Page 1
for
NEPTUNE
SERIES 6000 “dia-PUMP”
MODELS 6100 thru 6250
Lansdale, PA. 19446 • Tel.: 215-699-8700 • FAX: 215-699-0370
ZL107602
Page 2
WARNING
LOCKOUTS ARE REQUIRED BEFORE
SERVICING THIS EQUIPMENT.
Shut off/Lockout pump Power before Servicing.
2
SAFETY INSTRUCTIONS:
Be certain pump isolation valves are
Closed and chemical is shut off.
Bleed pressure before servicing.
Page 3
SECTION PARAGRAPH
I
II
1
2
3
4
5
6
III NORMAL MAINTENANCE
7
IV 8 MOTOR OPERATING CONDITIONS 13
V TROUBLE SHOOTING CHART 14
VI PARTS 15
9
VII ELECTRONIC STROKE CONTROL
10
VIII DRAWINGS
IX DOUBLE DIAPHRAGM OPTION
11
X MATERIAL SAFETY DATA SHEETS 21
NOTES 24
GENERAL DESCRIPTION 4
LIMITED WARRANTY 5
PARTS ORDERING INSTRUCTIONS 6
INSTALLATION INSTRUCTIONS
GENERAL
SUCTION PIPING
DISCHARGE PIPING
ADJUSTMENT OF INTERNAL RELIEF VALVE
INSTALLATION OUTDOORS
STARTUPPROCEDURE
MAINTENANCE
SPAREPARTS
PARTS LIST
SPECIAL INSTRUCTIONS
DIRECTION OF MOTOR ROTATION
INTERNAL RELIEF VALVE SETTINGS
LIQUID HEAD ASSEMBLY
PARTS DRAWING
ELECTRONIC STROKE CONTROL
INSTALLATION AND OPERATION
TABLE OF CONTENTS
PAGE
7
8
8
8
10
11
12
15
17
19
7
10
11
16
18
20
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SECTION I
GENERAL DESCRIPTION
The Neptune Series 6000 “dia-PUMP” is a reliable metering pump of the high-pressure diaphragm type. Under
constant conditions of temperature, pressure, and capacity adjustment settings, a +/- 1% metered discharge
volume is maintained.
A plunger reciprocating at a fixed stroke displaces hydraulic fluid, which actuates a flexible, chemically inert,
Teflon diaphragm to create pumping action. The capacity of the pump is regulated by controlling the volume of
hydraulic fluid, which bypasses the diaphragm cavity.
Metering accuracy is maintained by a control rod, which allows hydraulic fluid replacement and air venting
automatically with each stroke, while also taking into account temperature changes of the hydraulic fluid. Metering accuracy is also insured by the use of double ball check valves on the suction and discharge of the pump.
PLEASE READ THE INSTRUCTION MANUAL COMPLETELY BEFORE INSTALLING THE PUMP
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IMPORTANT NOTICE
All equipment returned to the factory for repair or service must first be thoroughly flushed and have
t which has been in contact with chemicals must be accompanied by a copy of the
Failure to comply with the above instructions will result in equipment being returned to sender,
SECTION I
NEPTUNE CHEMICAL PUMP COMPANY
LIMITED WARRANTY
All Neptune Pumps are tested at the factory prior to shipment. Each part used in their construction has been
carefully checked for workmanship.
If the pump is installed properly, Neptune Chemical Pump Company, Inc. warrants to the purchaser of this
product for a period of twelve months from the date of first use or eighteen months from shipment, whichever
occurs first, this product shall be free of defects in material and/or workmanship, as follows:
1. Neptune Chemical Pump Company, Inc. will replace, at no charge, any part that fails due to a defect in
material and/or workmanship during the warranty period, FOB our factory, Lansdale, Pennsylvania. To
obtain warranty service, you must forward the defective parts to the factory for examination, freight pre-paid.1
2. This warranty period does not cover any product or product part, which has been subject to accident,
misuse, abuse or negligence. Neptune Chemical Pump Company, Inc. shall only be liable under this
warranty if the product is used in the manner intended by the manufacturer as specified in the written
instructions furnished with this product.
Any express warranty not provided in this warranty document, and any remedy for breach of contract that, but
for this provision, might arise by implication or operation of law, is hereby excluded and disclaimed. Under no
circumstances shall Neptune Chemical Pump Company, Inc. be liable to purchaser or any other person for any
charge for labor, repairs, or parts, performed or furnished by others, nor for any incidental consequential
damages, whether arising out of breach of warranty, express or implied, a breach of contract or otherwise.
Except to the extent prohibited by applicable law, any implied warranty of merchantability and fitness for a
particular purpose are expressly limited in duration to the duration of this limited warranty.
Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations
on how long any implied warranty lasts, so the above limitations may not apply to you. This warranty gives you
specific legal rights, and you may have other rights, which may vary from state to state.
IMPORTANT
SHOULD IT BE NECESSARY TO SEND THE PUMP TO THE FACTORY FOR REPAIR OR MAINTENANCE
REBUILDING; DRAIN ALL OIL AND CHEMICAL FROM PUMP BEFORE SHIPPING. FAILURE TO DO SO
CAN CAUSE EXTENSIVE DAMAGE TO THE MOTOR.
SEE IMPORTANT NOTICE - RETURN GOODS AUTHORIZATION
1
RETURN GOODS AUTHORIZATION
(1) All equipment returned to Neptune Chemical Pump Company, Inc. requires proper Returned
Goods Authorization Number (RGA) and tags.
(2)
all chemical contact areas neutralized.
(3) All equipmen
Chemical Product Material Safety Data Sheet (MSDS).
(4)
freight collect, without service.
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SECTION I
PARTS ORDERING INSTRUCTIONS
The complete model number and serial number of the pump must be furnished to insure prompt and
accurate parts service. These numbers are found on the name plate (sample below) located on the
side of the pump. Refer to Section VI for complete parts lists.
Send all orders or inquiries for parts to:
Parts Department
Neptune Chemical Pump Company, Inc.
P.O. Box 247
Lansdale, PA 19446
Tel.: 215-699-8700
1 -888-3NEPTUNE (888-363-7886)
FAX: 215-699-0370
NOTE: PLEASE SUPPLY BOTH MODEL AND SERIAL NUMBERS.
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SECTION II
INSTALLATION INSTRUCTIONS
1.0 GENERAL (REFER TO PARTS DRAWING ON PAGE#16)
1.0.1 UNPACKING & INSPECTION
When unpacking a pump or chemical feed system, be certain that no parts are thrown away.
Examine the equipment for possible damage. If damage has occurred, file claim with the
common carrier within 24 hours. Neptune will assist in estimating the repair costs.
1.0.2 The “dia-Pump” should be located on a level surface. Three mounting holes are provided to
anchor the pump securely to the mounting surface. All piping to the pump should be supported
to prevent stress on the pump input and output fittings.
1.0.3 Before connecting the pump make sure that all fittings are completely clean by flushing
thoroughly. Any foreign matter entering the pump can damage the internal parts and severely
limit the life of the pump.
1.0.4 A “Y” STRAINER (AT LEAST ONE PIPE SIZE LARGER THAN SUCTION INLET SIZE OF
THE PUMP) MUST BE INSTALLED IN THE SUCTION LINE OF THE PUMP TO INSURE
AGAINST FOREIGN MATTER ENTERING THE PUMP
1.0.5 It is recommended that shut-off valves and unions be placed in the suction and discharge lines
if possible. Such an arrangement will facilitate servicing the pump.
1.0.6 The electrical supply to the pump must match the motor nameplate characteristics. The motor
rotation is counter clockwise when viewed from the top of the motor or looking down on the
pump. An arrow mark on the gearbox shows the rotation (See Figure 1)
IMPORTANT
On single-phase units, the rotation is set at the factory and must not be changed.
FIGURE 1
Please note Figure 1, indicating the correct rotation. Operation with the incorrect rotation will
damage the pump and motor.
1.0.7 Please note, that some items in the parts list have more than one part number for an individual
figure number. These different part numbers insure unique identification of parts, which are
available in more than one material of construction, or as in the case of gears, pistons etc,
more than one speed, sizes. Please use the part number, not the figure number when
ordering.
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1.0.8 Fill gearbox and pump by pouring the hydraulic fluid (drive lubricant) supplied through the fill
opening at the rear of the pump. Pour fluid in slowly until it covers the worm gear. The control
knob should be in the zero position during the filling.
PLEASE NOTE: TO VENT THE AIR, REMOVE VENT PLUG LOCATED ON TOP OF THE OIL HEAD
(# 54 on Parts Drawing).
Allow 30 minutes for hydraulic fluid to make its way into pump chamber and then recheck fluid
level.
The hydraulic fluid supplied by Neptune is EP SAE 90.
Common sources for hydraulic fluid are:
Shell Oil Omala #220
Mobil Oil Mobil Gear #629
Sun Oil Sun Oil #220
Texaco Meropa #220
2.0 SUCTION PIPING
2.0.1 The suction piping to the pump must be absolutely airtight and one size larger than suction
inlet size of the pump. It is suggested that the suction piping be tested with low air pressure
and a soap solution to assure that no leaks exist. Limit the total length of the suction line to 3-4
feet for suction lift or 6-7 feet for flooded suction. Minimize bends, elbows, or other restrictions.
2.0.2 NEPTUNE RECOMMENDS THAT THE “dia-PUMP” BE OPERATED WITH A FLOODED
SUCTION, AS THIS WILL FACILITATE START UP AND INCREASE THE SERVICE LIFE OF
THE PUMP.
2.0.3 It is highly recommended that all solution tanks be furnished with a low level cut off switch or
low-level alarm and cut off switch to prevent the pump from running dry. OPERATION
AGAINST A DRY SYSTEM WILL CAUSE DAMAGE TO THE PUMP DIAPHRAGM AND
REDUCE THE OPERATING LIFE OF THE PUMP.
3.0 DISCHARGE PIPING
3.0.1 It is recommended that the “dia-Pump” operate against a minimum discharge pressure of 50
psig.
3.0.2 All Neptune Series 6000 “dia-Pumps” are supplied with an internally pre-set relief valve. This
relief valve is set above the actual rated discharge pressure of the pump and is designed to
protect the pump should a discharge pressure’ beyond the rated limit of the pump occur.
3.0.3 To protect the piping system, it is recommended that an external relief valve as manufactured by
Neptune Chemical Pump Company, or equal, be placed in the discharge line of the pump.
3.0.4 Discharge piping should equal discharge port size.
4.0 ADJUSTMENT OF INTERNAL RELIEF VALVE
4.0.1 All Neptune Series 6000 “dia-Pumps” are supplied with an internally pre-set relief valve. The
internal relief valve is set as follows:
Model 1/2 HP 3/4 H/P 1 H/P 1-1/2 HP 2 HP
6100 1500 2500 3000 4000
6150 1500 2500 3000 3500
6250 600 1200 2000 2300 2500
APROXIMATE INTERNAL RELIEF VALVE SETTING (PSI)
4500
4000
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4.0.2 The internal relief valve is designed to protect the pump itself should a discharge pressure
beyond the relief valve setting occur.
4.0.3 If a customer order specifies a relief valve setting above those indicated above, the specified
setting will be set at the factory. All pumps are tagged with the relief valve setting used by the
factory.
4.0.4 To protect the external piping system, it is recommended that a relief valve as manufactured by
Neptune Chemical or equal be placed in the discharge line of the pump. It is further
recommended that this relief valve be piped into return of the tank with clear PVC tubing so
that it can be determined if the solution is bypassing through the valve and returning to the
tank, indicating a line blockage.
4.0.5 Drawing on page16 illustrates the locations of the internal relief valve (#32, #33, #34, #35, #36,
#37 on Parts Drawing).
4.0.6 The drawing shows a passage connecting the hydraulic fluid reservoir with the hydraulic fluid
side of the diaphragm.
4.0.7 The passage is interrupted by the relief valve ball (FIG. #37 on Parts Drawing), which is
backed up by a relief valve spring (#35 on Parts Drawing).
4.0.8 If, during the pump operation, the pressure on the hydraulic fluid side of the pump exceeds the
set pressure of the internal relief valve, the ball is forced from its seat allowing the hydraulic
fluid to flow back to the reservoir.
4.0.9 To reset the relief valve to a higher pressure (the relief valve setting cannot be reduced
because of design considerations), instructions are as follows:
4.0.10 Connect a test set-up as shown in Figure 2 (Page 10)
NOTE: All parts must have a working pressure rating above the required set pressure.
4.0.11 Start and run the pump until all air is relieved from the discharge liquid (hand valve open).
4.0.12 Remove relief valve cap (#32 on Parts Drawing).
4.0.13 Close hand valve; pressure gauge should read between 250 and 4500 psi depending on pump
model.
4.0.14 Use 5/16” Allen wrench to adjust spring tension by turning relief valve adjusting screw
(#34 on Parts Drawing).
(1) To increase pressure, turn relief valve adjusting screw (#34 on Parts Drawing) in.
(2) To decrease pressure, turn relief valve adjusting screw (#34 on Parts Drawing) out.
4.0.15 After resetting or adjusting pressure, replace relief valve cap (#32 on Parts Drawing).
CAUTION
Never turn relief valve adjusting screw (# 34 on Parts Drawing.) completely in.
Do not attempt to set the internal relief valve more than 25% in excess of nameplate rating.
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Take out Relief Valve cap to access Relief Valve screw (#32 on Parts Drawing). Insert Hex wrench to
adjust relief valve setting.
FIGURE 2
5.0 INSTALLATION OUTDOORS
The “dia-Pump” is a totally enclosed pump, which can be used outdoors or indoors. When installed outdoors, make sure that the pump is protected against extremes of nature as follows:
5.0.1 Running of the pump when exposed to tropical sunshine with ambient temperature above 90°F
(32°C) would cause excessive oil and motor temperatures. The pump should be shaded and
located in such a way as to permit an ample degree of air circulation.
5.0.2 Under cold conditions, the pump should be insulated and a heater should be supplied in order
to maintain the hydraulic fluid at an ambient temperature above 30°F (—1°C.)
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6.0 START UP PROCEDURE
The following start up procedure is complete and does repeat instructions on filling the gearbox and
pump.
6.0.1 Remove backpressure spring, if any (anti-siphon spring, Part#100198 on Fig 3) for start up.
Reinstall after pump is operational if needed.
6.0.2 Flooded Suction: Refer to Section II, Paragraph 1.0.9, for instructions on filling gearbox with
hydraulic fluid.
6.0.6 On initial start-ups: Set the pump capacity at 0%.
Check for proper motor rotation (Refer to Paragraph 1.0.6).
6.0.3 Open air bleed port (#51 on the drawing). Let all the air escape from the oil side. Keep it open
until only oil comes out from the port. Close the port tight. Run pump for 10-15 seconds couple
of times and listen for any abnormal motor or crank noises, and if present, refer to trouble
shooting chart.
FIGURE 3
6.0.4 Make sure that the pumping chamber is flooded by loosening Discharge Cap (Part#002073 on
Fig 3) and allowing solution to appear. Then tighten Discharge Cap (Part#002073 on Fig 3).
This procedure will also allow air to vent from pumping chamber. THE “dia-PUMP” WILL NOT
FUNCTION IF AIR IS TRAPPED IN THE HYDRAULIC FLUID OR LIQUID INSIDE OIL PUMP
CHAMBER.
6.0.5 After having let pump stand for 30 minutes and having rechecked fluid level, set pump capacity
indicator at approximately 30%. Be certain that pump suction and discharge lines are open.
6.0.5 Start pump. Slowly adjust to the required capacity.
WARNING
BEWARE APPLICATIONS WHERE WATER IS NOT COMPATIBLE WITH CHEMICAL TO BE PUMPED.
EXAMPLE: NEVER FORCE PRIME WHEN PUMPING ACID OR OIL BASED PRODUCTS.
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SECTION III
NORMAL MAINTENANCE
7.0 MAINTENANCE
Under normal conditions, the “dia-Pump” should not require any significant amount of maintenance. It
is advised that periodic visual observations be made of the oil level to make sure that it is over the
worm gear. The liquid end of the pump should also be inspected for leakage. These observations
should be made regularly.
The hydraulic fluid should be drained and replaced twice a year, using the drain plug (# 68 on Parts
Drawing) at the back of the pump. This change can be scheduled with the normal factory maintenance
at seasonal periods.
7.0.1 Check Valves: Removing, cleaning, replacing.
The “dia-Pump” incorporates a unique check valve design whereas the discharge and suction
piping NEED NOT be disturbed in order to service the valves.
Should the valves need cleaning, remove as follows:
7.0.2 Remove discharge valve cap (# 002073 on Figure 3).
7.0.3 Remove ball retainer (# 000215 on Figure 3), using 5/16” Allen wrench.
7.0.4 Remove discharge valve cartridge (# 000209 on Figure 3). Using special wrench
provided. Be certain that valve “0” ring (# 100204 on Figure 3) is removed with valve
cartridge.
7.0.5 Remove suction valve cap ((# 000207 on Figure 3).
7.0.6 Remove suction valve cartridge (# 000217 on Figure 3), using 5/16” Allen wrench. Be
certain that valve “0” ring (# 100204 on Figure 3).) is removed with valve cartridge.
7.0.7 Clean valve cartridges with suitable solvent. The valve cartridge is a complete and
integral unit and should not be disassembled for cleaning. If the valves are found to be
worn and in need of replacement, an entire valve cartridge in either suction or
discharge should be ordered. The suction valve is the longer of the two valve
cartridges.
7.0.8 To replace reverse above procedure using a small amount of grease to hold valve “0”
rings in place. Do not over tighten the valve cartridges as this could damage the valve
“0” rings.
FOR THE FOLLOWING OPERATIONS REFER TO PART DRAWING ON PAGE 16
7.1.1 Procedure for replacing Control Rod “0” RING (#50,51 on Parts Drawing) and Sealing Plate “0”
RING (#52 on Parts Drawing).
7.1.2 Remove hydraulic fluid from gearbox.
7.1.3 Remove indicator plate (#46 on Parts Drawing), by removing two indicator plate screws
(#45 on Parts Drawing)
7.1.4 Remove control rod assembly with control rod attached for all pumps;(#42, 43, 44, 53
on Parts Drawing) by turning counter clockwise until threads are disengaged, then
pulling out.
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7.1.5 Remove sealing nut (#39 on Parts Drawing)
7.1.6 Remove seal plate (#38 on Parts Drawing) using small brass hook to pry loose
7.1.7 Replace control rod “0” ring (#50 on Parts Drawing) & BACKUP RINGS (#51 on Parts
Drawing)
7.1.8 When replacing sealing plate take care so as to not shear the sealing plate “0” ring and
backup ring (#52 and #68 on Parts Drawing). Apply grease to “0” rings before
assembly. Take special care to place the outside backup ring (#68 on Parts Drawing)
in the right place when replacing the outside “O” ring and backup ring.
7.1.10 Replace balance of parts and fill pump with hydraulic fluid per previous instructions.
7.1.11 Follow startup procedure as if starting a new pump. Refer to Section II, Paragraph
1.0.9 and 6.0.
7.2.1 Removal of pump-head and replacement of diaphragm.
7.2.1 Remove drain plug (#67 on Parts Drawing), and drain hydraulic fluid.
7.2.2 Remove pump head bolts and washers (#65 and #66 on Parts Drawing). Move pump
head (#62 on Parts Drawing) away from pump.
7.2.3 Remove and examine teflon diaphragm (#47 on Parts Drawing). Remove and examine
the liquid side diaphragm backup plate (#64 on Parts Drawing). Replace with new
backup plate and Diaphragm, if required. When replacing the Teflon diaphragm, be
certain to line it up properly with the sealing grooves.
7.2.4 To reassemble reverse the above procedure. Laying the pump on its side facilitates
reassembly. Be certain to tighten all bolts evenly. Tighten to 65 ft. lbs.
SECTION IV
MOTOR OPERATING CONDITIONS
8.0 The normal temperature rise for standard motors is 40°C above ambient temperature and, thus, it
might appear that the motor is operating at a higher than normal temperature. This situation is normal
and should not cause concern.
As a precaution against motor overheating, it is recommended that the pump be located where
adequate ventilation is available, It is also recommended that a MOTOR STARTER WITH THE
PROPER OVERLOAD PROTECTION BE SUPPLIED AS AN ADDITIONAL SAFETY DEVICE.
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SECTION V
TROUBLE SHOOTING CHART
SYMPTOMS CAUSES REMEDIES
1. Pump Motor Will Not
Operate.
2. Pump Does Not Deliver
Rated Capacity
3. Pump delivers erratically. A. Leaky suction line. Repair or replace piping.
4. Motor overheats thermal
overload activates,
5. Noisy Operation
1. In Pump A. Pump Valves. Valves must move to open and close,
2. In Gear Reducer A. Pounding noise at high discharge
6. Oil level overflows
reservoir,
A. Blown Fuse. Check for short circuit or overload
Open thermal overload device in
starter.
C. Low liquid level in tank (where low level
cut-off is used).
D. Broken wire. Locate and repair.
E. Low voltage. Check for too light wiring.
F. Oil “frozen” in pump. Thaw out.
A. Starved suction.
B. Leaky suction piping.
C. Excessive suction lift.
D. Liquid too close to boiling point.
Air or gas trapped in oil or chemical
solution.
F Worn or dirty valves or seats, or both. Clean or replace.
G. Viscosity of liquid too high. 1. Reduce viscosity by heating or other
2. Increase size of suction piping
3. Increase suction pressure slightly
H. Insoluble materials, crystallization or
solids settling.
I. Low discharge pressure. A minimum discharge pressure of 50 psi
B. Worn or dirty valves or seats, or both. Clean or replace valve assembly.
C. Excessive excursion of ball valves from
seats (indicated by ball chatter).
D. Insufficient suction pressure Increase suction pressure.
Raise tank level.
E. Liquid too close to boiling point, Reduce temperature or raise suction
F Leaky system relief valve. Repair or replace relief valve
G. Low hydraulic fluid level. Add hydraulic fluid.
A. Power supply does not match motor. Check power supply against motor
B. Overload caused by operating pump
beyond rated capacity
pressure.
A. Flexible diaphragm punctured Replace diaphragm and hydraulic fluid
Reset.
Fill tank.
Replace suction piping with larger size.
Pressure test, repair or replace defective
piping.
Rearrange equipment location to reduce
suction lift.
Lower temperature or increase suction
pressure slightly.
Decrease capacity to 20% for 7 mins.
then increase to 100% for 7 mins. Bleed
air from valve system
means.
Limit solution strength to 5% by weight.
Flush and clean solution tank
periodically. Suction connection should
be 2 to 4” from bottom of solution tank.
is required to insure proper capacity
control
Increase backpressure.
pressure.
nameplate data.
Check operating pressure against pump
manufacturer data plate maximum rating
and they will make a clicking noise as
they operate. These noises are
sometimes amplified by natural
resonances in piping system. They are
usually indications of normal valve
functioning.
Fluid compressibility causes reversal of
load on gears at end of pressure stroke,
Not considered detrimental.
(drive lubricant) if contaminated.
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SECTION VI
9.0.1 SPARE PARTS
9.0.2 Important—When ordering spare parts, please show MODEL NUMBER AND SERIAL
NUMBER of pump for which parts are being ordered. This information can be found on a
stainless steel nameplate riveted to the side of the pump.
9.0.3 Recommended Spare Parts (Spare parts Kit Part#004353)
It is recommended that the following parts be kept in stock for a pump:
ITEM# PART# DESCRIPTION QTY.
47 004108 Teflon Diaphragm 1
52 100082 Sealing Plate “0” Ring 2
50 100323 Control Rod “0” Ring 2
51 106547 Control Rod Backup Ring 4
60 100204 Valve “0” Ring 8
56 100200 Discharge & Suction Cap “0” Ring
59 000209 Discharge Valve Cartridge 1
61 000217 Suction Valve Cartridge 1
68 108019 Sealing Plate backup Ring 1
PARTS ORDERING INSTRUCTIONS
Note:
For prompt entry of orders for this pump, your order must include both model number
and serial number.
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PARTS LIST FOR PUMP MODELS 6100 to 6250
(REFER TO PART DRAWING ON PAGE 16)
ITEM# DESCRIPTION QTY. PART#
1 Gear Box 1 004089
2 Thrust Washers 4 107595
3 Worm Gear 58 SPM 1 004098
Worm Gear 117 SPM 1 004099
4 Eccentric 1 004100
5 Gear Shaft 1 107598
6 Shaft Retainer O-Ring 1 107580
7 Gear Shaft Retainer Screws 7 100211
8 Gear Shaft Retainer 1 004094
9 3/8” Lock Washers 4 100217
10 3/8-16 X 1" lg. screws 4 100216
11 Wave Spring 1 107599
12 Fill/Vent Plug 1 000191
13 Oil Seal 1 106586
14 Motor Adapter O-Ring 1 107600
15 Ball Bearing 1 106180
16 Worm Shaft 58 SPM 1 004096
Worm Shaft 117 SPM 1 004103
17 Motor Coupling Key 1 106589
18 Woodruff Key 1 107601
19 Worm Shaft Bushing 1 107736
20 Bearing Cone 1 107596
21 Bearing Cup 1 107597
22 Worm 58 SPM 1 107592
Worm 117 SPM 1 107593
23 Spring Pin 2 100010
24 Gasket 1 107581
25 Motor Adapter 1 004095
26 Connecting Rod 1 004091
27 Connecting Rod Pin 1 100304
28 Connecting Rod Sleeve 1 000359
29 Pump Body 3/4” Dia. 1 004109
Pump Body 1” Dia. 1 004110
ITEM# DESCRIPTION QTY. PART#
30 Piston 3/4” Dia. 1 004231
Piston 1” Dia. 1 004232
31 1/8 NPT Pipe Plug 1 100196
32 Relief Valve Cap 1 000365
33 Relief Valve Cap O-Ring 1 100200
34 Relief Valve Adjusting Screw 1 000364
35 Relief Valve Spring 1 100310
36 Relief Valve Ball Guide 1 000379
37 1/4" Dia. Ball 1 100559
38 Sealing Plate 3/4” & 1” pistons 1 004111
39 Sealing Nut 1 004102
40 Knob Friction O-Ring 1 100327
41 Pump/Head Screws 4 105081
42 Control Rod Screw 1 004093
43 Control Knob Screw 1 100308
44 Control Knob 1 004092
45 Indicator Plate Screws 2 100190
46 Indicator Plate 1 000188
47 Teflon Diaphragm 1 004108
48 Oil Side Back-up Plate 1 000194
49 Control Rod Spring Pin 1 100063
50 Control Rod O-Ring 1 100323
51 Control Rod Parbak Rings 2 106547
52 Sealing Plate O-Ring 1 100082
53 Control Rod, for 3/4” or 1” Piston 1 000385
54 Air Bleed Plug 1 100210
56 Valve Cap O-Rings 2 100200
60 Valve Seat O-Rings 2 100204
65 Pump Head Screws 8 107575
66 Washers 8 107577
67 Drain Plug 1 100300
68 Sealing Plate backup Ring 1 108019
PARTS FOR PUMPS WITH METAL HEADS
ITEM# DESCRIPTION QTY. SST - PART NO. C20 - PART NO.
55 Discharge Valve Cap 1 002073
57 Anti-Siphon Spring 1 100198
58 Discharge Valve Nut 1 000215 000216
59 Discharge Cartridge 1 000209
61 Suction Valve Cartridge 1 000217 000218
62 Liquid Head 1 004104 004106
63 Suction Valve Cap 1 000207 000208
64 Diaphragm Back Up Plate, Liquid Side 1 000195 000196
002072
100199
000210
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SECTION VII
SPECIAL INSTRUCTIONS FOR SERIES 6000 “dia-PUMPS”
WITH ELECTRONIC STROKE CONTROL MODEL #SM-1020
Neptune Electronic Stroke Control Unit adjusts the capacity of the 6000 Series Pump over its full
operating range by changing the stroke length in response to an external signal. Manual hand crank is
optional.
Neptune Electronic Stroke Control consists of a Linear Actuator with required fittings and Adapters
needed to mount the Actuator on a Neptune 6000 Series Pump. The stroke control is mounted to the
pump prior to shipment.
Drawing#004253
An optional Remote Control Station is available for use with the Stroke Control to permit remote
Manual control and Remote indication of the Pump capacity settings.
For installation, Calibration setting, maintenance and troubleshooting, see “NEPTUNE ELECTRONIC
STROKE CONTROL INSTRUCTION manual”.
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SECTION IX
DOUBLE DIAPHRAGM OPTION
Special Instructions for Series 6000 “dia-Pumps” with Double Diaphragm
The instructions below are for Neptune’s optional Double Diaphragm Kit.
Use of a double diaphragm allows diaphragms to be
monitored and provides an early warning upon failure of
either diaphragm allowing repairs to be made before
process fluid can mix with the pump’s hydraulic fluid.
Neptune’s double diaphragm is a kit, which may be
retrofitted to any pump currently in service or may be
installed on a new pump at the factory.
Figure 4, illustrates a Double Diaphragm Assembly.
An intermediate plate is located between the oil and
liquid heads with one diaphragm on each side of the
intermediate plate. The Intermediate Plate is
connected to a rupture alarm or pressure switch via a
capillary system. The area between the diaphragms
is evacuated. Rupture in either diaphragm produces
an increase in volume and, therefore, a pressure
increase, which can be sensed by a pressure switch
for alarm purposes.
DISASSEMBLY OF INTERMEDIATE PLATE
11.0.0 Shut pump off and disconnect suction and
discharge piping. Remove drain plug and
drain hydraulic fluid from the gearbox.
11.0.1 Remove 8 Screws and remove the liquid
head assembly. Some hydraulic oil and
process fluid will spill out when the head is
removed.
11.0.2 The intermediate plate, which is between the
pump heads can be removed easily.
11.0.3 Remove the rupture alarm (pressure switch)
and clean the capillary system.
11.0.4 Replace one or both diaphragms if needed.
11.0.5 To reassemble reverse above procedure. Be
certain that parts align properly.
FIGURE 4
VACUUM AIR FROM INTERMEDIATE SPACE
11.0.6 Open valve Item No. 5 (Figure 5).
11.0.7 To remove air, attach the vacuum pump with a hose connection Item No. 6 to the valve
Item No. 5 (Figure 5). The intermediate space is evacuated to 3 psig for normal operating
conditions.
11.0.8 Close valve Item No. 5 (Figure 5).
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11.0.9 Remove the vacuum pump. Plug valve Item No. 5 with a 316SS pipe plug Item No. 12
(Figure 5)
11.0.10 Reinstall the Pump
11.0.11
Follow procedure in Neptune Standard Operating and Instruction Manual for Initial Pump
Startup
Figure 5
NOTE: Neptune furnishes a Mityvac
at many automotive parts store. (Unit furnished by Neptune is less gage and automotive adapters)
vacuum pump from
22
Mityvac
No. 6810 automotive test kit available
Page 23
MSDS
SECTION I - Material Identity
Item Name............................... HYDRALIC LUBRICATING FLUID
Part Number/Trade Name.................. EP SAE 90 GEAR OIL
National Stock Number................... 9150P557
CAGE Code............................... 18632
Part Number Indicator................... A
MSDS Number............................. 181070
HAZ Code................................ B
SECTION II - Manufacturer's Information
Manufacturer Name....................... NORTON PETROLEUM CORP.
Street.................................. 290 POSSUM PARK ROAD
City.................................... NEWARK
State................................... DE
Country................................. US
Zip Code................................ 19711
Emergency Phone......................... 302-731-8200
Information Phone....................... 302-731-8220
MSDS Preparer's Information
Date MSDS Prepared/Revised.............. NONE
Active Indicator........................ N
Alternate Vendors
Vendor #1 CAGE.......................... 18632
SECTION III - Physical/Chemical Characteristics
Appearance/Odor......................... LUBE OIL COLOR AND ODOR
Boiling Point........................... 500 F
Melting Point........................... N/A
Vapor Pressure.......................... @ 110F-1.0
Vapor Density........................... N/A
Specific Gravity........................ .86
Solubility in Water..................... NEGLIGIBLE
Container Pressure Code................. 4
Temperature Code........................ 8
Product State Code...................... L
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DO NOT USE WATER AS A SOLID STREAM ON ANY
AL ATTN.
WATER AND INDUCE VOMITING. OBTAIN MEDICAL
SECTION IV - Fire and Explosion Hazard Data
Flash Point Method...................... UNK
Lower Explosion Limit................... 1%
Upper Explosion Limit................... 7%
Extinguishing Media..................... DRY CHEMICAL, CO2, FOAM
Special Fire Fighting Procedures........ WEAR SCBA WHEN FIRE-FIGHTING IN ENCLOSED
SPACES
Unusual Fire/Explosion Hazards..........
QTY OF BURNING OIL AS IT MAY CAUSE
FROTHING OF OIL & SPREAD THE FIRE.
SECTION V - Reactivity Data
Stability............................... YES
Stability Conditions to Avoid........... NONE LISTED
Materials to Avoid...................... STRONG ACIDS, ALKALINES, OXIDIZERS (I.E.
LIQUID CHLORINE)
Hazardous Decomposition Products........ BURNING/EXCESSIVE HEATING MAY PRODUCE
HARMFUL GASES/VAPORS
Hazardous Polymerization................ NO
Polymerization Conditions to Avoid...... WILL NOT OCCUR
SECTION VI - Health Hazard Data
Route of Entry: Skin.................... YES
Route of Entry: Ingestion............... YES
Route of Entry: Inhalation.............. YES
Health Hazards - Acute and Chronic...... THIS PRODUCT IS EXPECTED TO BE NON-
IRRITATING
Symptoms of Overexposure................ NONE
Medical Cond. Aggrevated by Exposure.... NONE
Emergency/First Aid Procedures.......... EYES: FLUSH W/WATER. OBTAIN MEDIC
SKIN: NONE INHALE: NONE INHALE: GIVE
SECTION VII - Precautions for Safe Handling and Use
Steps if Material Released/Spilled...... CLEAN UP W/OIL ABSORBANT MATERIAL
Waste Disposal Method................... DISPOSE OF IN ACCORDANCE TO ALL FEDERAL,
Handling and Storage Precautions........ KEEP OUT OF REACH OF CHILDREN! DO NOT
Other Precautions....................... WATER CONTAMINATION SHOULD BE AVOIDED.
24
ATTN.
STATE AND LOCAL LAW.
STORE HEAT OR FLAME.
Page 25
SECTION VIII - Control Measures
Respiratory Protection.................. NONE NEEDED UNDER ANTICIPATED USE
W/ADEQUATE VENTILATION
Ventilation............................. NONE NEEDED
Protective Gloves....................... NONE NEEDED
Eye Protection.......................... NEEDED IF SPRAYING/SPLASHING
Other Protective Equipment.............. NONE
Work Hygenic Practices.................. WASH AFTER SKIN CONTACT
Disposal Code........................... O
SECTION IX - Label Data
Protect Eye............................. YES
Protect Skin............................ NO
Protect Respiratory..................... NO
Chronic Indicator....................... NO
Contact Code............................ NONE
Fire Code............................... UNKNOWN
Health Code............................. UNKNOWN
React Code.............................. UNKNOWN
SECTION X - Transportation Data
Container Quantity...................... 32
Unit of Measure......................... OZF
SECTION XI - Site Specific/Reporting Information
Volatile Organic Compounds (P/G)........ 0
Volatile Organic Compounds (G/L)........ 0
SECTION XII - Ingredients/Identity Information
Ingredient #............................ 01
Ingredient Name......................... NONE LISTED BY MANUFACTURER
Percent................................. 0
25
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NOTES:
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