................................................................................................... 6
Installation of the PT-Series Stationary Pump ................................................................................................................ 7
Coupling alignment ...................................................................................................................................................... 7
Driver Installation ......................................................................................................................................................... 8
Operation of the PT-Series Stationary Pump ................................................................................................................. 8
Maintenance of Your Pump System................................................................................................................................ 9
Pump Maintenance Schedule ...................................................................................................................................... 9
Bearing Lubrication ...................................................................................................................................................... 9
Strainers ..................................................................................................................................................................... 10
Pump Disassembly Instructions ................................................................................................................................ 10
Pump Assembly Instructions ..................................................................................................................................... 10
Vane Replacement ..................................................................................................................................................... 12
Bypass Valve Assembly ............................................................................................................................................. 12
Air Operated Valve (AOV) Assembly .......................................................................................................................... 12
Repair Kits for the PT-Series Petroleum Pumps ........................................................................................................... 13
Appendix A—Model Number and Identification Codes.................................................................................................14
Appendix B—Technical Specifications for PT-Series ................................................................................................... 15
Appendix C—Performance Curves ............................................................................................................................... 16
Appendix D—Outline Dimensions................................................................................................................................. 18
Appendix E—Part Details .............................................................................................................................................. 25
Appendix F—Trouble Shooting Guide for the PT-Series Pumps .................................................................................. 35
Appendix G—Flush and Storage Instructions for the PT-Series Pumps ...................................................................... 36
3
Principles of the PT-Series Pumps
Exclusive Features of the
The PT-Series pumps are 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 inside a
cam that is machined eccentrically in relation to the rotor.
As the rotor turns, the liquid that is trapped between the
rotor, cam and vanes is displaced. The PT-Series pumps
are made with vanes produced from advanced polymers
which exhibit extremely low coefficients of friction. The
self adjusting vanes compensate for wear and help extend
the life of the pump.
Reliable mechanical
O-ring design delivers
maximum sealing
capability and is
available with optional
seal materials.
seal design with
optional seal materials.
PT-Series Pumps
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 manufacturing of the pump and
to its installation and operation.
In addition to being especially suited for handling volatile
liquids, the PT-Series pumps have a number of other features
to help make them more easily operated and maintained.
Corrosion resistant
bypass valve.
Available with
standard bypass
valve or optional
air operated
valve (AOV) for
high and low
flow control.
Heavy duty ball
bearings provide
greater durability
and strength.
Conveniently located
drain plug allows you to
empty the pump quickly
when necessary.
Optional flanges and
strainer available.
Hollow rotor helps
reduce weight.
Self adjusting
vanes compensate
for wear.
4
Installation of the PT-Series
Truck Pump
The mechanical installation of the PT-Series pump is a simple
matter. A rotation arrow is located on the side of the pump.
Examine the PTO and determine the direction of its rotation
before installing the pump. The PT-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. For maximum
performance , the pump requires a PTO with an average
output speed of 500 to 700 RPM. In addition, the truck engine
must be operating at the appropriate RPM to maintain oil
pressure, water circulation, and the electrical system.
THE DRIVESHAFT that connects the pump to the PTO
should be of the “splin ed” or slip type. This ty p e of driveshaf t
permits the shaft to adjust for PTO movement and twisting
of the truck frame. A fixed driveshaft will transfer the
forces directly to the pump and PTO and shorten the life
of both considerably. The yokes of the driveshaft universal
joints must be positioned as shown in Figure 1. Improper
positioning will cause premature wear and potentially
destroy the bearings in the pump and PTO.
INLET PIPING should be as short as possible and at
least the minimum diameter specified for the model with
few restrictions so that the pressure drop is limited.
The outlet piping should include the following:
1. A pressure gauge should be installed in the pump
outlet or near it. A pressure gauge is necessary to
determine the efficiency of your pumping system.
2. If a meter with an air eliminator is installed, never pipe
the eliminator directly into the pump inlet piping or
into the liquid part of the system at any point (refer to
the meter installation manual).
3. The discharge piping should be at least the same size
as the meter piping.
Power Take-Off Drive Systems
Proper pump operation and long life is directly dependent
upon a good drive system. Many truck pumps utilize a power
train consisting of shafts and universal joints located between
the power take-off shaft of the truck engine and the pump.
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. Again, the drive shaft
should be of t h e “splined” or slip typ e to permit the shaf t to
adjust for PTO movement and twisting of the truck frame. A
fixed 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. Figure 1 below illustrates the proper
arrangement of the yokes.
Improperly installed U-joints will cause premature failure of
U-joints as we ll as bearings in the pump and PTO. Properly
mounted, the second universal gives uniform motion to
the drive shaft by compensating for the rotational error
intr oduced by the f irst U-joint. An even number of uni versal
joints (2, 4, 6 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 account 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.
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 ‘’floating’’ shaft must be 15°
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.
There are several basic principles that should be followed
in designing a PTO drive. To produce a workable power
train that results in long pump life and reduced drive wear,
these principles SHOULD NOT be violated.
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
flow which results in noise, vibration and abnormal wear.
Second, the angle of the ‘’floating’’ shaft should be within
Figure 1: Shaft alignment
Note: A drive shaft guard between the pump and
PTO should be installed (not shown).
6. Always use the least practical number of shafts.
5
PTO selection and drive system design is extremely important.
The PTO should have an average output speed up to 640 RPM
to maximize the performance of the PT-Series pump 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.
Be certain the shaft protector (see Part
Details) is mounted over the non-driven shaft
end. Operation without shaft protector can
cause serious personal injury, major property damage,
or death.
If the pump must be disassembled to reverse rotation. Refer to
the “Maintenance of Your Pump System” for instructions.
Hydraulic Drive Installation
Hydraulic motors must be well supported and keep their
shafts parallel to the pump shaft. To drive PT pumps
hydraulically, Liquid Controls Group provides a closecoupled hydraulic motor adapter. The adapter aligns the
hydraulic motor drive and the pump shaft via a lockring
and a flexible coupling connected to a keyed shaft. This
adapte r must be lubricated with g rease at least eve ry thre e
months. Refer to the “Bearing Lubrication” section of this
manual for instructions.
Figure 2: Hydraulic Drive (see Appendix E for Part Details)
Pump Rotation
For proper pump rotation, make sure the pump’s rotation
arrows match the pump driver rotation (see Appendix E for
parts details). NOTE: PT-Series pumps are double ended
shafts and can be mounted in either position.
Direction of Rotation
Operation of the PT-Series
Truck Pump
The following steps should be performed for the initial
pumping operation:
1. Close the shutoff valve on the end of the delivery hose.
2. Start the pump and cycle the nozzle open and closed
to clear all air from the system.
3. Check the discharge pressure on the outlet of the
pump. This pressure is typically set at 80 to 95 psi.
4. Bypass Valve Adjustment
For a standard bypass valve, locate the adjustment
set screw under the bypass valve cap (see Appendix
E for parts details). Turn adjustment screw clockwise
to increase pressure and flow. Turn counter clockwise
to decrease pressure and flow.
Close the nozzle and check the bypass pressure. If
too high, turn adjustment screw counter clockwise
until desired pressure is reached.
With the hose nozzle open, adjust the pump bypass valve
setting to the desired flow rate. Close the nozzle slowly
and check the system pressure. CAUTION: DO NOT
EXCEED A CLOSED NOZZLE PRESSURE OF 125 PSI.
Replace bypass valve cap and bypass valve cap
gasket with seal washer and tighten.
5. Air Operated Valve (AOV) Adjustment
Right hand/clockwise rotation
(PT25)
Figure 3: Direction of Rotation
Left hand/counter clockwise rotation
(PT25)
To Change Pump Rotation
The PT Series pump is equipped with a double ended rotor
and shaft, the pump moto rs can be driven from either shaft
end. To change rotation, rotate the pump 180 degrees. The
opposite shaft will then become the driven shaft.
Figure 4: Typical truck delivery system using an AOV.
6
For pumps equipped with an Air Operated Valve (AOV)
assembly, air must be supplied from the truck air system
via a flow sensing valve. Approximately 70 psi (4.8 bar)
minimum air pressure is required to properly operate
the air operated valve. THE AIR PRESSURE MUST NOT
EXCEED 125 psi (8.6 bar). The sensing valve should
be installed in accordance with the diagram shown in
Figure 4. This system depicts the additional use of a
throttle control which is optional. All adjustments must
be made at normal operating speeds.
5.1 Set the low pressure adjustment first by slowly
closing the nozzle to relieve the air pressure in
the AOV assembly.
5.2 Remove the AOV cap and O-ring (see Appendix
E for parts details).
5.3 Turn the low pressure adjustment stem counterclockwise to decrease the bypass pressure and
vice versa to increase the pressure.
5.4 Re-install the O-ring and AOV cap and tighten
securely.
5.5 Open and close the nozzle several times to ensure
proper setting and repeatability.
5.6 Slowly close the delivery nozzle again to relieve
the air pressure in the AOV assembly.
5.7 Remove the AOV cap and O-ring.
5.8 Adjust the locknuts clockwise to decrease delivery
flow rate and/o r pressure and vice versa to increase
the flow rate. NOTE: Make sure the locknuts are
securely locked against each other before reinstalling the adjustment stem cap and O-ring.
5.9 Slowly open the delivery nozzle and note delivery
flow rate and/or pressure.
5.10 Repeat steps 5.7–5.9 until desired flow rate and/or
pressure are achieved.
6. You may increase the speed of the pump as long as
it increases the flow through the delivery nozzle. It is
recommended to turn the pump at approximately 575
RPM for optimum performance. However, the pump
can be safely turned to 640 RPM if system conditions
permit (refer to Appendix B).
performance, the principles discussed in this book should
be followed. The piping details provided illustrate methods
proved by hundreds of installations. Your own needs may
require light variations, but every effort should be made to
follow the recommendations identified in this manual.
The foundation for the pump is important. The foundation
must be firm, level and preferably made of concrete. The
suggestions in figure 5 should be observed.
Figure 5
Coupling alignment
The coupling alignment must be near perfect to give
quiet, long-life service to the pump and driver. The pump
and driver shafts are carefully aligned at the factory but
always should be checked after the pump is installed and
before the initial operation.
Lay a straight edge across coupling halves, top, and side;
both positions must line up to be correct (see figure 6). If
misalignment exists, adjust the shims between the pump base
and the foundation until exact alignment is accomplished.
NOTE: IF PUMP SPEED IS INCREASED, BE CERTAIN
THE METER AND PIPING SYSTEM WILL HANDLE THE
INCREASED FLOW AND PRESSURE!
Installation of the PT-Series
Stationary Pump
NOTE: NEW PUMPS CONTAIN RESIDUAL TEST FLUID
SO IT MAY BE NECESSARY TO FLUSH THE PUMP
PRIOR TO USE. ALL PUMPS SHOULD BE INSTALLED
IN AN AREA THAT IS WELL VENTILATED.
The installation of the PT-Series pumps are simple.
However, in order for the pump to deliver optimum
Figure 6
No pump can discharge more liquid than it receives, so
the pump location and the inlet piping must be given
ca reful atten tion. If the inlet p iping is inadequ ate to su pply
the demand of the pump, you may expect trouble.
The installer and/or the user must take into account
the following:
• The pump must be located as near the storage tank
as possible. The complete inlet line, including the
7
vertical line from the tank must not exceed 12 feet (3.7
m) in length.
• The inlet must be the same size or next size larger than
the suction on the pump.
• Use an eccentric swage at the pump inlet nozzle to
change the line size (flat side up).
• Make certain the inlet line is level or sloped downward
to the pump.
• A strainer of the “Y” type, with 20 mesh screen or 1/16
in. perforated steel, must be on the inlet line of the
pump. (Mesh size indicates the number of openings
per lineal inch).
• Use a flexible connection in the pump inlet and outlet
piping to compensate for piping strains.
• The Inlet piping must be free of air leaks.
• All piping must be supported to avoid stress to the
pump casing.
• 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.).
• Qualification of the personnel.
• Type of liquid being transferred.
• Specific safety measures to be applied (e.g. gas
detection, automatic shut-off valves, personal protective
equipment, etc.).
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.
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
Motor
Hp
phase
31115 34.0 6 4 2
3230 9.6 121212
5 1 115 56.0 4 1 1/0
3 230 15.2 12 12 10
7-1/2 1 23 0 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 3 230 100.0 2/0 2/0 2/0
50 3 230 130.0 3/0 3/0 3/0
1
Based upon 3% voltage loss copper wire type TW. Single phase
motor calculations are based on two times distance.
Approximate
Volt s
220 17.0 12 8 8
46 0 4.8 12 12 12
230 28.0 10 6 4
46 0 7.6 12 12 12
450 11.0 121212
460 14.0 121212
460 21.0 101010
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,
Length of run (ft)
0–100 to 200 to 300
AWG
1
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
Operation of the PT-Series
Stationary Pump
Performance curves are provided in Appendix C.
The following steps should be performed for the initial
pumping operation:
1. Make sure the strainer screen is clean.
2. Rotate the pump by hand.
8
3. Check V-belt drive or direct drive coupling alignment.
Misalignment will accelerate wear on 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 the 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.
9. Record all pressure gauge readings, especially the
pressure gauge located at the discharge of the pump.
Start the pump and circulate the liquid through the
internal bypass valve.
replacement parts when repairing your PT-Series pump.
Follow the instructions provided with the parts.
When it becomes necessary to repair your pump or
remove it from the system, you must be absolutely
certain that all product being pumped is bled from the
pump and connected piping. Once all the product has
safely been bled from the pump and connected piping,
make c e r ta i n n o pre s s u r e is lef t in the syste m . S PECIAL
CARE MUST BE TAKEN DURING THE BLEED DOWN
PROCESS TO AVOID DANGER TO PERSONNEL AND
PROPERTY IN THE AREA. Take your time in bleeding
your system and make proper provisions to vent or
capture the product in accordance with local regulations.
ON LY A P ROPER LY T RA IN E D IND IVID U AL SH OU LD B E
ALLOWED TO BLEED A PUMPING SYSTEM.
Pump Maintenance Schedule
Make sure the transfer hoses are not “kinked’’. A kinked
hose can cause excessive pump discharge pressure.
Always make sure your hoses are not out of date.
10. Verify the proper pump rotation direction by referring
to the part details in Appendix E or the “Pump
Rotation” section at the beginning of this manual.
11. Your pump has an internal bypass valve so it must
be adjusted to the required setting. The internal
bypass valve may be adjusted while the pump is in
operation by removing the bypass valve cap. Turning
the adjusting screw clockwise increases the internal
bypass valve pressure setting and counterclockwise
decreases the pressure setting.
12. An amp meter may be used by adjusting the bypass
valve until the amp meter indicates the full load motor
amperage rating shown on the motor nameplate or
maximum rated differential, whichever comes first. If
the motor overload protection device stops the motor
in this period the bypass valve setting is too high
and should be readjusted. After a satisfactory setting
is achieved, “seal” the bypass valve cap to prevent
tampering with the adjustment.
13. After initial operation, re-check the strainer screen.
Maintenance of Your Pump System
Your PT-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.
Normal wear parts are the mechanical shaft seals,
bearings, vanes, vane drivers and sideplates. All of these
parts plus O-rings and grease seals are offered in the
“repair kit.” Use only genuine Liquid Controls Group
Daily Monthly 3 Months
Lubricate bearings •
Inspect drive coupling •
Clean Inlet Strainer •
Check for leaks •
Inspect hose and ttings •
Bearing Lubrication
NOTICE: AVOID ENTANGLEMENT IN MOVING PARTS.
DO NOT LUBRICATE PUMP BEARINGS, HYDRAULIC
ADAPTER COUPLING OR ANY OTHER PARTS WHILE
THE PUMP IS ACTIVE.
There are two lubrication points in which to grease
the pump bearings; one zerk per bearing cap located
at opposite ends of the pump. Two grease relief and
ventilation fittings have been provided—one at each
end of the pump—to help prevent over greasing the
bearings. Over greasing can cause seal failure if grease
passageways are blocked in some way. Remove relief
fittings or confirm free movement of relief prior to
greasing bearings. Clean each fitting before lubricating
the bearings. This practice helps to prevent foreign
material contamination of the bearings and accidental
over-pressurization of the mechanical seals. Use only
NLGI grade 2 ball bearing grease.
Lubricate ball bearings and hydraulic motor couplings (if
equipped) a minimum of every three months.
Greasing Procedure:
1. Remove grease relief fittings from bearing covers or
hydraulic motor adapter.
2. Grease with a hand gun until grease escapes from
grease relief fitting port.
3. Return grease relief fittings to bearing covers.
9
DO NOT over grease pump bearings. Some grease will
escape from the grease tell-tale hole after lubrication.
This is normal, but excessive grease on pumps that use
mechanical seals can cause seal failure.
Strainers
Clean strainers regularly to avoid pump starvation.
Intervals between cleaning depend upon the application
and conditions.
Pump Disassembly Instructions
1. Truck engine must be turned off and PTO disengaged.
2. Bleed all product from the system as described
above. NOTE: There is a 1/4 in. NPT connection at
the bot tom of some models that allows you to easily
drain the pump.
3. Remove the PTO shaft or hydraulic drive motor,
adapter, and coupling.
NOTICE: ADHERE CLOSELY TO ALL HAZARD
WARNINGS AND INSTRUCTIONS IN THE
“MAINTENANCE” SECTION OF THIS MANUAL.
4. Carefully clean the pump shaft. Begin at one end of
the pump, and make certain that the shaft is free of
nicks and burrs to prevent damage to the mechanical
seal when removing the head assembly.
Seal jacket
driver tabs
Seal jacket
Figure 7
5. Unscrew the bearing cover bolts and pull the
bearing cover and gasket off the shaft. Dispose of
the bearing cover gasket.
6. Unscrew the opposite bearing cover bolts and pull
the bearing cover and gasket off the shaft. Dispose
of the bearing cover gasket.
7. Remove the locknuts and lockwashers in place:
7.1 Bend the lockwasher tab up and unscrew the locknut
counterclockwise and remove it from the shaft.
7.2 Pull the lockwasher off the shaft. Check the
lockwasher for damage and replace if needed.
7.3 Repeat steps 7.1 and 7.2 on the opposite end of
the shaft.
8. Unscrew the head bolts and carefully pry the head
from the pump casing.
9. Pull the head off the shaft. The head O-ring, bearing
and mechanical seal will come off with the head
assembly. Detach and dispose of the head O-ring.
9.1 Take the bearing out of the housing in the head.
9.2 Remove the mechanical seal. Using two
screwdrivers, gently push the backside of the seal
jacke t to remove t he seal from the head (s ee Figure
7). Be careful when using the screwdrivers on the
seal faces. The seal faces can be damaged. Detach
and dispose of the mechanical seal O-rings.
10. Remove the rotor and shaft from the pump casing.
While removing the shaft, cup one hand underneath
the rotor so the vanes and vane drivers do not fall out.
Carefully set aside the rotor and shaft, vanes and vane
drivers for future reassembly.
11. Repeat steps 8 and 9 above to remove the remaining
components from the opposite side of the pump.
Pump Assembly Instructions
Before reassembly, check each component part for wear
or damage. If necessary, replace flawed parts. Wash out
the bearing/seal recess of the head and remove any burrs
or nicks from the rotor and shaft.
1. Reassemble the first side of the pump by inserting a
new head O-ring into the groove of the head. Lightly
lubricate the O-ring to facilitate installation. Start on
one side of the groove and stretch the O-ring into the
groove (see Figure 8).
10
13. Locknut In stallation
All bearing locknuts and lo ckwashers MUST be position ed
and adjusted properly. Overtightening locknuts can lead
to bearing failure or broken lockwasher tabs. If locknuts
are loose, the rotor will shift against the heads and
cause considerable wear (see Figure 9).
B
2 stops equals one
tab (.002 in.)
Figure 8
2. Attach the head to the pump casing. Insert four head
bolts 90° apart and tighten to 25 ft•lbs (34 Nm).
3. Mechanical Seal
Apply a small amount of light oil in the head recess. Press
the m echanica l seal assembly into the re ce ss of the h ead
so the seal jacket drive tabs face the rotor. The pin in the
stationary seat must be between the lugs in the back of
the head recess (see Figure 7).
4. Hand pack the ball bearing with grease. See the “Bearing
Lubrication” section for recommended grease.
5. Insert the bearing into the head recess. The bearing
balls should face outward, and the grease shield
should face inward. Make sure the bearing is square
and completely seated against the mechanical seal.
6. Turn the pump casing around to reassemble the
opposite side.
7. Place vanes into the upper rotor-shaft slots. Ensure
the curved tip of each vane faces radially outward and
all in the same direction of rotation (see Figure 10).
8. While cupping these vanes in place, rotate the rotor-shaft
over 180° and install the vane drivers.
9. Place rotor-shaft and vane assembly into pump case
with the vanes on the bottom. Ensure the ribs in the
vanes face the direction of pump rotation (see Appendix
E for parts details and pump rotation arrows).
10. Place the remaining vanes into the upper rotor-shaft slots
facing the same direction as the first vanes.
11. Install the remaining head, mechanical seal, and bearing
as mentioned in steps 1 through 5. Apply a thin coating
of motor oil to the shaft to facilitate installation.
12. Rotate the shaft by hand to engage the seal jacket
driver tabs. Check for binding or tight spots. If the rotor
does not turn freely, use a soft faced mallet and lightly
tap the rims of the heads until the rotor is in the correct
position. Tighten all remaining head bolts for each head
to 25 ft•lbs (34 Nm) of torque.
Locknut
Lockwasher
(Inner tab fits
1 stop
equals
.001 in.
rotor
movement
Figure 9: Locknut and lockwasher adjustment
A
in rotor slot)
13 .1 O n b ot h e nds of th e p um p s ha ft, s li de on a l oc kwas he r,
with the tabs facing outward, and then tighten a
locknut with the tapered end inward. Make sure the
inner tab (A) of the lockwasher is inserted in the slot
of the shaft threads. Bend slightly, if necessary.
13.2 Carefully tighten both locknuts until the bearings
have reached the bottom of the head recess. DO
NOT overtighten, Make sure the inner tab of the
lockwasher does not shear.
13.3 Loosen both locknuts one complete turn.
13.4 Tighten one locknut until you can feel a slight rotor
drag while turning the shaft by hand.
13.5 Back the locknut off one width of the lockwasher tab
(B). To secure the locknut, bend the closest aligned
lockwasher tab into the slot of the locknut. The pump
should now turn freely when rotated by hand.
13.6 Hand-tighten the opposite locknut until it is snug
against the bearing. Then, with a spanner wrench,
tighten the locknut one width of the lockwasher tab.
Tighten just past the tab width and then back off the
locknut until the tab is aligned with the slot of the
locknut. To secure the locknut, bend the aligned
lockwasher tab into the slot of the locknut. The pump
should still turn freely when rotated by hand.
13.7 Check the adjustment. The locknut and lockwasher
should turn back and forth by hand. If this is not
possible, one or both locknuts are too tight. They
must be alternately loosened one stop at a time
(.001 in.) (25 microns). Begin with the locknut
adjusted last.
11
14. If you have the standard bypass valve, remove the
bypass valve cap and turn the adjustment screw
counterclockwise to relieve the spring tension.
Remove the four 3/8 in. bolts from the bypass valve
cover. Use caution as a small amount of spring
tension will remain on the bypass valve spring
before complete bolt removal. Inspect bypass
valve, spring, and bypass valve cap gasket for wear,
abrasions, etc. Replace if damage is found.
15. If you have an Air Operated Valve (AOV), ensure the air
supply pressure has been relieved and the supply line
disconnected from the valve housing. Remove the AOV
cap and discard the O-ring from underneath. Remove
the retainer ring and locknuts from the adjustment stem.
Remove the four 3/8 in. bolts and lockwashers from
the AOV housing. Carefully remove the AOV assembly
from the pump. Remove and discard the gasket and
clean the gasket areas. Remove the two recessedhead machine screws and the diaphragm cover plate.
Slide the diaphragm assembly out from the housing.
Remove the intermediate vent plate from between the
two diaphragms. Inspect the diaphragms, spring, and
valve for abrasions and replace if necessary.
Vane Replacement
NOTICE: ONLY QUALIFIED TECHNICIANS SHOULD
PERFORM MAINTENANCE AND THEY MUST FOLLOW
THE APPROPRIATE PROCEDURES AND WARNINGS
PRESENTED IN MANUAL.
1. Follow steps 2–6 in the “Pump Disassembly Instructions”
section of this manual to remove the head assembly
from the non-PTO side of the pump.
2. Turn the shaft with your hand until a vane is in the top
(12 o’clock) position of the rotor. Remove the vane.
3. Position a new vane so the rounded edge faces out
from the pump and the relief grooves face towards the
direction of rotation (see Figure 10).
Bypass Valve Assembly
1. Place the bypass valve into the bypass valve bore of
the pump casing with the fluted end inward.
2. Insert the bypass valve spring and spring guide
against the bypass valve.
3. Attach a new bypass valve gasket and the bypass
valve cover onto the pump casing.
4. Tighten the bypass valve adjusting screw into the
bypass valve cover until it makes contact with the
spring guide.
NOTICE: THE BYPASS VALVE SETTING MUST BE
TESTED AND PROPERLY ADJUSTED BEFORE
PUTTING THE PUMP INTO SERVICE. PLEASE SEE
“BYPASS VALVE ADJUSTMENT”.
5. After the bypass valve has been adjusted correctly,
attach the bypass valve cap and gasket.
Air Operated Valve (AOV) Assembly
1. Install the intermediate vent plate between the two
diaphragms ensuring proper orientation with the screw
holes in the housing. Slide the diaphragm assembly
into the housing and install the diaphragm cover plate
and recessed-head machine screws and tighten
securely. Install this assembly with the valve, spring,
and gasket to the pump using the four 3/8 in. bolts
and lock washers and torque to 15 ft•lbs. Install both
locknuts all the way down the adjustment stem and
replace the retainer ring. Install the new O-ring and
AOV cap. Refer to Air Operated Valve Adjustment for
adjustment procedure.
2. Grease bearings per the instructions listed under
Maintenance of Your Pump System.
3. Install the pump according to the installation guidelines
mentioned previously.
4. Repeat steps 2 and 3 until all vanes have been replaced.
5. Follow steps 2–7 and 12–13 of the “Pump Assembly
Instructions” section of this manual to reassemble
the pump.
Relief grooves
face the direction
of rotation
Rounded edge out
Figure 10: PT30 model shown above
12
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