MULTIFLO

METERING PUMPS
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INSTRUCTION
MANUAL
FOR INSTALLATION, OPERATION
AND MAINTENANCE

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Manufactured by :
VK PUMP INDUSTRIES PVT LTD,
W-124A,M.I.D.C AMBAD, NASIK-422010, INDIA.
TEL. NO.:0253-2383609. FAX NO.: 0253-2381443
EMAIL:works@vkpumps.com,sales@vkpumps.com
 I N D E X
CONTENTS
FOREWORD

PUMP DATA

INTRODUCTION

WARRANTY

SECTION - 1
INSTALLATION

SECTION - 2
OPERATION

SECTION - 3
MAINTENANCE

SECTION - 4
METERING PUMPS WITH DIAPHRAGM HEADS

SECTION – 5
ACCESSORIES (As Applicable…)
A) MOTOR
B) STRAINER
C) PRESSURE RELIEF VALVE
D) BACK PRESSURE VALVE
E) PULSATION DAMPNER
 FOREWORD

DEAR CUSTOMER,

YOU ARE THE PROUD OWNER OF METERING PUMP MADE BY V.K. PUMP INDUSTRIES
PVT. LTD., ONE OF THE PREMIER METERING PUMP MANUFACTURERS. THE PUMP
SUPPLIED TO YOU HAS PASSED THROUGH EXHAUSTIVE AND RIGOROUS QUALITY
CHECKS, CONFORMING TO INTERNATIONAL STANDARDS, AT OUR FACTORY. THE
METERING PUMP IS A WELL ENGINEERED PRECISION MACHINE AND IT IS
IMPORTANT THAT IT IS HANDLED WITH PROPER CARE AT YOUR END. PROCEEDING
PAGES WOULD GIVE YOU DETAILED INSTRUCTIONS ON HOW TO OPERATE AND
MAINTAIN THE PUMP.

THE METERING PUMP IS THE HEART OF CHEMICAL PROCESS INDUSTRY. IT IS

DESIGNED TO PUMP VARIOUS CHEMICALS AT A PRECISE AND ACCURATELY
ADJUSTABLE RATE OF FLOW. IT IS A VITAL PART OF THE CHEMICAL PROCESS
PLANT AND NEEDS REGULAR MONITORING, CLEANING AND ADJUSTMENTS OR
REPLACEMENT OF WORN OUT PARTS. NORMAL PREVENTIVE AND ROUTINE
MAINTENANCE AND PROPER LUBRICATION WOULD ELIMINATE COSTLY
SHUTDOWNS AND EMERGENCY REPAIRS.

OUR EXPERIENCE REVEALS THAT MOST OF THE START UP PROBLEMS WITH THE
PUMPS ARE DUE TO IMPROPER PIPING, PIPING & WELDING DEBRIS CHOKING THE
VALVES AND STRAINERS OR UNSKILLED LABOURERS HANDLING THE PUMP
WITHOUT PROPER UNDERSTANDING OF ITS WORKING. PROPERLY INSTALLED AND
MAINTAINED, METERING PUMP CAN GIVE YEARS OF TROUBLE-FREE SERVICE. IT IS
EQUALLY IMPORTANT TO STOCK RECOMMENDED SPARES TO AVOID RUSH
PURCHASES AND AVOIDABLE DELAYS IN PROCUREMENT OF SPARES.

IN THIS MANUAL WE HAVE GIVEN GENERAL SERVICE INSTRUCTIONS AND

RECOMMENDATIONS BASED ON OUR EXPERIENCE. IT IS, HOWEVER, NECESSARY
THAT PLANT MAINTENANCE PERSONNEL ESTABLISH THEIR OWN PREVENTIVE
MAINTENANCE SCHEDULE BASED ON MAINTENANCE RECORD ESTABLISHED IN THE
EARLY STAGES OF OPERATION.

WE HOPE THE MANUAL SERVES AS A USEFUL GUIDE FOR ACHIEVING OPTIMUM

PERFORMANCE FROM THE METERING PUMP. SHOULD YOU STILL NEED
ASSISTANCE FOR MAINTAINING THE PUMPS, WE WOULD BE GLAD TO SEND OUR
TRAINED TECHNICIANS TO ASSIST YOU.

WE THANK YOU FOR SELECTING OUR METERING PUMP FOR YOUR PUMPING
APPLICATIONS AND WE ARE SURE THAT YOU WOULD CONTINUE TO PATRONISE
OUR PRODUCTS BASED ON THEIR PERFORMANCE.

MANAGING DIRECTOR
 PUMP DATA

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CUSTOMER’S
ORDER REF :
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OUR REF. : MP-

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PUMP
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MODEL NO. SERIAL NO.
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CAPACITY LPH MAX. PRESSURE KG/Cm.2 g.
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TEST MOTOR / MOTOR

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HP : RPM SERIAL NO.
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MAKE :
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IMPORTANT NOTE WHILE ORDERING SPARE PARTS

When ordering spare parts, the following information must be given :
1.Serial Number and Model of the Pump.
2.Discharge Pressure and Capacity of the Pump
3.Description and Part Number as given in the part list and Drawing.
4.Material of Construction for wetted parts of the pumping fluid.
 I N T R O D U C T I O N

The Pump supplied is a controlled volume, positive displacement, reciprocating pump

designed to deliver accurately measured liquid volumes against a positive differential pressure

between pump suction and discharge. Precision built, the pump performs this function with a

repetitive accuracy of at least plus or minus three percent and steady state of accuracy of plus

or minus one percent of mean delivered volume.

Basically, the pump consists of a Drive Unit and a Liquid Head Assembly. The Drive

Unit has a built-in speed reducer to bring down the speed of the prime mover. The Drive Unit

also has a variable Eccentric Drive Mechanism which steplessly adjusts the stroke length of

the Plunger from Zero to the maximum stroke. The stroke length setting can be adjusted to

get the desired capacity level and the pump will deliver the capacity with the accuracy as

stated above. The Liquid Head Assembly handles the process liquid and is essentially a

pressure chamber. The Liquid Head pressure chamber is subjected to alternating suction and

discharge cycles due to reciprocation of Plunger in Plunger type Liquid Heads. For

Diaphragm type Liquid Heads, a Diaphragm - actuated by hydraulic plunger, does the same

function. Liquid Head has suction and discharge non-return valves to allow flow from suction

side to discharge side. The pump delivers a controlled volume of liquid with each discharge

stroke in accordance with the stroke length setting.

Pump capacity is adjustable by changing stroke length. Capacity adjustment can be

made manually or automatically by a signal from remote control instrument. Selection of

capacity control methods is determined by the nature of the application.

 WARRANTY

V.K. Pump Industries Private Limited warrants its products against defects in
workmanship or materials for one year, under normal use, from the date of shipment except
that warranties on equipment and accessories furnished with the pump, but manufactured by
others , are limited to the warranties offered by the manufacturers for their respective
products.

All obligations and liabilities under this warranty are limited to repairing or replacing Ex-
works, our plant, such allegedly defective units as are returned to our plant, carrier charges
prepaid. Repairs or replacements are made subject to factory inspections of returned items.

This warranty does not extend to damage by corrosion or erosion. The materials of
construction offered, are recommendations subject in all cases to verification and acceptance
by the customer. These recommendations, based on previous company experience and best
available information, do not constitute guarantees against wear or chemical action.

Expressly excluded from this warranty are defects caused by mis-use, abuse, or
improper application, employment or operation of the unit . Expendable items and damage
resulting from unauthorised repair are not covered by this warranty. No liability for
consequential damage or reinstallation labour is accepted. Company will not assume
responsibility for contingent liability for alleged failure of its products.

This warranty is in lieu of all other warranties expressed or implied.

**********
 SECTION - 1

INSTALLATION
1.1. UNPACKING

The packing case should be carefully examined, upon receipt from the carrier, to
make sure, there is no obvious damage to contents. Pumps are shipped ex-works and
title passes to customer when carrier signs for receipt of it. The customer, therefore,
must file damage claims with the carrier. Open the crate carefully, as there are
sometimes accessory items fastened to the inside of the crate which may be lost or
damaged. Examine all material inside crate and check against packing list to be sure
that all items are accounted for and undamaged. All loose supplied items and
accessories are listed separately in the packing list along with the pump set.

1.2 MOUNTING

Support the pump firmly in a level position on a solid foundation, preferably with the
base above floor level to protect it from wash downs and provide easier access for
service. This model pump is provided with four/six tie-down points to accommodate
anchor bolts.

1.3. PIPING
1.3.1. General Information

a) Use piping materials that are resistant to corrosion by the pumped media.
Connection to the pump liquid end should be carefully selected.

b) Use piping to withstand maximum working pressure.

c) Flush and Blow out all lines before making final connections to pump.

d) Provide for pipe expansion when hot fluids are to be pumped.

e) Support piping so that pipe forces are not transferred to the pump. Never
“spring in” piping to make connections. Piping should be as short as possible &
sloped in a manner to prevent trapping of vapour in pockets. Vapour present in
liquid end will cause inaccurate pump delivery.

f) Install full flow type shut off valves with union/flanges on the suction and
discharge side to facilitate servicing. It is strongly recommended to have pipe
spools on suction and discharge side of pumps for ease of isolation of pump for
servicing.

1.3.2. Suction Piping

 a) 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; thus
decreasing frictional flow losses.
b) Suction piping must be absolutely air tight to ensure accurate pumping. After
installation, test suction piping with compressed air and soap solution for leaks.

c) A strainer should be used in the suction line to prevent foreign particles from
entering the liquid end. Any measures which prevent foreign matter from
entering and fouling the Pump NRVs will give trouble free service.

d) It is preferable to have the suction of the pump flooded by having the liquid end
located below the lowest level of the fluid, in the supply tank.

e) When pumping liquids at temperatures near the boiling point provide sufficient
suction head to prevent “flashing” of the liquid into vapour, when it enters the
liquid end on the suction stroke.

f) When suction piping is long, particularly at stroke speeds greater than 70

strokes per minute, the size of the piping should be larger than the liquid end
suction fitting provided on the Pump to prevent starving of the pump (see
NPSHA calculations). Provide stand pipe or float box near the suction of the
pump. In many cases installing an accumulator or pulsation dampner in the
suction line will facilitate flooded suction condition even when suction line is
long.

g) Sealed piping, sufficient suction pressure, and properly adjusted gland packings
are absolutely necessary for accurate and stable pump operations.

1.3.3. Discharge Piping

a) Install adequate size pipe to prevent excessive pressure losses on the

discharge stroke of the pump. Maximum pressure at the discharge fitting on
the liquid end must be kept at or below the maximum pressure rating as shown
on the name plate. The peak flow of this type of pump, during the discharge
stroke is approximately three times the average flow rate (because of harmonic
motion of the plunger) and discharge piping should be sized accordingly.

b) A pressure relief valve must always be provided immediately after the

discharge port. Pipe the outlet of the relief valve back to the suction tank (do
not pipe back into the pump suction line).

c) To maintain a smooth flow, a pulsation damping chamber should be installed

immediately after the discharge port. Contact us for correct sizing and
location.

d) The pump will not deliver a controlled flow if the discharge pressure is less than
the suction pressure. To guarantee proper functioning of the pump, the back
pressure at the discharge end must be at least 0.5 Kg./cm2 (7 Psi) higher than
the suction pressure. If these pressure conditions cannot be attained by
stated discharge head, a Spring Loaded Back Pressure Valve must be installed
on the discharge side. The pump produces only the required pressure to
overcome the back pressure or discharge pressure in the discharge line.
1.3..4. Precaution

When planning pipe installation, the following precautions must be taken.

1. Avoid lengthy pipelines of small diameter and sharp bends.

2. Avoid suction lines that are not self venting.

3. Avoid use of thin walled suction hoses without reinforcement.

They collapse during suction stroke

4. Avoid suction lines drawn from the lowest point of a reservoir.

5. Avoid filters whose elements cannot be changed or cleaned.

6. Discharge side isolation valve mist be provided after the external pressure
relief valve.

7. Avoid long vertical risers immediately after the delivery outlet of the pump.

8. When handling suspension, avoid pipeline systems, which do not feed the
pump with an uniform well mixed medium or tend to deposit sediment or cannot
be drained during shut down. We can provide, on request, our standard piping
recommendations for handling suspensions.

9. Avoid piping, relief valve discharge, back to the suction line.

10. Pipe line must be free of tension when fitted.

11. Pump heads must not be subjected to any strain by the weight or vibration of
the pipe line system.

12. Pipe lines and pump must be so installed that inspection overhaul or repairs
can be easily carried out. Ensure that a short piping spool is provided
immediately after pump suction and discharge connections for ease of pump
NRV access.

13. BY-PASS LINE WITH A VALVE AND NRV ARE A MUST WHEN PUMP HAS
TO START AGAINST FULL SYSTEM BACK PRESSURE.
1.4 SERVICE CONNECTION

1.4.1. Pump Drive

Check the name plate data on the pump driver (motor) and proper electric
power supply is to be provided to the driver before making any electrical
connection.
a) To ensure proper lubrication of pump drive elements, normally pumps
are supplied with pump drive shaft on the right hand side , as seen
from liquid end. In this configuration the direction of rotation is Anti-
clockwise; When seen from pump drive shaft end.
Note :- It is possible to drive the pump from left hand side extension of pump drive
shaft. This is achieved by interchanging Side Covers or Bell Housing and Side Covers,
after removing blank end cover. For this configuration the direction of pump drive shaft
rotation should be Clockwise, when seen from pump drive shaft end.
Connecting rod, Eccentric and Crank mechanism, which are the heart
of the pump, get splash lubricated by the correct motor shaft rotation. A severe
damage would occur if the motor shaft rotation is incorrect.

b) For drivers other than constant speed electric motor, refer to complete
manufacturer’s instructions and service information included with the pump.

1.4.2. Auxiliary (Accessories) Equipment

Service connections for auxiliaries or accessories, and electrical
equipment should be determined by reference to wiring diagrams, instruction
manuals, name plates and data sheets furnished with the equipment’s.

1.4.3. Drains
Provide drains conveniently close to the pump foundation so that any leakage
may be easily drained.
 SECTION - 2

OPERATION

2.1. PRINCIPLES OF OPERATION

Multiflo Metering Pumps are controlled volume positive displacement reciprocating

pumps, consisting of two basic mechanisms viz. the drive end and the liquid end.
The drive mechanism is essentially a slotted slider, driven by a worm gear reduction,
rotating about its axis in vertical plane. An Eccentric is linked to the slider by a guide
pin, which also rotates along with the Eccentric, in a fixed horizontal plane. The
cylindrical end of the guide pin is fitted in the Eccentric and the rectangular end is free
to slide in the slider slot. At zero stroke the axis of rotation of the Eccentric and the
slider coincide. By rotating the control knob/hand wheel, the slider can be moved up
or down resulting in the shift of the slider pin in the slider slot away from the axis.
Thus the desired Eccentricity is achieved, which in turn is converted into the
reciprocating motion of the plunger with the help of eccentric strap and cross head.
Stroke length can be set from 0 to 100% by rotating the control knob/hand wheel to the
required graduations on the scale/barrel or mechanical counter. This change in
stroke length results in proportional change in stroke volume and flow rate of the
pump.

Liquid End is essentially a pump chamber, with suction and discharge non-
return valves, at the bottom and at the top, allowing flow only from suction to discharge
side. Pumping action is achieved by a reciprocating plunger & sealing gland in the
case of Plunger Type of Liquid Ends. In Diaphragm type Liquid Ends, there is a
sealed diaphragm, which is actuated by hydraulic plunger through hydraulic fluid..
During suction stroke liquid is drawn into the Liquid End chamber through
suction non-return valve and during discharge/power stroke, liquid flows out through
discharge non-return valve. Thus due to continuous reciprocating motion of the
plunger or diaphragm, the liquid is alternatively drawn in, and pushed out of the
displacement chamber. By setting the desired stroke length with the help of the
control knob/hand wheel, the exact quantity of liquid displaced per stroke is controlled.

2.2. OPERATION
2.2.1. When installing, operating and maintaining Multiflo Metering pumps, keep
safety considerations foremost. Use proper tools, protective clothing and eye
protection when working on the equipment. Take additional safety measures
appropriate to the liquid being pumped. Be extremely careful in the presence of
hazardous substances. Install the equipment with a view towards ensuring safe
operations.

2.2.2. Pre-operational inspection

After the pump is installed, but before it is started for the first time, a number of checks
should be made.
a. Bolts and fittings : Make sure that all tie down bolts & nuts are tight.

b. Piping is installed properly.

 c. See correct oil level of recommended lubricant is maintained in the gearbox.
For nominal capacity of the gearbox see table No.3.1.2 and for recommended
lubricant Table No.3.1.3.
d. The stroke adjustment of the pump is kept at a low setting e.g. 20%.

e. All shut-off valves (isolating valves) are opened.

f. Make sure the suction lines are filled with system fluid. Open the vent screw on the
liquid head to check the fluid has reached the liquid head.

g. Check Pressure Relief Valve is mounted on the discharge line before first
isolation valve.

h. Ensure Pressure Gauge is mounted in discharge line to indicate line pressure. It

should be down stream of discharge pulsation dampner.

2.2.3. Capacity Adjustment

With the help of the Control Knob/Hand Wheel the capacity of the Pump can be
changed. The direction of rotation for increase/decrease is indicated on the Control
Knob/Hand Wheel label. By rotating the Control Knob/Hand Wheel in the
clockwise/anti-clock-wise direction, the stroke length can be increased/decreased and
in turn the capacity can be changed. The stroke scale has graduations from 0 to 100%
of stroke. For setting the desired stroke length, first loosen the lock screw of Control
Housing/Barrel, turn the knob/hand wheel and bring the indicator to the desired
position and relock the lock-screw.

2.2.4. Start-up Inspection

a. GENERAL: All pumps are thoroughly tested under simulated operating conditions
before they leave the factory, to verify the pump capacity and to check that the drive
motor is adequate for maximum rated condition. With the pump housing filled with
proper oil to required level and all piping and electrical connections made, the pump is
now ready for start-up.

b. WARNING:

1. Do not run pump without oil.

2. Use only approved oils.

3. Do not remove back plate of main housing while pump is running.

4. Do not run pump with coupling guard removed.

5. Do not put hands or fingers in gear box when pump is running.

FOR PLUNGER TYPE LIQUID ENDS:

New packing installed and shipped from the factory in a complete pump or liquid end,
have been “set” and “run in” during production / quality assurance testings, and require no
further adjustment for start-up, if pump is installed and operated within 6 months from the
date of supply. During operation, if leakage does occur, the gland nut should be tightened
a little at a time (1/6 turn or less) until leakage is minimized or stopped. The packing
should be allowed to resettle at least five minutes between adjustments. It is advisable to
tolerate a little leakage at the gland as the leaking liquid will help to lubricate and cool the
packing and plunger, greatly extending the life of both.

FOR DIAPHRAGM TYPE LIQUID ENDS:

The hydraulic oil (SAE 20W 40) would be filled up at the time of performance test of the
pump. This oil is retained at the time of shipment. It is, however, essential to check that the
chamber between the Diaphragm and Hydraulic Plunger is completely filled up by hydraulic
fluid, to ensure better metering accuracy. Please refer to SECTION 4 for more details.

c. INITIAL RUNNING
I. Start the pump for a moment and ensure the preferred direction of rotation as
marked on the blank end cover.
II . On initial start up, run the pump for 30 to 40 seconds. Repeat approximately 10
times. During these start runs listen for any abnormal noise and if you notice any,
refer trouble shooting chart for remedy.
III) Set stroke adjustment to maximum capacity and run pump for 30 minutes without
any discharge pressure. Check discharge line for indication of flow.

2.2.5. Calibration

1. General :
The metering pumps are calibrated on our test stands under the following
conditions :-

a) Suction Lift 0.3M / positive suction head of max.2.5 M.

b) Discharge Pressure as specified by the customer.
c) The required pressure is obtained by an adjustable
throttle valve on the discharge side.

The final calibration must be done under actual operating conditions at site.

2. External Pressure Relief Valve Calibration

Pressure Relief Valves are preset at the Factory. By slowly throttling the first
isolation valve, in the discharge line, gradually increase the discharge pressure to the
PRV set pressure and ensure that the PRV is functioning . If need be, reset the PRV,
and ensure its proper functioning by testing as described above.
 3. Capacity Calibration

After the initial running of the pump and adjustment of the gland packing for
Plunger Pump, and proper air-bleeding of Diaphragm type heads, test runs should be
made to determine the exact capacity of the controlled volume pump under the
specific operating conditions for various stroke length settings. It is necessary to
calibrate the pump at only four stroke length settings to determine its characteristics
throughout the entire range. The settings normally used are full stroke (100 percent),
75 percent, 50 percent and 25 percent stroke length. Two methods of measuring the
capacity in a given time limit can be used.

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

(2) Measure the quantity collected from the discharge side of the pump. Check the
capacity several times at four different stroke length settings and record them on
linear graph paper. For all stable conditions these points should describe a straight
line.

Precaution:

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

When the pump has to be started frequently against full system pressure it is
necessary to have the System Piping Layout as per our recommendation as shown in
the illustration. When starting the pump against full system pressure first the Bypass
valve is fully open and then it is gradually closed to load the pump to bring it to system
pressure. This is absolutely necessary to protect the pump from shock loading.
 SECTION - 3

MAINTENANCE

The Multiflo Metering Pump has been carefully designed, manufactured and tested to
give reliable service with a minimum amount of maintenance. A check up after 48 hours is
recommended to visually confirm proper operation of the pump.

Accurate records in the early stages of pump operation will reveal the type and
amount of maintenance that will be required. A preventive maintenance program based on
these record will ensure trouble free operation. It is not possible in these instructions to
forecast the life of such parts as the check valves, gland packing and other parts in contact
with the product you are handling. Corrosion rates and conditions of operation affect the
useful life of these materials so an individual metering pump must be gauged according to
particular service conditions.

3.1. LUBRICATION

3.1.1. Fill the gear reservoir of the pump main housing with recommended gear lubricant to
the oil level mark. Remove the breather plug labelled OIL and with the help of funnel fill the
oil in the reservoir up to RUN/OIL LEVEL. The oil should be changed every 500 hours of
operation or every 3 months, whichever is earlier. Use only recommended oils. Do not
overfill.

3.1.2. OIL CAPACITIES OF VARIOUS MODELS

(DRIVE SIDE)
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MODEL OIL REQUIRED (LITRES)
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PR-10 HD/SD 0.200
PR-20 HD/SD 0.500
PR-35 HD/SD 1.150
PR-50 HD/SD 1.150
PR-60 HD/SD 5.000
PR-60-E HD/SD 5.000
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 3.1.3. RECOMMENDED OILS
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S.NO. MANUFACTURER TRADE NAME
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1. In droll Lubricants Alpha SP 460
2. Castrol Alpha SP 460
3. Bharat Refinery Amocam 320
4. Bharat Refinery Amocam 460
5. Hindustan Petroleum Parthan EP320
6. Hindustan Petroleum Parthan EP460
7. Indian Oil Corporation Servo mesh 460
8. Indian Oil Corporation Servo mesh 320

3.1.4. CHECK EVERY 48 HOURS

I. Check oil level in the gear box.

II. Inspect the liquid end for indication of leakage.
Glands to be tightened as lightly as possible.
III. Grease or Oil all lubricating points.
Oil the cross head every 48 hours.
3.2. DISMANTLING PROCEDURE FOR REPLACING SPARE PARTS
(For PR-35/PR-35 HD/SD Models)

For attending to any spare replacement in Drive End or Diaphragm Head, the
Pump needs disassembly. While dismantling the Pump, first the Diaphragm
Head/Liquid side components are removed, then the Yoke is removed and then
all other sub-assemblies are dismantled.

Before dismantling the Diaphragm Head/Liquid Head from the Pump :

a) Remove all pressure from the piping system.

b) Close the inlet and outlet shut-off Valves.
c) Place a pan under the Diaphragm Head/Liquid Head to collect the
entrapped product.
d) Disconnect the Union/Flanges of the piping.

3.2.1. Dismantling Liquid Heads

a) Dismantling Hydraulic Head and Diaphragm Head (Refer Fig.No.6).
Follow instructions as given in Chapter “Metering Pump with Diaphragm Head”
under section “Instruction for Dismantling and Assembly” Point -1.

b) Dismantling Plunger Head (Refer Fig.Nos.2 & 3)

⇒ Loosen Lock Nut (39-20-12-0)
⇒ Loosen and remove Plunger Retainer (39-20-09-0)
⇒ Remove Lock Retainer/Liquid Head Clamping bolts.
⇒ Hold the Liquid Head with both the hands and pull out straight from
the Yoke (39-20-08-0). Liquid Head would come out loose with Plunger
and Plunger Seat and Plunger Retainer.

3.2.2. Dismantling Yoke (Refer Fig.2)

a) Remove Air Breather Oil Filter Plug (041-013000)
b) Remove Oil Drain Plug (042-006000) and drain out oil from the main
Housing (39-30-01-0).
c) Remove 4 Nos. Yoke Bolts or Lock Retainer.
d) Hold Yoke (39-20-08-0) with both the hands and pull out straight from the
main housing (39-30-01-0).

3.2.3. Dismantling Digit Counter type Stroke Adjusting Mechanism Assembly

(Refer Fig.No.1b & 1c).

a) Unlock the Lock Retainer [39-50-06-0] .

b) Unscrew Control Housing fixing Screw [001-008020].Hold the Control

Housing in left hand and turn the hand wheel in decrease direction to reduce
the stroke. Do not allow the Control Housing to turn. The Control Housing
assembly would start rising up, away from the Housing [39-30-01-0].
Continue hand wheel rotation in decrease direction till SL Controller [39-50-
 03-0] gets disengaged from the SL Adjuster (39-50-05-0). Then take out the
Control Housing Assembly.

c) Remove Top Cover Bolts [001-012035] and take out Top Cover [39-10-13-0]
and Thrust Plate (39-10-08-0).

d) Remove Back Cover Plate Bolts [001-006015] and Washers [083-006013]

and take out Back Cover Plate [39-30-02-0].

e) Hold the S.L. Adjuster [39-50-05-0] by right hand and Eccentric Strap [39-
20-01-0] by left hand and pull the Cross Head/Eccentric Strap/Slider/S.L.
Adjuster assembly out.

f) To dismantle S.L. Actuator Assembly with S.L. Indicator and Hand Wheel
from S.L. Controller, loosen S.L. Actuator Assembly fixing screw [005-
004050] and pull out the S.L. Actuator Assembly with Hand Wheel, S.L.
Indicator as a single piece.

g) For dismantling S.L. Actuator Assembly refer to Fig.No.1(C).

3.2.4. Dismantling of Worm Gear Reduction

a) Remove Bell Housing / Side Cover and B.E. Cover Bolts (001-008035) and
Washers (083-008017) and take out B.E. Cover (39-10-18-0) by slightly
tapping both the ends of the Worm Shaft (39-10-16-0), remove Side
Cover. (39-10-17-0) or Bell Housing (39-30-07-0). Both the Bearings will
retain on the Worm Shaft and Oil Seals in the Covers. Keep Worm Shaft
loose in Main Housing (39-30-01-0).

b) Tighten the Grub Screw (020-005010) at the bottom of the Housing and
push the Drive Shaft Assembly up till Slider Housing Assembly from the top
bore (Top Cover Bore) of the Housing. Dismantle Slider Housing Bearing
(090-621500), Spacer (39-10-14-0) and Worm Wheel (39-10-15-0) from
Slider Housing (39-10-11-0) after knocking out Spring Dowels (054-006030).

3.2.5. Dismantling Liquid Head Sub-Assembly (Refer Fig.3)

a) Hold Liquid Head Assembly and loosen Gland Retainer. Pull out the
PLUNGER. Remove Throat Bush Gland packings and Guide Rings.

3.2.6. Dismantling Liquid Head

a) For Liquid Head with square packings.

Remove the old packing rings by wooden sticks or soft metal strip. Cut the new
square rope of correct section to correct length. Give slant cuts to the
packings to get better overlap at the joints.

Insert the Guide Ring in the Liquid Head bore and push the Plunger through
it properly centring it. Insert the Gland Packings one by one in the recess
between Liquid Head bore and Plunger outside diameter. Number of
packings should be same as the old number of packings.
3.3. ASSEMBLY PROCEDURE FOR THE PUMP ASSEMBLY

First place the Worm Shaft in the Housing pushing it along with the Bearing
through the Side Cover bores. Assemble the Slider Housing Assembly. Lightly
push and tap side cover/bell housing locating them on Worm Shaft Bearing
and Housing bores. Fix the Side Cover/bell housing. Check that the Worm and
Worm Wheel moves freely. Side Covers and bell housings can be
interchanged to make a pump R.H. or L.H. Drive.

Replace all oil seals and take care not to damage seal lip while assembling new
seals. Use tapered bush for insertion of seals. Take the control assembly
complete without Top Cover and SL Indicator. Insert Cross Head end through
Yoke locating bore of the Housing and by tilting Slider and rotating Slider
Housing enter bottom rectangular end of Slider, into the Slider Housing
rectangular slot. Push Slider gently down. Fix Yoke locating it on Cross Head
outside diameter. Fix Top Cover using correct number of Gaskets. Check, that
the Thrust Plate does not get tightened up, after fixing the Top Cover.
Generally Thrust Plate should just rotate by hand when Top Cover and Yoke
are fully tightened. Assemble all the rest of the parts in reverse sequence of
dismantling. First turn the Pump by handle to see it turns freely.

ZERO SETTING
For resetting the S.L. Indicator to correct zero after full Pump Assembly is
complete. Turn the hand wheel in decrease direction till the pump stroke
becomes zero. Check stroke of the pump by turning the Worm Shaft by hand
checking the movement of Cross Head. At zero stroke, for few revolutions of
Worm Shaft, Cross Head movement should be zero. Now remove acrylic cover
of S.L. Indicator, set the S.L. Indicator reading to Zero by turning spindle by
hand. Now engage the Counter with Control Worm Shaft driving gear and
tighten Screws [009-003008]. Fix up Acrylic Cover [39-50-71-0] with screws
[005-004010].

PLUNGER FIXING
For proper Plunger fixing procedure, follow the instructions given below :

Insert the Plunger Assembly with Plunger Retainer, Lock Nut, and Plunger Seat
assembled on the Plunger, into cross head bore, tighten the Plunger Retainer
completely till the Plunger gets completely tight. Turn the Plunger Retainer 1/6
turn backwards to loosen. Plunger now becomes relatively free and it can align
with respect to the gland or plunger guide but would have negligible axial play.
Be careful not to loosen the Plunger retainer more that 1/6 turn otherwise
plunger would have excess axial play. Now hold the plunger retainer in this
position and jam the lock nut on the face of cross head.
CAPACITY ADJUSTMENT FOR MODELS WITH DIGIT COUNTER
ASSEMBLY
The capacity of the pump can be changed by rotating the Bakelite Hand Wheel on top of
the pump. The Mechanical Counter connected to Hand Wheel shows the percentage
setting of the stroke length.

To increase the capacity, turn the Hand Wheel in the direction of the arrow marked
“INCREASE” (clockwise).

To decrease the capacity rotate the Hand Wheel in the direction of the arrow marked
“DECREASE” (anti-clockwise).

CAUTION : Before turning the Hand Wheel, loosen the Lock Retainer
(39-50-06-0). When the desired stroke length is set, the
Lock Retainer should be tightened.

DO NOT OVER ADJUST ABOVE “100%” OR DO NOT GO BELOW

“O” % STROKE LENGTH.
 SECTION-4

METERING PUMP WITH DIAPHRAGM HEADS

DESIGN AND PRINCIPLE OF OPERATION OF DIAPHRAGAM

ACTUATED REPLENISHMENTS (DARS)
TYPE DIAPHRAGM HEADS

These heads are added on to our Multiflo Metering Pump Drive Ends. Variable
stroke mechanism of the “Multiflo” metering pumps is used for varying the flow
rate of the pump for variable stroke models. This “variable stroke mechanism”
moves a piston in closely guided bush. This piston displaces hydraulic fluid,
which acts on the diaphragm to deflect it. Displaced volume of hydraulic fluid is
changed by change of piston stroke. Volume of hydraulic fluid displaced by
piston is same as volume of process fluid displaced by diaphragm. For
accuracy of metering, the volume of the hydraulic fluid trapped between the
piston and diaphragm has to be maintained. This is achieved by vacuum
system in combination with Refill System. The replenishment of hydraulic fluid
to compensate for losses around piston, air bleed valve, and other places is
carried out only when the following conditions are met:

1) Refill Gate (XX-60-30-0) is pressed back by diaphragm so that the

vacuum system can communicate with piston chamber.

2) Vacuum in piston chamber is adequate to open up vacuum system. The main

advantage of this system is that the system cannot overfill the piston chamber
even if high vacuum is created due to clogged or blocked suction on process
fluid side. Vacuum System can fill up the piston chamber only in the retracted
condition of the diaphragm. This eliminates the possibility of overfilling of
piston chamber.

Diaphragm heads are superior to plunger heads due to the inherent advantage
of “No Leak Pumping of the Product” Diaphragm Heads also have a built-in
safety valve on hydraulic fluid side. This safety valve is designed to protect the
pump against excessive back pressure. If the pressure in the pump head rises
above the set pressure the safety valve opens and the hydraulic fluid displaced
by the plunger flows back into the oil chamber. The pump must not be run in
this condition for a long time. Air bleed valve is fitted either integrally with
safety valve or independently in all Head sizes above “O” Head. A small
leakage flow is set through it to eliminate any gas present in the piston chamber
on a continuous basis.
3) Pressure relief valve: In case of accidental closing of the delivery line, this
valve opens and allows the oil to flow out of the piston chamber.
HYDRAULIC FLUID
The recommended hydraulic fluid is SAE 40 OIL or SAE 20W-40 OIL for general
purposes. For specific recommendations; where operating conditions are different
from normal ambient conditions; please contact us for recommendation of
hydraulic fluid:
OIL CAPACITIES OF OIL CHAMBERS
Head ‘O’ - 0.20 Ltrs.
Head 1 & 2 - 1.01 Ltrs.
Head 3 - 3.50 Ltrs.
Head 4 - 4.60 Ltrs.

COMMISSIONING AND MAINTENANCE

Every pump is thoroughly checked before despatch. Hydraulic vacuum system
and safety relief valves are set. Vacuum system spring is so set that it would
open if the piston chamber pressure drops below 0.4 kg./cm2. Safety valve is
generally set at 1.4 times systems or operating pressure.

INSTALLATION
Sizes of all connections should be taken from pump data sheet. All joints must
be made so that no stress is imposed on the pump head. Piping and joints must
be thoroughly cleaned. Support and secure the pump to the foundation as per
foundation plan given in GA DRAWING. Before starting pump, check that
electrical connections are proper as per data sheet.

COMMISSIONING PROCEDURE
I. FOR METERING PUMPS (MODEL PR)
Fill up the recommended hydraulic fluid in the Hydraulic Chamber [XX-60-41-0]
up to the oil level mark. Turn the pump drive shaft and see that pump is free to
turn by hand. Set the stroke at 10% setting, open the Pump Isolation Valve on
the Suction side and start the pump. Increase the stroke and top up the oil
level in hydraulic chamber if it drops below level mark. Slowly all the air from
the diaphragm chamber would be bled off and the pump would eventually reach
rated capacity.
In extreme cases if the piston chamber gets air locked, adopt following
procedure. Disconnect power supply on pump motor. Set the pump at about
50% to 60% stroke setting. Unscrew and remove the safety valve assembly
from the Actuator Body. Move the piston backward and forward by hand and
pour hydraulic fluid in the safety relief valve fixing port. During suction stroke of
the piston, the oil would be sucked in, fill up the entire piston chamber by
hydraulic fluid by pouring it in safety relief valve port. Screw in the safety relief
valve carefully taking care that the “O” rings are not damaged during
reassembly. DO NOT START THE PUMP AT THIS STROKE SETTING. THIS
MAY CAUSE SERIOUS DAMAGE TO THE DIAPHRAGM. Change the stroke
setting to 100% and start the pump. Initially, the pump may discharge excess
 oil through the Air Bleed Valve. Pump would start pumping and within few
minutes would reach rated capacity.

II. FOR NON-METERING PUMPS

(FIXED STROKE MODEL SP)
First loosen the PRV-Air Bleed Valve. (Charge the oil chamber fully, Open
Pump Isolation Valve on the Suction side, start the pump, top up the Hydraulic
chamber to maintain the oil level, if necessary. After a few strokes, tighten PRV
fully. In case Pump does not deliver rated capacity, loosen PRV and use
compressed air in pump suction line to deflect the Diaphragm towards piston
side, fill up hydraulic fluid and then tighten the PRV, disconnect Air Line and
start the pump.

SERVICING
Check hydraulic fluid level in Hydraulic chamber at fortnighly intervals. It is
recommended that diaphragm should be changed after 5000 running hours.
-------------------------------------------------------------------------------------------------------
TYPE OF HYD.SNIFT INTIAL SPRING
VALVE COMPRESSION
kgf
-------------------------------------------------------------------------------------------------------
00-60-00-0 0.08 TO 0.09

01-60-00-0 0.08 TO 0.125

02-60-00-0 0.15 TO 0.2

03-60-00-0 0.25 TO 0.3

04-60-00-0 0.3 TO 0.4

-------------------------------------------------------------------------------------------------------
PRESSURE RELIEF VALVE SETTING
Release the tension on the spring of the PRV. Set the pump to zero stroke, run it
against closed discharge. Tension the PRV Spring very gradually and increase the
stroke to 20%. The pressure at which the pressure relief valve opens should be read
on the pressure gauge on the outlet of the pump. Gradually, increase the tension on
the springs till the desired pressure level is reached on the gauge. Tighten the Lock
Nut to secure the PRV setting. Now open the discharge valve and increase the stroke
setting to desired level.

METERING PUMP WITH SANDWICH DIAPHRAGM HEADS

DESIGN AND PRINCIPLE OF OPERATIONS
Sandwich Diaphragm Heads are improvement over conventional double diaphragm
heads. There are essentially two diaphragms which are in physical contact with each
other while maintaining very fine gap in between, to sense any leakage past the
diaphragm due to rupture of the Diaphragm. In the normal operation , intermediate
chamber between the two diaphragms is under atmospheric pressure and both the
Diaphragms act together as if they are mechanically coupled. If there is any rupture or
a pin hole to any of the Diaphragms, pressure in the intermediate chamber rises to the
System Pressure and this rise in pressure is sensed by the pressure sensor/pressure
gauge through the non-return valve which is at the upper side of the actuator body.
Intermediate chamber is in connection with this pressure sensor/pressure gauge
through a small orifice. The only difference between diaphragms heads with single
diaphragm and sandwich diaphragm heads is the additional diaphragm intermediate
chamber and the sensing elements which are extra. The entire operation of the
sandwich diaphragm head is identical to the single diaphragm heads. Please refer to
the section Metering Pumps with diaphragm heads for further details.

I. Intermediate fluid
It is possible to run these pumps without any intermediate liquid. However, it is
recommended to use distilled water as intermediate fluid. If it is compatible with
the process fluid. Any other compatible liquid also can be used in the intermediate
chamber.

II. Commissioning Procedure

For commissioning drive side, read instructions from section 2.

III. For Filling Intermediate Chamber with Liquid

1. Fill up the recommended intermediate fluid in the space between the two
diaphragms. Please refer to Fig. A. The reservoir containing intermediate fluid
can be kept at the height, (to give a positive head of about 1m) or can be
pressurized with compressed air (0.1 to 0.2 bar) and connected to lower nipple
via a flexible tube. Do not use pressure higher than 0.2 bar and ensure top
nipple is loosened before connecting tube to bottom nipple to avoid stretching
of diaphragms.
2. For the filling operation both nipples must be slackened off, the top one by at
least two turns. Intermediate fluid oozes from the upper nipple. Bleed off the
intermediate fluid till all the air has come out. Now first the lower and then the
upper nipple must be tightened. Intermediate Chamber between two
diaphragms is now full with intermediate fluid.
3. Pour hydraulic fluid into hydraulic chamber. Run the pump at full stroke.
Pressure gauge/Pressure sensor will sense some pressure. Release this
pressure by opening upper nipple. Retighten the nipple.
4. Run the pump for about ten minutes.
5. Charge and vent the intermediate chamber as described above, when the
pump is run against the back Pressure. Excess intermediate fluid with air
oozes from the upper nipple connection of the Sandwich Diaphragm, when it is
loosened. Repeat this procedure few times till the intermediate chamber
pressure, as shown the gauge, is brought to zero. Lock the upper and lower
nipples.
 INSTRUCTIONS ON PRESSURE RELIEF VALVE AND
VACUUM VALVES OF PUMPS
PRV ASSEMBLY
Check free movement of Part 1

Lap the faces of Item 5 and Item 6 on flat lapping

surface to ensure that full annular face seating is
achieved. This is essential to arrest leakage.

Check the ball 3 is in place and has proper seat and

is moving freely, in the hole of Item 6.

Check that O-ring part 4 is seated in its place.

3 Remove PRV and remove all the air from the

trapped volume of oil by filling oil from the PRV
opening in the actuator body.

6
1

Check O ring Part 1 is intact and is properly sealing

on the face.

Check and clean wire mesh Part 2

Set the spring setting so that the valve opens at

values of forces,
specified in the Instruction Manual.

Check that the ball Part 3 has proper seating on

Part 1. Lap the ball on seat area of Part 1 to ensure
leak proof seating.
VACUUM VALVE ASSEMBLY
 ΣΡ. ΝΟ. ∆ΕΣΧΡΙΠΤΙΟΝ ΜΑΤΕΡΙΑΛ ΘΤΨ.
1 ΜΑΙΝ ΗΟΥΣΙΝΓ ΣΣ316 1
2 ΥΠΠΕΡ ΡΕΤΑΙΝΕΡ ΣΣ316 1
3 ςΑΛςΕ ΣΠΙΝ∆ΛΕ ΣΣ316 1
4 ΛΟΩΕΡ ΡΕΤΑΙΝΕΡ ΣΣ316 1
5 ΣΠΡΙΝΓ Α∆ϑΥΣΤΕΡ ΣΣ316 1
6 ςΑΛςΕ ΓΥΙ∆Ε ΣΣ316 1
7 ςΑΛςΕ ΣΣ316 1
8 ςΑΛςΕ ΣΕΑΤ ΣΣ316 1
9 ΣΠΡΙΝΓ ΣΠΡ. ΣΤΕΕΛ 1
10 Α∆ϑΥΣΤΕΡ ΣΠΙΝ∆ΛΕ ΣΣ316 1
11 ΛΟΧΚ ΡΕΤΑΙΝΕΡ ΣΣ316 1
12 ΣΕΑΛΙΝΓ ΡΙΝΓ ΤΕΦΛΟΝ 1
PRESSURE RELIEF VALVE

The Pressure Relief Valve is an adjustable spring loaded valve. It is designed to

protect the pump against excessive system back pressure. The valve is factory
adjusted for set
pressure as originally specified or at 15% above the rated pump discharge pressure.

To readjust the valve to a lower relief pressure, unscrew the adjusting bolt (or Turn it
anti clock wise direction as seen from top).

Operation, with valve set too high, may overload the pump and may cause serious
damage to the pump. Operation, with valve set too low causes it to operate on each
stroke. This results in decreased pumping capacity and eventually affects the
efficiency of the valve.

The figure above is of a typical pressure relief valve. Individual valves vary in
appearance by model and application.

To check the pressure setting, install a pressure gauge in the discharge line between
the pump and a shutoff valve. With pump operating at maximum stroke, gradually
close down the shutoff valve and observe when the pressure relief valve starts to
operate. Dead end shutoff pressure will be higher but the cracking pressure of the
pressure relief valve must be at least 0 to 15% higher than maximum pressure of the
process. Occasional inspection of the valve and seat is recommended. Parts showing
wear should be replaced or re lapped.
 Ideal pump installation is shown in the figure on the top. Following points
must be taken care of during installation for trouble free operation of
metering pumps.

1. Pressure gauge must be installed in the system at the downstream of pulsation

dampener.

2. Pressure relief valve should be very close to the pump but should be down
stream of pulsation dampener.

3. All the throttle or shut off valves on discharge side must be after the Pressure
relief valve.

4. Pressure relief valve outlet or drain port must be separately piped back to
suction tank and should not be connected back to pump suction line.
 SECTION-6
ACCESSRIES

PULSATION DAMPENER

Pulsation dampener is essentially a pressure vessel, used in the system, to smoothen

out the flow and pressure fluctuations caused by the reciprocating pump. Pulsation
dampener stores the pulsating discharge of the pump and delivers it to the system with
almost all the pulsation smoothened out. It is essential to install a pulsation dampener
in system to get a steady uniform flow of process fluid. Pulsation dampeners reduce
pipe vibrations and system is saved from high pressure spikes. Pulsation dampeners
also save the energy by storing excess energy and supplying it when needed.
Pulsation dampener of correct size is essential for optimum results. Consult us for
proper estimation of dampener size.
 SR. DESCRIPTION MATERIAL QTY.
NO.
1 HOUSING SS316 1
2 MESH SS316 1
3 MESH WASHER TEFLON 1
4 RETAINER SS316 1
5 WASHER TEFLON 1

Y – TYPE STRAINER

Y type strainer is essentially a filter. It is used on suction line to filter out, any solids
larger than the mesh size, which are trying to pass through the suction line. This
strainer is essential for proper functioning of the pump non return valves. Non return
valves of the pump may become ineffective due to solids coming between the ball or
cone and seat. This may lead to loss of metering accuracy. Strainer is recommended
in the suction line for the process fluids which are likely to have undesirable solids or
lumps in them. Suction strainer has to be cleaned with a regular frequency to avoid
choking of suction. For cleaning suction strainer, close the suction side shut off valve
and unscrew retainer (4) and take out mesh (2) clean thoroughly with proper solvent or
water, soap etc. and refit it.
 SR. DESCRIPTION MATERIAL QTY.
NO.
1 RETAINER SS316 1
2 HOUSING SS316 1
3 SPRING SPR. STEEL 1
4 BALL SS316 1
5 SEALING RING TEFLON 1

BACK PRESSURE VALVE

Back Pressure Valve is similar in construction to inline non return valve. Back pressure
valves are used to prevent an uncontrolled through flow of the pump. When either in
static or dynamic condition pressure at the suction flange of the pump is higher than at
the discharge flange, back pressure valves are necessary. The back pressures
generally required, are very low and various calibrated springs can give different back
pressures from 0.5bar to 3 bar.

Back Pressure Valve is recommended when pump delivery to the system is found to
be more than its displaced volume.
 TROUBLE SHOOTING CHART

FOR HYDRAULIC DIAPHRAGM PUMPS

DIFFICULTY PROBABLE CAUSE REMEDY

Pump does not start 1. Coupling disconnected - Connect and align.

2. Faulty power source - Check power source
3. Blown fuse
4. Broken wire - Locate and repair
5. Wired improperly - Check diagram.

No delivery 1. Motor not running - Check power source

Check wiring diagram.
2. Supply tank empty. - Fill with liquid
3. Lines clogged. - Clean with flush
4. Closed line valve - Open pipeline Valve
5. Suction or discharge - Clean-inspect.
ball check valves held
open with solids.
6. Vapour lock, cavitation. - Increase suction pressure
7. Strainer - clogged - Remove and clean
8. Prime lost - Check for suction
pipeline leak.
9. Pipeline blockage - Locate and clear
pipelines.
10. Shut Off valve closed. - Open Valve.
11. Pumps not reciprocating - Shear Pins or Guide pin
even though Worm Shaft may be sheared . Replace
is rotating. them.

Low delivery 1. Motor speed too low - Check voltages,

frequency, wiring and
terminal connections,
check name plate vs.
specifications.
2. Discharge and Suction - Clean, replace if damaged.
check valves worn or dirty
3. Built-in pressure relief - Re-set pressure relief
valve opening each stroke valve, re lap if necessary.
4. Calibration system error. - Evaluate and correct.
5. Product viscosity too high - Lower viscosity by
Increasing product
temperature.

6. Pump cavitating. - Increase pump size.

Increase suction pressure.
Cool product, if necessary.
Vacuum system spring set
too tight. Set it as per the
Table.
• Increase NPSHA.
C
ONTD...2/-
 TROUBLE SHOOTING CHART

PAGE : TWO

DIFFICULTY PROBABLE CAUSE REMEDY

7. Plunger & bush worn-out - Replace worn-out parts.

8. By-pass leakage - Correct by-pass valve
leakage.
9. Vacuum system or safety - Tighten vacuum system
valve loosely fitted. and PRV.
10. Leakage rate through air - Replace ball of air bleed
bleed valve too great. valve,
11. Hydraulic trapped volume - Check air bleed valve ball
getting air locked. & seat in the built-in PRV
lap ball on seat, lap PRV
poppet on seat.

Delivery erratic 1. Leak in suction line - Locate and correct.

2. Pump cavitating - Increase suction pressure
or NPSHA.
3. Motor speed erratic - Check voltage frequency.
Check for motor overload.

Delivery higher than 1. Suction pressure - Install back pressure

rated higher than discharge valve or consult factory for
pressure piping recommendations.
2. Back pressure valve set Increase setting.
too low.

Pump loses oil 1. Leaky oil seal - Replace.

2. Leaky gasket - Replace.
3. Gearbox overfilled. - Remove excess oil.
4. Leaky grub screws on - Replace, use Teflon tape.
side covers or bottom cover.

Excessive Noisy 1. Discharge pressure high - Reduce pressure.

operation 2. Water hammer. - Install dampner.
3. Worn bearings - Replace.
4. Worn gear. - Replace.
5. End play in worm shaft - Correct for shaft play by
shims.
6. Play in Plunger - Tighten Plunger Retainer to
keep 0.1 axial play and
lock by lock nut.

7. Play in Slider and Eccentric- Replace.

or Slider Housing.
8. Loose Thrust Plate - Tighten top cover screws.
Adjust by changing no. of
shims.
9. Play in Eccentric and - Replace Bush.
Eccentric Strap Bush.
 TROUBLE SHOOTING CHART

PAGE: THREE

DIFFICULTY PROBABLE CAUSE REMEDY

Noisy Piping 1. Pipe size too small - Increase size of piping

2. Pipe runs too long - Install dampner.
3. No dampner used . - Install dampner.
4. Dampner full of liquid - Recharge with air.
5. Pipe supports inadequate - Properly install pipe.

No Pressure 1. PRV “O” Ring damaged. - Replace “O” Ring.

2. PRV Seat & PRV Poppet - Lap the seal and poppet.
not matching. Refer Instructions on
Pressure Relief Valve
Section.

Motor overheats 1. Motor overloaded. - Check operating conditions

against pump design.
2. Low voltage - Check power supply.
3. Loose wire - Trace and correct.

Pump overheats 1. Oil Level too low - Fill oil in gearbox.

2. Gear box over filled - Remove excess oil.
3. Wrong shaft rotation - Correct shaft rotation
4. Thrust plate over - tightened Correct
Thrust Plate play by-
tightening and proper
shims.

****************