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INSTRUCTION MANUAL

FOR INSTALLATION
OPERATING,
AND
MAINTENANCE.

Dosing pump
PRIMEROYAL
PN117(140)S(W)38.1UT160TX/ VV1.Z
This manual should be made available to the person responsible for installation,
operating and maintenance.

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

Date : 05/2007 O / Ref : 40031040-GAISA 2930


CONTENTS

I - DESCRIPTION
I - 1. Unpacking and storage
I - 2. Description
I - 3. Operating principle of the mechanical assembly
I - 4. Operating principle of the liquid end
I - 5. Safety and health instructions

II - INSTALLATION
II - 1. Hydraulic installation
II - 2. Drip collection
II - 3. Handling
II - 4. Setting up
II - 5. Electrical installation

III - START UP
III - 1. Procedures before start up
III - 2. Start up
III - 3. Failures on start up
III - 4. Operation - Schedule of checks and maintenance operations

IV - ROUTINE MAINTENANCE
IV - 1. Oil change
IV - 2. Other maintenance operations
IV - 3. Tracing causes of failure
IV - 4. Ordering spare parts

V - PREVENTIVE MAINTENANCE

VI - SERVICING THE MECHANICAL ASSEMBLY

VII - SERVICING THE LIQUID END

GUARANTEE

LIST OF « TECHNICAL ASSISTANCE » AND « SPARE PARTS » DEPARTMENTS

REPRESENTED BY:

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Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
PART I – DESCRIPTION

I - 1. UNPACKING AND STORAGE

UNPACKING

The packaging must be carefully examined on receipt in order to ensure that the contents have not
sustained any obvious damage. Precautions must be taken when opening the packaging in order to
avoid damaging accessories which may be secured inside the packaging. Examine the contents and
check them off against the delivery note.

STORAGE PRECAUTIONS

• Storage for less than six months

Equipment shall preferably be stored in its original packaging and protected from adverse
weather conditions.

• Storage for more than six months

- Grease all visible unpainted sections. Rubber parts (such as semi-flexible couplings) must be
protected from sunlight and sudden temperature changes.
- Store the pump in its original packaging. In addition, packaging in heat-sealing plastic cover
and dessicant bags must be provided for. The quantity of dessicant bags should be adapted to
the storage period and to the packaging volume.
- Store protected from adverse weather conditions.

I - 2. DESCRIPTION

The PRIMEROYAL Pump is a compact electro-mechanical metering pump, oil-lubricated with a sealed
housing, allowing adjustment of its capacity when stopped or in operation.
It is designed for industrial operation in continuous mode.
It is made up of the following items :
• a driving device consisting of a motor ,
• a mechanical assembly ,
• a liquid end assembly

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0226001 1 /7
I - 3. OPERATING PRINCIPLE OF THE MECHANICAL ASSEMBLY

Drawing 1066136410

The movement of rotation of the motor is transmitted by the worm [052] to the tangent wheel
The system of rod [014] and eccentric [016A] transforms the rotative movement in a linear movement
The crosshead [010] connected to the connecting rod [014] move with an adjusting linear stroke. The
stroke of the crosshead [010] depends to the position of the slide [016] and the eccentric female
[016A]

I - 4. OPERATING PRINCIPLE OF THE MECHANICAL ASSEMBLY

Refer to chapter VII « Servicing the liquid end »

1 - 5. SAFETY AND HEALTH INSTRUCTIONS

The personnel responsible for installing, operating and maintaining this equipment must become
acquainted with, assimilate and comply with the contents of this manual in order to:
• avoid any possible risk to themselves or to third parties,
• ensure the reliability of the equipment,
• avoid any error or pollution due to incorrect operation.

Any servicing on this equipment must be carried out when it is stopped. Any accidental start-up must
be prevented (either by locking the switch or removing the fuse on the power supply line).
A notice must be attached to the location of the switch to warn that servicing is being carried out on
the equipment.
During oil changing operations, the waste oil must be collected in a suitable receptacle. Any overflow
of oil which may result must be removed using a degreasing agent suitable for the operating
conditions.
Soiled cleaning cloths must be stored in suitable receptacles. The oil, degreasing agent and cleaning
cloths must be stored in accordance with the rules on pollution.
Switch off the power supply as soon as any fault is detected during operation: abnormal heating or
unusual noise.
Special care has to be taken for chemicals used in the process (acids, bases, oxiding/reducing
solutions, ...).

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0226001 2 /7
8 7 6 5 4 3 2 1

438 435B 438L 432 432B 432A


068E
435A 438G 435D
F F
G (1 : 1)

053

K (1 : 2)
431

435F
A A

E E

439G 052 439E

037

I (1 : 1)
072A

H (1 : 2) 434B D
438F 435E 068B 010 406
D
068

A-A
435A 016A
439F

016
439D

439B B
B C
C 439C
014 037A 052 438I 438K 438A 037B 434 438H 081A
438E
B-B 438J 435D 435F 081

439A
019C
435C

439
435J
434A

008 438C
435F
B 068A B

072 F (1 : 1)
056

435F
26.05.05 EMISSION INITIALE YChevallier DDeparrois 00
Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

406

PRIMEROYAL N A
A 435G ENS MECANIQUE A PISTON SIMPLEX
068D 438B 072C SX PLUNGER MECHANICAL ASSEMBLY
432B 072B 432B 435H
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr
434C Tel : +33 (0)2 32 68 30 00
A2 1:4 1/ 1 Fax : +33 (0)2 32 68 30 93 106.6136.410
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

8 7 5 1 SOLIDWORKS
6 4 3 2
PART II - INSTALLATION

II - 1. HYDRAULIC INSTALLATION

All the information concerning the hydraulic installation of a metering pump is detailed in a volume,
« Generalities about dosing pumps installation ». You should consult that manual to define the
installation required for your application. However the main items are describe hereafter.

GENERAL

• Piping layout
• There must be no swan-necks or stagnant volumes which can trap air or gas.
• Stresses due to incorrect alignment of piping with respect to the centreline of valves must be
avoided as far as possible.
• Remove burrs and clean the piping before fitting.
• It is advisable to provide for a calibrating chamber in order to calibrate the pump in service
conditions.

PIPING ON THE SUCTION CIRCUIT

• Provide for a filter with suitable mesh size upstream of the pump.
• Check whether the diameter and length of pipe are compatible with the pump's maximum
capacity.

PIPING ON THE DISCHARGE CIRCUIT

• Provide for a safety valve on the discharge pipe, designed to protect the installation.
• It is advisable to install a priming valve on the discharge circuit in order to make starting and
maintenance of the pump easier.

1 Tank 6 Utilization
2 Suction circuit isolating valve 7 Priming valve
3 Calibrating chamber 8 Safety valve
4 Pump 9 Return
5 Discharge circuit isolating valve 10 Filter

Fig. 1 : Installation example

M0226001 3 /7
REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
II - 2. DRIP COLLECTION

• It’s recommended to install a drain system to collect the leakage and the drip, especially if the
liquid pumped is harmful

II - 3. HANDLING

Handling the pump

The lifting equipment must be compatible with the pump weight.


Simplex pump without motor : 270Kg maxi
The handling requires the following precautions :
• Fit the sling through the rings on the pump
• Check that the assembly is correctly balanced before starting to move it.
• Fix the pump as soon as it is positioned in correct location (see Chapter II - 4. Setting up).

Handling the Motor

The lifting equipment must be compatible with the motor weight (Refer to the motor signaletic plate).
Fit a sling in each ring on the motor.
Check that the motor is correctly balanced before starting to move it.

II - 4. SETTING UP

Pump Installation

Fix by the fixing holes the pump to an horizontal support correctly dimensioned. Leave enough clear
space around the pump to be able to carry out servicing operations and adjustments.
Pumps installed outdoors must be protected by a shelter (according to the climatic conditions).
Noise level, in dB (A) < 75

II - 5. ELECTRICAL INSTALLATION

Connecting The Motor

Check the specifications of the motor and compare them with the voltage available on your installation
before making connections. Connect up the motor in accordance to the indications specified in the
connecting box.
Check the motor rotation as indicated on the motor spacer

Do not forget to connect the earth terminal of the motor [PE] to the equipment earth
conductor.

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

M0226001 4 /7
REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
PART III - START UP

III - 1. PROCEDURES BEFORE START UP

Special care has to be taken for chemicals product used in the process (acids, bases, oxyding
/reducing solutions, ...).
• Check the pump fixation(Chapter II - 4.).
• Fill the housing with the lubricating oil (Chapter IV-1)
• Check the opening of all isolating valves installed on the suction and discharge circuits.
Disconnect discharge circuit ( caution to the liquid pumped). This procedure is to verify that there is
liquid present (pump is installed in flooded suction), or to prime the pump (pump installed in suction
lift).
• Check that the pump capacity is set to "0%" (hand-knob).

III - 2. START UP
• Once all the checks and procedures described in the previous section have been carried out,
start up the pump.
• Check visually and by listening. (In particular, check that there are no suspicious noises).
• Make sure that the hand-knob is unlocked.
• Adjust the pump capacity gradually from 0 % to 100% and control the liquid output at priming
valve.
• As soon as the liquid to be pumped flows out of the priming valve, priming on the process side
has been achieved. Close the priming valve or reconnect the discharge pipe, as applicable.
• Once the priming is obtained, adjust the pump to the desired capacity.
• Lock the hand-knob with the locking screw

III - 3. F AILURES ON START UP

The motor runs with difficulty and heats up

• One phase is incorrectly connected.


• The characteristics of the electrical power supply do not match the specifications of the motor.
• The electrical connection used is not suitable.
• The housing does not contain any oil. Fill up with oil (See Chapter III - 1).

The flow rate is lower than desired

• The pump capacity is incorrectly adjusted: adjust the capacity to the desired value and lock
the hand-knob.
• The suction power is insufficient (pipe cross-section too small or pipe too long): replace the
pipe with ones that have a larger cross-section or install the pump in flooded suction.
• The leak -tightness of suction pipe is unsatisfactory.
• The viscosity of the liquid is incompatible with the pump's capabilities.

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
M0226001 5 /7
The capacity is greater than desired

• The stroke adjustment of debit of the pump is incorrect: to adjust the debit to the wanted value
• A syphoning phenomen is observed: check if the suction pressure is not superior to the
discharge pressure . So necessary, to place a back-pressure valve on the discharge line.


The capacity is variable

• This problem may be due to particles from the piping which interfere with the operation of the
valve assemblies: clean the piping and the valve assemblies (by checking the assembly sequence
of different components).

III - 4. SCHEDULE FOR CHECKS AND MAINTENANCE OPERATIONS

• The programme of checks and maintenance operations depends on the conditions in which
the equipment is used. For this reason, the following frequencies are given as an example only.
Individual users should adapt these frequencies to their own specific operating conditions.

When ? Check Maintenance See

After 2000 first hours Change lubrificating oil Chapter IV-1


Every month Check the oil level of the
housing and the spacer
Trace lubrificating oil leak
-if incorrect →

Every 3 months Check the oil temperature Verify


-if >95°C → -the date of the last oil change
-the oil contamination
-the equipment operating
conditions
Every 8 000 hours or Change lubrificating oil Chapter IV-1
1 year

Complete revision ** Chapter V


Frequency to be Check conformity of Check the pump capacity Chapter IV-2
defined according to capacity
process

** Our Technical Assistance Department staff is available for any maintenance matters on site (see
DOSAPRO adress at the end of this manual).
A model maintenance sheet is shown hereafter to help you ensure follow-up of your servicing actions
(checking or maintenance).

M0226001 6 /7
REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
MAINTENANCE SHEET

Pump code Contract Number :


Liquid pumped

Intervention Date functioning hours Comments

Maintenance sheet model

REPRESENTED BY:
M0226001 7 /7

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
PART IV - ROUTINE MAINTENANCE
IV - 1. OIL CHANGE

To avoid any risk of burning by the hot oil, protective gloves must be used..

• Perform the first oil change after 2000 hours' operation. Subsequent oil changes will be carried
out every 8000 hours operation or every 1 year

• Disconnect the pump electrically, check that the equipment cannot be switched on
accidentally. Position a notice at the location of the switch.

• Unscrew the plug and drain the oil into a tray. Degrease the plug and screw it into place.

• Remove any overflow of oil immediately with a suitable degreasing agent for the
operating conditions.

• Fit the plug [R1] and fill up the housing to the middle of the oil level indicator [L1] with
a mechanical oil suitable for service conditions.

For the diaphragm liquid end :

• Drain also the liquid end spacer and the displacement chamber

• Replace the filter

Use an hydraulic oil suitable for service conditions.

• Fit the plug [R2] and fill up the housing to the middle of the oil level indicator [L2] with
a hydraulic oil. Fill up the displacement chamber by the safety valve hole

R1 Mechanical oil level filling plug


R2 Hydraulic oil level filling plug
L1 Mechanical oil level
L2 Hydraulic oil level

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


M0202001a Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
Oil Quantity

Designation Quantity (liter)


Mechanical housing 20L
Mechanical housing for multiplex version 22L/housing
Liquid end spacer (diaphragm liquid end) 18L

Oil used for mechanical housing


Oil : FUCHS Renolin CLP320 Reference : 4370013065 N

Equivalencies :

AGIP BLASIA 320


ARAL PONTAMAC 320
AVIA GEAR RSX 320
BP ENERGOLE -GRXP 320

From -31°F(-35°C) to 23°F(-5°C) used the Sintofluid oil (FUCHS)

Oil used for diaphragm liquid end

Hydraulic oil FUCHS Renolin Extra 32S Part number : 437 0013 033N

Equivalencies :

BP HLPD 32
CASTROL HYSPIN VG 32
ELF OLNA 32
FINA CIRKAN 32
IGOL SONHYDRO 32
MOBIL DTE 24
SHELL TELLUS 32
TOTAL AZOLLAS ZS 32
ESSO NUTO H 32

From -31°F(-35°C) to 115°F(+46°C) used the Hydrofrima 15 (FUCHS)

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0202001a
IV - 2. OTHER MAINTENANCE OPERATIONS

CHECKING THE PUMP CAPACITY

This is a question of determining the straight line representing the pump's capacity according to its
adjustment. Four measurements are sufficient (adjustment at 100%, 75%, 50% and 25%).There are
two possible methods:
If the pump is installed in pressurizing mode
Measure the volume of pumped liquid in a calibrating chamber for a given period of time. It may be
necessary to reproduce actual operating conditions (suction pressure).

If the pump is installed in suction mode


Measure the volume of discharged liquid. It may be necessary to reduce actual operating conditions
(discharge pressure).

The first method is recommended. In addition, this method avoids placing the operator in contact with
the liquid, which is important if the pumped liquid is hazardous. For a precise check, it may be
necessary to use an electromagnetic flow-meter.

IV - 3. TRACING CAUSES OF FAILURE

PROBLEMS WITH MOTOR

The motor does not run :

• The thermal relay has been tripped.


• The motor is defective.
• Wiring is defective.

The motor heats abnormally :

• The quantity of lubricating oil is incorrect: trace the leak (see Chapter IV - 2.)
• The quality of the lubricating oil is incorrect. Check the date of the last oil change and the
specifications of the oil used.
• The pump is used in conditions it was not designed for.

PROBLEMS WITH NOISY MECHANICAL PARTS

• The bearings can be weared, replace them. if necessary


• The motor coupling can be weared, replace it if necessary

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0202001a
PROBLEMS WITH FLOW RATE

The pump produces no flow

• The pump capacity is adjusted to « 0 % » : Adjust the capacity to the desired value and lock
the hand-knob.

• Check the leak-tightness of the piping safety valve

• The liquid end is not primed: release the pressure on the discharge pipe and prime the liquid
end, or check the leak-tightness of the suction circuit.

• The balls of the valve assemblies are blocked by particles: clean or replace the valve
assemblies.

• First, check whether the presence of the particles in the valve assemblies is normal and take
corrective action if necessary.

• If the problem is not solved check the mechanical assembly and liquid end functioning

The pump does not provide the required flow rate

• The pump capacity is incorrectly adjusted: adjust the capacity to the desired value and lock the
hand-knob.

• The valve assemblies are blocked by particles: clean or replace the valve assemblies.

• The suction circuit leak-tightness is unsatisfactory

IV - 4. ORDERING SPARE PARTS


To make it easier to register your order for spare parts and ensure a quick delivery, please provide
us the following details:

• Information on the pump: type and contract number. These two items of information are shown
on the identification plate mounted on the pump.

• Information on the spare part: reference, description and quantity. These items of information
are specified in the spare parts list supplied with the pump.

You will find the phone and fax number of the Spare Parts Department at the end of this document

1 Type : Pump code


2 Dmax : maximum capacity
3 Pmax : maximun pressure
4 Date: date of manufacture
5 N° : Contract No
6 Item : your reference

Fig. 3 Typical identification plate

M0202001a
PART V - PREVENTIVE MAINTENANCE

V-1. GENERALITIES

The preventive maintenance consists in replacing the wear parts included in a "spare parts kit". This
kits are available on request at the spare part department (chapter IV -4)

The corresponding action is detailed in the chapter VI and VII : Servicing of the mechanical assembly
and servicing of the liquid end

V-2. MECHANICAL ASSEMBLY PRÉVENTIVE MAINTENANCE

Renewal Frequency* (hours)


Wheel and worm assembly 25 000 h
Bearings 25 000 h
Crosshead and his seals 8000 h
Flexible shock absorber 8000 h

V-3. LIQUID END ASSEMBLY PRÉVENTIVE MAINTENANCE

Renewal Frequency* (hours)


Plunger and plunger connection 15 000 h
Diaphragm (for the diaphragm liquid end)) 15 000 h
Plunger packing ring ( temperature < 194°F (90°C)) 8000 h
Check valves 8000 h

* Approximate hours number when operating under max performances and normal using
conditions

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0202001a
VI-SERVICING THE MECHANICAL ASSEMBLY

REMARKS

• By measure of simplification, the described procedures don't mention the washers fitted with
fasteners (such as screws and nuts) and the magnet.

Do not to forget to go up them

• Replace the seal at each servicing

PRECAUTION

Before all servicing perform the following operations :

• Disconnect the electrical power Any accidental start-up must be prevented. position a notice at the
switch location to avoid start up.
• Check that there is no temperature before starting to operate
• Disconnect the hydraulic power
• Drains the oil from the housing (refer to chapter V-1 oil change)

TO BE PREPARED BEFORE SERVICING

Handling material compatible to the weight of the equipment


Degreasing agent

REPRESENTED BY:

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Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M00017001a 1 /1
VI-1 Assembly / Disassembly setting guide
Drawing 1066136400D00 rev00 M0203001
Disassembly Assembly
Perform the following steps before this Position Torque
disassembly :
[439] 80 N.m - 30 N.m
- disassembly of the adjusting stroke system
- disassembly of the wheel-connecting rod [435A] 40 N.m
assembly
1. Unscrew the screw [435A] 1. Fit the part [016A],[016] and insert the part [037A] in the
same time

2. Remove the part [008] 2. Insert the bearing [439B] on the part [068A]

3. Remove the assembly [016],[016A] from 3. Heat the internal cage of the bearing [439B] (110°C)
the upper side of the mechanical housing

4. Remove the part [068A] with the bearings 4. Insert the heated internal cage on the part [016]
[439B]

5. Remove the bearings [439B] 3. Fit the external cages of the bearing [439B] on the part
[068A]

4. Insert the part [068A] into the part[016]

5. Insert the internal cage of the bearing [439B] on the


[016]

6. Fit a new washer [439A].

7. Degrease and place glue (Loctite 221) into the nut


[439].

8. Tighten the nut [439] ( two time)

9. Fold the washer [439A]

10. Fit the part [434A]

11. Insert the assembly into the mechanical housing from


the upper side

12. Fit the [016] in mechanical stop

13. Fit the part [008]

14. Tighten the screw [435A]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
4 3 2 1
B (1 : 2)
A-A

F F

E E

439A 008 439 439B 068A 434A 037A

C (1 : 3)
016A

D D
016

435A

A
C C
A

B B B

29.09.04 EMISSION INITIALE YChevallier DDeparrois 00


Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

PRIMEROYAL N
REGLAGE DE COURSE
A
A STROKE ADJUSTMENT
FORMAT Ech - Scale Folio - Page Matière - Material Numéro Plan Dwg-Nr

A4 1:4 1/ 1 selon AQTAB 70 106.6136.400.D00


Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

4 3 2 1 SOLIDWORKS
VI-2 Assembly / Disassembly of the wheel and
connecting rod
Drawing 1066136400D01 rev00 M0204001
Disassembly Assembly
Perform the following steps before this Position Torque
disassembly :
[435A] 40 N.m
- disassembly of the worm
[435E]-[435F] 280 N.m

1. Unscrew the screw [435F] 1. Grease the connecting rod [014]

2. Remove the part [037] 2. Position the connecting rod [014] on the part [016A]

3. Remove the parts[072A],[052] 3. Fit the part [068] equipped with the part [434B] to the
pump

4. Unscrew the screws [435A] 4. Tighten the screws [435E]

5. Remove the part [052] 5. Fit the parts [072A],[052]

6. Unscrew the screws [435E] 6. Tighten the screws [435A]

7. Remove the parts [068] 7. Insert the assembly into the pump

8. Remove the connecting rod [014] 8. Fit the parts [037] to the pump

9. Tighten the screws [435F]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
4 3 2 1

F F

A A

E E

072A

037
435E D
D
438F
B (1 : 4) 435A

068

C 434B C

052

016A

B B
435F 014 A-A
29.09.04 EMISSION INITIALE YChevallier DDeparrois 00
Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

PRIMEROYAL N
ROUE-BIELLE
A
A WHEEL-CONNECTING ROD
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr

A4 1:5 1/1 Tel : +33 (0)2 32 68 30 00


Fax : +33 (0)2 32 68 30 93 106.6136.400.D01
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

4 3 2 1 SOLIDWORKS
VI-3 Assembly / Disassembly of the worm
Drawing 1066136400D02 rev00 M0205001
Disassembly Assembly
Perform the following steps before this Position Torque
disassembly :
[439C] 80 Nm -30 Nm
disassembly of the motor
[435G] 20 Nm

[435F] 120 Nm

1. Unscrew the screws [435F] 1. Fit the external cages of the bearing [439F],[439G] to
the part[068D]

2. Remove the part [434C] 2. Heat the internal cage of the bearing [439G] (110°C)

3. Remove the part [068E] 3. Insert the internal cage of the bearing [439G] on the
worn [052]

4. Remove the seals [438I],[438G] 4. Insert the part [068D] on the worn [052]

5. Unscrew the screws [435G] 5. Insert the bearing cage [439F] on the worn [052]

6. Remove the worm [052] from the upper 6. Fit a new washer [439D]

7. Unscrew the nut [439C] 7. Tighten the nut [439C] in two time

8. Remove the part [068D] 8. Fold the washer [439D]

9. Fit the bearing [439E] on the worn [056]


9. Remove the bearing [439F],[439G],[439E]

10. Insert the worm [052] from the bottom of the housing

11. Tighten the screws [435G]

12. Protect the groove of the part [434C] with adhesive


ribbon
13. Insert the seal [438I],[438G] on the part [068E]

14. Fit the part [068E]

15. Tighten the screws [435F]

16. Fit the part [434C]


17. Fit the part [438]
18. Fit the part [434]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
4 3 2 1
068E 438G 434C

F F
435F

438I

A (1 : 2)
E E
052 439E

068D 439G

D C (1 : 2) D

434 438 435G

C C

439F 439C 439D

B B
B (1 : 2)
30.09.04 EMISSION INITIALE YChevallier DDeparrois 00
Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

PRIMEROYAL N
VIS SANS FIN
A
A WORM
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr

A4 1:5 1/1 Tel : +33 (0)2 32 68 30 00


Fax : +33 (0)2 32 68 30 93 106.6136.400.D02
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

4 3 2 1 SOLIDWORKS
VI-4 Assembly / Disassembly of the crosshead and spacer
Drawing 1066136410D00 rev00 M0227001
Disassembly Assembly
Perform the following steps before this Position Torque
disassembly :
[435B] 280 N.m
disassembly of the liquid-end assembly
[435A] 17N.m

1. Unscrew the screws [435B] 1. Protect the crosshead [010] with a cloth

2. Protect the crosshead [010] with a cloth 2. Position the crosshead [010] on the connecting rod
[014]

3. Remove the spacer [072B] 3. Insert the part [068B]

4. Remove the retaining ring [434] 4. Tighten the screws [435C] (mechanical stop)

5. Remove the parts [037B],[072C] 5. Unscrew the screws [435C] of ¼ turn

6. Remove the seals [438C]


The screws [435C] can not be use a second
time

6. Fit the seal [438C] to the part [037B]


7. Unscrew the 2 screws [435C]

8. Remove the part [068B] the lip of the seal [438C] must be positionned to
the internal side

7. Insert a seal [438B] into the spacer [072B]


9. Remove the crosshead [010]

8. Insert the part [072C] into the spacer [072B]

9. Insert a seal [438B] into the spacer [072B]

10. Insert the part [037B] into the spacer [072B]

11. Oil the internal diameter of the spacer 072B]

12. Fit the seals [438A],[438],[438L] on the spacer


[072B]

13. Fit the spacer [072B] to the pump

14. Fit the retaining ring [434]

15. Tighten the screws [435B]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
4 3 2 1

438A 438B

F 072C F

014

010

E 068B E
435C
B (1 : 3)
072B

A (1 : 3) 037B

D 434 D

438L
438C

438

C C
435B

B B

26.05.05 EMISSION INITIALE YChevallier DDeparrois 00


Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

PRIMEROYAL N
COULISSEAU-LANTERNE A PISTON
A
A CROSSHEAD-SPACER
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr

A4 1:7 1/1 Tel : +33 (0)2 32 68 30 00


Fax : +33 (0)2 32 68 30 93 106.6136.410.D00
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

4 3 2 1 SOLIDWORKS
VI-5 Assembly/ Disassembly of the adjusting stroke system
Drawing 1066136400D04 rev00 M0207001
Disassembly Assembly
Position Torque
[435F] 120N.m
[435] 17N.m
[435A] 10N.m

1. Unscrew the screws[435A] 2. Position the part [072] on the side [A]

3. Remove the assembly [440],[055] 4. Insert the seal [438] on the part [056]

5. Unscrew the screws [435F} 6. Screw the screw [056] into the part [072] to obtain the
dimension X=30mm

7. Remove the assembly [072],[056] 8. Tighten the locking assembly


[043],[438A],[056A],[440A]

9. Remove the seal [438E],[438] 10. Fit the seals [438E],[438B]

11. Unscrew the locking screw [440A] 12. Exit the nut [008] to the maximum

13. Remove the part [056] 14. Fit the assembly to the pump (left-hand) and screw
of 9 turns

15. Push the assembly into the housing

16. Tighten the screw [435F]

17. Fit the part [055]

18. Tighten the screw [435A]

19. Fit the part [440]

20. Tighten the screw [435B]

21. Turn of 10 turns to set the « 0% »(no crosshead


displacement)

22. Unscrew the screw [435A]. Set the « 0 » of the part


[055] with the « 0 » of the part [072]

23. Push the part [055] to the part [072].(dimension Z=0)

24. Tighten the screws [435A]

25. Set the pump « 100% » (10 turns)

26. Tighten the screw [056A]

27. Tighten the nut [435]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
4 3 2 1

008 081 438E 438A 435 056A 072 053 438B 440

F F

E 055
E

435A

438

Z
D 435B D
X

056 435F 056A 438A 440A 043

C C

B B

04.10.04 EMISSION INITIALE YChevallier DDeparrois 00


Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Revision

PRIMEROYAL N
REGLAGE MANUEL
A
A MANUAL STROKE ADJUSTMENT
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr

A4 2:5 1/1 Tel : +33 (0)2 32 68 30 00


Fax : +33 (0)2 32 68 30 93 106.6136.400.D04
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

4 3 2 1 SOLIDWORKS
VI-6.Assembly / Disassembly of the multiplexing
Drawing 1066136310 rev00 M0238001
Disassembly Assembly
Position Torque

[435] 60 N.m

[435B] 280 N.m

1. Unscrew the screws [435B] 1. Fit the part [052] on the worm of the driving pump

2. Disassembly the pump 2. Tighten the screw [435]

3. Remove the part [440] to replace it 3. Fit the second part [052] to keep a clearance of 2mm
between both half coupling

4. If necessary unscrew the screws [435] to remove 4. Tighten the screw [435]
the parts [052]

5. Fit the part [440]

6. Set the driving pump to place the crosshead in the


front position

For Duplex pump : (dephasing of 180°)


Set the crosshead drived pump in rear position

For Multiplex pump : (dephasing by the pump


number)

Set one of the drived pump to the rear position and


calculate the numbers of turns to go to front position
Divided this result by the numbers of pump. (this
final result is called A)

Position all drived pumps to rear position .

Turn the first drived pump of “A” turns, turn the


second drived pump of 2 x “A” turns.......

7. Fit the pumps together

8. Tighten the screws [435B]

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
1 2 3 4 5 6 7 8

A (1 : 1)
A A
434A

072

052 440 435 434C


438G

B B
438A

C C

D D

E E

21.09.04 EMISSION INITIALE YChevallier DDeparrois 00


Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Révision

PRIMEROYAL N
ENS EQUIPEMENT MULTIPLEX
F 435B MULTIPLEX EQUIPMENT ASSEMBLY
F
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr
Tel : +33 (0)2 32 68 30 00
A3 1:4 1/1 Fax : +33 (0)2 32 68 30 93 106.6136.310
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

1 2 3 6 7 8 SOLIDWORKS
VI-7.Assembly / Disassembly of the motor
Drawing 1066136200 rev 00 M0208001a
Disassembly Assembly
Position Torque

[435B] Mechanical stop

[435A]&[435C] Mechanical stop

[435] Mechanical stop

1. Unscrew the screws [435]. 1. Fit the part [052] to the worm (mechanical stop)

2. Remove the motor 2. Tighten the screw [435A]

3. Remove the part [440] 3. Fit the part [072] to the pump

4. Unscrew the screws [435A] 4. Tighten the screws [435B]

5. Remove the parts [052A] 5. Fit the part [052A] to the motor

6. Unscrew the screws [435B]. Respect the dimension E=35mm

7. Unscrew the screws [435B] 6. Tighten the screw [435A]

8. Remove the parts [072] 7. Fit the part [440]

9. Unscrew the screws [435A]. 8. Fit the motor

10. Remove the parts [052] 9. Tighten the screws [435]

Start up : Refer to chapter III

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
1 2 3 4 5 6 7 8

A A

A-A

072
B B

435A

052A

C C
434A

440

E
435B
D D
435 052

434

E E
27.12.04 Modif des vis de fixation + ajout repère 434A YChevallier DDeparrois 01
20/09/04 EMISSION INITIALE YChevallier DDeparrois 00
Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Révision

PRIMEROYAL N
ENS MONTAGE MOTEUR FF265
F FF265 MOTOR MOUNT ASSEMBLY
F
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr
Tel : +33 (0)2 32 68 30 00
A3 1:2 1/ 1 Fax : +33 (0)2 32 68 30 93 1066.136.200
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

1 2 3 6 7 8 SOLIDWORKS
1
PART VII-SERVICING THE LIQUID END

VII-1 GENERAL

Remarks

By measure of simplification, the described procedures don't mention the washers fitted with fasteners
(such as screws and nuts).

Do not to forget to go up them

Replace the seal at each servicing

Precaution

Special care has to be taken for chemicals used in the process (acids, bases, oxiding/reducing
solutions, ...).

Provide for the rinsing of the liquid end, if necessary, and provide for appropriate protective equipment

Check that there is no pressure and the temperature of components before starting to dismantle.

Before all servicing perform the following operations :

• Adjust the pump capacity at « 0% »


• Disconnect the electrical power Any accidental start-up must be prevented. position a notice at the
switch location to avoid start up.
• Disconnect the hydraulic power if used
• Drains the oil from the housing (refer to chapter V-1 oil change)

Specific equipement for servicing

PTFE Grease (ZEP 2000 or equivalent)

VII-2 OPERATING PRINCIPLE OF THE PLUNGER LIQUID END

The plunger is connected to the crosshead of the mechanical assembly and has the same
reciprocating linear motion.
In the suction phase, the displacement of the plunger creates a negative pressure and allows the
suction of a given volume (swept volume) through the valve assembly , while valve assembly closes
the discharge circuit.
During the discharge phase, the process is reversed. The plunger expels the fluid from the process
through valve assembly, while valve assembly closes the suction circuit.

M0020001a
REPRESENTED BY: 1 /1

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
VII.3- Assembly / Disassembly of the liquid end
drawing 1066148080D00 rev00 M0280001
Disassembly Assembly
Position Torque
[009] 100 N.m

M8 M12
[435]
30 Nm 120 Nm

1. Unscrew the nut [009] 1. Clean the liquid end [021]

2. Unscrew the screws [435] 2. Insert the part [438A] into the liquid end [021]

3. Remove the assembly 3. Insert the spring [438AB] into the liquid end [021]

4. Remove the plunger [012] 4. Grease with “Loctite 8105” the parts [438C], [438D],
[438E], [438F], [438G], [438H],

5. Remove the parts [438F], [438E], [438D], 5. Insert the “V” seals [438D] into the liquid end [021]
[438C], [438B], [438A]

6. Insert the part [438E] into the liquid end [021]

7. Fit the seals [438H] and [438G] to the part [438F]

8. Grease the internal diameter of the seal [438G] with


the “Loctite 8105”.

9. Insert the part [438F] into the liquid end [021]

10. Insert the plunger [012] into the liquid end [021]

11. Fit the assembly to the pump

12. Tighten the screws [435]

13. Screw the nut [009] into the crosshead

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
1 2 3 4 5 6 7 8

A A
021

438

012
B B
009

C 438A 438B 438C 438D 438E 438F C

435

D D

E E
438G 03.10.06 EMISSION INITIALE YChevallier DDeparrois 00
Date Texte de la modification - Modification Dessiné-Drawned / Visa Vérifié-Checked / Visa Révision

438H
ENS DOSEUR UTEX
F F
FORMAT Ech - Scale Folio - Page 27360 PONT-SAINT-PIERRE Numéro Plan Dwg-Nr
Tel : +33 (0)2 32 68 30 00
A3 1:4 2/ 2 Fax : +33 (0)2 32 68 30 93 106.6148.080.D00
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY

1 2 3 6 7 8 SOLIDWORKS
B-B (1 : 1)
VII.4- Assembly / Disassembly of the single ball check valve
Drawing 1065696000 rev03 réf : M0054001a
Disassembly Assembly
Position Torque

flange nuts 70 Nm

1. Unscrew the three flange clamping screws 1. Fit a seal on each face of the seats [024].
and remove the connecting assemblies

2. Remove the seal [025], ball guide [003], ball 2. Position a seat [024] either on the liquid end
[437] and seat [024] equipped with two seals body or on the connecting assembly , taking
[025]. care to comply with the direction of fitting.

3. Position a ball [437], a ball guide [003] and a


3. Clean the ball guide [003] if it is not to be
seal [025] (on the ball guide).
replaced.

4. On the liquid end, assemble the valve


assemblies with the connecting assembly by
means of nuts.

5. the flange must be perpendicular to the


centreline of the valves

6. Tighten the flange nuts

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834
GUARANTEE

The vendor guarantees his products according to the D.M.R. general conditions of sale.
The guarantee for components and sub-assemblies not fabricated by the vendor is limited
tothat given by the supplier.
The vendor’s guarantee only covers the replacement or the repair, at his cost and in his
factory, of all parts acknowledged by his technical services as being defective due to an error
in conception, of material or of execution.
It is the purchasers responsability to prove the said defects. The guarantee does not cover
the replacement of wear parts mentioned in part V - Preventive Maintenance.
The vendor reserves the right to modify all or part of his products in order to satisfy the
guarantee. The guarantee does not cover charges arising from dismantling, assembly,
transport and movements.
The replacement of one or several parts, for whatever reason, does not prolong the period of
guarantee.
The guarantee is not applicable notably in the following cases :
installation not in accordance with standard current practice.
deterioration or accident resulting from negligence.
lack of surveillance or maintenance.
modifications to conditions of use.
chemical corrosive or erosive attack. The proposed materials of construction are
recommendations subject in all cases to verification and acceptance by the client. The
recommendations, based on the experience of the vendor and the best available information,
do not guarantee against wear or chemical action.

The guarantee ceases :


if the storage of the material, outwith the vendors factory, does not conform to his
recommendations or to current standard practices.
in case of work or dismantling of the material by someone who does not respect written
recommendations of the instruction manual (when replacing wear parts).
if parts from another origin are substituted for the original parts supplied by the
manufacturer.

The purchaser cannot call on guarantee claims to justify differing payments.

INDUSTRIAL OWNERSHIP

This manual can only be used by the purchaser or the user. It cannot be distributed,
published, reproduced (partially or totally) or generally communicated to third parties without
the advance, formal written authorisation of the vendor.
Any breach of these rules may result in legel action being taken.

REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834

M0014001a 1 /1
F FRANCE
ASSISTANCE TECHNIQUE : Tél. 33.(0.2.32.68.30.02 Fax . 33.(0)2.32.68.30.96
PIECES DE RECHANGE : Tél. 33 (0)2.32.68.30.01 Fax . 33.(0)2.32.68.30.92
ACCUEIL : Tél. 33.(0)2.32.68.30.00 Fax . 33.(0)2.32.68.30.93
10 Grande Rue 27360 Pont-Saint-Pierre ,France
www.dosapro.com email: contact@dosapro.com

E ESPAÑA
ASISTENCIA TECNICA Y PIEZAS DE REPUESTOS :
Tél. 34.91 517 80 00 - Fax. 34.91 517 52 38
C/Embajadores, 100 - 28012 MADRID
www.dosapro.es email: madrid@dosapro.es

I ITALIA
ASSISTENZA TECNICA E PARTI DI RICAMBIO :
Tel. 39.039 60.56.891 - Fax. 39.039 60.56.906
Centro Direzionale Colleoni - Via Paracelso 16
Palazzo Andromeda - Ingresso 1
20041 AGRATE BRIANZA (Ml)
www.miltonroy.it

GB UNITED KINGDOM
TECHNICAL ASSISTANCE AND SPARE PARTS :
Tel. 44.11.89.77 10 66 - Fax. 44.11.89 77 11 98 -
Oaklands Park, fishponds Road, WOKINGHAM - Berkshire RG 11 2FD
www.miltonroypumps.co.uk

USA UNITED STATES


L.M.I. (LIQUID METRONICS, INC.)
Tel : 978 263-9800 - Fax : 978 264-9172
8 Post Office Square Acton, MA 01720
www.lmipumps.com

FLOW CONTROL DIVISION


TECHNICAL ASSISTANCE AND SPARE PARTS :
Tel. 215.441.0800 - Fax.215.293.0468
201 Ivyland Road, IVYLAND, PA, 18974
www.miltonroy.com email: customercervice@miltonroy.com

OTHER COUNTRIES :
Representatives in all countries, contact in FRANCE:
INTERNATIONAL SALES DEPARTMENT
Tel. 33.2.32.68.3004 - Fax. 33.2.32.68.3094
www.dosapro.com email: contact@dosapro.com

06/01
REPRESENTED BY:

Av. Córdoba 1351 Piso 10 - (1055)


Buenos Aires - Argentina
Tel.: (54-11) 5218.9828 (Lin. Rot.)
web site: www.gaisa.com.ar
e-mail: gaisa@gaisa.com.ar Fax: (54-11) 5218.9834