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

Series G Model G

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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: ___________________________

201 Ivyland Road

Ivyland, PA 18974
TEL: [phone]
FAX: [phone]

www.lmipumps.com

339-0089-000

ISSUED 02/2010

Precautions

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 Indicating Device:

!

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. Head Loss / Over Pressure Protection / Back Pressure-Anti-Siphon Valve:

!

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

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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.

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.

i

General Precautions For All Pumps

The following precautions should be taken when working with all 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 pre
to Material 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 time­weighted 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

•

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Liquid Compatibility

Verify if the materials of construction of the wetted components of your pu
solution (chemical) to be pumped.

!

Pumps Water “Primed”

All pumps are tested with water at the factory. If your process solution is n
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/pressure-relief 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

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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.

!

Electric protection of the motor (Thermal protection or by means of fuses) i
the rated current indicated on the motor data plate.

cautions should be taken depending on the solution being pumped. Refer

CONNECT THE PUMP TO EARTH

s to correspond to

mp are recommended for the

ot compatible with water, flush

ii

TABLE OF CONTENTS

SECTION 1 - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.6 LEAK DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.7 ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 3 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 4 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 SHIPPING PUMPS FOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.1 Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.1.1 Plastic Check Valves (PVC, PVDF, Polypropylene, & Sulfuric Acid

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4.1.2 Models SG6 & SG7 Liquid End - Stainless Steel Check Valves . . . . . . . . 16

4.4.1.3 Model SG5 Liquid End - Stainless Steel Check Valves . . . . . . . . . . . . . . . 17

4.4.1.4 Model SG5 Liquid End - Slurry Service Check Valves, use until

1 June 2008. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.4.1.5 Models SG5, SG6, & SG7 Liquid End - Slurry Service Check Valves . . . . 18

4.4.1.6 Models SG5, SG6 & SG7 Liquid End - Polymer Service Check Valves . . 18

4.4.2 Diaphragm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4.2.1 Diaphragm Removal (All types; Refer to Figures 6-13 ). . . . . . . . . . . . . . . 19

iii

TABLE OF CONTENTS (CONT.)

4.4.2.2 Disassembly (Only Those Units With a “Hex Head“

Diaphragm Cap Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.2.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.2.4 Reinstallation of Assembly (Refer to Figure 6 Through 13) . . . . . . . . . . . 19

4.4.3 Replacing Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 5 - TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 5 - PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.2 ILLUSTRATED PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.3 DRIVE, SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.4 DRIVE, TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.5 SG5 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.6 SG5 METALLIC LIQUID END - STAINLESS STEEL - NPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.7 SG6 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8 SG6 METALLIC LIQUID END - STAINLESS STEEL - NPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.9 SG7 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.10 SG7 METALLIC LIQUID END - STAINLESS STEEL - NPT. . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.11 CHECK VALVE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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THIS PAGE INTENTIONALLY BLANK

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SECTION 1

DESCRIPTION

1.1 GENERAL INFORMATION

The Series G Model G is a reciprocating, chemical
dosing pump capable of producing controlled flows
up to 310 gallons per hour (1175 L/H) at pressures
up to 150 psi (10 BAR) (depending on the model).
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. This design substantially reduces pressure
and flow pulsations contributing to an increase in
the life of system components and more continu­ous chemical injection. It is designed for industrial
service and offers an accuracy of ±2% of 100%
rated flow between 10% and 100% of its flow
range.

1.2 PRINCIPLES OF OPERATION

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 en d size and
stroke length. Stroke length can be adjusted while
the pump is running or stopped by turning the
stroke adjusting knob.

The drive motor transmits rotary motion to a worm
gear speed reduction unit which in turn drives the
variable eccentric crank. The adjustable crank
imparts reciprocating motion to the diaphragm
through an interposing connecting rod. The stroke
length is adjusted by changing the position of the
variable eccentric crank in the connecting rod
assembly.

As the diaphragm starts back on the suction stroke,
the pressure immediately drops inside the liquid
end. When the liquid end pressure 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. When
the suction stroke ends, the diaphragm movement
momentarily stops. The pressure in the liquid end
equalizes with the pressure in the suction line and
the suction ball check seats.

NOTE: It is important that the pressu re 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, negatively impacting
the performance of the pump. If you suspect
the possibility of cavitation, contact your LMI
Distributor for assistance.

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 reset. The cycle then starts
again.

1.3 GENERAL SPECIFICATIONS
FLOW RATE:

Up to 300 GPH (1175 L/H)

PRESSURE:

Up to 150 PSIG (10 BAR)

DESIGN:

Mechanically Actuated Diaphragm

DRIVE:

Variable Eccentric

ACCURACY:

±2% of 100% rated flow between 10% and 100%
of rated flow

ADJUSTMENT:

Lockable micrometer is adjustable from 0% to
100% while pump is running or stopped

LUBRICATION:

Oil bath Over 50ºF (10ºC), Zurn EP 95, 3 1/2
qt.(3.3 liter). Below 50ºF (10ºC), Zurn EP 35

WEIGHT:

90 lb (40.8kg)

1

Figure 1. Model/Product Code.

2

1.3 GENERAL SPECIFICATIONS (CONT.)

SUCTION LIFT

TEMPERATURE

Ambient and Liquid:

122 ºF (50 ºC) Maximum
14 ºF (-10 ºC) Minimum

5 ft. (2.5 meters) of water column maximum. 11
psia minimum internal pressure (4 psi maximum
vacuum).

PAINT

Powder Coating

3

1.4 PRODUCT CODE

Series G Model G pumps are available in a variety
of different configurations. For a breakdown of the
options included in a specific pump, co mpare the
pump model number and product code found on
the pump nameplate with the model/produ ct code
breakdown shown in Figure 1. A sample name­plate is shown in Figure 2.

Figure 2. Sample Nameplate

4

SECTION 2

WARNING

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 SAFETY PRECAUTIONS

WHEN INSTALLING, OPERATING, AND
MAINTAINING THE SERIES G MODEL 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
TAKING 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).

2.3 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 temperatur e 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 extent possible.

When the instructions given in this section are
completed, the equipment is to be stored shel­tered; protected from direct exposure to weather.

5

The prepared equipment should be co vered 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 Milton
Roy into long term storage, contact Milton Roy to
arrange for factory preparation.

Pump Drive

1. Flood the gearbox compartment 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. Remove drive motor and liquid end, and 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 closed. Contact your distributor or LMI/
Milton Roy Service Department for recommended
VPCI materials.

Support the pump firmly in a level position on a
solid, vibration-free foundation, preferably 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, pump adjustments, and/or oil filling or drain­ing procedures.

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

Some Series G Model G pumps are shipped with
motors dismounted. After anchoring pump in posi­tion, install motor, referring to Figure 7, Sheet 1.

Make sure spring (360) provided with pump is
installed in worm shaft prior to motor installation.

Pumps installed outdoors should be protected by a
shelter.

2.5 PIPING
NPSH Considerations

Size piping to accommodate peak instantaneous
flow. Because of the reciprocating motion of the
pump diaphragm, pump delivery follows an approx­imate sine curve with a peak instantaneous flow pi
(3.14) times the average flow. Therefore, piping
must be designed for a flow 3.14 times the pump
capacity; this means that a pump rated for 88 gal­lons per hour (333.1 L/hr.) requires piping sufficient
for 3.14 x 88 gph, or 276 gph (1044.7 L/ hr.).

2.4 MOUNTING

TO AVOID POSSIBLE DAMAGE TO
EITHER PUMP OR PERSONNEL, BOLT
PUMP DOWN AS SOON AS IT IS IN
POSITION.

Figure 3. Mounting Hole Dimensions

6

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 nearest LMI Distributor to determine the
necessary pipe size.

• Use piping heavy enough to withstand
maximum pressures.

• Remove burrs, sharp edges, and debris
from inside piping. Blow out all pipe lines
before making final connections to pump.

General Piping Considerations

• Use extreme care in piping to plastic liquid
end pumps with rigid pipe such as PVC. If
excessive stresses 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.

• Because vapor in the liquid end will cause
inaccurate pump delivery, piping should be
sloped to prevent 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 4 for a typical recommended
pump installation scheme.

Figure 4. Typical Recommended Pump Installation Scheme

7

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. Installing the supply vessel on
the suction line close to the pump can help
ensure a flooded suction line. (Consult with
your LMI distributor or the LMI/Milton Roy
technical support team for assistance in
such applications.)

• Avoid negative suction pressure conditions
(suction lift), as such conditions adversely
affect metering accuracy. A lift of 8.2 feet
(2.5 meters) of water column is the maxi­mum suction lift permissible.

• 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 ball-checks will give
increased maintenance-free service.
Check strainer frequently to prevent block ­age which could lead to cavitation.

• Keep suction piping as short and straight
as possible.

• Series G Model 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, in these
negative 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 Figure 5).

• When pumping a liquid near its boiling
point (max temp is 125 degrees F), provide
enough suction head to prevent the liquid
from “flashing” into vapor when it enters
the pump liquid end on the suction stroke.

• Piping size should be larger than the liquid
end suction fitting to prevent pump s tarva­tion.

• 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.

Discharge Piping Considerations

• 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
(Max. allowable working 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.
There are a number of ways to create an
artificial pressure, such as by installing a
back pressure valve. (Please contact your
LMI distributor for recommendations to
increase back pressure in slurry applica­tions.)

Figure 5. Suction Lift Installation

• When pumping water-treatment chemicals
directly into boiler drums, use one liquid
end assembly for each boiler drum. Dis-

8

charging 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.

Back Pressure Valves

A Milton Roy Back Pressure Valve (Figure 4)
should be installed in the discharge line near the
pump to ensure sufficient discharge head pressure
for proper pump metering action. 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 closed
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 LMI distributor for further information on
pulsation dampeners.

Safety 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 Milton Roy 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.

Install the safety valve in the discharge line
between the pump and the nearest shut-off valve.
(This will prevent pump damage from accidental
valve closure.) Pipe the safety valve outlet back to
the suction tank or to drain, but in either case
ensure that the pipe end is continuously visible so
safety valve leakage may be detected. Milton Roy
safety valves must be installed at top of supply tank
in order to function properly (see Figure 4).

Check Valves

A check valve should be installed at the point
where the discharge line enters a boiler or other
high-pressure vessel. This will prevent back flow
through the discharge piping and will isolate the
pump discharge from system pressures (a safety
consideration).

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 4 shows recom­mended valve locations.

2.6 LEAK DETECTION

The Series G Model G pumps are equipped with a
leak detection port. For ease of installation, each
pump has a plastic tubing connector installed in the
leak detection port (see item 448 in Figure 7, Sheet

2). In the event of a failure of the oil seal (70 in Fig­ure 7, Sheet 1) or PTFE diaphragm assembly (260
in Figures 8 through 13), pump drive oil or process
fluid will escape from this leakage port. During
pump installation, actions should be t aken to i nsure
that this leakage is safely collected by installing
tubing between the leak detection port and an
appropriate containment vessel.

2.7 ELECTRICAL CONNECTIONS

Ensure that the electrical supply matches the pump
motor nameplate characteristics.

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

9

Before operating the pump, check the direction of
rotation of the motor to be sure it matches the
direction of the arrow stamped on the motor (rota­tion should be clockwise when viewed from the top
of the motor). If motor rotation is incorrect, refer to
the motor data plate or motor manufacturer’s
instructions for reversing.

DO NOT FORGET TO CONNECT THE
PUMP TO AN EARTH GROUND!

Electric protection of the motor (fuses, overload
meters or relays) should correspond to the rated
current indicated on the motor data plate.

10

SECTION 3

WARNING

OPERATION

3.1 INITIAL START-UP

FAILURE TO CHECK TORQUE ON NON­METALLIC 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:

(1) Liquid End Size SG5 and SG6 non-metallic

head bolts to 90 inch pounds.

(2) Liquid End Size SG7 non-metallic head

bolts to 125 inch pounds.
Check that all mounting bolts are tight, piping is

installed properly, and the discharge line is open.
Check oil drain plug for tightness. Remove the oil

fill cap and fill the pump casing until level is
between the markings on the oil fill cap dipstick,
(approximately 3 quarts (2.8 Liters)).

NOTE: The oil furnished with the pump is
grade AGMA No. 5 EP with a viscosity of 1000
SSU at 100°F (218.4 cSt at 40°C). For opera­tion in ambient temperatures below 50°F
(10°C), substitute AGMA No. 2 EP with a vis­cosity of 400 SSU at 100°F (86.4 cSt at 40°C).
Manufacturers' equivalent oils are shown
below.NOTE:

ABOVE 50°F

Chevron
Exxon
Mobil
Texaco
Shell

................. N.L. Gear Compound 220

.................... Spartan E.P. 220

...................... Mobilgear 630

................ ... Meropa 220

...................... Omaha 220

BELOW 50°F

Chevron

................. N.L. Gear Compound 68

Exxon

.....................Spartan E.P. 68

......... ... ... ... ... .Mobilgear 626

Mobil
Texaco
Shell

.................. .Meropa 68

...................... .Omaha 68

BEFORE SWITCHING ON POWER TO
THE PUMP, TURN THE CAPACITY
ADJUSTMENT KNOB TO ZERO. CHECK
THAT ALL SHUT-OFF VALVES IN THE
SUCTION AND DISCHARGE LINES ARE
OPEN BEFORE INCREASING THE
CAPACITY ADJUSTMENT FROM ZERO.

DO NOT TRY TO ADJUST PUMP
CAPACITY BELOW O% OR ABOVE
100% OR DAMAGE TO PUMP MAY
OCCUR. KEEP ADJUSTMENT KNOB
BETWEEN 0 AND 100 %.

Manual Capacity Control

To adjust pump capacity, loosen the stroke locking
knob (320, Figure 7, Sheet 2) located in the pump­side cover. Pump capacity is adjusted by turning
the micrometer type stroke adjustment knob (330)
clockwise to decrease capacity or counterclock­wise to increase capacity as required. The adjust­ment scale is marked in percent (%) of full stroke,
with calibration lines on the knob at 1% intervals.
After adjusting the knob to the desired capacity set­ting, hand tighten the stroke locking screw to main­tain the capacity setting.

Filling Pumping System

It is especially important that pump suction and dis­charge lines be free of entrained air. To ensure this
condition, operate the pump without any discharge
pressure and fill the entire pumping system with liq­uid before starting pressure tests. A simple method
to assure priming of the pump is to install a tee an d
a shut-off valve at the discharge connection of the
pump.

11

If the pump is idle for long periods, temperature
changes in the process liquid may produce air in
the system. To discharge the air, install a valve in
the discharge line which will allow the process liq­uid to be pumped to exhaust when starting the
pump.

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. Milton Roy test-tube Calibration Col-

umns are available for convenient and accurate
calibration of any pump.

THE FOLLOWING METHOD IS NOT
GENERALLY RECOMMENDED AS IT
MAY EXPOSE OPERATING PERSON­NEL TO HAZARDOUS LIQUIDS. FUTH­ERMORE, THE PUMP MAY OVER PUMP
DRAMATICALLY AND THE POSITION
OF THE CAPACITY ADJUSTMENT
KNOB MAY HAVE LITTLE EFEECT ON
MEASURING FLOW RATE.

The pump can also be calibrated by collecting and
measuring pumped liquid at the pump discharge
port. It may be necessary to create discharge head
at the liquid takeoff point so that the pump will
operate properly. (See Section 2 for recommended
ways to do this.)

12

SECTION 4

MAINTENANCE

4.1 SPARE PARTS

To avoid excessive downtime in the event of a
parts malfunction, the spare parts shown below
should be stocked for each pump to pre vent seri­ous delays in repairs. Refer to Figures 8–14 and
the accompanying parts lists. For your conve­nience, these parts can be purchased either sepa­rately or packaged in the form of Routine
Preventive Maintenance (RPM) Kits. RPM kit
numbers are listed in Section 1.

RPM kit numbers RPM019 through RPM030 con­tain pre-assembled diaphragms, oil seal and check
valve parts. Cap piece (240), set screw (250), dia­phragm (260), and support nut (270) is pre-assem­bled in kits RPM019 through RPM030. A spanner
wrench, which may not always be available in the
field, is required to disassemble the diaphragm
assembly.

RPM Kits RPM045 through RPM053 and RPM126,
through RPM220 contain a diaphragm, oil seal,
and check valve parts. Series G Model G pumps
built with the latest design do not need a spanner
wrench to disassemble the diaphragm assembly.
The diaphragm assembly can be disassembled
with a 30mm socket (Section 4, paragraph 4.4. 2).
The diaphragm can then be replaced.

All Other Liquid Ends

(1) Diaphragm (260)
(2) Oil Seal (70)
(3) Seat, O-Ring, Ball Set (423)
(See parts list)

Parts orders must include the following:

1. Quantity required

2. Part number

3. Part description

4. Pump serial number (found on nameplate)

5. Pump model number (found on nameplate)

6. Pump product code (found on nameplate)
Always include the serial number, model number,

and product code in all correspondence regarding
the unit.

Drive Worms and Gears

Either type of kit can be used for your pump. The
user must decide which type is better for them.
When ordering RPM Kits RPM045 through
RPM053 for an old style pump, where a spanner
wrench is required to disassemble the diaphragm
assembly, order a new hex head support nut (270)
with the RPM kit. Future maintenance on the Mac­roy pump will not require a spanner wrench.

SG5, Metallic Liquid End

(1) Diaphragm (260)
(2) Oil Seal (70)
(3) Check Valve Assemblies (425)
(See parts list)

Worms (Fig 7, Item 342) and gears (50) must be
sold in sets to assure proper operation.

4.2 SHIPPING PUMPS FOR REPAIR

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

13

ous residue in pump liquid end. A Materials
Safety Data Sheet must accompany a ll returns.

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

4.3 PREVENTIVE MAINTENANCE

LMI pumps are carefully designed, m anufactured,
assembled, and quality tested to give reliable ser­vice with minimal maintenance. However, a weekly
maintenance check is recommended to visually
confirm proper operation of the pump.

Drive

Inspect the ball check and seat for chemical or
physical damage. The ball should be perfectly
round and free of pits, mars, or scratches. The seat
should retain a sharp edge where the ball contacts
for proper sealing. If the seat edge is worn or dam­aged, or has any pits, mars, or scratches, it should
be replaced. If the ball and/or seat is excessively
damaged, the replacement schedule should be
shortened accordingly. If the ball and seat are both
in good condition, the replacement schedule can
be lengthened.

Complete instructions for replacing worn check
valve parts are given in the “Corrective Mainte­nance” section.

Initially, change gear drive oil after the first 250
hours of operation. Then change drive oil after
every 4000 hours of operation or every six months,
whichever comes first. Refer to “Initial Start-up” in
Section 3, Operation, for information on recom­mended oil and oil capacity.

NOTE: When adding oil, pour in a thin, slow
stream to avoid overflow.

Diaphragm Assembly

The Series G Model G diaphragm assembly should
be replaced every 4000 hours of operation to avoid
the possibility of failure. Refer to the instructions in
the “Corrective Maintenance” section.

Oil Seal

The Series G Model G oil seal should be replac ed
every 4000 hours of operation to avoid the possibil­ity of failure. Oil seal replacement requires the
removal of the diaphragm assembly, so it is recom­mended that the oil seal and diaphragm be
replaced at the same time. Refer to the instructions
in the “Corrective Maintenance” section.

Check Valves

4.4 CORRECTIVE MAINTENANCE

BEFORE CARRYING OUT ANY SERVIC­ING OPERATION ON THE METERING
UNIT OR PIPES, DISCONNECT ELEC­TRICAL POWER FROM THE PUMP,
AND TAKE THE NECESSARY STEPS
TO ENSURE THAT THE HARMFUL LIQ­UID THEY CONTAIN CANNOT ESCAPE
OR COME INTO CONTACT WITH PER­SONNEL. SUITABLE PROTECTIVE
EQUIPMENT MUST BE PROVIDED.
CHECK THAT ALL PRESSURE HAS
BEEN BLED FROM THE PUMP DRIVE
AND PUMP LIQUID END BEFORE PRO­CEEDING WITH DISMANTLING.

Cleaning Fouled Check Valves

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.

LMI recommends that check valve balls, seats,
gaskets, and o-rings be replaced on a annual
basis. If highly corrosive material (acids, slurries,
etc.) is being pumped, some applications may
require more frequent replacement.

To determine if check valves need maintenance,
disassemble the check valves following the instruc­tions in the “Corrective Maintenance” section.

4.4.1 Check Valve Replacement

General

Before beginning work on the valve assemblies,
make sure the shut-off valves are closed and that
pressure has been bled from the system. When
replacing the valves, take care to systematically
change their O-rings and/or gaskets. Take care to

14

properly assemble the valve assemblies; the ball
must be placed on the sharp edge of the seats.

Check valves are supplied in four different configu­rations: plastic, stainless steel, slurry, and polymer.
Be sure to refer to the appropriate instructional set
below.

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
SEVERE DAMAGE TO PUMP MECHA­NISM, (B) NO PUMPING, (C) REVERSE
PUMPING ACTION (FROM DISCHARGE
LINE INTO SUCTION LINE).

4.4.1.1 Plastic Check Valves (PVC, PVDF,
Polypropylene, and Sulfuric Acid Service, Fig.
14A or 14C):

Disassembly

Check pump data plate for model number.

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.

2. Unscrew the ball guide (424) from the liquid
end.

3. Screw the union nut part way (one or two
turns) onto the end of the ball guide 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 onto 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).

IF YOU ARE DISASSEMBLING UNIT
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.

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

6. Carefully remove the two or three o-rings (de­pending on model number) from the ball guide and
seat.

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

1. Fit new o-rings into position on the ball guide
and seat.

NOTE: To assure a tight, leak free seal, new
o-rings should be used each time the check
valves are disassembled.

2. Drop the ball into the curved inner chamber
end of the ball guide.

IF THE SEAT IS IMPROPERLY POSI­TIONED, THE BALL WILL NOT CREATE
A TIGHT SEAL AND POOR PUMPING
PERFORMANCE WILL RESULT.

3. Set the ball guide on a flat surface so that the
side with the ball faces upwards. Position seat on
the ball guide, trapping the ball inside. When the
seat is pressed into the ball guide, the beveled
edge of the seat must be facing outward. The

15

bevel should not face the inside of the check valve
(refer to Figure 14A or 14C). Use a flat surface
such as a board to press the seat into the ball
guide with firm, even pressure.

THE ORDER OF ASSEMBLY AND ORI­ENTATION OF THE SUCTION AND DIS­CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 8, 10,
12, 14A, AND 14C 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,
(C) REVERSE PUMPING ACTION
(FROM DISCHARGE LINE INTO SUC­TION LINE).

4. Position the union end (445) onto the correct
end of the ball guide. Refer to Figure 14A or 14C,
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 ball guide.

5. Screw the valve assembly into the liquid end
body (hand tight only). DO NOT OVER

TIGHTEN.

4.4.1.2 Models SG6 & SG7 Liquid Ends - Stain­less Steel Check Valves (Figure 14D):

Disassembly

ensure that they are compatible with the process
liquid.

Reassembly

1. Drop the ball into the curved inner chamber
end of the ball guide.

DO NOT REUSE OLD GASKETS (419).
EVEN IF BALL AND SEAT ARE NOT
WORN AND DO NOT NEED REPLAC­ING, NEW GASKETS MUST BE USED
ANY TIME THE CHECK VALVES ARE
DISASSEMBLED.

2. Place a new gasket on the rim of the ball guide
(424), and sit the seat on top of the ball guide, trap­ping the ball and gasket between the seat and ball
guide.

THE ORDER OF ASSEMBLY AND ORI­ENTATION OF THE SUCTION AND DIS­CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 11, 13,
AND 14D 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, (C) REVERSE
PUMPING ACTION (FROM DISCHARGE
LINE INTO SUCTION LINE).

1. Unscrew the three screws (441 & 442) and
remove them and their three washers (439).

2. Remove the valve clamp (437).

3. The connection (435), seat (420), ball (422)
and ball guide (424) should all now slip apart eas­ily.

4. Remove and discard the three gaskets (419).

5. Carefully clean any parts to be reused. If any
chemicals are used in the cleaning process,

3. Position the connection (435) onto the correct
end of the ball guide with a gasket trapped
between the two metal surfaces. Refer to Figure
14D, as the correct end is determined by whether
the valve is intended for the suction or discharge
port of the liquid end.

4. Position the check valve assembly onto the liq­uid end, trapping a gasket between the two metal
surfaces (seat and pump head).

5. Slide the valve clamp (437) over the connec­tion (435) and screw into the liquid end using the

16

three screws (441,442) and their split washers
(439). Since one screw (441) is shorter than the
others, be sure that it is screwed into t he appropri­ate hole.

4.4.1.3 Model SG5 Liquid End - Stainless Steel
Check Valve (Fig. 14B):

Disassembly

SG5 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 ball guide (424) from the liquid
end.

3. Remove and discard the o-rings (419).

4. 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

NOTE: To assure a tight, leak free seal, new
o-rings 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, 423)
between the coupling and the check valve assem­bly.

4.4.1.4 Model SG5 Liquid End - Slurry Service
Check Valves, use until 1 June 2008 (Fig. 14E) :

Replacement

THE ORDER OF ASSEMBLY AND ORI­ENTATION OF THE SUCTION AND DIS­CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 8 AND
14E 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, (C) REVERSE PUMPING
ACTION (FROM DISCHARGE LINE INTO
SUCTION LINE).

1. Unscrew the coupling (445).

THE ORDER OF ASSEMBLY AND ORI­ENTATION OF THE SUCTION AND DIS­CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 9 AND
14B 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, (C) REVERSE PUMPING
ACTION (FROM DISCHARGE LINE INTO
SUCTION LINE).

1. Screw the correct end of the check valve
assembly into the liquid end (refer to Figure 14B),
trapping a new o-ring between the liquid end and
the check valve assembly.

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

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

4. Clean the new valve assembly and threaded
port in the head (280).

NOTE: To assure a tight, leak free seal, new
o-rings should be used each time the check
valves are disassembled.

5. Screw correct end of check valve assembly into
liquid end (refer to Figure 14E), trapping a new o­ring (419) between liquid end and check valve
assembly.

17

6. Screw coupling (445) on to check valve asse m­bly, trapping a new o-ring (419) between coupling
and check valve assembly.

4.4.1.5 Models SG5, SG6 & SG7 Liquid End ­Slurry Service Check Valves (Figure 14E &
14G):

Replacement

new o-ring (419) between liquid end and check
valve assembly.

8. Screw coupling (445) onto check valve assem­bly, trapping a new o-ring (419) between coupling
and check valve assembly.

4.4.1.6 Models SG5, SG6 & SG7 Liquid End ­Polymer Service Check Valves (Figure 14F):
Replacement

Suction

THE ORDER OF ASSEMBLY AND ORI­ENTATION OF THE SUCTION AND DIS­CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 14G
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, (C) REVERSE PUMPING
ACTION (FROM DISCHARGE LINE INTO
SUCTION LINE).

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

2. Remove the valve assembly (425): assembly
includes ball (421 or 422), seat (420), retain pin
(428, SG5 only), valve body (424), and two (SG5)
or three (SG6 & SG7 O-rings (419).

3. Remove and discard o-rings (419), seat (420)
and ball (421 or 422).

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

Follow the instruction for replacement of ball, seat,
& seal: liquid end SG6 and SG7 - plastic check
valves paragraph 4.4.1.1. The procedures are the
same.

Discharge

1. Unscrew valve body (425) from pump head
(280).

2. Remove valve assembly: assembly includes
two O-rings (419), seat (420), ball (422), poppet
(426), spring (423) and check valve body (425).

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

4. Clean valve body (425) and threaded port in
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 OVERTIGHTEN

.

5. Place a new O-ring (419) around seat (420).
Place new seat (420) and new ball (421 or 422)
inside valve body (424).

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

NOTE: To assure a tight, leak free seal, new
o-rings should be used each time the check
valves are disassembled.

7. Screw correct end of chec k v alv e ass em b ly in to
liquid end (refer to Figure 14E or 14G) , trapping a

4.4.2 Diaphragm Replacement

BEFORE BEGINNING DIAPHRAGM
REPLACEMENT, MAKE SURE THAT
ALL SHUT-OFF VALVES ARE CLOSED
AND ALL PRESSURE IS BLED FROM
THE LIQUID END. MAKE SURE POWER
TO PUMP IS TURNED OFF AND CAN­NOT BE ACTIVATED.

18

It is recommended that the oil seal and diaphragm
be replaced at the same time. The instructions
given under “Replacing the Oil Seal” are com plete
instructions for replacing both th e oil seal and dia­phragm. If you plan to replace both, refer to the
“Replacing the Oil Seal” instructions, and disregard
the instructions below. These instructions are
intended for use only if the diaphragm is being
replaced independent of the oil seal.

4.4.2.1 Diaphragm Removal (All types; Refer to
Figures 6-13)

1. Set the stroke adjusting knob to 100%.

2. Disconnect the suction and discharge piping.

3. Unscrew the six diaphragm head bolts (290).

4. Remove the pump head (280) from the pump
body.

5. Turn the motor fan by hand (remove the motor
shroud if necessary) until the end of the diaphragm
(240) is fully forward, and unscrew the diaphragm
assembly from the connecting rod (60).

4.4.2.2 Disassembly (Only Those Units With a
“Hex Head “ Diaphragm Cap Design, Figure 6)

1. Secure the hex cap (240) in a vise, and loosen
the support nut (270) using a 30mm hex socket.

2. After complete disassembly inspect the sup­port nut (270). It should be free of corrosion and
clean. The angled surface must be smooth to pro­tect the diaphragm from damage. If the support
nut does not meet these requirements, replace it.

4.4.2.3 Reassembly

1. Mount the hex cap (240) in a vise (do not over­tighten), and with surfaces cleaned place a new
diaphragm (260) onto the cap as shown Figure 6
through Figure 13 (convolution pointing toward the
support nut).

2. The set screw (250) hand tight in the cap (240)
with the hex socket end visible.

3. Screw the support nut (270) onto the set screw
until hand tight

4. DO NOT OVERTIGHTEN the support nut.
Use a 30mm hex socket and torque wrench to
tighten the support nut. The torque depends on
pump model number.

Figure 6. Diaphragm Assembly

• For model numbers SG5 & SG6: Torque is
20 foot pounds.

• For model number SG7: Torque is 30 foot
pounds.

4.4.2.4 Reinstallation of Assembly (Refer to
Figures 6 Through 13)

1. With the stroke adjusting knob at 100% and
the diaphragm fully forward as in steps 1 and 5 of
paragraph 4.4.2.1, screw the diaphragm assembly
into the connecting rod until it reaches its natural
mechanical stop.

2. Turn the motor fan by hand until the diaphragm
rests properly on the diaphragm support (230).
Reinstall the motor shroud if previously removed.

3. Fit the diaphragm head back into place on the
pump body.

19

4. Torque the six diaphragm head bolts to the fol­lowing inch pounds in a crisscross pattern:

diaphragm from the connecting rod (60), using a
30mm hex socket on diaphragm cap (240).

(1) Liquid End Size SG5 and SG6 metallic and

non-metallic head bolts to 90 inch pounds.

(2) Liquid End Size SG7 non-metallic head

bolts to 125 inch pounds.

(3) Liquid End Size SG7 metallic head bolts to

250 inch pounds.

4.4.3 Replacing Oil Seal

BEFORE BEGINNING OIL SEAL
REPLACEMENT, MAKE SURE THAT
ALL SHUT-OFF VALVES ARE CLOSED
AND ALL PRESSURE IS BLED FROM
THE LIQUID END. MAKE SURE POWER
TO PUMP IS TURNED OFF AND CAN­NOT BE ACTIVATED.

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. Therefore,
the instructions below include the “Diaphragm
Replacement” instructions, and can be used for
both oil seal replacement and diaphragm replace­ment.

Disassembly (Refer to Figure 6 through 13).

1. Drain oil from the pump by unscrewing drain
plug and O-ring, located underneath capacity
adjustment knob (330).

7. Remove the diaphragm support ring (230).

8. Remove the retaining ring (220) from the con­necting rod.

9. Slide the small oil seal clamp (210) off the
connecting rod.

10. Remove the large oil seal clamp (80) by
unscrewing the four slotted screws (90).

11. Pull the oil seal (70) off of the connecting rod.

Reassembly (Refer to Figure 6 through 13).

1. Install a new oil seal (70) onto the connecting
rod.

2. Slide small oil seal clamp (210) onto the end of
the connecting rod and secure in place with the
retaining ring (220). A drive socket large enough to
fit over the end of the connecting rod should be
used to push the retaining ring until it snaps into
place in the retaining ring groove in the connecting
rod.

3. Secure the large oil seal clamp (80) over the oil
seal with the four slotted screws (90).

4. Place the diaphragm support ring (230) into
position making sure beveled side (for diaphragm
support) is facing up (refer to Figure 6 through 13).
For SG7 liquid ends, the support ring (230) has
stepped diameters. Make sure that the larger
diameter is installed into the metal adapter ring
(225 Figure 12 and 13).

2. Set the capacity adjusting knob (330) to 100%.

3. Disconnect the suction and discharge piping.

4. Unscrew the six diaphragm head bolts.

5. Remove the diaphragm head assembly from
the pump body.

6. Turn the motor fan by hand (remove the
shroud if necessary) until the end of the diaphragm
assembly (240) is fully forward, and unscrew the

5. With the stroke adjusting knob at 100% and
the diaphragm fully forward as in steps 2 and 6 of
disassembly instructions, screw the diaphragm
assembly into the connecting rod until it reaches its
natural mechanical stop.

6. Turn the motor fan by hand until the diaphragm
rests properly on the diaphragm suppor t r ing ( 230 ).
Reinstall the motor shroud if previously removed.
With the stroke adjusting knob at 100% and the
diaphragm fully forward as in steps 2 an d 6 of dis­assembly instructions, screw the diaphragm
assembly into the connecting rod until it reaches its
natural mechanical stop.

20

7. Fit the diaphragm head back into place on the
pump body.

8. Torque the six diaphragm head bolts to the fol­lowing inch pounds in a crisscross pattern:

(1) Liquid End Size SG5 and SG6 metallic and

non-metallic head bolts to 90 inch pounds.

(2) Liquid End Size SG7 non-metallic head

bolts to 125 inch pounds.

(3) Liquid End Size SG7 metallic head bolts to

250 inch pounds.

4. Add oil to pump, following directions given in
“Initial Start-up” in Section 3.

21

SECTION 5

TROUBLESHOOTING GUIDE

SYMPTOMS REMEDIES

Pump will not operate • Low process liquid level in the tank. Add liquid

• Worn or dirty check valves. Clean or replace.

• Blocked discharge line. Clear line.

• Frozen liquid. Thaw liquid throughout pumping system.

• Blown fuse. Replace fuse.

• Open thermal overload device in motor starter. Reset
device

• Broken wire. Locate and repair.

• Low voltage. Investigate and correct (wiring may be too
light).

• Pump not primed. Allow suction line and pump head to fill
with liquid before pumping against pressure. Refer to
“Filling Pumping System” in Section 3.

• Capacity adjustment set at zero. Readjust capacity.

Insufficient delivery • Incorrect capacity adjustment. Readjust capacity setting.

• Incorrect pump seed. Match live voltage and frequency to
pump motor data plate.

• Starved suction. Increase piping size or suction head.

• Leaky suction piping. Repair piping.

• High suction lift. Rearrange equipment to decrease lift.

• Liquid near boiling. Cool liquid or increase suction head.

• Leaky safety valve in discharge line. Repair or replace
safety valve.

• High liquid viscosity . Reduce viscosity (e.g., heat or dilute
liquid).

• Worn or dirty check valve seats. Clean or replace.

Erratic delivery • Leaky suction piping. Repair piping.

• Leaky safety valve. Repair or replace safety valve.

• Insufficient suction head. Raise suction tank level or pres­surize tank.

• Liquid near boiling. Cool liquid or increase suction head.

• Worn or dirty check valves. Clean or replace.

• Clogged or dirty line strainer. Clean strainer.

Motor and pump body hot • Normal operating temperat ur e 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 is being operated at greater than rated perfor­mance. Reduce pressure or stroke speed. If this is not
practical, contact service facility.

• Pump improperly lubricated. Drain oil and refill with
proper amount of recommended lubricant.

22

SYMPTOMS REMEDIES

Pump still pumps even at zero capac­ity setting

Gear noise • Excessive backlash. Consult service facility.

Loud knock with each stroke • Excessive gear set wear. Consult service facility.

Noisy operation in liquid end • Nosie in check valves. Ball chec ks mo ve up and do wn

• Improperly adjust micrometer knob. Readjust capacity
setting.

• Insufficient discharge pressure. Correct condition (e.g.,
install a back pressure valve).

• Worn bearings. Consult service facility.

• Wrong or insufficient lubricant. Replace or replenish lubri­cant.

• Worn bearings. Consult service facility.

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

23

SECTION 6

PARTS

6.1 GENERAL

This section gives information regarding replace­able components.

6.2 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. Part Number Column
a) The supplier’s part number is listed in the

part number column.

4. Quantity Column
a) The numbers appearing in the quantity col-

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

5. 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 “A1”, “B1”, “C1”,
etc. is entered in this column, the part is
used only in the model (liquid end and
material codes, see Figure 1 and pump
data plate) at which the symbol appears. If
the column is blank, the part is used in all
models.

24

Figure 7 (Sheet 1 of 2). Series G Model G Drive Parts - Side View

25

6.3 DRIVE, SIDE VIEW

FIGURE

NUMBER

7 40 Bearing Cup (Timken) 4090116050 1

ITEM

NUMBER

60 Connecting Rod S60654 1
70 Oil Seal, Buna N 60048 1
80 Oil Seal Clamp, Aluminum 60034 1
90 Slotted Pan Head Screw, M3x10,

304 SS
340 Bearing Cone (Timken) (See Note 1) 4090116040 1
342 Worm, 8:1 (See Note 1) S60198 1
342 Worm, 10:1 (See Note 1) S60195 1
342 Worm, 14:1 (See Note 1) S60828 1
342 Worm, 20:1 (See Note 1) S60196 1
342 Worm, 40:1 (See Note 1) S60197 1

- Worm Assembly (43 SPM, 56C, 40:1),
Gear S60011 (See Note 1)

- Worm Assembly (36 SPM, IEC 80
Frame, 40:1), Gear S60011 (See Note

1)

DESCRIPTION PART

NUMBER

60294 4

60397 1

60224 1

QTY REFERENCE

CODE

344 Spring Pin, 0.187 x 1-1/8 STL (See

346 Worm Shaft Coupling, 56C (See Note

346 Worm Shaft Coupling, IEC 71 (See

- Items not shown

- Worm Assembly (86 SPM, 56C, 20:1),
Gear S60009 (See Note 1)

- Worm Assembly (72 SPM, IEC 80
Frame, 20:1), Gear S60009 (See Note

1)

- Worm Assembly (173 SPM, 56C, 10:1),
Gear S60007 (See Note 1)

- Worm Assembly (144 SPM, IEC 80
Frame, 10:1), Gear S60007 (See Note

1)

- Worm Assembly (180 SPM, IEC 80
Frame, 8:1), Gear S60050 (See Note 1)

Note 1)

1)

Note 1)

60396 1

60223 1

60395 1

60222 1

60221 1

4010005101 1

60261 1

60260 1

26

7 346 Worm Shaft Coupling, IEC 80 (See

Note 1)

360 Spring (56C) (See Note 2) 60264 1
360 Spring (IEC 80) (See Note 2) 60225 1
370 Vent with Dip Stick 70067 1
376 IEC 80 Motor Adapter Ring 60199 1
377 Hex Head Screw, M10 x 25MM Steel

(IEC 80 motor)

60194 1

4350001732 4

390 Motor (1 hp, 1 ph, 1800 rpm, 115/230,

60 hz, 56C)

390 Motor (1 hp, 3 ph, 1500 rpm, 220/380,

50 hz, 56C)

390 Motor ( 1hp, 3 ph, 1800 rpm, 230/460,

60 hz, 56C)

390 Motor (1 hp, 1750 rpm, 90 VDC, PM-

TEFC-56C)

390 Motor (1 hp, W/VAR SPD AC Drive) 60297 1
400 Hex Head Screw (3/8-16 x 1) (56C

motor)

400 Hex Head Screw (M10 x 25 mm) (IEC

80 motor)

410 Flat Washer (3/8) (56C motor) 4040009012 4
410 Flat Washer (M10) (IEC 80 motor) 4340005152 4
417 Caution, Motor Decal G 60148 1
450 Base 61266 1
460 Hex Head Screw (M8 x 35 mm) 4350035542 4
465 Spring Lock Washer (8 mm) 4340009002 4
470 Hex Nut (M8) 4350000042 4

4112008010 1

4112008315 1

4112008310 1

4112008610 1

4050018119 4

4350001732 4

- Items not shown
Note 1: Worm-Gear-Shaft Assembly includes gear (50) worm (342), spring pin (344), spring (360),

worm shaft coupling (346), and bearing cone (340). Gear (50) and worm (342) sold only as assembly
(343)

Note 2: Part number for 56C motor spring (60264) applies to two-piece worm assembly: worm and
motor coupling piece joined together by a spring pin (344). If worm is previous one-piece design (no
spring pin), the correct 56C motor spring part number is 60059.

27

Figure 7 (Sheet 2 of 2). Series G Model G Basic Parts - Top View

28

6.4 DRIVE, TOP VIEW

FIGURE

NUMBER

7 10 Drive Housing Assembly (Includes

ITEM

NUMBER

Items 30, 40, and 448))

10 Housing, Stroke Counting (Includes

Items 30, 40, and 448)
30 Thrust Bearing, Bronze 60014 1
50 Gear (36/43 SPM), 50 Hz/60 Hz (See

Note 1)
50 Gear (72/86 SPM), 50 Hz/60 Hz (See

Note 1)
50 Gear (103/123 SPM), 50 Hz/60 Hz (See

Note 1)
50 Gear (144/173 SPM), 50 Hz/60 Hz (See

Note 1)
50 Gear (180 SPM), 50 Hz (See Note 1) S60050 1

100 Sliding Crank 60002 1
101 Spring Pin, 0.125 x 1/2 4010003031 1
110 Eccentric, Steel 60003 1
110 Eccentric, Stroke Counting 60875 1

DESCRIPTION PART

NUMBER

60001 1

60877 1

S60011 1

S60009 1

S60829 1

S60007 1

QTY REFERENCE

CODE

120 Shoe 60052 1
140 Single Row Bearing 4099994000 1
150 Truarc Retaining Ring 4040107231 1
160 Parker O-ring, Buna N 4080095171 1
170 Stroke Adjustment Screw Asse mbly 60950 1
171 Stroke Screw, Part of Item 170 H60768 1
172 Bearing Retainer, Part of Item 170 H60757 1
174 Socket Head Screw M4 x 8MM, part of

175 Stroke Scale 2530046062 1
185 Dowel Pin 1/8 x 1-3/8, Part of Item 170 4010021143 1
190 Parker O-ring (2-246), Buna N 4080095371 1
200 Cover H60767 1
205 Hex Head Screw (M8 x 16 mm) 4350001622 4
210 Oil Seal Clamp, Aluminum 60043 1
220 Truarc Retaining Ring 4040133060 1

- Items not shown.

41663 4

item 170

29

7 - M12 Lockwasher, 18-8 SS 4340009095 6

- M12 Hex Nut, 304 SS 4350000085 6
310 Ball 5/16, Nylon 60152 1
320 Stroke Locking Knob 60398 1
322 O-Ring, 2-012 Bunan N 4080109091 1
330 Stroke Adjustment Knob 70066 1
331 Flat Washer 1/4”, 18.8 SS 4040005012 1
332 Pan Head Screw #8 x 1-1/2”, 18.8 SS 40722 1
335 Logo Decal (Stroke Knob) 70022 1
448 Tubing Connector (1/4” OD x 1/4” ID) 4020479028 1

- Gear Oil (AGMA 5 EP, ZURN EP95) - 1

Quart Can

- Items not shown.
Note 1: Worm-Gear-Shaft Assembly includes gear (50) worm (342), spring pin (344), spring (360),

worm shaft coupling (346), and bearing cone (340). Gear (50) and worm (342) sold only as assembly
(343)

Note 2: Part number for 56C motor spring (60264) applies to two-piece worm assembly: worm and
motor coupling piece joined together by a spring pin (344). If worm is previous one-piece design (no
spring pin), the correct 56C motor spring part number is 60059.

4070152010 3

30

Figure 8. SG5 Plastic Liquid End

31

6.5 SG5 PLASTIC LIQUID END

Model:
Liquid End: Material: Reference Code:
SG5_ _ _ _ _ _8_ _ _ _ _ _ A (PVC)
SG5_ _ _ _ _ _1_ _ _ _ _ _ B (POLY)
SG5_ _ _ _ _ _2_ _ _ _ _ _ C (PVDF)

Model:
Liquid End: Material: ReferenceCode:
SG5_ _ _ _ _ _ P_ _ _ _ _ E (POLYMER)
SG5_ _ _ _ _ _ L_ _ _ _ _ F (SLURRY)
SG5_ _ _ _ _ _ N_ _ _ _ _G (H

2SO4

)

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

8 230 Diaphragm Support Ring 60035 1

240 Diaphragm Cap, Part of Item 261 60628 1 A, E, F, G
240 Diaphragm Cap, Part of Item 261 60629 1 B
240 Diaphragm Cap, Part of Item 261 60630 1 C
250 Set Screw, Dog Pt., M10 x 45 mm, Sin-

4350071284 1 A, B, C, E

gle Diaphragm, Part of Item 261
260 Diaphragm, Part of Item 261 60618 1
261 Diaphragm Assy , (Replaceable Design ,

60150 1 A, E, F, G

Consists of Items 240, 250, 260, and

270), See Note 1

261 Diaphragm Assembly, (Replaceable

3050976110 1 B
Design, Consists of Items 240, 250,
260, and 270), See Note 1

261 Diaphragm Assy , (Replaceable Design ,

3050976130 1 C
Consists of Items 240, 250, 260, and

270), See Note 1

270 Diaphragm Support Nut, Part of Item

60632 1

261

280 Diaphragm Head, PVC 60033 1 A, E, F, G

QTY REFERENCE

CODE

280 Diaphragm Head, PP 60032 1 B
280 Diaphragm Head, PVDF 60031 1 C
290 Hex Head Screw, M8 x 90, Single Dia-

4350035655 6 A, B, C
phragm

290 Hex Head Screw, M8 x 110, Double

4350001655 6 A, B, C
Diaphragm

300 Flat Washer (M8) 4340005085 6
300 Back-up Plate SG5/SG6 60754 1 B

Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.

32

Figure 9. SG5 Metallic Liquid End

33

6.6 SG5 METALLIC LIQUID END - STAINLESS STEEL- NPT

Model:
Liquid End: Material:
SG5_ _ _ _ _ _7_ _ _ _ _ _

FIGURE

NUMBER

9 230 Diaphragm Support Ring 60035 1

ITEM

NUMBER

240 Diaphragm Cap, Part of Item 261 60631 1
250 Set Screw, Dog Pt., M10 x 45 mm, Sin-

gle Diaphragm, Part of Item 261

260 Diaphragm, Part of Item 261 60618 1
261 Diaphragm Assy , (Replaceable Design ,

Consists of Items 240, 250, 260, and

270), See Note 1

270 Diaphragm Support Nut, Part of Item

261

280 Diaphragm Head 210760016 1
290 Hex Head Screw, M8 x 90, Single Dia-

phragm

300 Flat Washer (M8) 4340005085 6

DESCRIPTION PART

NUMBER

4350071284 1

3050976120 1

60632 1

4350035655 6

QTY REFERENCE

CODE

Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.

34

Figure 10. SG6 Plastic Liquid End

35

6.7 SG6 PLASTIC LIQUID END

Model:
Liquid End: Material: ReferenceCode:
SG6_ _ _ _ _ _8_ _ _ _ _ _ A (PVC)
SG6_ _ _ _ _ _1_ _ _ _ _ _ B (POLY)
SG6_ _ _ _ _ _2_ _ _ _ _ _ C (PVDF)

Model:
Liquid End: Material: ReferenceCode:
SG6_ _ _ _ _ _ P_ _ _ _ _ E (POLYMER)
SG6_ _ _ _ _ _ L_ _ _ _ _ F (SLURRY)
SG6_ _ _ _ _ _ N_ _ _ _ _G (H

2SO4

)

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

10 230 Diaphragm Support Ring 60070 1

240 Diaphragm Cap, Part of Item 261 60633 1 A, E, F, G
240 Diaphragm Cap, Part of Item 261 60634 1 B
240 Diaphragm Cap, Part of Item 261 60635 1 C
250 Set Screw, Dog Pt., M10 x 45 mm, Sin-

4350071284 1

gle Diaphragm, Part of Item 261
260 Diaphragm, Part of Item 261 60624 1
261 Diaphragm Assy , (Replaceable Design ,

60151 1 A, E, F, G

Consists of Items 240, 250, 260, and

270), See Note 1

261 Diaphragm Assembly, (Replaceable

3050976090 1 B
Design, Consists of Items 240, 250,
260, and 270), See Note 1

261 Diaphragm Assy , (Replaceable Design ,

3050976230 1 C
Consists of Items 240, 250, 260, and

270), See Note 1

270 Diaphragm Support Nut, Part of Item

60637 1

261

280 Diaphragm Head, PVC 60130 1 A, E, F, G
280 Diaphragm Head, PP 60883 1 B

QTY REFERENCE

CODE

280 Diaphragm Head, PVDF 60068 1 C
290 Hex Head Screw, M8 x 90, Single Dia-

4350035655 6
phragm

300 Flat Washer (M8) 4340005085 6
300 Back-up Plate SG5/SG6 60754 1 B

Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.

36

Figure 11. SG6 Metallic Liquid End

37

6.8 SG6 METALLIC LIQUID END - STAINLESS STEEL - NPT

Model:
Liquid End: Material:
SG6_ _ _ _ _ _7_ _ _ _ _ _

FIGURE

NUMBER

11 230 Diaphragm Support Ring 60070 1

ITEM

NUMBER

240 Diaphragm Cap, Part of Item 261 60636 1
250 Set Screw, Dog Pt., M10 x 45 mm, Sin-

gle Diaphragm, Part of Item 261

260 Diaphragm, Part of Item 261 60624 1
261 Diaphragm Assy , (Replaceable Design ,

Consists of Items 240, 250, 260, and

270), See Note 1

270 Diaphragm Support Nut, Part of Item

261

280 Diaphragm Head 210761016 1
290 Hex Head Screw, M8 x 90, Single Dia-

phragm

300 Flat Washer (M8) 4340005085 6

DESCRIPTION PART

NUMBER

4350071284 1

3050976320 1

60637 1

4350035655 6

QTY REFERENCE

CODE

Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.

38

Figure 12. SG7 Plastic Liquid End

39

6.9 SG7 PLASTIC LIQUID END

Model:
Liquid End: Material: ReferenceCode:
SG7_ _ _ _ _ _8_ _ _ _ _ _ A (PVC)
SG7_ _ _ _ _ _1_ _ _ _ _ _ B (POLY)
SG7_ _ _ _ _ _2_ _ _ _ _ _ C (PVDF)

Model:
Liquid End: Material: ReferenceCode:
SG7_ _ _ _ _ _ P_ _ _ _ _ E (POLYMER)
SG7_ _ _ _ _ _ L_ _ _ _ _ F (SLURRY)
SG7_ _ _ _ _ _ N_ _ _ _ _G (H

2SO4

)

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

12 225 Adapter Ring, Aluminum 60165 1

227 Socket Head Screw (M8 x 25 mm), Zinc

4350003473 6

PLT
230 Diaphragm Support Ring 60159 1
240 Diaphragm Cap, Part of Item 261 60638 1 A, E, F, G
240 Diaphragm Cap, Part of Item 261 60639 1 B
240 Diaphragm Cap, Part of Item 261 60640 1 C
250 Set Screw, Dog Pt., M10 x 70 mm, Sin-

4350071334 1 A, B, C, F

gle Diaphragm, Part of Item 261
260 Diaphragm, Part of Item 261 60162 1
261 Diaphragm Assy , (Replaceable Design ,

60226 1 A, F, G

Consists of Items 240, 250, 260, and

270), See Note 1

261 Diaphragm Assembly, (Replaceable

60227 1 B
Design, Consists of Items 240, 250,
260, and 270), See Note 1

261 Diaphragm Assy , (Replaceable Design ,

60229 1 C
Consists of Items 240, 250, 260, and

270), See Note 1

QTY REFERENCE

CODE

270 Diaphragm Support Nut, Part of Item

60642 1
261

280 Diaphragm Head 60171 1 A, E, F, G
280 Diaphragm Head 60174 1 B, C
290 Hex Head Screw, M8 x 90, Single Dia-

4350036035 6 A, B, C

phragm

300 Flat Washer (M8) 4340055073 6

Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.

40

Figure 13. SG7 Metallic Liquid End

41

6.10 SG7 METALLIC LIQUID END - STAINLESS STEEL - NPT

Model:
Liquid End: Material:
SG7_ _ _ _ _ _7_ _ _ _ _ _

FIGURE

NUMBER

13 225 Adapter Ring, Aluminum 60165 1

ITEM

NUMBER

227 Socket Head Screw (M8 x 25 mm), Zinc

PLT

230 Diaphragm Support Ring 60159 1
240 Diaphragm Cap, Part of Item 261 60641 1
250 Set Screw, Dog Pt., M10 x 70 mm, Sin-

gle Diaphragm, Part of Item 261

260 Diaphragm, Part of Item 261 60162 1
261 Diaphragm Assy , (Replaceable Design ,

Consists of Items 240, 250, 260, and

270), See Note 1

270 Diaphragm Support Nut, Part of Item

261

280 Diaphragm Head 60180 1
290 Hex Head Screw, M12 x 130, Single

Diaphragm

300 Flat Washer (M12) 4340055073 6

DESCRIPTION PART

NUMBER

4350003473 6

4350071334 1

60228 1

60642 1

4350036035 6

QTY REFERENCE

CODE

42

FIGURE 14. CHECK VALVE PARTS

Figure 14A. Model SG5 Plastic Check Valve

Parts (Item Number 425)

Figure 14B. Model SG5 Metallic Check Valve

Parts (Item Number 425)

Figure 14C. Model SG6 & SG7 Plastic Check

Valve Parts (Item Number 425)

Figure 14D. Model SG6 & SG7 Metallic Check

Valve Parts (Item Number 425)

43

FIGURE 14. CHECK VALVE PARTS (CONT.)

DISCHARGE SHOWN

CHECK VALVE CONNECTOR
(445) IS PAR T OF THE PUMP.
CONNECTORS ARE INTER­CHANGEABLE WITH NEW
CHECK VALVES.

Figure 14E. Model SG5 Slurry Check Valve

Parts (Item Number 425)

Figure 14G. Model SG6 & SG7 Slurry Check

Valve Parts (Item Number 425)

Figure 14F. Model SG5, SG6, and SG7 Polymer

Check Valve Parts (Item Number 425)

44

6.11 CHECK VALVE PARTS

Model:
Liquid End: Material: ReferenceCode:
SG5_ _ _ _ _ _ 7 (316SS) A1
SG5_ _ _ _ _ _8 (PVC) A2
SG5_ _ _ _ _ _1 (POLY)A3
SG5_ _ _ _ _ _2 (PVDF) A4
SG5_ _ _ _ _ _P (POLYMER) A6
SG5_ _ _ _ _ _L (SLURRY)A7
SG5_ _ _ _ _ _N (H2SO4) A8

SG6_ _ _ _ _ _7 (316SS) B1
SG6_ _ _ _ _ _8 (PVC) B2
SG6_ _ _ _ _ _1 (POLY)B3
SG6_ _ _ _ _ _2 (PVDF) B4

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

Model:
Liquid End Material ReferenceCode:
SG6_ _ _ _ _ _P (POLYMER) B6
SG6_ _ _ _ _ _L (SLURRY)B7
SG6_ _ _ _ _ _N (H2SO4)B8

SG7_ _ _ _ _ _7 (316SS) C1
SG7_ _ _ _ _ _8 (PVC)C2
SG7_ _ _ _ _ _4 (POLY) C3
SG7_ _ _ _ _ _2 (PVDF) C4
SG7_ _ _ _ _ _P (POLYMER) C6
SG7_ _ _ _ _ _L (SLURRY)C7
SG7_ _ _ _ _ _N (H2SO4)C8

QTY REFERENCE

NUMBER

CODE

14 419 O-ring, 2-117, Viton A 4080068075 4 A1, A2, A3,

A6, A7, A8
419 O-ring, 2-117, Teflex Parker 40348 4 A4
419 Gasket, Teflon, 1 inch Ball,

(See Note 3)

419 O-ring, 2-123, Viton A 4080068135 6 B2, B3, B6, B7

419 O-ring, Teflex-V-123 60765 6 B4, C4
420 Seat, (See Note 2) 92006 4016 2 A1
420 Seat, 5/8 PVDF 2240173078 2 A2, A3, A4
420 Seat, 5/8 UHMWPE 2240173073 2 A3
420 Seat, PVC, Double Ball 920064071 2 A2
420 Seat, 5/8 316SS 2240173 016 2 A6
420 Seat, 166mm 316SS 2240089016 2 B1, C1
420 Seat, 1 inch Polyethylene 60240137073 2 B2, B3, C2, C3
420 Seat, PVDF 60240137078 2 B4, C4
420 Seat, 1 inch 316SS 240137016 2 B6, B7, C6, C7

2250075275 6 B1, C1

C2, C3, C6,

C7, B8, C8

- Items not shown.

45

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

QTY REFERENCE

CODE

14 420 Seat, 316SS, Used after 1

June 2008
420 Seat, 1 inch CA20 61216 2 B8, C8
420 Seat, 5/8 CA20 60855 2 A8
421 Ball, 14mm 316SS, (See Note

1 and 4)
421 Ball, 14mm 316SS, Not used

after 1 June 2008, Use PN

CV102314 (See Note 1 and 4)
421 Ball, 14mm Ceramic, Double

Ball
422 Ball, 22mm 316SS, ( See Note

2)
422 Ball, 5/8 inch Ceramic 4070015171 2 A2, A3, A4
422 Ball, 5/8 inch PVC 4070170173 2 A2
422 Ball, 7/8 inch Ceramic, Double

Ball
422 Ball, 5/8 inch CA20 4070014173 2 A2, A8
422 Ball, 5/8 inch 316SS 4070014172 2 A2, A6

69022 2 A7

60709 2 A1

60709 2 A7

4370000140 2 A2

60710 2 A1

4070015211 2 A2

- Items not shown.

422 Ball, 9/16 inch 316SS, Used

after 1 June 2008
422 Ball, 1 inch 316SS 4070014232 2 B1, B6, B7,

422 Ball, 1 inch Ceramic 4070015231 2 B2, B3, B4,

422 Ball, 1 inch CA20 4070014233 2 B8, C8
423 Seat, Seal, and Ball Set (See Note 2) 2 A1
423 Seat, Seal, and Ball Set 3050436322 2 B1, C1
423 Seat, Seal, and Ball Set 3050879500 2 A2, A3
423 Seat, Seal, and Ball Set 3050879700 2 A4
423 Seat, Seal, and Ball Set 3050629500 2 B2, B3, C2, C3
423 Seat, Seal, and Ball Set 3050629700 2 B4, C4

423A Spring Hastelloy, Polymer (Dis-

charge)

423A Spring Hastelloy, Polymer (Dis-

charge)

CV102314 2 A7

C1, C6, C7

C2, C3, C4

800123026 1 A6

60800083026 1 B6, C6

46

FIGURE

NUMBER

14 424 Ball Guide, 316SS, (See Note 2)210696016 2 A1

ITEM

NUMBER

424 Ball Guide, 316SS 2920052016 2 B1, C1
424 Ball Guide, PVDF 60024 2 A2, A3, A4, A8
424 Ball Guide, PVC 60030106071 2 B2, C2, C8
424 Ball Guide, PP 030106070 2 B3, C3
424 Ball Guide, PVDF 60030106078 2 B4, C4, B8

DESCRIPTION PART

NUMBER

QTY REFERENCE

CODE

424 Ball Guide, PVDF, Polymer

(Suction)
424 Ball Guide, PVC, Spring

Loaded, Polymer (Discharge)
424 Ball Guide, PVC (Polymer Suc-

tion)
424 Ball Guide, PVC Spring

Loaded, Polymer (Discharge)
424 Ball Guide, Slurry, 316SS, Not

used after 1 June 2008 (See

Note 1 and 4)
424 Body, Slurry, 316SS, Used

after 1 June 2008
424 Ball Guide, Slurry, 316SS,

(See Note 1 and 4)
424 Double Ball Guide, PVC 210696071 2 A2
425 Check Valve Assembly, 316SS

(See Note 1 and 2)
425 Check Valve Assembly, 316SS

(See Note 1)

60024 1 A6

030156071 1 A6

60030106071 1 B6, C6, C8

60030134071 1 B6, C6

60818 2 A7

69023 2 A7

61118 2 B7, C7

3050876602 2 A1

3050583022 2 B1, C1

- Items not shown.

425 Check Valve Assembly , PVC

(See Note 1)
425 Check Valve Assembly , PVC

(See Note 1)
425 Check Valve Assembly, POLY

(See Note 1)
425 Check Valve Assembly, POLY

(See Note 1)
425 Check Valve Assembly, PVDF

(See Note 1)
425 Check Valve Assembly, PVDF

(See Note 1)

47

3050870007 2 A2

3050629007 2 B2, C2

3050870009 2 A3

3050629009 2 B3, C3

3050870008 2 A4

3050629008 2 B4, C4

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

QTY REFERENCE

CODE

14 425 Check Valve Assembly, Poly-

mer (Discharge)

425 Check Valve Assembly , Poly-

mer (Suction)

425 Check Valve Assembly , Slurry

used for pumps built before 1
June 2008, Replaced with PN
69026 (See Note 1 and 4)

425 Check Valve Assembly , Slurry,

used for pumps built after 1

June 2008
425 Check Valve Assembly, Slurry 61277 2 B7, C7
425 Ball Guide PVC For Spring

(Discharge)
426 Poppet, PVDF 440090078 1 A6
426 Dowel Pin, 316SS, Not used

after 1 June 2008 (See Note 4)
426 Spring Seat, PVC 60440045071 1 B6, C6
427 Ball Guide, 316SS, Used after

1 June 2008

61645 1 B6, C6

61646 1 B6, C6

60827 2 A7

69026 2 A7

60030134071 1 B6, C6

60820 2 A7

69024 2 A7

- Items not shown.

428 Pin, Retain, 316SS, Used after

1 June 2008
435 Union Nut, 1/2 PVC 4320236038 2 A2, A3, A4,

435 Union Nut, PVC (1”) 4320236058 2 B2, B3, B4,

435 Connection (1” NPT Male) 450128116 2 B1, C1
435 Connection (1” BSP Male) 450128016 2 B1, C1
437 Valve Clamp, Steel 040215010 2 B1, B2, B3,

439 Split Washer (M10) 304 SS 4340009015 6 B1, B2, B3,

441 Hex Head Screw (M10 x 65

mm) 304 SS

69025 2 A7

A6, A7, A8

B6, B7, B8,

C2, C3, C4,

C6, C7, C8

B4, C1, C2,

C3, C4

B4, C1, C2,

C3, C4

4350035765 2 B1, B2, B3,

B4, C1, C2,

C3, C4

48

FIGURE

NUMBER

ITEM

NUMBER

DESCRIPTION PART

NUMBER

QTY REFERENCE

CODE

14 442 Hex Head Screw (M10 x 75

mm) 304 SS

445 Union End, PVC (1/2” NPT

Female)

445 Union End (1” NPT) 60132 2 B2, B3, B6, B7

445 Union End (Metric Socket 15 x

20)

445 Union End (Metric Socket 25 x

32), PVC w/Solvent Weld
445 Union End (1/2” NPT) 60119 2 A4
445 Union End (1/2” BSP) 60146 2 A4
445 Union End (1” NPT) 60133 2 B4, C4
445 Union End (1” BSP) 60147 2 B4, C4
445 Coupling, 316SS (1” BSP x 1/

2” NPT)

445 Coupling (1” BSP x 1/2” BSP) 450420016 2 A1

4350035785 4 B1, B2, B3,

B4, C1, C2,

C3, C4

60117 2 A2, A3, A6, A7

C2, C3, C6,

C7, C8

4320350028 2 A2, A3

4320350008 2 B2, B3, C2, C3

60135 2 A1

447 Elbow, PVC w/1” Tube 61395 2 B2, B4

- Items not shown.

Note 1: Item 425 (Check Valve Assembly) consists of items 424 (Ball Guide), 420 (Seat), 422 (Ball),
419 (Seal), and 421(Ball), (Metallic Liquid End Codes SG5, 316SS and Slurry only).

Note 2: SG5 stainless check valves does not contain a removable ball seat (seat is integral to ball
guide). Ball guide, ball and seal are not sold separately. Replacement requires purchase of the com­plete check valve assembly (part # 305-0876-602).

Note 3: Seal is a PTFE gasket for the SG6 and SG7 stainless steel check valves. For all others the
seal is an O-ring.

Note 4: Check Valve Assembly (425, P/N 60827) does not contain a removable ball seat. Replace­ment of ball (421, P/N 60709), ball guide (424, P/N 60818) and dowel pin (426, P/N 60820) requires
purchase of the complete check valve assembly.

49