Milton Roy MILROYAL D Instruction Manual

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Page 1

MILROYAL® D Drive With Packed Plunger Liquid End

Instruction Manual

Manual No : 53941 Rev. : 00 Rev. Date : 01/2016

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PRECAUTIONS

The following precautions should be taken when working with metering pumps. Please read this section carefully prior to installation.

Protective Clothing

ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump. Additional precautions should be taken depending on the solution being pumped. Refer to Safety Data Sheets for the solution being pumped.

Hearing Protection

It is recommended that hearing protection be used if the pump is in an environment where the time- weighted average sound level (TWA) of 85 decibels is exceeded. (as measured on the A scale - slow response)

Electrical Safety

• Remove power and ensure that it remains off while maintaining pump.

• DO NOT FORGET TO CONNECT THE PUMP TO EARTH/ GROUND.

• Electric protection of the motor (Thermal protection or by means of fuses) is to correspond to the rated current indicated on the motor data plate.

Liquid Compatibility

Verify if the materials of construction of the wetted components of your pump are recommended for the solution (chemical) to be pumped.

Pumps Water “Primed”

All pumps are tested with water at the factory. If your process solution is not compatible with water, ush the Pump Head Assembly with an appropriate solution before introducing the process solution.

Plumbing and Electrical Connections

Always adhere to your local plumbing and electrical codes.

Line Depressurization

To reduce the risk of chemical contact during disassembly or maintenance, the suction and discharge lines should be depressurized before servicing.

Over Pressure Protection

To ensure safe operation of the system it is recommended that some type of safety/pressurerelief valve be installed to protect the piping and other system components from damage due to over- pressure.

Lifting

This manual should be used as a guide only - Follow your company’s recommended lifting procedures. It is not intended to replace or take precedence over recommendations, policies and procedures judged as safe due to the local environment than what is contained herein. Use lifting equipment that is rated for the weight of the equipment to be lifted.

ii Instruction Manual

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TABLE OF CONTENTS

SECTION 1 - INSTALLATION ................................................................1

1.1 INTRODUCTION .................................................................1

1.2 UNPACKING .................................................................... 1

1.3 MOUNTING ..................................................................... 1

1.4 PIPING ....................................................................... 1

1.4.1 General Information ............................................................. 1

1.4.2 Suction Piping .................................................................. 2

1.4.3 Discharge Piping................................................................ 2

1.5 SERVICE CONNECTIONS .........................................................2

1.5.1 Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.5.2 Auxiliary (Accessory) Equipment.................................................... 3

1.5.3 Drains ....................................................................... 3

SECTION 2 - OPERATION .................................................................. 4

2.1 PRINCIPLES OF OPERATION ...................................................... 4

2.2 OPERATION .................................................................... 4

2.2.1 Pre- Operational Inspection ....................................................... 4

2.2.2 Capacity Adjustment: Stroke Length................................................. 4

2.2.3 Capacity Adjustment: Stroke Speed .................................................5

2.3 START-UP ...................................................................... 5

2.3.1 General.......................................................................5

2.3.2 Packing.......................................................................5

2.3.3 Capacity Calibration .............................................................5

SECTION 3 - MAINTENANCE INSTRUCTIONS- DRIVE SECTION................................... 6

3.1 LUBRICATION................................................................... 6

3.2 SPARE PARTS .................................................................. 6

3.3 RETURNING PUMPS TO THE FACTORY ............................................. 6

3.4 REPLACING SPARE PARTS........................................................ 7

3.4.1 Removal of Gear Cage ...........................................................7

3.4.2 Removal of Crosshead ........................................................... 7

3.4.3 Assembly and Installation of Crosshead.............................................. 7

3.4.4 Assembly of Gear cage into Pump Housing ...........................................8

SECTION 4 - MAINTENANCE INSTRUCTIONS- LIQUID END 1/8” and 1/4” DIAMETER PLUNGERS...... 10

4.1 SPARE PARTS ................................................................. 10

4.2 RETURNING PUMPS TO THE FACTORY ............................................ 10

4.3 LUBRICATION.................................................................. 11

4.4 CHECK VALVE MAINTENANCE .................................................... 11

4.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT ............................. 11

4.5.1 Replacing Packing ............................................................. 11

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SECTION 5 - MAINTENANCE INSTRUCTIONS- LIQUID END 7/16” and 5/8” DIAMETER PLUNGERS .... 13

5.1 SPARE PARTS ................................................................. 13

5.2 RETURNING PUMPS TO THE FACTORY ............................................ 13

5.3 LUBRICATION.................................................................. 14

5.4 CHECK VALVE MAINTENANCE ....................................................14

5.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT ............................. 14

5.5.1 Types of Packing............................................................... 15

5.5.2 Replacing Packing ............................................................. 15

SECTION 6 - TROUBLESHOOTING .......................................................... 17

LIST OF ILLUSTRATIONS

FIGURE 1. Pump dimensions ................................................................ 18

FIGURE 2. Polar Crank Mechanism ........................................................... 19

FIGURE 3. Basic Drive Assembly Drawing (102-2906-0001) ........................................ 20

FIGURE 4.1/8” and 1/4” Liquid Ends Assembly Drawing (102-290-600-015) ............................23

FIGURE 5. 7/16” and 5/8” Liquid Ends Assembly Drawing (102-290-600-012)........................... 25

LIST OF TABLES

TABLE 1. Drive Spare Parts .................................................................. 6

TABLE 2. Spare Parts for Liquid Ends with 1/8” and 1/4” Diameter Plunger. ............................ 10

TABLE 3. Spare Parts for Liquid Ends with 7/16” and 5/8” Diameter Plunger. ........................... 13

TABLE 4. Basic Drive Assembly Drawing Location Reference Chart .................................. 21

TABLE 5. 1/8” and 1/4” Liquid Ends Assembly Drawing Location Reference Chart ....................... 24

TABLE 6. 7/16” and 5/8” Liquid Ends Assembly Drawing Location Reference Chart ......................26

iv Instruction Manual

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SECTION 1 - INSTALLATION

1.1 INTRODUCTION

The MILROYAL® D Controlled Volume Pump is a reciprocating plunger, positive displacement pump designed to deliver accurately measured liquid volumes against a positive differential pressure (or head) between pump suction and discharge. Precision built, the pump performs this function with a repetitive accuracy of plus or minus one percent of mean delivered volume.

Basically, the pump consists of a drive unit, plunger and displacement chamber or liquid end in which the plunger reciprocates. The pump delivers a controlled volume of liquid with each discharge stroke.

Pump capacity is adjustable by changing plunger stroking speed and / or length. Capacity adjustment can be made manually or automatically by signal from remote process control instruments. Selection of capacity control methods is determined by the nature of the application.

1.3 MOUNTING (Refer to Figure 1)

Support the pump rmly in a level position on a

solid foundation, preferable with the base above floor level to protect it from wash downs and provide easier access for service. This model pump is provided with three tie-down points to accommodate anchor bolts. Table-top operation is possible without need for tie-down with 1/8” or 1/4” plunger diameter liquid end, but tie-down is necessary for 7/16” and 5/8” plunger diameter liquid ends. Up to six units can be easily multiplexed to a single standard motor without special support.

1.4 PIPING

1.4.1 General Information

1. Use piping materials that are resistant to corrosion by the liquid being pumped. Use care in selection of materials to avoid galvanic corrosion at points of connection to the pump liquid end.

1.2 UNPACKING

Pumps are shipped Free on Board (FOB) from the factory and title passes to the customer when carrier signs for receipt of it. The customer,

therefore, must le damage claims with the carrier.

The shipping crate should be carefully examined upon receipt from carrier to be sure there is no obvious damage to the contents. Open the crate carefully, as there are sometimes accessory items fastened to the inside of the crate which may be lost or damaged. Examine all material inside crate and check against packing list to be sure that all items are accounted for and undamaged.

2. Use piping sufficiently heavy to withstand maximum pressures.

3. Blow out all lines before making nal connections

to pump.

4. Provide for pipe expansion when hot uids are to

be pumped. Support piping so that pipe weight is not placed on the pump. Never spring piping to make connections.

5. Piping should be sloped in a manner to prevent trapping of vapor pockets. Vapor present in liquid end will cause inaccurate pump delivery.

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SECTION 1 - INSTALLATION

1.4.2 Suction Piping

1. If possible use metal or plastic tubing for the suction line because tubing has a smooth inner surface and can be formed into sweep bends,

thus decreasing frictional ow losses.

2. Suction piping must be absolutely air tight to insure accurate pumping. After installation, test suction piping with air and soap solution for leaks.

3. A strainer should be used in the suction line to prevent foreign particles from entering the liquid end. Any measures which prevent foreign matter from entering and fouling the ball checks will give increased maintenance free service.

4. It is preferable to have the suction of the pump

ooded by having the liquid end located below the level of the uid in the supply tank.

5. When pumping liquids at temperatures near the

boiling point, provide sufcient suction head to prevent “ashing’’ of the liquid into vapor when

it enters the liquid end on the suction stroke.

6. Suction piping need to be one or two sizes larger

than the liquid end suction tting, ensure NPIP

(Net Positive Inlet Pressure).

7. Sealed piping, sufficient suction pressure, and properly adjusted packing are absolutely necessary for accurate and stable pump operation.

1.4.3 Discharge Piping

1. Install adequate size pump to prevent excessive pressure losses on the discharge stroke of the pump. Maximum pressure at the discharge fitting on the liquid end must be kept at or below the maximum pressure rating as shown on the pump data plate. The peak flow of this type pump during the discharge stroke is

approximately three times the average ow rate

(because of harmonic motion of the plunger) and discharge piping should be sized accordingly.

2. The pump will not deliver a controlled ow if

the discharge pressure is less than the suction pressure. Piping should be arranged to provide at least 5 psi (34.5 kPa) positive pressure differential from the discharge side to the suction side. There are a number of ways to create an

articial discharge pressure, such as the use of

a vented riser or a back pressure valve.

1.5 SERVICE CONNECTIONS

1.5.1 Pump Drive

1. Check the nameplate data on the pump drive (motor) and insure proper power supply is available before making any connections.

2. Preferred motor shaft rotation is marked on the

drive side ange of the pump. Although severe

immediate damage will not occur if motor rotation is incorrect, preferred rotation should be observed. (See Maintenance Instructions, Assembly of Gear Cage into Pump Housing.) Where possible, correct drive rotation will be established at shipment by the factory.

3. For drives other than constant speed electric motors, refer to complete manufacturer’s instructions and service information included with pump.

Instruction Manual

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SECTION 1 - INSTALLATION

1.5.2 Auxiliary (Accessory) Equipment

1. Service connections for auxiliary or accessory electrical equipment should be determined by reference to wiring diagrams, instruction manuals, and data plate requirements furnished with the equipment.

2. Air operated equipment will normally require two sources of air supply. A standard 60 psig (414 kPa) (80-100 psi (552-690 kPa) at compressor) plant air supply will usually be satisfactory for the power elements. An instrument air signal is required for control instruments.

1.5.3 Drains

Provide drains convenient to the pump so that any leakage may be easily removed. The pump catchall area is provided with a cast hole which may be drilled and tapped or otherwise altered to receive desired piping for drainage.

3Instruction Manual

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SECTION 2 - OPERATION

2.1 PRINCIPLES OF OPERATION

MILROYAL® D Pumps consist of two basic mechanisms; the drive system and the liquid end. The drive mechanism (Figure 1) is unique and operates on a patented polar crank principle (Figure 2). Essentially, a crank driven by a worm gear reduction system rotates on a plane whose slope is variable.

As the slope of the plane is changed OFF the vertical, a link transmits the resulting reciprocating motion from the crank to the plunger. Stroke length of the pump is increased from zero to maximum by adjusting the slope of the plane from vertical.

As the plunger reciprocates in the liquid end, the pumped liquid is alternately drawn into and discharged from the liquid end. On the suction (rearward) stroke the liquid follows the plunger, unseating the double suction ball checks and seating the discharge ball checks (Figure 4 or 5). The discharge ball checks prevent

back-ow of liquid into the displacement chamber.

On the discharge stroke (plunger moving forward) the plunger exerts pressure on the liquid, causing the discharge ball checks to rise, allowing liquid to flow out of the displacement chamber and seating the suction ball checks. Thus, by repetitive reciprocating plunger strokes, liquid is caused to

ow in only one direction from the suction port,

through the displacement chamber, and out the discharge port.

2.2 OPERATION

2.2.1 Pre-Operational Inspection

After the pump is installed, but before it is started for

the rst time, a number of checks should be made:

1. Be sure all tie down bolts are tight, piping is installed properly, and the discharge line is open.

2. Check the pump housing and ll to the correct

level with the recommended lubricant listed in the table below. The nominal capacity of the MILROYAL® D housing is 1 pint. Fill to the level of the drain plug.

Liquid

End

Packed Plunger

2.2.2 Capacity Adjustment: Stroke Length

Pump capacity is adjusted by turning the micrometer type stroke adjustment knob clockwise to decrease or counterclockwise to increase the capacity as required. The adjustment scale is marked in percent of full stroke, with calibration lines on the knob at 1.0% intervals. There is a friction plug and setscrew threaded into the side of the boss enclosed by the stroke adjustment knob. Periodic adjustment (tightening) may be required to provide enough friction to keep the stroke adjustment from creeping. The nylon friction plug should be replaced when worn to keep from bearing the steel setscrew against the stroke adjustment screw threads and damaging this part.

Operating Oil

Temperature

15°F to 125°F (-9°C to 52°C)

Type Oil

AGMA No. 7 Compounded

Nevastane SL 100, Food Grade

Instruction Manual

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SECTION 2 - OPERATION

2.2.3 Capacity Adjustment: Stroke Speed

Capacity of the MILROYAL® D Pump is directly proportional to the input drive speed. Most pumps are supplied with a constant speed electric motor as the input power source. With a constant speed input power source, the stroking speed is established by the worm and worm gear set installed in the pump housing, and may be changed only by changing this gear set. The use of a variable speed input power source, however, allows continuous variation of stroking speed and,

therefore, output ow rate variation over a broader

range.

2.3 START- UP

2.3.1 General

All pumps are thoroughly tested under simulated operating conditions before they leave the factory to verify the pump capacity and to check the drive motor for satisfactory operation at maximum rated

pressure. With the pump housing lled to the proper

oil level and all piping and electrical connections made, the pump is now ready for start- up.

2.3.2 Packing

New packing, installed and shipped from the factory in a complete pump or liquid end, has been “set’’ and run-in during production quality assurance testing and requires no further breaking in for start- up. During operation, if leakage does occur, the gland nut should be tightened a little at a time (1/6 turn or less) until leakage is minimized or stopped. The packing should be allowed to resettle

at least ve minutes between adjustments. If it is

possible to tolerate a little leakage at the gland, the leaking liquid will help to lubricate and cool the packing and plunger, greatly extending the life of both.

2.3.3 Capacity Calibration

After the initial break-in period and adjustment of the packing, test runs should be made to determine the exact capacity of these controlled volume pump

under the specic operating conditions for various

stroke length settings. Usually it is necessary to calibrate the pump at only three stroke length settings to determine its characteristics throughout the entire range. The settings normally used are full stroke (100%), 50%, and 20% stroke length.

Two methods of measuring the capacity in a given

time limit can be used:

1. Measure the drop in liquid level from calibrated vessel (preferred).

2. Measure the quantity collected from the discharge side of the pump.

It is essential that the suction lines of controlled volume pumps be absolutely free of entrapped air or vapor to prevent gas movement into the liquid end. Milton Roy liquid ends are designed to rapidly discharge any small bubbles which may enter. However, any large amounts of gas in the liquid end is alternately compressed and expanded with each plunger stroke and causes inaccuracies in pumping. In severe case the liquid end may become vapor bound and cease pumping altogether.

5Instruction Manual

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SECTION 3 - MAINTENANCE INSTRUCTIONS-DRIVE SECTION

The MILROYAL® D Pump has been carefully designed, manufactured, assembled, and tested to give reliable service with a minimum amount of maintenance. However, in normal operation, a periodic check of the pump is recommended to

visually conrm proper operation of the pump.

3.1 LUBRICATION

Fill the gear section of the MILROYAL® D housing with recommended gear lubricant (see page 8 for oil type) to the oil level plug hole. The oil should be changed every 2500 hours of operation or every

six months, whichever comes rst. This can often

be scheduled with winter and summer oil change.

3.2 SPARE PARTS (Figure 3)

It is recommended that a standard group of spare parts (shown in Table 4) be kept on hand at all times to prevent serious delays in repairs. The following list of spare parts represents those which should be kept on hand for each pump drive (see liquid end section for spare parts for liquid end).

Parts orders must include the following information:

1. Quantity required.*

2. Part number.*

3. Part description.*

4. Pump serial number (include in all correspondence regarding the pump).**

5. Full model number.**

* Found in this manual.

** Found on pump nameplate.

EXAMPLE:

Two No. 200 Clevis Pins for model DB2-C-175R, serial number IP-0009 Milton Roy Pump.

3.3 RETURNING PUMPS TO THE FACTORY

Pumps will not be accepted for repair without a Return Material Authorization, available from the Factory Repair Department. Pumps returned to the Factory for repairs should be clearly labeled to indicate the liquid being pumped. Process liquid

should be ushed from the pump liquid end and oil

should be drained from the pump housing before the pump is shipped.

Note:

Federal law prohibits handling of equipment that is not accompanied by an OSHA Safety Data Sheet (SDS). A completed SDS must be packed in the shipping crate with any pump returned to the factory. These safety precautions will aid the troubleshooting and repair procedure and preclude serious injury to repair personnel from hazardous residue in pump liquid end. A Safety Data Sheet must accompany all returns.

All inquiries or parts orders should be addressed

to your local Milton Roy representative or sent to:

www.miltonroy.com.

Item

Number

160 Crank Pin 1

165 Crank Pin Shoulder 1

142

270 Friction Plug 2

152 Dowel Pin 1

210 Snap Ring 2

40 Shaft Oil Seal 4

112 Worm Shaft Bearing 2

211-0042-006 Journal Nut Tool 1

None

Part Name Qty

Connecting Rod Assembly (Includes Spherical Bearing)

Coupling Insert for 300 Coupling

None LOCTITETM Grade 222

Instruction Manual

0.10 cc tube

Table 1. Drive Spare Parts.

Page 11

SECTION 3 - MAINTENANCE INSTRUCTIONS-DRIVE SECTION

3.4 REPLACING SPARE PARTS (Figure 3)

3.4.1 Removal of Gear Cage

1. Remove pump housing assembly from No. 272 motor mounting adapter.

2. Remove No. 290 shaft cover.

3. Remove No. 25 oil drain plug and drain oil from housing.

Note:

At this point the entire pump body should be securely held in a comfortable working position, such as in a large vise.

4. Remove No. 300 coupling from worm shaft.

5. Turn stroke control to 100%. Using journal nut tool, unscrew No. 100 journal nut (right hand thread) from housing.

Note:

The journal nut can be removed more easily by applying a steady force on the wrench rather than by attempting to hammer the wrench to break the nut free.

6. Unscrew the journal nut and pull it OFF the shaft. Bearing No. 112 should come out with the journal nut.

7. Remove worm shaft from housing.

8. Unscrew and remove crankpin and crankpin shoulder, No. 160 & 165.

9. Remove No. 210 snap rings and push clevis pin No. 200 aside to disengage stroke adjusting screw.

10. Lift gear cage out of housing. The remaining

bearing should come out with the cage. The cage cannot be removed unless this bearing is in place in the cage.

11. Remove nut No. 100 and worm gear from the

crank. Take care not to lose the key which pins worm gear to crank.

3.4.2 Removal of Crosshead (Figures 4 & 5)

1. The above disassembly procedure for removal of Gear Cage must be accomplished prior to removal of Crosshead.

2. Unscrew Plunger Adapter Nut No. 235 until the thread is free of the Crosshead.

3. Pull Crosshead out of its bore from the rear, taking care not to lose Thrust Washer No. 245 if it remains in Crosshead when Nut No. 235 is removed.

4. Use a drift pin to remove No. 152 Dowel Pin joining Crosshead and Connecting Rod Assembly No. 142.

CONNECTING ROD ASSEMBLY

MAY BE OF TWO PIECE

CONSTRUCTION, HAVING A THREADED SHANK SPHERICAL

BEARING SCREWED INTO CONNECTING ROD. IF SO, DO NOT

CHANGE THE RELATIONSHIP OF CONNECTING ROD AND

SPHERICAL BEARING HOLES BY SCREWING THE BEARING IN

OR OUT. IF THE RELATIONSHIP IS CHANGED, DAMAGE TO

THE PUMP WILL OCCUR WHEN PUT BACK INTO OPERATION.

3.4.3 Assembly & Installation of Crosshead

1. Support Crosshead in a “V” block of soft

material to protect Crosshead outside nish.

Insert No. 142 Connecting Rod Assembly into Crosshead slot so the dog-leg of the Connecting Rod points the Spherical Bearing to the open side of the slot.

2. Push No. 152 Dowel Pin into Crosshead (slip fit) and tap pin through hole in the

Connecting Rod (force t). Make sure Dowel

Pin ends are not sticking out either side of Crosshead and that connecting rod oscillates freely without binding.

3. Insert assembled Crosshead into Pump Housing, gently working it forward through No. 52 Oil Seal.

12. Bronze bearing No. 72 must be pressed onto crank if replacement of bearing is required.

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Page 12

SECTION 3 - MAINTENANCE INSTRUCTIONS-DRIVE SECTION

3.4.4 Assembly of Gear cage into Pump Housing

Before assembly, several of the parts may need special preparation.

The Journal Nut threads (on nut and housing), Crankpin and Crankpin Shoulder, Worm Shaft, Crank threads, Crank Nut, and if bearings or oil seals are removed the outside of bearings and seals and inside of mating housing surfaces must be thoroughly cleaned of oil and foreign matter. This will require scraping of parts to remove

original lm of LOCTITETM and use of solvent for

degreasing.

DO NOT IMMERSE SEALS IN

SOLVENT AS THIS MAY CAUSE

SEVERE SWELLING OF SEAL MATERIAL.

The following special tools and equipment

are required: MILROYAL® D Journal Nut Tool

No. 211-0042-006, and LOCTITETM Grade 222.

1. Replace Oil Drain Plug No. 25.

2. If bearings and / or oil seals have been removed

for replacement:

c. After the bearings are installed, lightly

coat the outside of Shaft Oil Seals with LOCTITETM Grade 222 and press into place

until ush with bearing recess. Be sure seal

lips are facing toward the bearings. When all bearings and shaft seals are installed there should be one seal in the drive side of the Housing, one bearing in the drive side of the Gear Cage, and a bearing and oil seal in the Journal Nut, all LOCTITED ™ sealed in place.

3. Insert Crank No. 216 with its pressed-on Bearing No. 72 through bore in Gear Cage, and insert No. 90 Key into key way. Slide Worm Gear onto Crank with side of Worm Gear having stamped

identication numbers facing stroke adjustment

end of pump. Apply 2 to 3 drops of LOCTITETM Grade 222 to crank threads and tighten nut No. 100 to 125-130 Inch-pounds (46-48 N). Check to insure free rotation of Crank and Worm Gear.

4. Insert Clevis Pins No. 200 into holes in Gear Cage with tongs pointed inward.

a. Crosshead Oil Seal No. 52 should be installed

with sealing lip facing stroke adjustment end of pump. Apply a thin coat of LOCTITETM Grade 222 to outside of Seal Casing and

press in Seal until it is rmly seated in the

bottom of its recess.

b. The motor-side Shaft Bearing should

be pressed into its recess with grade HV LOCTITETM. Seat the Bearing into the recess as far as it will go. The same procedure should be followed for installing the other bearing into the Journal Nut.

5. Place Gear Cage into housing. Position driveside bearing into its recess in housing.

6. Insert Shaft and Worm through Cage and Bearing. Apply 3 to 4 drops of LOCTITE™ Grade 222 to a single thread of Journal Nut about mid-way on the Nut, coating the thread for an entire revolution.

7. Slip Journal Nut over Shaft and screw it nger

tight into Housing. Make sure both shaft bearings are seated in their recesses. Using Journal Nut Tool, tighten Journal Nut to approximately 30 inch-pounds (11 N) torque.

Instruction Manual

Page 13

SECTION 3 - MAINTENANCE INSTRUCTIONS-DRIVE SECTION

8. Adjust stroke adjustment screw to 10% and pull Gear Cage to align No. 200 Clevis Pins with groove in stroke adjustment screw. Slide Clevis Pins into the groove and install No. 220 “E” Rings so concave sides of rings bear against cage.

9. Pin No. 142 Connecting Rod Bearing to No. 216 Crank using No. 160 and No. 165 Crank Pin and Crank Pin Shoulder in the following manner. Determine operating direction of rotation of crank. Place a drop of LOCTITETM Grade 222 on threaded section of No. 160 Crank Pin. Insert No. 165 Crank Pin Shoulder through leading side hole of crank and No. 160 Crank Pin through following side hole of crank. This allows the solid crank pin to perform the heavy duty cycle portion of the pumping stroke.

10. If applicable, assemble Liquid End and Plunger into Pump Body as outlined in Liquid End Maintenance section.

9Instruction Manual

Page 14

SECTION 4 - MAINTENANCE INSTRUCTIONS-LIQUID END 1/8” AND 1/4” DIAMETER PLUNGERS

4.1 SPARE PARTS (Figure 4)

It is recommended that a standard group of spare parts be kept on hand at all times to prevent serious delays in repairs. The following list of spare parts represents those which should be kept on hand for each liquid end (see pump drive section for spare parts for pump drive).

Parts orders must include the following information:

1. Quantity required.*

2. Part number.*

3. Part description.*

4. Pump serial number (include in all correspondence regarding the pump).**

5. Full model number.**

* Found in this manual.

** Found on pump nameplate.

EXAMPLE:

Four No. 384 Clevis Pins for model DB2-C-175R, serial number IP-0009 Milton Roy Pump.

NOTE:

Unless otherwise specied, plunger size and

materials of construction of spare parts will be

the same as specied on the original pump

order.

NOTE:

All inquiries or parts orders should be addressed to your local Milton Roy representative or sent to: www.miltonroy.com.

Item

Number

383 Ball Seat 4

385 Cap Gasket 6

222 Plunger Assembly 1

245 Thrust Washer 1

250 Thrust Washer Ring 1

384 Ball Check 1

425 Packing 2 Sets

Part Name Qty

Table 2. Spare Parts for Liquid Ends with

1/8” and 1/4” Diameter Plunger.

4.2 RETURNING PUMPS TO THE FACTORY

Pumps will not be accepted for repair without a Return Material Authorization, available from the Factory Repair Department. Pumps returned to the Factory for repairs should be dearly labeled to indicate the liquid being pumped. Process liquid

should be ushed from the pump liquid end and oil

should be drained from the pump housing before the pump is shipped.

Instruction Manual

Page 15

SECTION 4 - MAINTENANCE INSTRUCTIONS-LIQUID END 1/8” AND 1/4” DIAMETER PLUNGERS

4.3 LUBRICATION

No lubrication is required. All sliding surfaces which would normally require lubrication are in contact

with a self- lubricating uorocarbon material.

4.4 CHECK VALVE MAINTENANCE

Suction and discharge cartridge assembly 405 are designed to be self cleaning and should give long, trouble free service. If the check valves do become fouled, a hot detergent solution cleaning will usually remove all but the most stubborn contaminants. Prepare a hot detergent solution and pump it freely through the pump for 10 to 15 minutes. Flush with hot water and return the pump to normal service.

If ushing does not prove adequate, remove the

cartridges and inspect for chemical damage. A cotton swab is often helpful in cleaning the seat area. Replace cartridge assembly with Ball Checks, Seats, and Gaskets in the order shown on Figure 4. This cartridge design depends on compression of the Cap Gaskets (No. 385) to prohibit leakage from around outside of Ball Seats and exterior thread of No. 381 Caps; therefore, on

reassembly tighten Caps down rmly.

4.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT

New Packing, installed and shipped from the factory in a complete pump or liquid end, has been “set” and run-in during production quality assurance testing and requires no further breaking in for startup. If, during operation, leakage does occur, Gland Nut No. 430 should be tightened a little at a time (1/6 turn or less) until leakage is minimized or stopped. Wait at least five minutes between adjustments to allow packing to resettle. If it is possible to tolerate a little leakage at the Gland, the leaking liquid will help to lubricate and cool Packing and Plunger, greatly extending the life of both.

4.5.1 Replacing Packing

1. To replace packing it is necessary to remove liquid end from the pump.

2. Loosen No. 430 Gland Cap.

3. Remove two screws which retain No. 410 Adapter to Pump Housing and pull liquid end straight forward, taking care not to bend plunger. Inspect plunger for scoring or pitting and replace if necessary.

4. With liquid end OFF pump, remove gland cap and packing follower.

5. Remove old packing with a small hook

(do not scratch stufng box) and thoroughly clean stufng of any foreign material.

6. Install new packing with female portions facing forward so they may react with applied hydraulic

pressure and expand against stufng box walls

and plunger to effect a good seal.

7. Replace packing follower and screw gland cap on lightly.

8. Install plunger if it has been removed, making sure the two thrust washers are replaced. If necessary, moisten solid washer with a drop of clean light oil to insure it remains seated in plunger adapter nut during installation.

9. After tightening plunger adapter nut, loosen it 1/8 turn (no more or thrust washer may unseat).

10. Carefully slide entire liquid end over plunger

and back onto pump and secure it with the two screws.

11. Tighten gland cap nger tight to center plunger,

then tighten plunger adapter nut rmly.

12. Tighten No. 430 gland cap 1/4 turn past nger

tight and hold packing under this compression for 10 minutes to allow packing to settle in

stufng box.

11Instruction Manual

Page 16

SECTION 4 - MAINTENANCE INSTRUCTIONS-LIQUID END 1/8” AND 1/4” DIAMETER PLUNGERS

13. Loosen gland cap and retighten 1/6 turn

(one HEX at) past nger tight.

14. Start pump at 100% stroke length but without pumping load. It is permissible to run liquid end

dry, or pump uid to atmospheric pressure.

Run for about 1/2 hour.

15. At end of this break-in period put pump into full operation against normal pumping load. Adjust capacity to the desired chemical feed.

16. Adjust packing as explained under “Packing Adjustment, Start- Up and Replacement”.

Instruction Manual

Page 17

SECTION 5 - MAINTENANCE INSTRUCTIONS-LIQUID END 7/16” AND 5/8” DIAMETER PLUNGERS

5.1 SPARE PARTS (Figure 5)

Parts orders must include the following information:

1. Quantity required.*

2. Part number.*

3. Part description.*

4. Pump serial number (include in all correspondence regarding the pump).**

5. Full model number.**

* Found in this manual.

** Found on pump nameplate.

EXAMPLE

Four No. 435 Clevis Pins for model DB2-C-175R, serial number IP-0009 Milton Roy Pump.

5.2 RETURNING PUMPS TO THE FACTORY

should be ushed from the pump liquid end and oil

should be drained from the pump housing before the pump is shipped.

NOTE:

All inquiries or parts orders should be addressed

to your local Milton Roy representative or sent to:

www.miltonroy.com.

NOTE:

Unless otherwise specied, plunger size and

materials of construction of spare parts will be

the same as specied on the original pump

order.

Item

Number

222 Plunger Assembly 1

250 Thrust Washer 1

250 Thrust Washer Ring 1

9001 Ball Check Cartridge Assembly 2

428 Gland Bearing Liner 2

425 Packing 2 Sets

Part Name Qty

Table 3. Spare Parts for Liquid Ends with

7/16” and 5/8” Diameter Plunger.

13Instruction Manual

Page 18

SECTION 5 - MAINTENANCE INSTRUCTIONS-LIQUID END 7/16” AND 5/8” DIAMETER PLUNGERS

5.3 LUBRICATION

Once each day lubricate the packing lightly with lubricant recommended on pump data face sheet

(front of manual). A grease tting located on the

liquid end is provided for this purpose.

5.4 CHECK VALVE MAINTENANCE

The ball check cartridge assemblies, each with double ball checks are designed to give long, trouble- free service. If the check valves do become fouled, cleaning with a hot detergent solution will usually remove all but the most stubborn contaminants. Prepare a hot detergent solution and pump freely through the pump for 10 to 15 minutes. Flush with hot water and return to normal service.

If ushing does not prove adequate, remove and

disassemble cartridges to inspect for chemical damage. To remove balls and seats from cartridge,

perform the following:

1. Using a 5/16” (7.93 mm) diameter pin, push out No. 383 seats and No. 386 ring insert from small end of No. 381 body.

2. Using a 1/16” (1.59 mm) diameter pin, push out No. 385 limit pin from seat.

3. Remove No. 384 ball check and inspect ball and seat for marks, pits and scratches. The important portion of the seat is where ball contacts edge of the hole. This area should be a smooth bright band when viewed under

10X magnication. Any imperfections in either

ball or seat is cause for replacement.

4. It is recommended that No. 382 O-ring and No. 386 ring insert be replaced after disassembly.

5. After cleaning all parts, reassemble as shown in gure 5. Make sure O-ring end of seat is placed

into body rst, and that the entire assemblies

are screwed into liquid end with arrows on body pointing upward.

ONE OF THE FOLLOWING WILL

RESULT FROM INCORRECT

BALL CHECK CARTRIDGE ASSEMBLY: (A) IMMEDIATE SEVERE

DAMAGE TO PUMP MECHANISM, (B) NO PUMPING, (C)

REVERSE PUMPING ACTION (FROM DISCHARGE LINE INTO

SUCTION LINE).

6. Threads on cartridges should be prepared with sparing amount of pipe dope or, preferably,

with a thread sealant tape to prevent air or uid

leakage past threads.

5.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT

New packing, installed and shipped from the factory in a complete pump or liquid end has been set and run-in during Production Quality Assurance and requires no further break-in prior to full load start- up.

If, during operation, leakage does occur, gland cap no. 403 should be tightened a little at a time (1/6 turn or less) until leakage is minimized or stopped. Wait at least five minutes between adjustments to allow packing to resettle. If it is possible to tolerate a little leakage at Gland Cap, the leaking liquid will help to lubricate and cool packing and plunger, greatly extending the life of both.

Instruction Manual

Page 19

SECTION 5 - MAINTENANCE INSTRUCTIONS-LIQUID END 7/16” AND 5/8” DIAMETER PLUNGERS

5.5.1 Types of Packing

There are two general types of packing used in this pump, automatic and compression.

Automatic type packing is made up of a series of shaped rings which have sealing lips that react

with applied hydraulic pressure to form a good uid

seal against both the moving plunger and walls

of the stufng box. This type packing is generally

preferred over the compression type because of its lower friction against plunger and somewhat self-adjusting characteristics which allow it to compensate for wear and maintain good sealing.

Automatic packing must never be adjusted so

tightly that it loses its capability to properly ex

during operation. It is seldom necessary to adjust

this type of packing any more than nger tight.

Packings of square or round cross section which

must be rmly compressed in the stufng box are

known as compression types. These are available in many materials, and are usually used only when the somewhat limited materials of automatic

type are not compatible with the pumped uid. They depend on mechanical compression in stufng b o x b y t h e f o l l o w e r a n d g l a n d c a p f o r  u i d s e a l i n g .

If compression type packing is too tightly compressed against the moving plunger, frictional force will be reflected back through the drive

mechanism as an overload, or develop sufcient

localized heat to destroy sealing surfaces of both plunger and packing.

Compression type packing is very dependent on proper break-in to develop a good sealing surface.

5.5.2 Replacing Packing

1. To properly replace packing, it is necessary to remove liquid end from pump.

2. Loosen No. 430 Gland Cap (do not remove).

3. Remove the two No. 270 screws which attach liquid end to pump housing.

4. Pull liquid end straight OFF pump and plunger, taking care not to damage plunger by bending. Inspect plunger for scoring or pitting and replace if necessary.

5. Remove No. 430 Gland Cap and No. 427 Gland follower. Inspect No. 428 gland bearing liner and replace if worn. Remove rear section of packing with a small hook or corkscrew device,

taking care not to scratch wall of stufng box.

Remove No. 419 lantern ring, remaining forward section of packing and No. 418 neck ring. Thoroughly clean lantern ring, neck ring, and

stufng box of all foreign matter.

6. Refer to gure 5. It can be seen that the total packing set consists of a neck ring, a lantern ring, a gland follower, and two separate sets of packing material. The forward set of packing (nearest check valves) is intended to seal

against pumped uid. The rear set is intended to seal lubricant in and force lubricant to ow

forward at injection. A new packing set should be made up to the following dimensions with a tolerance of +0 to -1 packing ring.

a. Length of neck ring and front set of packing

(automatic packing to include one male and one female adapter) 1 1/2” (38 mm).

b. Total overall length of both front and rear

packing sets, neck ring, and lantern ring (including adapters for automatic type packing) 2 3/4” (70 mm).

15Instruction Manual

Page 20

SECTION 5 - MAINTENANCE INSTRUCTIONS-LIQUID END 7/16” AND 5/8” DIAMETER PLUNGERS

7. To install packing, coat each piece with recommended lubricant and install in order shown in gure 5. Place each piece into stufng

box individually, insuring each piece is rmly

seated. Automatic packing should be installed with lips facing forward; if rings are split, locate the joints so they are not in line.

8. Install No. 427 gland follower with it No. 428 liner in place. Install follower with its bore lip facing away from packing.

9. Screw No. 430 gland cap loosely onto liquid end.

10. To replace thrust washer, adjust pump stroke

length setting to 0%. Unscrew No. 245 oating

plunger nut from crosshead and remove plunger assembly. Replace worn rings if necessary.

11. With plunger installed, carefully slip liquid end

back over plunger and onto pump body with

grease tting up and secure with washers and bolts. Observe to ow direction arrows

stamped onto No. 9001 ball check cartridge assembly; arrows should both be pointing up.

12. After new packing is installed and liquid end is mounted on pump, the new packing must be broken in to develop a reliable sealing surface and insure long, trouble free packing

life. Tighten gland cap 1/4 turn past nger tight

and hold packing under this compression for at least 10 minutes. While under compression, inject a small amount of recommended

lubricant into tting provided.

13. Loosen gland cap and retighten 1/6 past nger

tight.

14. Start pump at 100% stroke length but without pressure load. It is permissible to operate liquid

end dry, or to pump clear uid to atmospheric

pressure. Run for about 1/2 hour.

NOTE:

Often, compression type packings will expand due to frictional heat generated during initial break-in. If gland cap becomes uncomfortably hot to touch during break-in, gland cap should be loosened slightly (by less than 1/6 turn) to relieve excessive frictional force.

15. At the end of this break-in period, put pump into full operation against normal operating load.

Instruction Manual

Page 21

Pump mechanism will not operate

Pump does not deliver rated ow

Motor and pump body hot

Noisy operation

Pump is not at zero stroke when adjustment reads zero

Leaking oil

Stroke knob “creeps” OFF setting

SECTION 6 - TROUBLESHOOTING

• Incorrect or inoperative electrical circuit to motor. Check and repair / reset power supply, fuses, thermal overload protectors, wiring.

• Incorrect or inoperative electrical circuit to motor. Correct controlling devices such as liquid level, speed control, etc.

• Discharge line blocked. Remove blockage (open valve,thaw discharge lines).

• Discharge line blocked. Check maximum pressure rating of pump from data plate.

• Fluid vapor in liquid end. Eliminate suction line leaks, tighten line

ttings, increase available suction head by increasing suction line size; decrease suction line length; heat uid to decrease its viscosity or cool uid farther away from its boiling point.

• Suction or discharge check valves fouled. Clean per liquid end maintenance instructions or replace.

• Capacity adjustment improperly set or pump not operating at proper speed. Adjust capacity and insure electrical requirements of motor are available .

• Packing leaking excessively. Adjust or replace per liquid end maintenance instructions.

• Normal operating temperature of both motor and pump body is frequently uncomfortable to the touch. However, neither should exceed 200°F (93°C).

• Power supply does not match electrical requirement of motor. Insure proper matching of power supply and motor.

• Pump being operated at greater than rated performance. Reduce pressure or stroke speed. If this is not practical, contact factory.

• Pump improperly lubricated. Drain oil and rell with proper amount

of recommended lubricant.

• Check valves may emit a clicking sound in normal operation.

• In pump housing- Insure proper lubrication, replace worn bearings, clevis pins, or gears.

• Stroke adjustment knob is set incorrectly (a normal pump may not be able to obtain absolute zero stroke at any setting). Minimum obtainable stroke should not exceed 0.015” (0.381 mm). Adjust pump to minimum stroke obtainable, loosen knob set- screw, reset to zero indication, and retighten knob wet- screw. Adjust pump to minimum stroke obtainable, loosen knob setscrew reset to zero indication, re- tighten knob setscrew.

• Worn crosshead oil seal. Replace seal, inspect crosshead for scoring, replace if necessary.

• Worm shaft seals. Clean and inspect oil seal bushings, replace seals, bushings, and O-rings as necessary.

• Loose friction plug. Tighten friction plug setscrew, replace plug if necessary.

17Instruction Manual

Page 22

20” with

largest

motor

75/16

41/16

37/16

121/4

57/8

(3) 7/16 dia.

43/8

71/2

103/4

Typ

11/8

(4) 7/16 dia. when

supplied with

HPD liquid end

41/8

33/4

41/4

(REF)

15/8

TYP

Top View

79/32

CLLiquid end

53/32

93/8

21/2

103/4

Side View

Figure 1. Pump dimensions.

18 Instruction Manual

Page 23

Figure 2. Polar Crank Mechanism.

19Instruction Manual

Page 24

0310

0295

0296

0020

0330

0190

0200

0325

0210

0200

6060

0300

0040

6065

0112

0080

APPLY LOCTITE

TO O.D. OF BEARING

APPLY LOCTITE

THREADS & O.D. OF

0100

0042

0270

0275

910

0295

0290

0280

OIL LEVEL

0250

0260

APPLY LOCTITE

TO THREADS

0040

6030

0020

0025

0296

0240

0170

0165

LOCATETM ON THIS SIDE.

APPLY LOCTITE ON THREADS

0160

0230

0220

6050

0142

6070

Figure 3. Basic Drive Assembly Drawing (102-2906-0001).

20 Instruction Manual

0152

0132

0060

0072

0100

0055

0090

0052

0010

Page 25

Drawing Location

Reference

20 A/R Loctite™ #242

220 1 Stop Collar Set Screw #8-32 NC

275 1 Friction Plug Set Screw 1/4-20 NC

250 2 Knob Set Screw #8-32 NC

190 1 Stroke Adjusting Screw

260 1 Knob Stroke Adjustment

240 1 Stroke Scale

270 1 Friction Plug

230 1 Stroke Stop Collar

300 1 Coupling (mounting to pump)

330 4 Motor Screw 3/8-16 NC

295 4 Shaft Cover Lock Washer 1/4

325 4 Motor Lock Washer 3/8

290 1 Shaft Cover

272 1 Motor Mountin Adapter (NEMA 56 C Flange)

80 1 Gear Set (specify gear ratio)

170 1 Crank Pin Retaining Ring

72 1 Crank Bronze Bearing

112 2 Worm Shaft Bearing

52 1 Crosshead Oil Seal

40 2 Shaft Oil Seal

100 1 Crank Nut 7/16-14 NC 2

296 4 Motor Adapter Screw 1/4 20 NC

6060 4 Drive Cover Screw #10-24 NC

20 4 Nameplate Drive Screw

90 1 Crank Key 1/8 Sq

210 2 Clevis Pin Samp Ring

6065 4 Drive Cover Lock Washer #10

295 4 Motor Adapter Lock Washer 1/4

25 2 Plug

152 1 Dowell Pin

55 1 Gear Cage

6070 1 Catchall Cover Assembly

6050 1 Drive Cover

Quantity Required Description

Table 4. Basic Drive Assembly Drawing Location Reference Chart.

21Instruction Manual

Page 26

Drawing Location

Reference

10 1 Housing

6030 1 Nameplate

100 1 Journal Nut

280 1 Cover Gasket

142 1 Connecting Rod Assembly

165 1 Crank Pin Shoulder

160 1 Crank Pin

200 2 Clevis Pin

132 1 Cross head

Table 4. Basic Drive Assembly Drawing Location Reference Chart Contd.

Quantity Required Description

22 Instruction Manual

Page 27

DISCHARGE

384

402

LIQUID END BODY ASS’Y

405

LIQUID END BODY ASS’Y

384

385

381

385

381

383

385

SUCTION

384

383

410

408

425

415

PUMP HOUSING

384

270

280

430

426

427

222

235

245

250

Figure 4. 1/8" and 1/4" Liquid Ends Assembly Drawing (102-290-600-015).

23Instruction Manual

Page 28

Drawing Location

Reference

222 1 Plunger Assembly

235 1 Floating Plunger Nut

245 1 Thrust Washer

250 1 Thrust Washer Ring

402 1 Liquid End Body Assembly Consist of:

405 1 Discharge cartridge Assembly Consist of:

381 1 Cap

383 2 Ball Seat

385 3 Cap Gasket

384 2 Ball Check

405 1 Suction Cartridge Assembly consisting of:

381 1 Cap

383 2 Ball Seat

385 3 Cap Gasket

384 2 Ball Check

405 1 Liquid End Body

426 1 Packing

427 1 Packing Follower

430 1 Gland Cap

415 1 Liquid End Nut

410 1 Adapter Liquid End Mounting

408 1 Key Pin

270 2 Cap Screw 1/4-20

280 2 Lock Washer 1/4

384 A/R Loctite™

Quantity Required Description

Table 5. 1/8” and 1/4” Liquid Ends Assembly Drawing Location Reference Chart.

24 Instruction Manual

Page 29

384

385

386

280

270

382

383

381

405

222

9001

*AVAILABLE ONLY AS ASSEMBLY

435

419

425

418

PUMP HOUSING (REF)

430

235

245

250

427

428

Figure 5. 7/16” and 5/8” Liquid Ends Assembly Drawing (102-290-600-012).

25Instruction Manual

Page 30

Drawing Location Reference Description

222 Plunger Assembly Consisting of:

222 Plunger

250 Thrust Washer (Ring)

245 Plunger Adapter

235 Nut, Floating Plunger

9001 Ball Check Cartridge Assembly Consisting of:

381 Body

383 Seat

382 O-Ring

385 Limit Pin

384 Ball Check

386 Ring Insert

419 Lantern Ring

418 Neck Ring

430 Gland Cap

250 Thrust Washer (Solid)

405 Liquid End

428 Liner, Gland Bearing

427 Gland Follower

280 Washer

270 Liquid End Bolts

435 Grease Fitting

425 Packing

Table 6. 7/16” and 5/8” Liquid Ends Assembly Drawing Location Reference Chart.

26 Instruction Manual

Page 31

Page 32

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and technologically advanced ow control systems and

industrial compressors. Delivering consistently high levels of performance, we enable customers in the most important industries and harshest environments around the world to accomplish their missions.

Info@miltonroy.com www.miltonroy.com

MILROYAL® is a registered trademark of Milton Roy, LLC.