Nova-Tech LMI Series G - SD Metering Pump User Manual

Series G Model D

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METERING
PUMP

INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL

Please record the following data for file reference

Tag Number(s): _____________________________________

Model Number: _____________________________________

Serial Number: _____________________________________

Installation Date: ____________________________________

Installation Location: ________________________________

339-0080-000

ISSUED JULY 2011

Precautions Amendment to Pump Manual

For Pumps with PVC & 316SS Liquid Ends

WHEN USED IN SWIMMING POOLS OR SPAS/HOT TUBS

(ANSI/NSF 50)

1. Caution on Chemical Concentration:

!

There is a potential for elevated chemical concentration during periods of no flow, for example,
during backwash in the system. Steps, such as turning the pump off, should be taken during
operation or installation to prevent this. Contact your sales representative or distributor about
other external control options to help mitigate this risk.

2. Flow

!

To ensure operation of the pump it is recommended that some type of Flow Indicating Device be
installed to measure water flow rates and be appropriate for the output of the pump. Contact your
distributor or sales representative for further information.

3. He

!

3.1 Milton Roy metering pumps are positive displacement. Head loss is not applicable to the
pump.

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

3.3 If you are pumping downhill or into low or no system pressure, a back pressure/anti-siphon
device should be installed to prevent over pumping or siphoning. Contact your distributor or sales
representative for further information.

4. A

!

4.1 Application of this pump to swimming pool/spas only evaluated to NSF/ANSI 50.

4.2 There is a potential for elevated chemical concentration during periods of no flow, for
example, during backwash in the system. Steps, such as turning the pump off, should be taken
during operation or installation to prevent this. See your sales representative or distributor about
other external control options to help mitigate this risk.

Indicating Device:

ad Loss / Over Pressure Protection / Back Pressure-Anti-Siphon Valve:

dditional Operation and Installation Instructions for 316SS or PVC Liquid Ends:

4.3 Liquid Compatibility CAUTION: Determine if the materials of construction included in the liquid
handling portion of your pump are adequate for the solution (chemical) to be pumped. 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 MSDS precautions from your solution supplier. Reference a Milton Roy Material
Selection Chart for aid in selecting appropriate material of construction for fluids of your specific
metering pump. Contact your sales representative or distributor for further information.

PLACE THIS AMENDMENT TO THE MACROY SD MANUAL (339-0080-000) BEHIND
THE COVER SHEET (APRIL 2008)

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

Series G Model D Pump Model Number and Options ................................................................................ iii

1.0 DESCRIPTION

1.1 General Information ........................................................................................................................... 1

1.2 Principles of Operation ...................................................................................................................... 2

1.3 General Specifications ...................................................................................................................... 3

2.0 INSTALLATION

2.1 Unpacking ........................................................................................................................................... 5

2.2 Storage ................................................................................................................................................ 5

2.3 Safety Precautions ............................................................................................................................. 5

2.4 Mounting ............................................................................................................................................. 6

2.5 Drip Collection .................................................................................................................................... 6

2.6 Installation .......................................................................................................................................... 6

2.6.1 NPSH Considerations ............................................................................................................... 8

2.6.2 General Piping Considerations ............................................................................................... 8

2.6.3 Suction Piping Considerations ................................................................................................ 8

2.6.4 Discharge Piping Considerations ............................................................................................ 9

2.7 Valves .................................................................................................................................................. 9

............................................................................................................................................

...........................................................................................................................................

1

5

2.8 Electrical Connections ..................................................................................................................... 10

3.0 OPERATION

3.1 Start-Up Procedures and Checks .................................................................................................... 11

3.2 Checking the Electrical Connection of the Motor .......................................................................... 11

3.3 Start-Up .............................................................................................................................................. 11

3.4 Capacity Calibration ........................................................................................................................ 11

4.0 MAINTENANCE

4.1 Preventative Maintenance............................................................................................................... 13

4.2 Returning Pumps to the Factory for Repair ................................................................................... 13

4.3 Routine Maintenance ....................................................................................................................... 13

4.4 Spare Parts ....................................................................................................................................... 14

4.4.1 Size SD2 and SD4 Liquid Ends - PVC, PVDF, Polymer, and H2SO4.................................... 14

4.4.2 Size SD4 Liquid Ends - PVC, PVDF, Polymer, H2SO4, and Slurry ...................................... 15

4.4.3 Size SD2 and SD4 Liquid Ends - Stainless Steel ................................................................. 15

4.4.4 Size SD7 and SD8 - Liquid Ends - PVC, PVDF, H2SO4, Polymer, and Slurry ...................... 15

.............................................................................................................................................

.........................................................................................................................................

11

13

4.4.5 Size SD7 and SD8 - Liquid Ends - Stainless Steel .............................................................. 16

i

SECTION DESCRIPTION PAGE

4.5 Corrective Maintenance ................................................................................................................... 16

4.5.1 Check Valve Assemblies Replacement: Liquid Ends SD2 and SD4 - PVC, PVDF, and

H2SO4........................................................................................................................................ 16

4.5.2 Check Valve Replacement: Liquid End Sizes SD2 and SD4 - Polymer ............................. 17

4.5.3 Check Valve Replacement: Liquid End Sizes SD2 and SD4 - Metallic .............................. 17

4.5.4 Check Valve Replacement: Liquid End Sizes SD4 - Slurry ................................................. 18

4.5.5 Replacement of Ball, Seat, and Seal: Liquid End SD7 and SD8 - PVC and PVDF ........... 18

4.5.6 Check Valve Replacement: Liquid End Size SD7 and SD8 - Polymer .............................. 19

4.5.7 Check Valve Replacement: Liquid End Size SD7 and SD8 - Slurry.................................. 19

4.5.8 Check Valve Replacement: Liquid End Size SD7 and SD8 - Stainless Steel .................. 19

4.6 Diaphragm and Oil Seal Bellows Replacement ........................................................................... 20

4.6.1 Diaphragm Replacement: Liquid End Size SD2 ................................................................. 20

4.6.2 Diaphragm Replacement: Liquid End Size SD4, SD7, and SD8 ....................................... 20

4.7 Oil Seal Bellows Replacement ....................................................................................................... 21

4.8 Restarting the Pump ........................................................................................................................ 22

5.0 PARTS LIST ............................................................................................................................................. 23

5.1 Parts List for Drive ............................................................................................................................ 25

5.2 Parts List for D2 Plastic Liquid End PVC, PVDF, H2SO4, and Polymer-NPT / PVC,

PVDF - Tubing ................................................................................................................................... 27

5.3 Parts List for SD2 Metallic Liquid End Stainless Steel-NPT .......................................................... 28

5.4 Parts List for SD4 Metallic Liquid End Stainless Steel-NPT .......................................................... 29

5.5 Parts List for SD4 Plastic Liquid End PVC, PVDF, H2SO4, Slurry, and Polymer-NPT / PVC,

PVDF, and H2SO4 - Tubing ................................................................................................................ 31

5.6 Parts List for SD7 and SD8 Plastic Liquid End PVC-NPT / Tubing, PVDF-NPT, Polymer-NPT,

Slurry-NPT, & H2SO4-NPT .................................................................................................................. 35

5.7 Parts List for SD7 and SD8 316SS-NPT Liquid End ........................................................................ 38

6.0 TROUBLESHOOTING

...............................................................................................................................

39

Change Bars

The areas in this manual which are different from previous editions are marked with change bars (as
shown to the right of this paragraph) to indicate the addition of new or revised information.

ii

MACROY D PUMP MODEL NUMBER AND OPTIONS

Frame and Liquid End

Frame and Liquid End (D Frame)

Code

SD2

SD4

SD7

SD8

Description

Max 0.7 GPH / 175 PSI

Max 14.4 GPH

Max 50 GPH

Max 127 GPH

Stroking Speed

Code Description

1 43 SPM

2 86 SPM

6 120 SPM

3 173 SPM

Motor

Code Description

X NEMA 56C Flange Less Motor

8 115/230 VAC, 60 Hz,1 PH, 1800 RPM

9 115/230 VAC, 50 Hz,1 PH, 1500 RPM

J 230/460 VAC, 60 Hz, 3 PH, 1800 RPM

L 220/380 VAC, 50 Hz, 3 PH, 1500 RPM

P DC Variable Speed Drive

Stroking Speed

Motor

Liquid End Material

Code Description

2 PVDF

7 316ss

8 PVC

P Polymer Service

L Slurry Applications

NH

Connections

Code Description

P NPT

T Tubing

B Outgassing Liquid Applications (NPT)

C Outgassing Liquid Applications (Tubing)

Liquid End Material

Connections

Applications

2SO4

iii

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iv

SECTION 1

DESCRIPTION

1.1 GENERAL INFORMATION

The Series G Model D is a reciprocating, chemical dos­ing pump capable of producing flows up to 115 gallons
per hour (430 liters per hour) at pressures up to 175 psi
(12 Bar). These pumps feature a mechanically actu­ated diaphragm liquid end, which eliminates the need
for flow-restricting contour plates, and a stroke adjust­ment mechanism based on the variable eccentric prin­ciple instead of the traditional lost-motion design. It is
designed for industrial service and offers an accuracy of
±2% of full rated flow between 10% and 100% of its flow
range.

Figure 1:
Pump Assembly

1

The basic pump components as illustrated in Figure 1
are:

• a drive device comprising a motor (1)

• a mechanical assembly (2)

• a liquid end (3).

An elastomeric bellows provides a leak-tight seal be­tween the mechanical assembly and the liquid end.

Capacity adjustment is manually controlled by a stroke
adjustment knob (4).

7

2

8

3

4

6

5

1
2
3
4

Motor
Mechanical Assembly
Liquid End
Stroke Adjustment Knob

5
6
7
8

Liquid End Mounting Assembly
Check Valve Assembly (Suction)
Check Valve Assembly (Discharge)
Stroke Lock Knob

1

Figure 2:
Stroke Control Operating
Principle

1

2

(A) (B)

3

4

5

(A)

7

(B)

Suction Phase

Setting to Maxmum Stroke

1
2
3
4

Worm
Worm Gear
Eccentric
Connecting Rod

5
6
7
8

1.2 PRINCIPLES OF OPERATION

Drive Assembly (See Figure 2)

The pump consists of two major assemblies; the drive
and the liquid end. Pump delivery is a function of the
drive's stroke rate, liquid end size and stroke length.
Stroke length can be increased while the pump is run­ning by counterclockwise turning of the stroke adjust­ment knob. The drive assembly works on the principle
of a variable eccentric. The rotational motion of the motor
is transmitted by the worm (1) to the worm gear (2)
which is linked to an eccentric system (3). The eccen­tric system then converts the rotary gear motion into
linear reciprocating motion of the connecting rod (4). At
0% capacity setting, the connecting rod axis (B) is
aligned with the gear axis (A) and no movement of the
connecting rod takes place. At 100% capacity setting,
an eccentricity exists between the connecting rod axis
(B) and the gear axis (A) which results in linear move­ment of the connecting rod and resulting pumpage.

Drive parts (See Fig. 8 for limited drive parts available)
are no longer sold by Milton Roy. When drive parts are
found to be bad a complete new painted pump body
with all gears, stroke controls, etc. can be purchased
from Milton Roy. The customer will only need to mount
the liquid end/motor from the existing pump.

Zero Stroke Setting

(A)

(B)

Discharge Phase

6

8

Diaphragm
Stroke: two times the distance between (A) and (B)
Position at rear neutral point
Position at forward neutral point

Mechanically Actuated Diaphragm Liquid End
(See Figure 2)

The diaphragm assembly (5) is mechanically linked to
the connecting rod (4) and has the same reciprocating
motion. As the diaphragm starts back on the suction
stroke, the pressure immediately drops inside the liq­uid end. When the pressure in the liquid end drops
below the suction line pressure, the suction ball check
is “pushed” upward and the process fluid in the suction
line flows into the liquid end chamber (diaphragm head).
When the suction stroke ends, the diaphragm move­ment momentarily stops and the pressure in the liquid
end equalizes with the pressure in the suction line caus­ing the suction ball check to reseat.

NOTE: It is important that the pressure in the
liquid end remain above the vapor pressure of
the process fluid during the suction stroke. If
the fluid pressure drops below the vapor pres­sure, cavitation will occur which will have a nega­tive impact on the performance of the pump.
If you suspect the possibility of cavitation, con­tact your dealer for assistance.

2

As the diaphragm starts forward on the discharge stroke
the pressure immediately rises inside the liquid end.
When the liquid end pressure rises above the discharge
line pressure, the discharge ball check is “pushed” up­ward and the process fluid in the liquid end flows into
the discharge line. When the discharge stroke ends,
the diaphragm momentarily stops again. The pressure
in the liquid end equalizes with the discharge line pres­sure and the discharge ball check reseats. The cycle
then starts again.

PAINT:

Power Coating

SUCTION LIFT:

6.6 Ft (2 meters) of water column maximum

11.5 psia minimum internal pressure (3.2 psi maximum
vacuum)

1.3 GENERAL SPECIFICATIONS

FLOW RATE:

Up to 115 GPH (430 L/H)

PRESSURE:

Up to 175 PSIG (12 BAR)

LIQUID END TYPE:

Mechanically Actuated Diaphragm

DRIVE TYPE:

Variable Eccentric

STEADY STATE ACCURACY:

±2% of pump full rated capacity between 10% and 100%
of rated capacity.

WEIGHT:

38 lb (17.2 kg)

CAPACITY ADJUSTMENT:

Lockable stroke adjustment knob is adjustable from 0%
to 100% while pump is running.

LUBRICATION:

Drive is lubricated in an oil bath (Mobil SHC 629, 1 Quart).

TEMPERATURE:

Ambient and Liquid:

122 0F (50 0C) Maximum

14 0F (-10 0C) Minimum

3

THIS PAGE INTENTIONALLY BLANK

4

SECTION 2

INSTALLATION

2.1 UNPACKING

Pumps are shipped f.o.b. factory or representative ware­house and the title passes to the customer when the
carrier signs for receipt of the pump. In the event that
damages occur during shipment, it is the responsibility
of the customer to notify the carrier immediately and to
file a damage claim. Carefully examine the shipping
crate upon receipt from the carrier to be sure there is no
obvious damage to the contents. Open the crate care­fully so accessory items fastened to the inside of the
crate will not be damaged or lost. Examine all material
inside the crate and check against packing list to be
sure that all items are accounted for and intact.

2.2 STORAGE

Short Term Storage (Less than 6 Months)

It is preferable to store the material under a shelter in its
original package to protect it from adverse weather con­ditions. In condensing atmospheres, follow the long term
storage procedure.

Long Term Storage (Longer than 6 Months)

The primary consideration in storage of pump equipment
is to prevent corrosion of external and internal compo­nents. This corrosion is caused by natural circulation
of air as temperature of the surroundings change from
day to night, day to day, and from season to season. It
is not practical to prevent this circulation which carries
water vapor and other corrosive gasses, so it is neces­sary to protect internal and external surfaces from their
effects to the greatest extent possible.

When the instructions given in this section are com­pleted, the equipment is to be stored in a shelter; pro­tected from direct exposure to weather. The prepared
equipment should be covered with a plastic sheet or a
tarpaulin, but in a manner which will allow air circulation
and prevent capture of moisture. Equipment should be
stored 12 inches or more above the ground.

If equipment is to be shipped directly from the factory
into long term storage, contact the factory to arrange for
factory preparation.

Pump Drive

1. Remove motor and flood the gearbox compartment
(Item 2 in Figure 1) with a high grade lubricating oil/rust
preventative such as Mobile Oil Corporation product
Mobilarma 524. Fill the compartment completely to mini­mize air space and water vapor condensation. After stor­age, drain this material and refill the equipment with the
recommended lubricant for equipment commissioning.

2. Brush all unpainted metal surfaces with multipurpose
grease (NLGI grade 2 or 3). Store these unattached.

Electrical Equipment

1. Motors should be prepared in the manner prescribed
by their manufacturer. If information is not available,
dismount and store motors as indicated in step 3 be­low.

2. Dismount electrical equipment (including motors) from
the pump.

3. For all electrical equipment, place packets of Vapor
Phase Corrosion Inhibitor (VPCI) inside of the enclo­sure, then place the entire enclosure, with additional
packets, inside a plastic bag. Seal the bag tightly.

2.3 SAFETY PRECAUTIONS

WHEN INSTALLING, OPERATING, AND
MAINTAINING THIS SERIES G PUMP, KEEP
SAFETY CONSIDERATIONS FOREMOST.
USE PROPER TOOLS, PROTECTIVE CLOTH­ING, AND EYE PROTECTION WHEN WORK­ING ON THE EQUIPMENT AND INSTALL THE
EQUIPMENT WITH A VIEW TOWARD ENSUR­ING SAFE OPERATION. FOLLOW THE IN­STRUCTIONS IN THIS MANUAL AND TAKE
ADDITIONAL SAFETY MEASURES APPRO­PRIATE TO THE LIQUID BEING PUMPED. BE
EXTREMELY CAREFUL IN THE PRESENCE
OF HAZARDOUS SUBSTANCES (E.G., COR­ROSIVES, TOXINS, SOLVENTS, ACIDS,
CAUSTICS, FLAMMABLES, ETC.).

THE PERSONNEL RESPONSIBLE FOR IN­STALLATION, OPERATION AND MAINTE­NANCE OF THIS EQUIPMENT MUST BECOME
FULLY ACQUAINTED WITH THE CONTENTS
OF THIS MANUAL.

ANY SERVICING OF THIS EQUIPMENT MUST
BE CARRIED OUT WHEN THE UNIT IS
STOPPED AND ALL PRESSURE HAS BEEN
BLED FROM THE LIQUID END. SHUT-OFF
VALVES IN SUCTION AND DISCHARGE
SIDES OF THE LIQUID END SHOULD BE
CLOSED WHILE THE UNIT IS BEING SER­VICED. ACTIONS SHOULD BE TAKEN TO
ELIMINATE THE POSSIBILITY OF ACCIDEN­TAL START-UP WHILE SERVICING IS TAK-

5

Figure 3:
Series G Model D
Dimensional Outline

ING PLACE. A NOTICE SHOULD BE POSTED
BY THE POWER SWITCH TO WARN THAT
SERVICING IS BEING CARRIED OUT ON THE
EQUIPMENT. SWITCH OFF THE POWER
SUPPLY AS SOON AS ANY FAULT IS DE­TECTED DURING OPERATION (EXAMPLES:
ABNORMALLY HIGH DRIVE TEMPERATURE,
UNUSUAL NOISE, DIAPHRAGM FAILURE).

2.4 MOUNTING

Support the pump firmly in a level position on a solid,
vibration-free foundation. The pump should preferably
be positioned with the base above floor level to protect
the pump from wash downs and to provide easier ac­cess for service. Be sure to allow enough space around
the pump for easy access during maintenance opera­tions and pump adjustments.

The pumps are provided with mounting holes to accom­modate anchor bolts. Refer to Figure 3 for mounting
hole dimensions.

Pumps installed outdoors should be protected by a shel­ter.

2.5 DRIP COLLECTION

In the event of a failure of the diaphragm or oil seal bel­lows, provisions need to be made to contain the pro­cess fluid or pump oil. This is particularly important
when handling fluids which may be harmful to plant per­sonnel.

To collect fluid in the event of a diaphragm or oil seal
rupture, (See Figure 1) position a tray under the plain
hole located at the bottom of the liquid end mounting
assembly (5). For SD7 or SD8 pumps, position tray
under tube fitting located at bottom of liquid end mount­ing assembly. Alternatively, a tube may be installed
onto this tube fitting to drain any leakage to a suitable
container.

2.6 INSTALLATION

Figure 4 displays typical installations (both correct and
incorrect). Figure 5 illustrates the recommended piping
and accessories in a metering pump installation.

As illustrated in the upper right portion of Figure 4, there
must be no swan-necks or stagnant volumes in the suc­tion line. In this illustration, the loop at the top of the
tank forms an air trap. Eventually, air or gases will bubble
out of solution and accumulate in the trap leading to a
loss of prime condition.

6

Figure 4:
Typical Installation

4

6

5

3

4

6

1

5

1

3

2

4

6

1

9

3

5

7

1
2
3
4
5

Tank
Foot Valve (with Filter)
Metering Pump
Process Piping
Bleed Valve

8

6
7
8
9

-

Injection Nozzle
Shut-off Valve
Filter
Pulsation Damper

-

7

Figure 5:
General Piping

2.6.1 NPSH CONSIDERATIONS

Size piping to accommodate peak instantaneous flow.
Because of the reciprocating motion of the pump dia­phragm, peak instantaneous flow is approximately equal
to 5 times the average flow. For example, a pump rated
for 16 gallons per hour (61 L/hr.) requires piping suffi­cient for 5 x 16 gph, or 80 gph (303 L/hr.).

To minimize viscous flow losses when handling viscous
liquids, it may be necessary to use suction piping up to
four times larger than the size of the suction connection
on the pump. If in doubt, contact your dealer to deter­mine the necessary pipe size.

2.6.2 GENERAL PIPING CONSIDERATIONS

Use extreme care in piping to plastic liquid end pumps
with rigid pipe such as PVC. If excessive pipe stress or
vibration is unavoidable, flexible connections are rec­ommended.

Use piping materials that will resist corrosion by the
liquid being pumped. Use care in selecting materials to
avoid galvanic corrosion at pump liquid end connections.

Use piping heavy enough to withstand maximum pres­sures. Remove burrs, sharp edges, and debris from
inside piping. Blow out all pipelines before making final
connections to pump.

Because vapor in the liquid end will cause inaccurate
pump delivery, piping should be sloped up from pump
suction check to the supply tank to prevent formation of
vapor pockets.

When pumping suspended solids (such as slurries), in­stall plugged crosses at all 90° line turns to permit line
cleaning without dismantling piping.

See Figure 5 for a typical recommended pump installa­tion scheme.

2.6.3 SUCTION PIPING CONSIDERATIONS

It is preferable to have the suction of the pump flooded
by locating the liquid end below the lowest level of the
liquid in the supply tank.

To minimize the chances of a loss-of-prime condition,
the pump should be installed as close as possible to
the supply vessel.

Avoid negative suction pressure conditions (suction lift),
as such conditions adversely affect metering accuracy.
A lift of 6.6 feet (2 meters) of water column is the maxi­mum permissible suction lift.

Series G pumps are designed to operate with process
liquid supplied at or above atmospheric pressure. Al­though these pumps can move liquids supplied at less
than atmospheric pressure (suction lift), in these nega-

8

tive pressure applications it is important that all con­nections be absolutely drip free and vacuum tight, and
that a foot valve be installed at the bottom of the suction
line (see upper left illustration of Figure 4).

When pumping a liquid near its boiling point, provide
enough suction head to prevent the liquid from “flash­ing” into vapor when it enters the pump liquid end on the
suction stroke.

If possible, use metal or plastic tubing for the suction
line because tubing has a smooth inner surface and
can be formed into long, sweeping bends to minimize
frictional flow losses.

A strainer should be used in the suction line to prevent
foreign particles from entering the liquid end. This and
any other measures which prevent debris from entering
and fouling the liquid end check valves will give increased
maintenance-free service. Check strainer frequently to
prevent blockage which could lead to cavitation. Keep
suction piping as short and straight as possible.

Piping size should be larger than the liquid end suction
fitting to prevent pump starvation.

If long suction lines are unavoidable, install a stand pipe
near the pump in the suction line.

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

2.6.4 DISCHARGE PIPING CONSIDERATIONS

2.7 VALVES

Back Pressure Valves

All metering pumps are prone to overpumping (exces­sive output) at low discharge pressures. To prevent this
condition from occurring, it is necessary to maintain
approximately 10 psi (0.7 bar) back pressure against
the pump. This can be accomplished through the in­stallation of a back pressure valve in the discharge line.
Typically, the valve should be located near the pump.
However, back pressure valves for large pumps with long
and extremely small discharge lines may have to be
installed near the point of discharge into the process (to
minimize siphoning tendencies).

Pulsation Dampeners

An accumulator, surge chamber, surge suppressor, or
pulsation dampener should be used with the back pres­sure valve in the discharge line to absorb the flow peaks
between the pump and the back pressure valve. With­out the pulsation dampener the valve mechanism will
snap open and close with the surge from each pump
stroke. The pulsation dampener will allow the back pres­sure valve to oscillate about a partly-closed position,
thus minimizing wear on the valve. Discharge line pul­sation dampeners offer the further advantage of limiting
the flow and pressure variations characteristic of this
kind of pump. Installing a properly sized pulsation damp­ener will improve pump performance and may reduce
system costs dramatically by permitting the substitu­tion of smaller piping. Please contact your dealer for
further information on pulsation dampeners.

Install pipe large enough 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 rated pressure (shown on the
pump nameplate).

The pump will not deliver a controlled flow unless the
discharge line pressure is 10 psi greater than the suc­tion line pressure. One way to create an artificial pres­sure is the installation of a back pressure valve. (Please
contact your dealer for recommendations to increase
back pressure in slurry applications).

When pumping water treatment chemicals directly into
boiler drums, use one liquid end assembly for each boiler
drum. Discharging into a manifold having the slightest
pressure difference between its several discharge con­nections can diminish metering accuracy as the outlet
with the lowest pressure will receive more liquid than
the other outlets.

Safety Valves and Priming Valves

Motor-driven positive displacement pumps can develop
excessive discharge pressures long before thermal over­load devices interrupt the motor electrical circuit. To
prevent a blocked discharge line from causing damage
to the pump, piping, or process equipment, install a
safety valve in the pump discharge line. This valve is
designed and sized to handle system flow rates and
pressures safely while resisting corrosion by the pro­cess liquid.

To aid in pump start-up, it is advisable to install a prim­ing valve on the discharge side of the liquid end.

Shut-off Valves

Provide shut-off valves in both suction and discharge
lines next to the pump. Locate discharge line shut-off
valve downstream from the inlet connection of the safety
valve. Figure 5 shows recommended valve locations.

9

2.8 ELECTRICAL CONNECTIONS

OPERATION WITH THE WRONG MOTOR RO­TATION MAY DAMAGE THE PUMP AND MO­TOR AND VOID THE WARRANTY.

DO NOT FORGET TO CONNECT THE EARTH
TERMINAL ON THE MOTOR TO THE EQUIP­MENT EARTH CONDUCTOR.

Ensure that the electrical supply matches the pump
motor nameplate characteristics. Connect the motor
in accordance with the instructions and connection dia­grams on the motor (or in the motor terminal box).

Note: Before operating the pump, check the
direction of rotation of the motor to be sure it
matches the direction of the arrow on the motor
fan cover (rotation should be clockwise when
viewed from the top of the motor).

The electrical protection installed for the motor (fuse or
thermal protection) must be suitable for the motor's rated
current.

10

14

SECTION 3

OPERATION

3.1 START-UP PROCEDURES AND CHECKS

Check that the pump is secured to its support.

If oil was previously removed for any reason, make sure
pump drive has the correct volume (1 quart) of oil (Mobil
SHC 629).

Make sure all isolation valves installed on the suction
and discharge lines are open. If the discharge line is
equipped with an injection nozzle or a back-pressure
valve, open the priming valve for discharge (if there is no
priming valve, disconnect the discharge pipe). This al­lows for verification that liquid is present in the liquid
end when the pump is installed in flooded suction con­dition. If the pump is installed in a suction lift condition,
this allows for priming of the pump during start-up.

Make sure that pump is set at 0% capacity.

3.2 CHECKING THE ELECTRICAL CONNECTION OF
THE MOTOR

Start up the pump to check the motor's direction of rota­tion. It must comply with that indicated by the arrow
marked on the motor fan cover (clockwise as viewed
from the top of the motor). If the rotation is incorrect,
refer to Section 2.8 Electrical Connections.

flowing from the priming valve. If no priming valve is in
place, when the liquid end is primed, the discharge
check valves can be heard to be operating (should hear
a clicking noise caused by movement of check valve
balls). When liquid end is primed, stop the pump and
close the priming valve.

Adjust the pump to the desired capacity. Lock the stroke
adjustment knob (Item 8 in Figure 1).

3.4 CAPACITY CALIBRATION

After the first 12 hours of operation, the pump may be
tested and calibrated to find the exact pump capacity
under specific operating conditions. Usually, calibrat­ing the pump at only 100, 50, and 10 percent capacity
settings is enough to indicate pump performance through­out the adjustment range.

The pump can be calibrated by measuring the decrease
in liquid level pumped from a calibrated vessel. This
method is recommended for hazardous liquids because
it eliminates operator contact with the liquid. Calibra­tion columns are available for convenient and accurate
calibration of the pump. Contact your dealer for more
information.

3.3 START-UP

FAILURE TO CHECK TORQUE ON NON-ME­TALLIC HEAD BOLTS PRIOR TO STARTUP
AND AFTER ONE WEEK OF OPERATION MAY
EXPOSE OPERATING PERSONNEL TO HAZ­ARDOUS LIQUIDS.

Check the torque on all non-metallic head bolts prior to
startup. Recheck torque on all non-metallic head bolts
after pump has been operating for one week. Torque the
head assembly screws in a crosswise pattern as fol­lows:

a) Liquid End Size D2 and D4 to 45 inch pounds.

b) Liquid End Size D7 and D8 to 90 inch pounds

Once all the checks and procedures described above
have been carried out, start the pump.

Conduct a visual and audio check of the pump (in par­ticular, listen for the presence of any “suspicious” noises).

Make sure that the stroke adjustment knob is unlocked.

THIS METHOD IS GENERALLY NOT RECOM­MENDED AS IT MAY EXPOSE OPERATING
PERSONNEL TO HAZARDOUS LIQUIDS.
FURTHERMORE, IF NO BACK PRESSURE IS
PRESENT ON THE DISCHARGE SIDE, THE
PUMP MAY OVERPUMP DRAMATICALLY IN
WHICH CASE THE POSITION OF THE CA­PACITY ADJUSTMENT KNOB MAY HAVE
LITTLE EFFECT ON ACTUAL FLOW RATE.

FOR SAFETY REASONS, A CHECK VALVE
IS RECOMMENDED FOR USE IN THE DIS­CHARGE LINE NEAR THE POINT WHERE
THE LINE ENTERS A HIGH-PRESSURE PRO­CESS VESSEL.

The pump can also be calibrated by collecting and mea­suring pumped liquid at the pump discharge port. It
may be necessary to create backpressure at the col­lection point to allow for proper pump operation (see
Section 2.7 Back Pressure Valves for recommenda­tions).

Gradually increase the capacity until liquid can be seen

11

15

ITEM
NO. NOMENCLATURE

ITEM
NO. NOMENCLATURE

ITEM
NO. NOMENCLATURE

ITEM
NO.

NOMENCLATURE

10 Housing 110 Female Eccentric 190 O-Ring 335 Sticker

11 Gasket 111 Spring Pin 200 Side Cover 340 Bearing

19 O-Ring 120 Stroke Adjust Key 205 Screw 342 Worm

20 Oil Drain Plug 121 Gear Key 206 Washer 346 Motor Coupling

50 Gear 130 Retaining Ring 310 Stroke Lock Ball 347 Screw

60 Connecting Rod 140 Bearing 320 Stroke Lock Screw 360 Set Screw

100 Male Eccentric 150 Retaining Ring 322 O-Ring 510 Breather Plug

101 Drive Shaft Seal Seal 330 Stroke Adj. Knob

102 Spring Pin 170 Stroke Adj. Screw 332 Screw

Figure 6. Drive Assembly

12

SECTION 4

MAINTENANCE

4.1 PREVENTATIVE MAINTENANCE

Drive

Initially, change the oil in the pump drive assembly after
the first 1000 hours of operation. Thereafter, change
drive oil on an annual basis or after every 5000 hours of
operation.

The drive should be refilled with 1 quart of Mobil SHC
629:

Viscosity @ 100 oF = 726 SSU

Viscosity Index = 149

ISO Grade = 150

Diaphragm Assembly

The Series G Model D diaphragm should be replaced
annually or every 5000 hours of operation to avoid the
possibility of failure. Refer to the instructions in Sec­tion 4.6 Diaphragm and Oil Seal Bellows Replacement.

Oil Seal Bellows

The Series G Model D oil seal bellows should also be
replaced annually. Oil seal bellows replacement requires
the removal of the diaphragm assembly, so it is recom­mended that the oil seal and diaphragm assembly be
replaced at the same time. Refer to the instructions in
Section 4.6 Diaphragm and Oil Seal Bellows Replace­ment.

Check Valves

As in the case of the diaphragm, LMI/Milton Roy Com­pany recommends that check valve balls, seats, gas­kets, and O-rings be replaced on an annual basis or
every 5000 hours of operation. If highly corrosive mate­rial (acids, slurries, etc.) is being pumped, more fre­quent replacement may be required. Complete instruc­tions for replacement of worn check valves are given in
Section 4.5 Corrective Maintenance.

4.2 RETURNING PUMPS TO THE FACTORY FOR
REPAIR

packed in the shipping crate with any pump
shipped for repair. 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 Materials Safety Data Sheet must ac­company all returns.

All inquiries or parts orders should be addressed to your
local representative or distributor.

4.3 ROUTINE MAINTENANCE

LMI/Milton Roy Series G pumps are carefully designed,
manufactured, assembled, and quality tested to give
reliable service with minimal maintenance. However, a
weekly maintenance check is recommended to confirm
proper operation of the pump.

Visual Check of Seal Integrity of Mechanical
Assembly, Figure 6.

Check for leaks in the following components. If leaks
exist, contact the factory for assistance.

1. Motor flange: If leaking, replace motor flange sealing
gasket (Item 11 in Figure 6).

2. Stroke adjustment knob: If leaking, replace stroke
adjustment seal (Item 160 in Figure 6).

Checking the Pump Capacity

Assuming the pump has been calibrated as described
in Section 3, the capacity can be checked by shutting
the valve from the supply vessel and opening the valve
from the calibration column to the suction side of the
liquid end. Measure the volume of pumped liquid for a
given period of time at the various settings.

If a calibration column is not installed in the suction
piping, place the foot valve (or suction line) in a calibrat­ing chamber (graduated reservoir). Measure the volume
of pumped liquid for a given period of time at the various
settings.

Occurrence of Leak From Detection Ports

Pumps can not be accepted for repair without a Return
Material Authorization. Pumps should be clearly labeled
to indicate the liquid being pumped. Process liquid
should be flushed from the pump liquid end and oil should
be drained from the pump housing before the pump is
shipped.

Note: United States of America Federal law
prohibits handling of equipment that is not ac­companied by an OSHA Material Safety Data
Sheet (MSDS). A completed MSDS must be

Determine whether the product collected at the detec­tion port in the liquid end mounting assembly is lubri­cating oil or the pumped fluid.

If the product is pumped fluid, the diaphragm has failed.
If the product is lubricating oil, the oil seal bellows has
failed. Proceed with its replacement (see Section 4.6
Diaphragm and Oil Seal Bellows Replacement).

13

17

Figure 7:
Diaphragm Assemblies
By Liquid End Size and Material

260

240

260

260

252

SD2 SD4 (Plastic)

274

271

240

250

270

260

251

240

274

271

274

271

250

270

SD7 and SD8 SD4 (316SS)

4.4 SPARE PARTS

The following spare parts should be stocked for each
pump to prevent serious delays in repairs. (Refer to
Figures 7 thru 14).

Parts orders must include the following:

1. Quantity required

2. Part number

3. Part description

4. Pump serial number (found on nameplate)

5. Pump product code (found on nameplate)

Note: Always include the serial number and
product code in all correspondence regarding
the unit.

250

270

253

4.4.1 SIZE D2 LIQUID ENDS - PVC, PVDF, POLY­MER, AND H2SO4.

Liquid End Kit for D2 PVC/PVDF

RPM 099, Includes:

1 each, Diaphragm: Item 260 in Figure 9.

1 each, Oil Seal Bellows: Item 70 in Figure 9.

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item
422, Cartridge: Item 426 and Washer: Item 427 in
Figure 9.

Liquid End Kit for D2 Polymer

RPM 196, Includes:

1 each, Diaphragm: Item 260 in Figure 9.

1 each, Oil Seal Bellows: Item 70 in Figure 9.

14

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item
422, Cartridge: Item 426, Washer: Item 427 and
Spring: Item 428 (Discharge Only) in Figure 9.

Liquid End Kit for D2 H

2SO4

Includes:

1 each, Diaphragm: Item 260 in Figure 9.

1 each, Oil Seal Bellows: Item 70 in Figure 9.

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item
422, Cartridge: Item 426, and Washer: Item 427
Figure 9.

4.4.2 SIZE D4 LIQUID ENDS - PVC, PVDF, POLY­MER, H2SO4, AND SLURRY.

Liquid End Kit for D4 PVC/PVDF/Polypropylene

1 each, PTFE Washer: Item 274 in Figure 12.

2 each, Cartridge Assy.: (P/N 39461) Included in
Kit and Coupling Nut: Item 428 in Figure 12.

Liquid End Kit for D4 Slurry

RPM 212, Includes:

1 each, Diaphragm: Item 260 in Figure 12.

1 each, Oil Seal Bellows: Item 70 in Figure 12.

2 each, Check Valve Assembly: Item 425 in Figure

12.

Note: Liquid end sizes D2 and D4 metallic
check valves (except Slurry) are precision as­sembled at the factory. Do not attempt to dis­assemble these cartridges.

RPM 102, Includes:

1 each, Diaphragm: Item 260 in Figure 12.

1 each, Oil Seal Bellows: Item 70 in Figure 12.

1 each, PTFE Washer: Item 274 in Figure 12.

2 each, Cartridge Assy.: (P/N 36306) Included in
Kit.

Liquid End Kit for D4 Polymer

RPM 196, Includes:

1 each, Diaphragm: Item 260 in Figure 12.

1 each, Oil Seal Bellows: Item 70 in Figure 12.

1 each, PTFE Washer: Item 274 in Figure 12.

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item
422, Fitting: Item 424, Cartridge: Item 426, Washer:
Item 427 and Spring: Item 428 in Figure 12.

Liquid End Kit for D4 H2SO4 NPT

RPM 173, Includes:

1 each, Diaphragm: Item 260 in Figure 12.

4.4.3 SIZE D2 AND D4 LIQUID ENDS - STAINLESS
STEEL

Liquid End Kit for D2/D4 316SS

RPM 101/RPM 104, Includes:

1 each, Diaphragm: Item 260 in Figure 10/11.

1 each, O-Ring: Item 253 in Figure 11 (D4 only).

1 each, PTFE Washer: Item 274 in Figure 11 (D4
only).

1 each, Oil Seal Bellows: Item 70 in Figure 10/11.

2 each, Check Valve Assembly: Item 425 in Fig­ures 10 & 11.

Note: The check valves for the size D7 and
D8-PVC, PVDF, and Polypropylene liquid ends
contain a removable seat, which permits the
replacement of the seat, O-ring, and ball into a
reusable valve body. The liquid end size D7
and D8-Stainless Steel check valve has an in­tegral ball seat, which necessitates replacement
of the entire check valve assembly.

1 each, Oil Seal Bellows: Item 70 in Figure 12.

1 each, PTFE Washer: Item 274 in Figure 12.

2 each, Cartridge Assy.: (P/N 39461) Included in
Kit.

Liquid End Kit for D4 H2SO4 Tubing

RPM 174, Includes:

1 each, Diaphragm: Item 260 in Figure 12.

1 each, Oil Seal Bellows: Item 70 in Figure 12.

4.4.4 SIZE D7 AND D8 - PVC, PVDF, H2SO4, POLY­MER, AND SLURRY LIQUID ENDS

Liquid End Kit for D7/D8 PVC/PVDF/H2SO

4

RPM 135/105(PVC)

RPM 136/106(PVDF)

RPM 175/183(H2SO4), Includes:

1 each, Diaphragm: Item 260 in Figure 13.

1 each, Oil Seal Bellows: Item 70 in Figure 13.

1 each, PTFE Seal Ring: Item 210 in Figure 13.

15

2 each, Seat: Item 420, Ball: Item 422 in Figure 13.

4 each, O-Ring: Item 419 in Figure 13.

Liquid End Kit for D7/D8 Polymer

RPM 211/210, Includes:

1 each, Diaphragm: Item 260 in Figure 13.

1 each, Oil Seal Bellows: Item 70 in Figure 13.

1 each, PTFE Seal Ring: Item 210 in Figure 13.

4.4.5 SIZE SD7 AND SD8 - STAINLESS STEEL
LIQUID ENDS

Check Valve Replacement

General

Before beginning work on the valve assemblies, make
sure the suction and discharge shut-off valves are closed
and that pressure has been bled from the pump liquid
end. When replacing the valves, be sure to replace the
valve O-rings. Pay close attention to the proper assem­bly and orientation of the check valves as shown in each
Liquid End figure. In the case of plastic check valves for
liquid end size SD7 and SD8, be certain that the ball is
placed on the sharp edge of the valve seat.

1 each, Diaphragm: Item 260 in Figure 6

1 each, Oil Seal Bellows: Item 70 in Figure 7

2 each, Check Valve Assembly: Item 425 in Figure

14.

Note: The check valves for the size SD7 and
SD8-PVC and PVDF liquid ends contain a re­movable seat, which permits the replacement
of the seat, O-ring, and ball into a reusable
valve body. The liquid end size SD7 and SD8­Stainless Steel check valve has an integral ball
seat, which necessitates replacement of the
entire check valve assembly.

4.5 CORRECTIVE MAINTENANCE

BEFORE CARRYING OUT ANY SERVICING
OPERATION ON THE PUMP OR PIPING, DIS­CONNECT ELECTRICAL POWER FROM THE
PUMP, AND TAKE THE NECESSARY STEPS
TO ENSURE THAT ANY HARMFUL LIQUID
CANNOT COME INTO CONTACT WITH PER­SONNEL. SUITABLE PROTECTIVE EQUIP­MENT MUST BE PROVIDED. BE SURE THAT
THERE IS NO FLUID PRESSURE IN THE
PUMP LIQUID END AND PIPING.

Cleaning Fouled Check Valves

BE SURE TO FOLLOW INSTRUCTIONS
CAREFULLY AND REFER TO THE APPRO­PRIATE FIGURE WHEN REASSEMBLING
CHECK VALVES. IF CHECK VALVE CAR­TRIDGES ARE INSTALLED INCORRECTLY,
ONE OF THE FOLLOWING WILL OCCUR:

(A) IMMEDIATE AND SEVERE DAMAGE TO

PUMP MECHANISM.

(B) NO PUMPING OF FLUIDS.

(C) REVERSE PUMPING ACTION (FROM

DISCHARGE LINE INTO SUCTION LINE).

Preliminary Operations

1. Set the pump capacity knob to 0%. If stroke locking
screw (Item 320 in Figure 8) was previously tightened,
slightly loosen the locking screw.

2. Disconnect power to pump motor. Check that the
equipment cannot be accidentally started. Place a no­tice at the location of the power switch indicating that
the pump is being serviced.

3. Disconnect the pump hydraulically by removing pipe
or tubing connections to suction and discharge check
valves.

4.5.1 CHECK VALVE ASSEMBLIES REPLACEMENT:
LIQUID ENDS SD2 AND SD4 - PVC, PVDF, AND
H2SO4 (SEE FIGURE 9 OR 12)

Check valve assemblies are designed to be self-clean­ing and should seldom need servicing. Fouled check
valves can usually be cleaned by pumping a solution of
mild detergent and warm water (if compatible with liquid
being pumped) for 15 minutes, followed by flushing with
water.

IMPROPER BALL AND SEAT INSTALLATION
CAN CAUSE DAMAGE TO THE PUMP. SEE
FIGURE 9 OR 11 FOR PROPER BALL AND
SEAT ORIENTATION FOR BOTH THE SUC­TION AND DISCHARGE VALVES

16

Suction

1. Unscrew the valve body (424) from the pump head
(280).

DO NOT APPLY PTFE TAPE TO THE
THREADS OF CHECK VALVE BODY THAT
SCREWS INTO THE HEAD (280), AS THIS
MAY PREVENT ADEQUATE SQUEEZE FROM
BEING APPLIED TO THE VALVE O-RING
WHICH COULD RESULT IN LEAKAGE.

1. Unscrew the valve body (424) from the pump head
(280).

2. Remove the cartridge valve assembly: cartridge in­cludes ball (422), seat (420), ball guide (426), O-ring
(419), and washer (427).

3. Clean the valve body (424) and threaded port in the
head (280).

4. Press a new washer (427) into valve body (424).

5. Install new check valve assembly in orientation shown.

On discharge side, drop cartridge assembly (425) into
threaded port in head. The O-ring should be stretched
around outside of cartridge on same end as ball seat.
Screw valve body into discharge side of diaphragm head
until valve is hand tight. DO NOT OVERTIGHTEN.

On suction side, drop the cartridge assembly into check
valve body. The O-ring should be stretched around out­side of cartridge on opposite end of ball seat. Screw
the suction valve body with cartridge valve into suction
side of head. DO NOT OVERTIGHTEN.

4.5.2 CHECK VALVE REPLACEMENT: LIQUID
ENDS D2 AND D4 - POLYMER (SEE FIGURE 9 OR

12)

NOTE THAT THE SEAT ORIENTATION IS DIF­FERENT INSIDE THE SUCTION AND DIS­CHARGE CHECK VALVES, BUT THE SEAT
MUST ALWAYS BE BELOW THE BALL WHEN
INSTALLED.

2. Remove the valve assembly: assembly includes ball
(422), seat (420), Cartridge (426), O-ring (419), and
washer (427).

3. Clean the valve body (424) and threaded port in the
head (280).

4. Place a new washer (427) into valve body (424). Place
new seat (420) and new ball (422) inside new cartridge
(426) and place into valve body.

5. Add O-ring (419) and install new check valve assem­bly in orientation shown.

On suction side, drop the cartridge assembly into check
valve body. The O-ring should be stretched around out­side of cartridge on opposite end of ball seat. Screw
the suction valve body with cartridge valve into suction
side of head hand tight. DO NOT OVERTIGHTEN.

Discharge

1. Unscrew the valve body (424) from the pump head
(280).

2. Remove the valve assembly: assembly includes O­ring (419), seat (420), ball (422), spring (428), cartridge
(426), and washer (427).

3. Clean the valve body (424) and threaded port in the
head (280).

4. Place a new washer (427) into valve body (424). Place
new spring (428), new ball (422), and new seat (420)
inside new cartridge (426) and place into valve body.

5. Add O-ring (419) and install new check valve assem­bly in orientation shown.

On discharge side, drop cartridge assembly into threaded
port in head. The O-ring should be stretched around
outside of cartridge on same end as ball seat. Screw
valve body into discharge side of diaphragm head until
valve is hand tight. DO NOT OVERTIGHTEN.

4.5.3 CHECK VALVE REPLACEMENT: LIQUID END
SIZES D2 AND D4 - METALLIC (SEE FIG. 10 OR 11)

DO NOT APPLY PTFE TAPE TO THE
THREADS OF CHECK VALVE BODY THAT
SCREWS INTO THE HEAD (280), AS THIS
MAY PREVENT ADEQUATE SQUEEZE FROM
BEING APPLIED TO THE VALVE O-RING
WHICH COULD RESULT IN LEAKAGE.

The metallic check valves used on liquid end sizes D2
and D4 (except slurry) are precision assembled at the
factory. Do not attempt to disassemble these cartridges.
If they become inoperative, flush them with solvent, wash
them with warm detergent and blow them out with com­pressed air to remove any foreign matter. If this treat­ment does not eliminate the trouble, the cartridge as­sembly should be replaced.

17

Disassembly

Remove the check valves by unscrewing them from the
pump head.

Reassembly

Apply a small amount of thread sealing compound and
PTFE pipe tape to check valve threads and install check
valves by screwing them into the pump head with the

flow arrows pointing up. DO NOT OVERTIGHTEN

CHECK VALVES.

4.5.4 CHECK VALVE REPLACEMENT: LIQUID END
SIZE D4 - SLURRY (SEE FIGURE 11)

1. Unscrew the valve body (424) from the pump head
(280).

2. Remove the valve assembly: assembly includes ball
(422), check valve body (424), and retainer sleeve (428).

3. Clean the valve body (424) and threaded port in the
head (280).

5. Install new check valve assembly in orientation shown.

On discharge side, drop cartridge assembly into threaded
port in head. Screw valve body into discharge side of
diaphragm head until valve is hand tight. DO NOT OVER-
TIGHTEN.

On suction side, drop the cartridge assembly into check
valve body. Screw the suction valve body with cartridge
valve into suction side of head hand tight. DO NOT
OVERTIGHTEN.

2. Unscrew the check valve assembly (425) from the
pump head (280).

3. Screw the union nut part way (one or two turns) onto
the end of the ball guide (424) that has the seat in it. Be
sure the union nut is on loosely. This will allow a gap for
the seat (420) to fall into as it is removed from the ball
guide.

4. Set the ball guide/union nut on a flat surface with the
union nut down. Looking into the top of the ball guide,
you will see four large holes surrounding one small hole.
Insert a thin, blunt instrument such as a hex head screw­driver into the small center hole until it rests on the top
of the ball (422).

5. Tap screwdriver gently with a hammer until the ball
and seat are released from the ball guide.

IF THE UNIT IS DISASSEMBLED FOR IN­SPECTION ONLY, BE SURE TO USE A BLUNT
INSTRUMENT AND TAP GENTLY TO AVOID
DAMAGING THE BALL. IF THE BALL AND/
OR SEAT ARE DAMAGED DURING DISAS­SEMBLY, THEY WILL HAVE TO BE RE­PLACED. IF AVAILABLE, TO AVOID DAM­AGE, IT IS ADVISABLE TO USE GENTLE AIR
PRESSURE (APPLIED AT END OPPOSITE
THE SEAT (420) FOR BALL AND SEAT RE­MOVAL.

6. Carefully remove the two O-rings (419) from the ball
guide and seat.

THE CHECK VALVES WILL NOT OPERATE
IF THEY ARE INSTALLED UPSIDE DOWN.
INSTALL CHECK VALVES WITH THE FLOW
ARROW POINTING IN THE DIRECTION OF
PROCESS FLOW (UP). TURN CHECK VALVE
ASSEMBLIES INTO LIQUID END BY HAND
AND TIGHTEN. DO NOT OVERTIGHTEN,
DAMAGE TO THE CHECK VALVES MAY OC­CUR.

4.5.5 REPLACEMENT OF BALL, SEAT, & SEAL:
LIQUID END SD7 AND SD8 - PVC, PVDF, AND
H2SO4 (SEE FIGURE 13)

Disassembly

1. Unscrew the union nut (435). The union end (445) is
held in place by the union nut and will separate easily
from the other liquid end parts.

7. Carefully clean any parts to be reused. If any chemi­cals are used in the cleaning process, ensure that they
are compatible with the process liquid.

Reassembly

THE ORDER OF ASSEMBLY AND ORIENTA­TION OF THE SUCTION AND DISCHARGE
CHECK VALVES IS DIFFERENT. REFER TO
FIGURE 13 FOR PROPER ASSEMBLY OR­DER AND ORIENTATION. IF CHECK VALVE
CARTRIDGES ARE INSTALLED INCOR­RECTLY, ONE OF THE FOLLOWING WILL
OCCUR:

(A) IMMEDIATE SEVERE DAMAGE TO PUMP

MECHANISM

(B) NO PUMPING

18

(C) REVERSE PUMPING ACTION (FROM

DISCHARGE LINE INTO SUCTION LINE)

1. Drop the ball (422) into the curved inner chamber end
of the body (424).

2. Set the body on a flat surface so that the end with the
ball faces upward. Position seat (420) on the body,
with the beveled edge of the seat facing outward. When
the seat is pressed into the body, the ball should be
sitting on the side with sharp corners as shown in Fig­ure 13. The bevel should not face the inside of the
check valve. Use a flat surface such as a board to
press the seat into the body with firm, even pressure.

If the seat is improperly positioned, the ball will not cre­ate a tight seal and poor pumping performance will re­sult.

3. Fit new O-rings (419) into position on the body (424)
and seat (420).

DO NOT APPLY PTFE TAPE TO THREADS
OF CHECK VALVE BODY (424) AS THIS MAY
PREVENT ADEQUATE SQUEEZE FROM BE­ING APPLIED TO THE VALVE O-RING WHICH
WOULD RESULT IN LEAKAGE.

Note: To assure a tight, leak free seal, new O­rings should be used each time the check
valves are disassembled.

4. Position the union end (445) onto the correct end of
the body. Refer to Figure 12, as the correct end is
determined by whether the valve is intended for the suc­tion or discharge port of the liquid end. Slip the union
nut (435) over the union end and screw tightly (hand
tight only) onto the body.

5. Screw the valve assembly into the pump head (hand
tight only). DO NOT OVERTIGHTEN.

2. Remove the valve assembly: assembly includes two
O-rings (419), seat (420), ball (422), poppet (426), spring
(423) and check valve body (424).

3. Replace O-rings (419), seat (420), ball (422), poppet
(426), and spring (423).

4. Clean the valve body (424) and threaded port in the
head (280).

5. Install new check valve assembly in orientation shown.

On discharge side, drop cartridge assembly into threaded
port in head. Screw valve body into discharge side of
diaphragm head until valve is hand tight. DO NOT OVER-

TIGHTEN.

4.5.7 CHECK VALVE REPLACEMENT: LIQUID END
SIZES D7 AND D8 - SLURRY (SEE FIGURE 13)

1. Unscrew the valve body (424) from the pump head
(280).

2. Remove the valve assembly: assembly includes two
O-rings (419), slurry seal ring (420), ball (422), check
valve body (424), and dowel pin.

3. Clean the valve body (424) and threaded port in the
head (280).

5. Install new check valve assembly in orientation shown.

On discharge side, drop cartridge assembly into threaded
port in head. Screw valve body into discharge side of
diaphragm head until valve is hand tight. DO NOT OVER-
TIGHTEN.

On suction side, drop the cartridge assembly into check
valve body. Screw the suction valve body with cartridge
valve into suction side of head hand tight. DO NOT

OVERTIGHTEN.

4.5.8 CHECK VALVE REPLACEMENT: LIQUID END
SIZE SD7 AND SD8 - STAINLESS STEEL (SEE
FIGURE 14)

4.5.6 CHECK VALVE REPLACEMENT: LIQUID END
SIZES D7 AND D8 - POLYMER (SEE FIGURE 13)

Suction

Follow the instruction for replacement of ball, seat, &
seal: liquid end D7 and D8 - PVC, PVDF, H2SO4 and
polypropylene paragraph 4.5.5. The procedures are

the same.

Discharge

1. Unscrew the valve body (424) from the pump head
(280).

Disassembly

Stainless steel check valves differ from the plastic ver­sions in that the ball seat is integral to the ball guide.
The seats cannot easily be inspected for damage or
wear. If you suspect that the check valve may be dam­aged or worn, replace the entire check valve assembly
as per the instructions below.

1. Unscrew the coupling (445).

2. Unscrew the check valve assembly (425) from the
liquid end.

19

Reassembly

THE ORDER OF ASSEMBLY AND ORIENTA­TION OF THE SUCTION AND DISCHARGE
CHECK VALVES IS DIFFERENT. REFER TO
FIGURE 14 FOR PROPER ASSEMBLY OR­DER AND ORIENTATION. IF CHECK VALVE
CARTRIDGES ARE INSTALLED INCOR­RECTLY, ONE OF THE FOLLOWING WILL
OCCUR:

(A) IMMEDIATE SEVERE DAMAGE TO PUMP

MECHANISM

4.6.1 DIAPHRAGM REPLACEMENT: LIQUID END
SIZE SD2 (SEE FIGURES 6, 9, AND 10)

1. Loosen the head screws (Item 290 in Figure 9) and
remove the diaphragm head (Item 280 in Figure 9). Mark
the suction and discharge ports on the diaphragm head
prior to removal.

2. Remove the motor fan cover and turn the motor by
hand while adjusting the capacity control knob to 100%.
With the capacity set at 100%, turn the motor fan until
the diaphragm (Item 260 in Figure 9) is in the full for­ward position (top dead center).

3. Hold the outer edge of the diaphragm and turn it coun­terclockwise to unscrew it from the pump drive.

(B) NO PUMPING

(C) REVERSE PUMPING ACTION (FROM

DISCHARGE LINE INTO SUCTION LINE)

1. Screw the correct end of the check valve assembly
into the pump head, trapping a new O-ring between the
pump head and the check valve assembly.

DO NOT APPLY PTFE TAPE TO THREADS
OF CHECK VALVE BODY AS THIS MAY PRE­VENT ADEQUATE SQUEEZE FROM BEING
APPLIED TO THE VALVE O-RING WHICH
WOULD RESULT IN LEAKAGE.

Note: To assure a tight, leak free seal, new O­rings should be used each time the check
valves are disassembled.

2. Screw the coupling (445) onto the check valve as­sembly, trapping a new O-ring (419) between the cou­pling and the check valve assembly.

4. Discard and replace with new diaphragm. Make sure
that adaptor (Item 252 in Figure 9) is screwed in tightly
to connecting rod (Item 60. in Figure 7). Make sure that
seat ring (Item 230 in Figure 9) is in place. Apply a thin
layer of silicone grease to back (rubber side) of dia­phragm before installation. Holding the edges of the
diaphragm, screw the diaphragm assembly onto the male
thread of the adaptor piece (Item 252 in Figure 9) until it
reaches its mechanical stop.

5. With the capacity still set at 100% turn the motor fan
until the new diaphragm is in the farthest rearward posi­tion (bottom dead center).

6. Reattach the diaphragm head with the suction and
discharge ports in the correct positions. Tighten the
screws in a crosswise pattern to a torque of 45 in-lb.

7. While turning the motor fan, set the stroke adjust­ment knob to the 0% position.

8. Reinstall motor fan cover.

4.6.2 DIAPHRAGM REPLACEMENT: LIQUID END
SIZE SD4, SD7, AND SD8 (SEE FIGURES 6, 11 - 14)

4.6 DIAPHRAGM AND OIL SEAL BELLOWS RE­PLACEMENT

BEFORE BEGINNING DIAPHRAGM RE­PLACEMENT, MAKE SURE THAT ALL SHUT­OFF VALVES ARE CLOSED AND ALL PRES­SURE IS BLED FROM THE LIQUID END.

If failure of the oil seal bellows has occurred, it is rec
ommended that the diaphragm assembly and oil seal
bellows be replaced at the same time.

1. Mark the suction and discharge ports on the dia­phragm head prior to removal. Loosen the head screws
(290) and remove the diaphragm head (280).

2. Remove the motor fan cover and turn the motor by
hand while adjusting the capacity control knob to 100%.
With the capacity set at 100%, turn the motor fan until
the diaphragm cap (240) is in the full forward position
(top dead center).

3. Hold the outer edge of the diaphragm (260) and turn it
counterclockwise to unscrew it from the pump drive.

4. While clamping on the hex on the diaphragm cap
(240), disassemble diaphragm assembly by removing
the hex nut (271) on the back of the diaphragm support
nut (270).

20

5. Make sure that stainless steel support nut (270) is
clean and free of corrosion. When cleaning the support
nut, take care not to scratch the smooth angled surface
of the support nut. If corrosion cannot be removed with­out damaging the support nut, replace with a new one.

6. Install new diaphragm (260) onto diaphragm cap (240)
with the convolution in correct orientation. As shown in
Figure 6, the convolution in the Teflon diaphragm should
be facing down away from diaphragm cap (240) and
against (or pointing towards) the stainless steel sup­port nut (270)

7. For Size SD4-stainless steel liquid ends, slide bolt
(250), washer (251), and O-ring (253) through the dia­phragm cap and diaphragm as shown in Figure 6. For
all other liquid ends, install set screw (Item 250 in Fig­ure 6) into diaphragm cap (240), with hex hole in screw
facing outward, until it is bottomed out (hand tight only)
in the diaphragm cap.

8. Slide support nut (270) onto set screw in correct ori­entation shown in Figure 6.

9. Install hex nut onto back of support nut and tighten to
the following torque values dependent on liquid end size
and material. Torque diaphragm assembly as follows:

a) Liquid End Size SD7 and SD8 to 20 foot pounds.

b) Liquid End Size SD4-Plastic to 45 inch pounds.

c) Liquid End Size SD4-Stainless Steel tighten

until washer (Item 251 in Figure 6) is
contacting diaphragm cap (Item 240 in Figure

6).

10. Make sure that support ring (230) is in place and
then reinstall diaphragm assembly.

11. Apply thin layer of O-ring type grease to back of hex
nut (271) and reinstall thin PTFE washer (274) to back
of support nut.

12. Make sure that oil seal clamp ring (Item 210 in Fig­ure 12) is in place. Screw diaphragm assembly into
connecting rod (Item 60 in Figure 7) until it reaches its
mechanical stop.

Note: Steps 11 and 12 are applicable to Liquid
End Size SD4 (See Figure 6).

13. Apply a thin layer of grease to the back of hex nut
(271).

14. Make sure that spring (Item 272 in Figure 13) is in
place and connecting rod is in full-forward position (at
100% capacity setting). Screw diaphragm assembly
into connecting rod cross piece (Item 61 in Figure 13)
until it reaches its mechanical stop.

Note: Steps 13 and 14 are applicable to Liquid
End Size SD7 and SD8 (See Figure 6).

15. With the capacity still set at 100% turn the motor
fan until the diaphragm is pulled back to the rearward
position (bottom dead center).

16. Reattach the diaphragm head with the suction and
discharge ports in the correct positions. Torque the
head assembly screws in a crosswise pattern as fol­lows:

a) Liquid End Size SD2 and SD4 to 45 inch pounds.

b) Liquid End Size SD7 and SD8 to 90 inch pounds.

17. While turning the motor fan, set the stroke adjust­ment knob to the 0% position.

18. Reinstall motor fan cover.

4.7 OIL SEAL BELLOWS REPLACEMENT (ITEM 70
IN FIGURE 7)

BEFORE BEGINNING OIL SEAL REPLACE­MENT, MAKE SURE ALL SHUT-OFF VALVES
ARE CLOSED AND ALL PRESSURE HAS
BEEN BLED FROM THE LIQUID END (PUMP
HEAD). WHEN REPLACING THE OIL SEAL,
THE DIAPHRAGM ASSEMBLY MUST BE RE­MOVED FIRST. FOR EASE OF SERVICE, IT
IS RECOMMENDED THAT THE OIL SEAL BE
REPLACED IN CONJUNCTION WITH THE DIA­PHRAGM ASSEMBLY.

1. Disconnect connections to the pump motor terminal
box. Be sure to note the wiring layout before discon­necting from box.

2. Set the stroke adjusting knob to 100%.

3. Disconnect the suction and discharge connections
to the pump head check valves.

4. Mark the suction and discharge ports on the dia­phragm head prior to removal. Loosen the head screws
(Item 290 in Figure 12) and remove the diaphragm head
(Item 280 in Figure 12).

5. Remove the motor fan cover and turn the motor by
hand while adjusting the capacity control knob to 100%.
With the capacity set at 100%, turn the motor fan until
the diaphragm assembly (Figure 6) is in the full forward
position (top dead center).

6. Hold the outer edge of the diaphragm assembly (Item
260 in Figure 6) and turn it counterclockwise to unscrew
it from the pump drive.

21

7. Remove the diaphragm support ring (Item 230 in Fig­ure 12) from the spacer (225).

8. Drain the oil out of the pump drive by removing the
drain plug from the pump housing (Item 20 in Figure 8).

9. Remove oil seal bellows clamping components as
follows:

a) On Liquid End Size SD2 models (Figures 9 &

10), remove adaptor piece (252), clamp ring
(210), mounting screws (227), and spacer (225).

b) On Liquid End Size SD4 models (Figures 11 &

12), remove oil seal clamp ring (210), mounting
screws (227), and spacer (225).

c) On Liquid End Size SD7 and SD8 models

(Figure 13 & 14), remove spring (272), unscrew
adapter (61), seal ring (210) mounting
screws (227& 228), and spacer (225).

10. Pull the oil seal (70) off the connecting rod (60).

11. Install a new oil seal onto connecting rod.

12. Apply a thin layer of O-ring type grease to top of oil
seal (part adjacent to connecting rod).

4.8 RESTARTING THE PUMP

1. Reconnect the pump to the piping system.

2. Check that capacity is set to 0%.

3. Open system suction and discharge shut-off valves
and restart pump.

4. Set the pump to 100% to obtain faster priming of
liquid end.

5. After priming, set the pump to the desired capacity.
Retighten locking screw (320).

13. Reinstall parts removed in step 9. For Liquid ends
SD2, SD7, and SD8, install adaptor piece (252) or cross
piece (61) before mounting spacer.

14. Remove the motor and refill pump drive with oil (1
quart of Mobil SHC 629).

15. Reinstall motor.

16. Reinstall liquid end components in accordance with
the procedures found in the following:

a) For Liquid End Size SD2 models, refer to

paragraph 4.6.1, steps 4 thru 7.

b) For Liquid End Sizes SD4, SD7, and SD8

models, refer to paragraph 4.6.2, steps 10 thru

17.

17. Connect the motor in compliance with the direc­tions marked during the prior disconnection (see also
Section 2: ELECTRICAL CONNECTIONS).

22

26

SECTION 5

PARTS LIST

GENERAL

1. This section gives information regarding
replaceable components.

ILLUSTRATED PARTS LIST

1. Figure and Item Number Column

(a) The item numbers shown in the detailed parts

list correspond to the item numbers
appearing on the exploded view illustration.
To find an unknown part number, locate the
part on the illustration and note the item
number. Look for the item number on the
detailed parts list. The part number is on the
same line. A dash (-) precedes non-illustrated
item numbers.

2. Description Column

(a) The name of the item is in the description

column.

3. Additional Information

(a) When “Consists of” is indented under a part,

that part consists of the corresponding parts
referenced by part number.

4. Part Number Column

(a) The supplier’s part number is listed in the part

number column.

5. Quantity Column

(a) The numbers appearing in the quantity

column are the total quantity of the listed part
required in its immediate assembly.

6. Reference Code Column

(a) This column is used to denote assembly and

detail part variations among similar
components (models) covered by this
publication. When the symbol “A”, “B”, etc.
is entered in this column, the part is used
only in the model at which the symbol
appears. If the column is blank, the part is
used in all models.

23

27

Figure 8. Drive Assembly

24

5.1 PARTS LIST FOR DRIVE

FIGURE

NUMBER

8

ITEM

NUMBER

10

11
11
19

20
130
140
150
160
170
205
206
330
332
335
340

-

-

-

-

-

-

-

-

-

-

510

DESCRIPTION

Drive Housing Assembly, D2, 43 SPM, (NE56C)
Drive Housing Assembly, D2, 43 SPM, (IEC71)
Drive Housing Assembly, D2, 86 SPM, (NE56C)
Drive Housing Assembly, D2, 86 SPM, (IEC71)
Drive Housing Assembly, D2, 173 SPM, (NE56C)
Drive Housing Assembly, D2, 173 SPM, (IEC71)
Drive Housing Assembly, D2, 120 SPM, (NE56C)
Drive Housing Assembly, D2, 120 SPM, (IEC71)
Drive Housing Assembly, D4/7, 43 SPM, (NE56C)
Drive Housing Assembly, D4/7, 43 SPM, (IEC71)
Drive Housing Assembly, D4/7, 86 SPM, (NE56C)
Drive Housing Assembly, D4/7, 86 SPM, (IEC71)
Drive Housing Assembly, D4/7, 173 SPM, (NE56C)
Drive Housing Assembly, D4/7, 173 SPM, (IEC71)
Drive Housing Assembly, D4/7, 120 SPM, (NE56C)
Drive Housing Assembly, D4/7, 120 SPM, (IEC71)
Drive Housing Assembly, D8, 43 SPM, (NE56C)
Drive Housing Assembly, D8, 43 SPM, (IEC71)
Drive Housing Assembly, D8, 86 SPM, (NE56C)
Drive Housing Assembly, D8, 86 SPM, (IEC71)
Drive Housing Assembly, D8, 173 SPM, (NE56C)
Drive Housing Assembly, D8, 173 SPM, (IEC71)
Drive Housing Assembly, D8, 120 SPM, (NE56C)
Drive Housing Assembly, D8, 120 SPM, (IEC71)
Gasket Motor (NEMA 56C Flanged Motor)
Gasket Motor (IEC71, V1 Flanged Motor)
O-Ring
Oil Drain Plug
Retaining Ring
Bearing
Retaining Ring
Seal, Side Cover
Stroke Adjust Screw
Socket Head Screw, M6 X 16, 304SS
Washer M6 304SS
Stroke Adjust Knob
Pan Head Screw, M6 X 20
Knob, Sticker MacRoy
Bearing
Spring Pin (for IEC Motors Only)
Motor Mounting Bolt (IEC Motors: M8 X 25)
Motor Mounting Bolt (NEMA 56C Motors: 3/8-16 X 1)
Motor Mount Washer (IEC Motors: Spring

Lockwasher 8mm)
Motor Mount Washer (NEMA 56C Motors: 3/8 SAE)
Base (Optional)
HEX HD, Screw, 3/8-16X1 GR5
Washer, 3/8
HEX Nut, 3/8-16NC Z PL
Gear Oil - 1 quart
Breather Plug/Oil Fill Cap, P/O Item 10

PART

NUMBER

SD-40-01-NE56C

SD-40-01-IEC71

SD-20-01-NE56C

SD-20-01-IEC71

SD-10-01-NE56C

SD-10-01-IEC71

SD-15-01-NE56C

SD-15-01-IEC71

SD-40-06-NE56C

SD-40-06-IEC71

SD-20-06-NE56C

SD-20-06-IEC71

SD-10-06-NE56C

SD-10-06-IEC71

SD-15-06-NE56C

SD-15-06-IEC71

SD-40-10-NE56C

SD-40-10-IEC71

SD-20-10-NE56C

SD-20-10-IEC-71

SD-10-10-NE56C

SD-10-10-IEC71

SD-15-10-NE56C

SD-15-10-IEC71

2250115099
2250121099
4080068031

60086

60064
4099994000
4040107231

2502110067N

61331

4350003375N
4340009065N

70066

70054

60996

61116
4010003031
4350038522
4050018119
4340009002

40476
61266

4050018119

40476
4050066016
4070324030

41065

QUANTITY

PUMP

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
3
3
1
2
1
1
3
4
4
4

4
1
4
4
4
1
1

- Items not shown.

25

Figure 9:
D2 Plastic Liquid End

26

5.2 PARTS LIST FOR D2 PLASTIC LIQUID END PVC, PVDF, H2SO4, AND POLYMER-NPT / PVC, PVDF ­TUBING.

Model: Reference Code: Model: Reference Code:

D2_ _ 8P _ _ _ _ A (PVC NPT) D2_ _ NP _ _ _ _ E (H

2SO4

NPT)

D2_ _ 8T _ _ _ _ B (PVC TUBE) D2_ _ PP _ _ _ _ F (POLYMER NPT)

D2_ _ 2P _ _ _ _ C (PVDF NPT)

D2_ _ 2T _ _ _ _ D (PVDF TUBE)

FIGURE

NUMBER

9

ITEM

NUMBER

70
210
225
227
230
252
260
280
280
280

-281
290
300
300
419
419
420
420
420
422
422
422
424
424
425
425
426
426
427
428

-435

-445

-

-

DESCRIPTION

Diaphragm/Oil Seal Bellows
Oil Seal Clamp Ring
Spacer
Pan Head Screw, M6 X 20
Diaphragm Seat Ring
Adapter
Diaphragm, PTFE
Diaphragm Head, PVC
Diaphragm Head, PVDF
Diaphragm Head, POLYMER
Decal
Pan Head Screw, #10-24 X 3/4
Flat Washer, 1/4 18.8SS
Flat Washer, #10 18.8SS
O-Ring, 0.549 ID X 103W(AFLAS)
O-Ring, 2-113 Viton
Ball Seat, 9/32 Ball, C-22
Ball Seat, CA20
Ball Seat, 3/8 Ball, 316SS
Ball 9/32 Ceramic
Ball 9/32, CA20
Ball 3/8, 316SS
Valve Body 1/4” NPT
Fitting, 1/4 PVDF
Check Valve Assembly, PVC/PVDF - NPT
Check Valve Assembly, PVC/PVDF - TUBE
Ball Cartridge
Ball Cartridge
Molded Washer, Cartridge Valve
Spring, HAST-C
Coupling Nut, PP 3/8
Ferrule, 1/4” OD
Liquid End Kit, PVC/PVDF/H
Liquid End Kit, POLYMER

2SO4

PART

NUMBER

60048
60043
61035
70054
61088
61083
30916
61089
61090
69001
60534

61059
4040005012
4040002053

36103

40905

61107

61439

61270

35751

41655
4070014112

36106

36081

61141

61142

36113

36116

36107

61275

10299

28663

RPM 099
RPM 196

QUANTITY

1
1
1
4
1
1
1
1
1
1
1
1
4
4
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1

REF.

CODE

A, B, E

C, D

F

A, E

B, C, D

F

A, B, C, D

E
F

A, B, C, D,

E
F

A, C, E, F

B, D
A, C
B, D

A, B, C, E

F

F
B, D
B, D

A, B, C, D, E

F

- Items not shown.

27

Figure 10:
SD2 Metallic Liquid End

227

ASSEMBLY

425

230

290

260

280

ASSEMBLY

425

225

252

70

210

5.3 PARTS LIST FOR SD2 METALLIC LIQUID END STAINLESS STEEL-NPT

Model: SD2 _ _ 7P

FIGURE

NUMBER

10

ITEM

NUMBER

70
210
225
227
230
252
260
280
290
425

-

DESCRIPTION

Diaphragm/Oil Seal Bellows
Oil Seal Clamp Ring
Spacer
Pan Head Screw, M6 X 20
Diaphragm Seat Ring
Adapter
Diaphragm
Diaphragm Head
Pan Head Screw, #10-24 X 3/4
Check Valve Assembly - NPT
Liquid End Kit, 316 SS

PART

NUMBER

60048
60043
61035
70054
61088
61083
30916
61106
61059
21082

RPM 101

- Items not shown.

QUANTITY

PUMP

1
1
1
4
1
1
1
1
4
2
1

REFERENCE

CODE

28

Figure 11:
SD4 Metallic Liquid End

230

227

ASSEMBLY

425

280

290

240

251

250

253

ASSEMBLY

425

270

225

271

210

274

260

5.4 PARTS LIST FOR SD4 METALLIC LIQUID END STAINLESS STEEL-NPT

Model: SD4 _ _ 7P

FIGURE

NUMBER

11

ITEM

NUMBER

210
225
227
230
240
250
251
253
260
270
271
274
280

DESCRIPTION

Oil Seal Clamp Ring
Spacer
Pan Head Screw, M6 X 20
Supporting Ring
Diaphragm Cap, 316SS
Hex Head Screw, M8 X 50, 316SS
Washer, 8M, 316SS
O-Ring, Viton
Diaphragm
Support Nut, 316SS
Hex Nut, M8 Thin
PTFE Washer
Diaphragm Head, 316SS

PART

NUMBER

60043
61035
70054
61075
61074
61071
61072
61073
60995
61051
61054
61055
61070

QUANTITY

PUMP

1
1
4
1
1
1
1
1
1
1
1
1
1

REFERENCE

CODE

- Items not shown.

29

5.4 PARTS LIST FOR D4 METALLIC LIQUID END STAINLESS STEEL-NPT

Model: D4 _ _ 7P _ _ _ _ A (316SS)

FIGURE

NUMBER

11

ITEM

NUMBER

290
425

-

Pan Head Screw, #10-24 X 3/4
Check Valve Assembly
Liquid End Kit, 316SS

- Items not shown.

Figure 12:

D4 Plastic Liquid End

DESCRIPTION

PART

NUMBER

61059
CV202294
RPM 104

QUANTITY

PUMP

4
2
1

REFERENCE

CODE

30

5.5 PARTS LIST FOR D4 PLASTIC LIQUID END PVC, PVDF, H2SO4, SLURRY, AND POLYMER-NPT / PVC,
PVDF, AND , H2SO4-TUBING.

Model: Reference Code: Model: Reference Code:

D4_ _ 8P _ _ _ _ A (PVC NPT) D4_ _ NP _ _ _ _ E (H2SO4 NPT)

D4_ _ 8T _ _ _ _ B (PVC TUBE) D4_ _ NT _ _ _ _ F (H2SO4 TUBE)

D4_ _ 2P _ _ _ _ C (PVDF NPT) D4_ _ PP _ _ _ _ G (POLYMER)

D4_ _ 2T _ _ _ _ D (PVDF TUBE) D4 _ _ LP _ _ _ _ H (SLURRY)

FIGURE

NUMBER

12

ITEM

NUMBER

70
210
225
227
230
240
240
240
250
250
253
260
270
271
274
280
280
280

-

­290
300
419
419
420
420
420
421
422
422
422
422
424
424
424

425*

425*

425

DESCRIPTION

Diaphragm/Oil Seal Bellows
Oil Seal Clamp Ring
Spacer
Pan Head Screw, M6 X 20
Diaphragm Support Ring
Diaphragm Cap - PVC
Diaphragm Cap - 316SS
Diaphragm Cap - PVDF
Socket Set Screw, M8 X 50
Socket Set Screw, M8 X 50, 316SS
O-Ring, 8MM ID, T=2MM, Viton
Diaphragm, PTFE
Support Nut, 316SS
Hex Nut, M8 X 50
Washer, PTFE
Diaphragm Head - PVC
Diaphragm Head - PVDF
Diaphragm Head - 316SS (SLURRY)
Decal
Decal, EAC Logo
Pan Head Screw, #10-24 X 3/4
Flat Washer, #10 18.8SS
O-Ring, AFLAS
O-Ring, Viton
Ball Seat, 0.375, PTFE
Ball Seat, 3/8” Ball, CA-20
Ball Seat, 3/8” Ball, 316SS
O-Ring, AFLAS
Ball, 3/8” CERAMIC,+/-.001
Ball, 3/8” 316SS, Grade 50
Ball, 3/8” CA-20, Grade 50
Ball, 7/16” 316SS, P/O 22312, Item 425
Fitting, 1/4 PVDF - TUBE
Fitting, 1/2 PVDF - TUBE
Check Valve Body, P/O 22312, Item 425
Check Valve Assembly - NPT, 1/4”
Check Valve Assembly - TUBE, 1/2”
Check Valve Assembly - H

2SO4

PART

NUMBER

60048
60043
61035
70054
61075
61052
61074
61053
61058
61071
61073
60995
61051
61054
61055
61056
61057
61070
60534

2530118099

61059

404000205

36103
40905
39425
61316
61270
39413

10338
4070014112
4070014113

CV102313

36081

36138

22313

36366

36360

39461

QUANTITY

PUMP

1
1
1
4
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

REFERENCE

CODE

A, B, E, F, G, H

C, D

H
H

A, B, E, F, G

C, D

H

E, F

G, H

A, B, C, D

E,F

I
A, B, C, D
A, B, C, D

G

E, F

H

E, G

F
H

A, C

B, D

E, F

- Items not shown. * Item 425 includes items 419, 420, 422, 424, 426, and 427.

31

5.5 PARTS LIST FOR D4 PLASTIC LIQUID END PVC, PVDF, H2SO4, SLURRY, AND POLYMER-NPT / PVC,
PVDF, AND , H2SO4-TUBING.

Model: Reference Code: Model: Reference Code:

D4_ _ 8P _ _ _ _ A (PVC NPT) D4_ _ NP _ _ _ _ E (H

D4_ _ 8T _ _ _ _ B (PVC TUBE) D4_ _ NT _ _ _ _ F (H

2SO4

2SO4

NPT)

TUBE)

D4_ _ 2P _ _ _ _ C (PVDF NPT) D4_ _ PP _ _ _ _ G (POLYMER)

D4_ _ 2T _ _ _ _ D (PVDF TUBE) D4 _ _ LP _ _ _ _ H (SLURRY)

FIGURE

NUMBER

12

ITEM

NUMBER

425
426
427

­428
428

-

-

-

-

-

DESCRIPTION

Check Valve Assembly - SLURRY
Cartridge, 0.375 PVDF
Washer
Coupling Nut, 1/2”
Spring, Lee LC-016C-8-HAST-C, (Suction Only)
Retainer Sleeve
Liquid End Kit, PVC, PVDF NPT/TUBE
Liquid End Kit, H
Liquid End Kit, H

2SO4

2SO4

NPT

TUBE
Liquid End Kit, POLYMER
Liquid End Kit, SLURRY

PART

NUMBER

22312
36116
36107
10411
61275

61071
RPM 102
RPM 173
RPM 174
RPM 196
RPM 212

QUANTITY

PUMP

2
2
2
2
1
1
1
1
1
1
1

REF.

CODE

H
G, H, I
G, H, I

H

I

J

A,B,C,D

G
H

I

J

32

THIS PAGE INTENTIONALLY BLANK

33

44

Figure 13: D7 & D8 Plastic

Liquid End

34

5.6 PARTS LIST FOR D7 AND D8 PLASTIC LIQUID END PVC-NPT/TUBING, PVDF-NPT, POLYMER-NPT,
SLURRY-NPT, & H2SO4-NPT.

Model: Reference Code: Model: Reference Code:

D7/D8_ _ 8P _ _ _ _ A (PVC NPT) D7/D8_ _ NP _ _ _ _ D (H

2SO4

NPT)

D7/D8_ _ 2P _ _ _ _ B (PVDF NPT) D7/D8_ _ PP _ _ _ _ E (POLYMER NPT)

D7/D8_ _ LP _ _ _ _ C (SLURRY NPT) D7/D8_ _ 8T _ _ _ _ F (PVC TUBE)

D7/D8_ _ NP _ _ _ _ D (H

FIG.

NO.

13

ITEM

NO.

61
62
70

­225
227
228
230
240

240
250
260
270
271
272
273
280

280
281
282
290
300

302

-304
305

419*

419*
420*
420*

420
420
422

422*

422

Adapter
Socket Head Set Screw, M8 X 20
Oil Seal Bellows
PTFE Seal Ring
Spacer
Socket Head Set Screw, M6 X 16, 304SS
Socket Head Set Screw, M6 X 30, 304SS
Diaphragm Support Ring
Diaphragm Cap - PVC

Diaphragm Cap - PVDF
Socket Set Screw, Dog PT M10 X 45
Diaphragm, PTFE
Support Nut
Hex Nut, M10 Thin, 316SS
Spring
Spring Cup
Head PVC

Head PVDF
Decal, Tighten MacRoy Plastic
Decal, EAC Logo
Hex Head Screw, M8 X 110mm, LG 304SS
Flat Washer, M8, Regular 304SS

Split Washer M8, 304SS
Nut Spacer
Hex Nut, M8, 304SS
O-Ring, Viton, 2-117

O-Ring, PTFE, TEFLEX 2-117
Seat, PVDF
Slurry Seal Ring, 316SS
Seat, 5/8” Ball 316SS
Seat, 5/8” Ball CA20
Ball, 14MM 316SS
Ball, 5/8 Ceramic
Ball, 5/8 CA20

NPT)

2SO4

DESCRIPTION

D7

PART NO.

61155

4350016075N

60048
61154

61156
4350003375N
4350047395N

60035

60628

60630

4350071284

60618

61065

61068

70081

61153

60033

60031

60534

2530118099
4350001655
4340005085

4340009005

61152

4350000045
4080068075

40348

2240173078

60819

240173016

60855

60709

4070015171
4070014173

D8

PART NO.

61155

4350016075N

60048
61154

61156
4350003375N
4350047395N

60070

60633

60635

4350071284

60624

61146

61068

70081

61153

61148

61147

60534

2530118099
4350001655
4340005085

4340009005

61152

4350000045
4080068075

40348

2240173078

60819

240173016

60855

60709

4070015171
4070014173

QTY.

PUMP

1
1
1
1
2
2
1
1

1
1
1
1
1
1
1
1
1

1
1
6
6
1

6
6
4
4

2
2
2
2
2
2
2
2

REF.

CODE

A, C, D, E,

F
B

A, C, D, E,

F
B

A, B, C, D,

E, F

A, C, D, E,

F
B

A, B, F

C
E
D
C

A, B, F

D

- Items not shown.

* Items included as part of item number 425.

35

5.6 PARTS LIST FOR D7 AND D8 PLASTIC LIQUID END PVC-NPT/TUBING, PVDF-NPT, POLYMER-NPT,
SLURRY-NPT, & H2SO4-NPT.

Model: Reference Code: Model: Reference Code:

D7/D8_ _ 8P _ _ _ _ A (PVC NPT) D7/D8_ _ NP _ _ _ _ D (H2SO4 NPT)

D7/D8_ _ 2P _ _ _ _ B (PVDF NPT) D7/D8_ _ PP _ _ _ _ E (POLYMER NPT)

D7/D8_ _ LP _ _ _ _ C (SLURRY NPT) D7/D8_ _ 8T _ _ _ _ F (PVC TUBE)

D7/D8_ _ NP _ _ _ _ D (H2SO4 NPT)

FIG.
NO.

13

ITEM

NO.

422
423
423

423

423

424*

424
424
425

425

425

-

426

435
445

445

-

-

448

-

-

-

-

-

DESCRIPTION

Ball, 5/8 316SS
Spring, Hastelloy, (Discharge Only)
Kit - Ball, Seat & O-Rings, PVC, Includes
items 419, 420, and 422
Kit - Ball, Seat & O-Rings, Includes items
419, 420, and 422
Kit-Ball, Body, & Dowel Pin, Includes Items
422, 424, & 426
Cartridge Body, PVDF

Slurry Valve Body
Ball Guide, PVC, Spring Loaded
Check Valve Assembly, PVC, Includes
Items 423 and 424
Check Valve Assembly, PVDFIncludes
Items 423 and 424
Check Valve Assembly, Slurry, Includes
Items 419, 420, & 423
Dowel Pin, 3/16 X 1.5, 416SS
Poppet, PVDF
Union Nut, 1/2” PVC
Union End, 1/2” NPT PVC

Union End, 1/2” NPT PVDF
Elbow 1” MPT X 1” BARB PVDF
Elbow 1/2” MPT X 1/2” BARB PVDF
Blow-Off Nozzle
Liquid End Kit, PVCNPT/TUBE
Liquid End Kit, PVDF NPT
Liquid End Kit, Slurry NPT
Liquid End Kit, Polymer NPT
Liquid End Kit, H

2SO4

NPT

D7

PART NO.

4070014172

800123026

3050879500

3050879700

61238

60024

030156071

60818

3050870007

3050870008

60827

60820

440090078

4320236038

60117

60119

61396

470096073N

RPM 135
RPM 136
RPM 215
RPM 211
RPM 175

D8

PART NO.

4070014172

800123026

3050879500

3050879700

61238

60024

030156071

60818

3050870007

3050870008

60827

60820

440090078

4320236038

60117

60119
61395

470096073N

RPM 105
RPM 106

RPM 210
RPM 183

QTY.

PUMP

2
1
2

2

2

2

1
2
2

2

2

2
1
2
2

2
2
2
1
1
1
1
1

REF.

CODE

E
E
A

B

C

A, B, D, E,

F
E

C

A

B

C

C

E

A, C, D,

E, F

B
F
F

A, F

B

C

E

D

- Items not shown.

* Items included as part of item number 425.

36

Figure 14: D7 & D8 316SS

Liquid End

37

5.7 PARTS LIST FOR SD7 AND SD8 316SS-NPT LIQUID END

Model: SD6 _ _ 7P or SD8 _ _ 7P

FIG.

NO.

14

ITEM

NO.

61
62

70
210
225
227
228
230
240
250
260
270
271
272
273
280
290
300
302
304
305
419
425
445
448

-

DESCRIPTION

Adapter
Socket Head Set Screw, M8 X 20
Oil Seal Bellows
PTFE Seal Ring
Spacer
Socket Head Set Screw, M6 X 16, 304SS
Socket Head Set Screw, M6 X 30, 304SS
Support Ring
Diaphragm Cap - 316SS
Socket Set Screw, Dog PT M10 X 45
Diaphragm
Support Nut
Hex Nut, M10 Thin, 316SS
Spring
Spring Cup
Head, 316SS
Hex Head Screw, M8 X 110mm, LG 304SS
Flat Washer, M8, Regular 304SS
Split Washer M8, 304SS
Nut Spacer
Hex Nut, M8, 304SS
O-Ring, Viton
Check Valve Assembly
Coupling, 1/2” NPT
Blow-Off Nozzle
RPM Kit, 316SS

SD7

PART NO.

61155

4350016075N

60048
61154

61156
4350003375N
4350047395N

61066

60631

4350071284

60618

61065

61068

70081

61153

210760016
4350001655
4340005085
4340009005

61152
4350000045
4080068075
3050876602

60135
470096073N

RPM137

SD8

PART NO.

61155

4350016075N

60048

61154

61156
4350003375N
4350047395N

61066
60631

4350071284

60624

61146

61068
70081

61153

210760016
4350001655
4340005085
4340009005

61152
4350000045
4080068075
3050876602

60135

470096073N

RPM107

QTY.

PUMP

1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
6
6
6
6
6
4
2
2
1
1

REF.

CODE

- Items not shown.

38

SECTION 6

TROUBLESHOOTING

SYMPTOMS POSSIBLE CAUSE REMEDY

1. Pump motor won't operate.

a) Low process liquid level in the

tank.

b) Worn or dirty check valves.

c) Blocked discharge line.

d) Frozen liquid.

e) Blown fuse.

f) Open thermal overload device in

motor starter.

g) Broken wire.

h) Low voltage.

i) Pump not primed.

j) Capacity adjustment set at zero.

a) Add liquid.

b) Clean or replace.

c) Clear line.

d) Thaw liquid throughout pumping

system.

e) Replace fuse.

f) Reset device.

g) Locate and repair.

h) Investigate and correct (wiring

may be too tight).

i) Allow suction line and pump

head to fill with liquid before
pumping against pressure.

j) Readjust capacity.

2. Insufficient pump delivery.

a) Incorrect capacity adjustment.

b) Incorrect pump speed.

c) Starved suction.

d) Leaky suction piping.

e) High suction lift.

f) Liquid near boiling.

g) Leaky safety valve in discharge

line.

h) High liquid viscosity.

a) Readjust capacity setting.

b) Match line voltage and frequency

to pump motor data plate.

c) Increase piping size or suction

head.

d) Repair piping.

e) Rearrange equipment to de-

crease lift and/or install foot valve
in suction line.

f) Cool liquid or increase suction

head.

g) Repair or replace valve.

h) Reduce viscosity (e.g., heat or

dilute liquid), or consult the
factory for special check valve
options.

i) Worn or dirty check valve seats.

39

45

i) Clean or replace.

SYMPTOMS POSSIBLE CAUSE REMEDY

3. Erratic pump delivery.

4. Motor and pump body hot.

a) Leaky suction piping.

b) Leaky safety valve.

c) Insufficient suction head.

d) Liquid near boiling.

e) Worn or dirty check valves.

f) Clogged or dirty line strainer.

a) Normal operating temperature of

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

b) Power supply does not match

electrical requirement of motor.

c) Pump is being operated at

greater than rated performance.

a) Repair piping.

b) Repair or replace valve.

c) Raise suction tank level and/or

install foot valve in suction line.

d) Cool liquid or increase suction

head.

e) Clean or replace.

f) Clean strainer.

a) N/A

b) Insure proper matching of power

supply and motor.

c) Reduce pressure or stroke

speed. If this is not practical,
contact service facility.

5. Pump still pumps even at zero
capacity setting.

6. Gear noise.

7. Loud knock with each stroke.

8. Noisy operation in liquid end.

d) Pump improperly lubricated.

a) Misadjusted capacity knob.

b) Insufficient discharge pressure.

a) Excessive backlash.

b) Worn bearings.

c) Wrong or insufficient lubricant.

a) Excessive gear set wear.

b) Worn bearings.

a) Noise in check valves.

d) Drain oil and refill with proper

amount of recommended
lubricant.

a) Readjust capacity setting.

b) Correct condition (e.g., install a

back pressure valve).

a) Consult service facility.

b) Consult service facility.

c) Replace or replenish lubricant.

a) Consult service facility.

b) Consult service facility.

a) Ball checks move up and down

with some force. A distinct
"clicking" noise is normal,
especially in metal piping
systems.

40

THIS PAGE INTENTIONALLY BLANK

41

201 Ivyland Road • Ivyland, PA 18974 USA • [phone] • Fax: [phone]• www.lmipumps.com

E-mail: [e-mail]