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Manual - Milton Roy Serie-G
Manual - Milton Roy Serie-G
Instruction Manual
Manual No : 53942
Rev. : 00
Rev. Date : 12/2015
PRECAUTIONS
The following precautions should be taken when working with metering pumps.
Please read this section carefully prior to installation.
Protective Clothing
ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or
near your metering pump. Additional precautions should be taken depending on the solution
being pumped. Refer to Safety Data Sheets for the solution being pumped.
Hearing Protection
It is recommended that hearing protection be used if the pump is in an environment where the
time- weighted average sound level (TWA) of 85 decibels is exceeded (as measured on the A
scale- slow response).
Electrical Safety
• Remove power and ensure that it remains off while maintaining pump.
• DO NOT FORGET TO CONNECT THE PUMP TO EARTH/ GROUND.
• Electric protection of the motor (Thermal protection or by means of fuses) is to correspond
to the rated current indicated on the motor data plate.
Liquid Compatibility
Verify if the materials of construction of the wetted components of your pump are
recommended for the solution (chemical) to be pumped.
Line Depressurization
To reduce the risk of chemical contact during disassembly or maintenance, the suction and
discharge lines should be depressurized before servicing.
ii Instruction Manual
SECTION 4 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 SHIPPING PUMPS FOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 ROUTINE PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.1 Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.2 Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.3 Cleaning Fouled Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.4 Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.5 Oil Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.1 3- Function Hydraulic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.2 “MARS” Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.3 Refill Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.4 Diaphragm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.5 Removal of Pump Liquid End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 5 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1 SYMPTOMS & REMEDIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 - PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 BASIC PARTS LIST- PUMP DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 BASIC PARTS LIST- LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.1 Mars Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.2 Refill Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.3 3- Function Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.4 Check Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.5 PVC Liquid End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.6 Metallic Liquid End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 REMAINING LIQUID END PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LIST OF ILLUSTRATIONS
FIGURE 1. Model/Product Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FIGURE 2. Sample Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FIGURE 3. Mounting Hole Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FIGURE 4. Typical Recommended Pump Installation Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FIGURE 5. Pump Drive Parts- Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FIGURE 6. Pump Drive Parts- Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FIGURE 7. Liquid End- Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FIGURE 8. Liquid End- Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FIGURE 9. Mars Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FIGURE 10. Double- Ball Check Valve Parts (1-1/4”-plastic;1-3/4, 2-1/2”-PVC & metallic) . . . . . . . . . . . . . . . . . . 40
FIGURE 11. Plastic Single- Ball Check Valve Parts: 1-3/4, 2-1/2, & 3” Plungers . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FIGURE 12. Plastic Check Valves for 1-1/4” Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FIGURE 13. Metallic Check Valves for 1-1/4” Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FIGURE 14. PVC 4- Function Bleed Valve for 1-1/4” Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Instruction Manual 1
SECTION 1 - DESCRIPTION
The mechanical drive system of the pump drives As the pump operates, a small quantity of hydraulic
the plunger back and forth in the High Performance oil is continuously bled through the air bleed system
Diaphragm (HPD) liquid end supplied with the (970, 960, 980 in Figure 8) in the three- function
pump. At the start of a suction stroke, the plunger hydraulic valve (air bleed/relief/purge- Figure 8).
moves away from the liquid end, drawing hydraulic An additional small quantity of hydraulic oil is
fluid with it. As the hydraulic fluid is drawn back, also lost on every stroke through the clearance
the flexible diaphragm (510) follows, lowering the between the plunger and displacement chamber
pressure of the process fluid in the liquid end. bore. After a while, these normal losses result in
This pressure drop causes the ball(s) in the suction a shortage of hydraulic oil in the displacement
check valve (Figure 10) to be lifted up thereby chamber. When this happens, the diaphragm will
allowing process fluid to pass through the suction be pulled back tight against the back contoured
line into the diaphragm head (1020). At the same surface of the displacement chamber, and part of
time, the pressure drop in the diaphragm head the diaphragm will press against the Mechanically
causes the ball(s) in the discharge check valve Actuated Refill System (MARS) valve (Figure 9).
(Figure 10) to be pulled closed, blocking flow back Now, when the plunger draws back, a vacuum is
through the discharge line. created in the displacement chamber. These two
factors (diaphragm pressing against MARS valve &
Note:
It is important that the pressure in the liquid vacuum in the displacement chamber) must occur
end remain above the vapor pressure of the together to trigger the MARS valve.
process fluid during the suction stroke. If the When both of these conditions are met, the MARS
fluid pressure drops below the vapor pressure,
cavitation will occur, negatively impacting the valve is forced to its rearward position, and the
performance of the pump. If you suspect the poppet (760) opens, allowing hydraulic oil from
possibility of cavitation, contact your Milton Roy the reservoir to enter through the refill valve
Representative for assistance. (740 in Figure 8) and replenish the lost oil. In this
At the end of the suction stroke, the process manner, proper hydraulic balance is constantly
reverses, beginning the discharge stroke. maintained in the displacement chamber.
Now the plunger moves forward, pushing hydraulic
fluid before it. The hydraulic oil must therefore press
against the diaphragm, flexing it forward and raising
the pressure of the process fluid in the liquid end.
This pressure increase causes the process fluid
to flow outward, forcing the discharge ball check
open and the suction ball check to seat, blocking
back flow through the suction line. The process
fluid flows out of the diaphragm head and into the
discharge line. This suction/discharge action is
repeated with every stroke of the pump plunger,
and is the direct cause of the pumping action.
2 Instruction Manual
SECTION 1 - DESCRIPTION
1.3 GENERAL SPECIFICATIONS
Maximum Capacity Range 20 GPH (76 LPH) to 130 GPH (492 LPH)
Maximum Pressure Range 100 PSIG (7 Bar) to 600 PSIG (41 BAR)
Hydraulically Actuated Diaphragm with Mechanically Actuated Refill
Liquid End Design
System (MARS).
Drive Design Non-Lost Motion Variable Eccentric Type.
Plunger Diameters 1-1/4”(32mm), 1-3/4”(45mm), 2-1/2”(63mm), 3”(75mm)
Liquid End Materials of
PVC, 316 SS, Alloy 20.
Construction
Steady State Accuracy ±1% of 100% rated flow between 10% and 100% of rated flow
Micrometer (Standard): Lockable micrometer is adjustable from
0% to 100% while pump is running or stopped
Capacity Adjustment
Electronic (Optional): Electronic stroke length adjustment from
4-20ma input.
130ºF Maximum
Ambient Limit:
0ºF Minimum
Note: Limited by standard lubricants. Modifications are available through
Temperature Limits Applications Engineering.
Liquid Temperature Limits:
Plastic Liquid Ends: 20ºF to 140ºF
Metallic Liquid Ends: 20ºF to 190ºF
Minimum Internal Pressure: 3 psia (11.5 psi maximum vacuum)
Suction Pressure Limits
Maximum Suction Pressure: 100 psig at 80ºF and below.
Lubrication Oil bath drive lubrication.
Paint Two part epoxy, yellow RAL 1018
Instruction Manual 3
SECTION 1 - DESCRIPTION
1.4 PRODUCT CODE
MILROYAL® G pumps are available in a variety of different configurations. The complete product code
is composed of the pump “model number” + “product code”. For a breakdown of the options included
in a specific pump, compare the pump model number and product code found on the pump nameplate
with the model/product code breakdown shown in Figure 1. A sample nameplate is shown in Figure 2.
MODEL NUMBER
MGH
4 5 6
PRODUCT CODE
7 8 9 10 11 12 13 14 15 16 17 18 19 20
Digits 11 & 12: Capacity Adjustment Connection Digit 13 & 14: Check Valve
Description Code Description Code
Manual, Plastic micrometer knob Electronic(4-20 ma input) M2 Pipe- NPT SE
NEMA 4, 115V E1 Pipe- BSP SN
NEMA 4, 230V E2 Pipe- DN (Socket Weld) SQ
Explosion Proof, 115V EA
Explosion Proof, 230V EB
Electronic 4-20 ma input, 24 VDC EG
Digit 15 & 16: Base Diaphragm Digits 17 & 18: Rupture Detection/Double
Description Code Description Code
No Base (Standard) NN No Rupture Detection, Single Diaphragm (Standard) NN
No Base (Optional) 11 No Rupture Detection, Double Diaphragm (Optional) DD
Rupture Detection (Gauge), Double Diaphragm (Optional) C5
4 Instruction Manual
SECTION 2 - INSTALLATION
2.1 UNPACKING 2.3.2 Long Term Storage
(Longer than 6 Months)
Pumps are shipped Free on Board (FOB) factory Primary Considerations
or representative warehouse and the title passes to The primary consideration in storage of pump
the customer when the carrier signs for receipt of equipment is to prevent corrosion of external and
the pump. In the event that damages occur during internal components. This corrosion is caused
shipment, it is the responsibility of the customer to by natural circulation of air as temperature of the
notify the carrier immediately and to file a damage surroundings change from day to night, day to day,
claim. and from season to season. It is not practical to
Carefully examine the shipping crate upon receipt prevent this circulation which carries water vapor
from the carrier to be sure there is no obvious and other corrosive gasses, so it is necessary to
damage to the contents. Open the crate carefully so protect internal and external surfaces from their
accessory items fastened to the inside of the crate effects to the extent possible.
will not be damaged or lost. Examine all material When the instructions given in this section are
inside the crate and check against packing list to completed, the equipment is to be stored sheltered/
be sure that all items are accounted for and intact. protected from direct exposure to weather.
The prepared equipment should be covered with a
2.2 SAFETY PRECAUTIONS
plastic sheet or a tarpaulin, but in a manner which
When installing, operating, and maintaining the
will allow air circulation and prevent capture of
MILROYAL® G pump, keep safety considerations
moisture. Equipment should be stored 12” or more
foremost. Use proper tools, protective clothing, and
above the ground.
eye protection when working on the equipment
If equipment is to be shipped directly from
and install the equipment with a view toward
Milton Roy into long term storage, contact
ensuring safe operation. Follow the instructions
Milton Roy to arrange for factory preparation.
in this manual and take additional safety
measures appropriate to the liquid being pumped. 2.3.3 Pump Drive
Be extremely careful in the presence of hazardous 1. Flood the pump drive housing with a high grade
substances (e.g., Corrosives, toxins, solvents, lubricating oil/rust preventative such as Mobile
acids, caustics, flammables etc.). Oil Corporation product “Mobilarma 524”.
Fill the housing completely to minimize air space
2.3 STORAGE
and water vapor condensation. After storage,
2.3.1 Temporary Storage (Less than 6 Months) drain this material and refill the equipment to the
It is preferable to store the material under a shelter correct oil level with the recommended lubricant
in its original package to protect it from adverse for equipment commissioning.
weather conditions. In condensing atmospheres, 2. Remove drive motor and brush all unpainted
follow the long term storage procedure. metal surfaces with multipurpose grease
(NLGI grade 2 or 3). Store motor unattached.
Instruction Manual 5
SECTION 2 - INSTALLATION
2.3.4 Electrical Equipment 2.5 CONVENTION PROCEDURE
1. Motors should be prepared in the manner A MILROYAL® G pump can, in some cases, be
prescribed by their manufacturer. If information converted from one liquid end plunger size or
is not available, dismount and store motors as material of construction to another. For more
indicated in step 3 below. information on converting between different liquid
2. Dismount electrical equipment (including end models, please contact the Milton Roy factory
motors) from the pump. or your local authorized representative.
3. For all electrical equipment, place packets of
2.6 PIPING CONNECTIONS
Vapor Phase Corrosion Inhibitor (VPCI) inside of
the enclosure, then place the entire enclosure, 2.6.1 NPSH Considerations
with additional packets, inside a plastic bag. The MILROYAL® G HPD liquid end is far superior
Seal the bag tightly closed. Contact Milton Roy to conventional diaphragm liquid ends for suction
Service Department for recommended VPCI lift and many other NPSH- critical applications.
materials. In these demanding applications, the patented
diaphragm and refill mechanism give this liquid
2.4 MOUNTING end truly exceptional performance.
Support the pump firmly in a level position on a For NPSH apply a 3 psia limitation (instead of
solid, vibration- free foundation, preferably with 9 psia) in evaluating applications for this liquid end.
the base above floor level to protect the pump
Size piping to accommodate peak instantaneous
from wash downs and to provide easier access
flow. Because of the reciprocating motion of
for service. Be sure to allow enough space around
the pump diaphragm, pump delivery follows an
the pump for easy access during maintenance
approximate sine curve with a peak instantaneous
operations, pump adjustments, and/or oil filling or
flow equal to pi (3.14) times the average flow.
draining procedures.
Therefore, piping must be designed for a flow
MILROYAL® G pumps are provided with mounting 3.14 times the pump capacity; this means that a
holes to accommodate anchor bolts. Refer to pump rated for 100 gallons per hour (379 L/hr.)
Figure 3 for mounting hole dimensions. requires piping sufficient for 3.14 x 100 gph, or
Some MILROYAL® G pumps are shipped with 314 gph (1188 L/hr.).
motors dismounted. After anchoring pump in To minimize viscous flow losses when handling
position, install motor, referring to Figure 5. viscous liquids, it may be necessary to use suction
To avoid damage to pump drive during piping up to four times larger than the size of
operation, make sure spring (360) provided with the suction connection on the pump. If in doubt,
pump is installed in worm shaft prior to motor contact your nearest Milton Roy representative to
installation. Pumps installed outdoors should be determine the necessary pipe size.
protected by a shelter.
6 Instruction Manual
SECTION 2 - INSTALLATION
2.6.2 General Piping Considerations 3. MILROYAL ® G pumps are intended to be
1. Use extreme care in piping to plastic liquid operated with process liquid supplied at or
end pumps with rigid pipe such as PVC. If any above atmospheric pressure. Although these
stresses or vibration are unavoidable, flexible pumps can move liquids supplied at less
connections are recommended. than atmospheric pressure, in these negative
2. Use piping materials that will resist corrosion by pressure applications it is important that all
the liquid being pumped. Use care in selecting connections be absolutely drip free and vacuum
materials to avoid galvanic corrosion at pump tight.
liquid end connections. 4. When pumping a liquid near its boiling point,
3. Use piping heavy enough to withstand maximum provide enough suction head to prevent the
pressures. liquid from “flashing” into vapor when it enters
the pump liquid end on the suction stroke.
4. Remove burrs, sharp edges, and debris from
inside piping. Blow out all pipelines before 5. If possible use metal or plastic tubing for the
making final connections to pump. suction line because such tubing has a smooth
inner surface and can be formed into long,
5. Because vapor in the liquid end will cause
sweeping bends to minimize frictional flow
inaccurate pump delivery, piping should be
losses.
sloped down to pump suction check valve to
prevent vapor pockets. 6. A strainer should be used in the suction line to
prevent foreign particles from entering the liquid
6. When pumping suspended solids (such as
end. This and any other measures to prevent
slurries), install plugged crosses at all 90° line
debris from entering and fouling the ball-checks
turns to permit line cleaning without dismantling
will give increased maintenance-free service.
piping.
Check strainer frequently to prevent blockage
7. See Figure 4 for a typical recommended pump which could lead to cavitation.
installation scheme.
7. Keep suction piping as short and straight as
2.6.3 Suction Piping Considerations possible.
1. It is preferable to have the suction of the pump 8. Piping size should be one or two sizes larger
flooded by locating the liquid end below the than the liquid end suction fitting to prevent
lowest level of the liquid in the supply tank. pump starvation.
Installing the supply vessel on the suction line 9. If long suction lines are unavoidable, install a
in close proximity to the pump will help ensure stand pipe or suction accumulator dampener
a flooded suction line. near the pump in the suction line.
2. Avoid negative suction pressure conditions 10. Suction piping must be absolutely airtight to
(suction lift), as such conditions adversely ensure accurate pumping. After installation,
affect metering accuracy. A lift of 20 Ft. of water test suction piping for leaks with air and soap
column straight out of a supply tank is the solution.
maximum suction lift permissible.
Instruction Manual 7
SECTION 2 - INSTALLATION
2.6.4 Discharge Piping Considerations 2.6.6 Pulsation Dampeners
1. Install pipe large enough to prevent excessive An accumulator, surge chamber, surge suppressor,
pressure losses on the discharge stroke of the or pulsation dampener should be used with the
pump. Maximum pressure at the discharge back pressure valve in the discharge line to
fitting on the liquid end must be kept at or below absorb the flow peaks between the pump and
the rated pressure (Max. allowable working the back pressure valve. Without the pulsation
pressure shown on the pump nameplate). dampener the valve mechanism will snap open
2. The pump will not deliver a controlled flow unless and closed with the surge from each pump stroke.
the discharge line pressure is 35 psi greater than The pulsation dampener will allow the back
the suction line pressure. There are a number of pressure valve to oscillate about a partly-closed
ways to create an artificial pressure, such as by position, thus minimizing wear on the valve.
installing a back pressure valve. (Please contact Discharge line pulsation dampeners offer the
Milton Roy for recommendations to increase further advantage of limiting the flow and pressure
back pressure in slurry applications.) variations characteristic of this kind of pump.
Installing a properly sized pulsation dampener
3. When pumping water-treatment chemicals
will improve pump performance and may reduce
directly into boiler drums, use one liquid
system costs dramatically by permitting the
end assembly for each boiler drum.
substitution of smaller piping. Please contact
Discharging into a manifold having the slightest
Milton Roy for further information on pulsation
pressure difference between its several
dampeners.
discharge connections can diminish metering
accuracy as the outlet with the lowest pressure
will receive more liquid than the outer outlets.
8 Instruction Manual
SECTION 2 - INSTALLATION
2.6.7 Pressure Relief Valve (PRV) 2.6.9 Shut- OFF Valves
Maximum safety and reliability may be ensured by In order to isolate the pump during maintenance,
protecting liquid ends and piping with an external provide shut- OFF valves in both suction and
pressure relief valve installed in the system discharge lines next to the pump. Locate discharge
discharge line. Although the pump is protected line shut- OFF valve downstream from the inlet
against excessive pressure by an internal relief connection of the safety valve. Figure 4 shows
valve, to prevent a blocked discharge line from recommended valve locations.
causing damage to the piping or process equipment,
install a Milton Roy pressure relief valve in the pump 2.7 ELECTRICAL CONNECTIONS
discharge line. This valve is designed and sized to Ensure that the electrical supply matches the pump
handle system flow rates and pressures safely motor nameplate characteristics. Before operating
while resisting corrosion by the process liquid. the pump, check the direction of rotation of the
Install the safety valve in the discharge line motor to be sure it matches the direction of the
between the pump and the nearest shut- OFF arrow stamped on the motor (rotation should be
valve. (This will prevent potential system damage clockwise when viewed from the top of the motor).
from accidental valve closure.) Pipe the pressure If motor rotation is incorrect, refer to the motor
relief valve outlet back to the suction tank or to data plate or motor manufacturer’s instructions
drain, but in either case ensure that the pipe end for reversing.
is continuously visible so pressure relief valve
OPERATION WITH THE WRONG
leakage may be detected. Milton Roy pressure MOTOR ROTATION WILL DAMAGE
relief valve must be installed in accordance with its THE PUMP AND MOTOR AND VOID THE WARRANTY.
user manual top of supply tank in order to function
properly. DO NOT FORGET TO CONNECT
THE PUMP TO AN EARTH
2.6.8 Check Valves GROUND!
A check valve should be installed at the point Electric protection of the motor (fuses, overload
where the discharge line enters a boiler or other meters or relays) should correspond to the rated
high-pressure vessel. This will prevent back flow current indicated on the motor data plate.
through the discharge piping and will isolate the
pump discharge from system pressures (a safety
consideration).
Instruction Manual 9
SECTION 3 - OPERATION
Texaco Meropa 68
Shell Omaha 68
Food Grade
Nevastane EP220
Alteration
10 Instruction Manual
SECTION 3 - OPERATION
3.1.2 Start- Up of Pump Containing No Oil 3. Fill the opening in the displacement chamber
in Casing and Displacement Chamber (600) through the port uncovered by removal
The following instructions assume that both the of the 3- function valve in step 1 with the same
pump casing and liquid end (displacement chamber) oil used to fill the pump casing. Fill the chamber
contain no oil. This condition typically exists when slowly, allowing air bubbles to escape, until
the pump is subjected to annual maintenance the oil level reaches the level of the drain tube
during which oil may be drained from the pump (640).
casing and oil may escape from the displacement 4. Reinstall 3- function valve:
chamber during diaphragm replacement.
New pumps received from the factory will have a. Gently gripping the top of the relief valve
an empty pump casing and a filled displacement poppet (960) with needle-nose pliers, drop
chamber (liquid end). Please refer to the previous the poppet assembly down into the empty
section for start- up of new pumps. After pump relief valve port.
casing is filled to correct oil level (between top two b. Drop spring (950) back into relief valve port.
dashes on oil cap dipstick), perform the following
c. Make sure washer (935) is in place above
operations before placing the pump into service.
the O-ring (940) on purge stem (930) and
Numbers refer to item numbers shown in assembly
reinstall purge and relief valve adjustment
drawings (Figures 7-9) located in the back of this
assembly by screwing large adjustment nut
manual.
(910) back into place. Make sure adjustment
1. Remove hydraulic 3- function valve (refer to nut (910) is tight.
Figure 8):
d. Reinstall relief valve cap piece (850).
a. Remove relief valve cap piece (850).
5. The pump is now properly filled with oil and ready
b. Make sure relief valve locknut (900) is tight for service. If the relief valve locking nut (900)
to maintain previous relief valve setting upon remained tight during the above procedure, the
start- up. relief valve setting should remain unchanged.
c. Remove purge button and relief valve If not, refer to next section for instructions on
adjustment assembly by removing large how to set relief valve.
adjustment nut (910). BEFORE SWITCHING ON POWER
TO THE PUMP, TURN THE CAPACITY
d. Using needle-nose pliers, remove spring ADJUSTMENT KNOB TO ZERO. CHECK THAT ALL SHUT- OFF VALVES
(950). IN THE SUCTION AND DISCHARGE LINES ARE OPEN BEFORE
INCREASING THE CAPACITY ADJUSTMENT FROM ZERO.
e. Using same pliers, remove relief valve poppet
by gently gripping the top of the valve body 6. Make sure that all air has been bled from the
(960). suction piping and pump head. This can be
accomplished by opening all suction line valves
2. Make sure pump capacity adjustment is set to
as well as the system drain (Prime/Air Purge)
100%.
valve shown in Figure 4 and allowing fluid to flow
into drain until all air has been purged. If drain
valve not present, with the pump capacity set
to 100%, operate the pump under no discharge
pressure until the entire pumping system has
been filled.
Instruction Manual 11
SECTION 3 - OPERATION
3.2 RELIEF VALVE ADJUSTMENT 2. Start pump and set capacity at 100%. If a drain
All MILROYAL G liquid ends have a built in relief
® valve is present in the discharge line, pump
valve which allows hydraulic fluid to return to the process liquid to drain or other safe point to
pump casing if excessive pressure builds up in the establish proper pumping action. Close drain.
discharge line. This effectively stops the pump from 3. Slowly increase system pressure until:
pumping, since the forward stroke of the piston a. Significant flow is observed from the drain
will not displace the hydraulic fluid and force the tube (640, figure 8) as viewed through the
diaphragm to flex. During operation of the pump, a sight glass (630, figure 7) or
relief condition caused by over pressurization can
easily be seen by looking through the sight glass b. The system pressure reaches 15% over the
(630, Figure 7) for excessive oil flow from the drain desired system pressure.
tube (640, Figure 8). 4. For condition (a) in step 4, if relief condition
occurs at less than 15% above desired pump
Note:
operating pressure, the relief valve setting
Under normal operation, a few drops of oil
should escape from the drain tube during each must be increased. Remove valve cover
pump stroke due to normal oil flow through the (850) and increase relief valve setting by
air bleed ball (970, figure 8). If a stream of oil turning the adjustment screw (890) clockwise
from the drain tube is evident on each pump
until only a few drops of oil escape on each
stroke, the system pressure has exceeded the
pump relief valve setting and the pump is in a pump stroke (normal leakage past air bleed
relief condition. ball-980). Increase system pressure to 15%
above desired operating pressure to verify that
The MILROYAL® G liquid end relief valve may be
pump is now in relief condition. If it is not, reduce
adjusted to operating conditions by the following
relief valve setting by turning adjustment screw
procedure. Adjust the relief valve after first installing
(890) counterclockwise until relief is observed
the pump and after any maintenance procedures.
in sight glass drain tube at a pressure equal to
THE PRESSURE RELIEF VALVE IS 15% greater than desired operating pressure.
FACTORY SET TO OPEN AT A
Lock-in relief valve setting by tightening locking
PRESSURE 15% OVER THE CUSTOMER SPECIFIED OPERATING
PRESSURE OR AT 15% ABOVE THE MAXIMUM PRESSURE
nut (900) while holding adjustment screw (890)
RATING OF THE PUMP IF NO OPERATING PRESSURE IS stationary. The relief valve is now properly
SPECIFIED BY THE CUSTOMER. WHEN ADJUSTING THE VALVE adjusted. Reinstall valve cover (850).
SETTING, NEVER SET THE VALVE AT A PRESSURE GREATER
THAN 15% OVER THE PUMP MAXIMUM PRESSURE RATING.
5. For condition (b) in step 4, the setting of the
relief valve should be reduced. Remove valve
3.2.1 Relief Valve Adjustment (With an cover (850) and turn adjustment screw (890)
Adjustable System Back pressure Valve).
Refer to Figures 7 & 8. counterclockwise until relief is observed in
sight glass drain tube at a pressure equal to
The following procedure assumes that a back
15% greater than desired operating pressure.
pressure valve and pressure gauge are installed
Lock-in relief valve setting by tightening locking
in the discharge line. If these components are not
nut (900) while holding adjustment screw (890)
installed, refer to next section.
stationary. The relief valve is now properly
1. Make sure all system shut- OFF valves are
adjusted. Reinstall valve cover (850).
open and that the back pressure valve is backed
out to allow for flow against zero discharge
pressure.
12 Instruction Manual
SECTION 3 - OPERATION
3.2.2 Relief Valve Adjustment (Without an 3.3 USE OF AIR PURGE BUTTON
Adjustable System Back Pressure Valve). Refer to Figure 7 & 8:
If no adjustable back pressure valve is present As with any hydraulically actuated diaphragm
in the discharge line, use the following simplified pump, dissolved air will come out of solution
procedure to check and/or set the relief valve during normal operation which can negatively
setting. impact pump performance if not removed
1. If pump is in a relief condition at normal f r o m t h e p u m p d i s p l a c e m e n t c h a m b e r.
operating pressure, the relief valve setting The MILROYAL® G hydraulic 3- function valve is
should be increased. Remove valve cover (850) equipped with two mechanisms for removal of this
and increase relief valve setting by turning the gas: a continuous air bleed and an air purge button.
adjustment screw (890) clockwise until only a The continuous air bleed portion of the valve is
few drops of oil escape on each pump stroke composed of a sealed ball (970) which allows for a
(normal leakage past air bleed ball) (970). controlled leakage of a few drops of oil, and any small
Turn adjustment screw an additional ½ turn to accumulations of evolved gas, on each pump stroke.
provide an adequate buffer zone. Lock-in relief Larger quantities of air can be quickly removed by
valve setting by tightening locking nut (900) pressing the spring-loaded purge button (860), until
while holding adjustment screw (890) stationary. it reaches its mechanical stop, for a few seconds.
The relief valve is now properly adjusted. Upon doing so, the operator will observe a stream
Reinstall valve cover (850). of oil and air escaping from the drain tube (640).
2. If pump is not in a relief condition at normal The need for use of the purge button to remove
operating pressure, and the operator wishes a large quantity of air can be caused by several
to reset the valve setting to approximately 15% factors:
above operating pressure(recommended), 1. Blocked suction line: A partially or fully blocked
use the following procedure. Remove valve suction line can create a vacuum pressure
cover (850) and decrease the relief valve condition in the hydraulic system which pulls
setting by turning the adjustment screw (890) significant quantities of dissolved gas from
counterclockwise until a stream of oil flows solution.
from the drain tube (640) on each pump stroke. 2. Oil Change: The recommended annual
Now slowly turn adjustment screw clockwise changing of the oil in the pump drive can lead to
until only a few drops of oil escape on each the presence of air pockets in the displacement
pump stroke (normal leakage past air bleed chamber (600).
ball). Turn screw an additional ½ turn to provide
3. Diaphragm Replacement: Results in significant
an adequate buffer zone. Lock-in relief valve
loss of oil from the displacement chamber.
setting by tightening locking nut (900) while
4. Pump Start- up After Long Idle Period: If the
holding adjustment screw (890) stationary.
pump has sat idle for a significant time, gas
The relief valve is now properly adjusted.
may come out of solution from the oil and collect
Reinstall valve cover (850).
into pockets which can negatively impact pump
flow. Depression of the purge button will quickly
evacuate these pockets and restore the pump
to desired performance.
Instruction Manual 13
SECTION 3 - OPERATION
The operator should only activate the purge button 3.5 FILLING PUMPING SYSTEM
if some type of pump upset occurs such as the For proper pump operation, it is especially important
above 4 examples. When activating the purge, only that pump suction and discharge lines be free of
press button for 2-3 seconds or until a stream of oil entrained air. To ensure this condition, operate the
flowing from the drain tube (640) is seen through pump without any discharge pressure and fill the
the sight glass (630). Immediately after activation entire pumping system with liquid before starting
of the purge button, a temporary reduction in flow pressure tests. A simple method to assure priming
will occur as the refill system replenishes oil lost of the pump is to install a tee and a shut- OFF valve
during the purge. However, the pump should return at the discharge connection of the pump.
to normal operation within 1 to 2 minutes after
If the pump is idle for long periods, temperature
activation of the purge button. If after that time, the
changes in the process liquid may produce air in
pump flow rate is still less than it should be, repeat
the system. To discharge the air, install a valve in
the purge operation and wait another 2 minutes.
the discharge line which will allow the process liquid
If flow has still not resumed to expected levels,
to be pumped to a drain when starting the pump.
consult the troubleshooting section of this manual.
3.6 CAPACITY CALIBRATION
3.4 MANUAL CAPACITY CONTROL
After the first 12 hours of operation, the pump
To adjust pump capacity on standard pumps
should be tested and calibrated to find the exact
equipped with manual stroke adjustment, first
pump capacity under specific operating conditions
loosen the stroke locking screw located in
and capacity settings for the specific fluid being
the pump side cover. Pump capacity is then
pumped. Typically, calibrating the pump at 100,
adjusted by turning the micrometer-type stroke
50, and 10 percent capacity settings is enough to
adjustment knob clockwise to decrease capacity or
establish a pump performance curve throughout
counterclockwise to increase capacity as required.
the adjustment range.
The adjustment scale is marked in percent (%)
The pump can be calibrated by measuring the
of full stroke, with calibration lines on the knob at
decrease in liquid level pumped from a calibrated
1% intervals. After adjusting the knob to the desired
vessel. This method is recommended for hazardous
capacity setting, hand tighten the stroke locking
liquids because it eliminates operator contact
screw to maintain the capacity setting.
with the liquid. Milton Roy test-tube Calibration
Columns are available for convenient and accurate
calibration of any pump. The pump can also be
calibrated by collecting and measuring pumped
liquid at the pump discharge port in which case it
will be necessary to create discharge head at the
liquid takeoff point so that the pump will operate
properly. (See Section 2 for recommended ways
to do this.)
THIS METHOD IS NOT
GENERALLY RECOMMENDED
AS IT MAY EXPOSE OPERATING PERSONNEL TO HAZARDOUS
LIQUIDS.
14 Instruction Manual
SECTION 4 - MAINTENANCE
Note:
It is not necessary to purge the liquid end
displacement chamber of oil during annual oil
replacement.
Instruction Manual 15
SECTION 4 - MAINTENANCE
4.3.2 Check Valves 4.3.3 Cleaning Fouled Check Valves
Milton Roy recommends that check valve balls, Check valve assemblies are designed to be self
seats, gaskets, and O-rings be replaced on an cleaning and should seldom need servicing.
annual basis. If highly corrosive material (acids, Fouled check valves can usually be cleaned by
slurries etc.) is being pumped, some applications pumping a solution of mild detergent and warm
may require more frequent replacement. water (if compatible with liquid being pumped) for
Milton Roy recommends an annual tune up using 15 minutes, followed by flushing with water.
a Routine Preventive Maintenance (RPM) Kit.
4.3.4 Check Valve Replacement
RPM kits contain replacements for those parts
Before beginning work on the valve assemblies,
which are subject to wear; specifically the ball
make sure the shut- OFF valves are closed and
checks, check valve seats, gaskets/seals, and the
that pressure has been bled from the system. When
strainer. Replacing these parts annually with an
replacing the valves, take care to systematically
RPM kit can reduce the possibility of unexpected
change their O-rings and/or gaskets. Take care to
downtime and will help to extend pump life.
properly assemble the valve assemblies. In valves
To determine if check valves need maintenance,
that permit replacement of ball and seat, the ball
disassemble the check valves following the
must be placed on the sharp edge of the seats.
instructions in the following “Check Valve
For each plunger size, check valves are supplied
Replacement” section. In valves that permit
in three different configurations: plastic- single
disassembly, inspect the ball check and seat for
ball, plastic-double ball, and metallic- double ball.
chemical or physical damage. The ball should be
Be sure to refer to the appropriate instructional set
perfectly round and free of pits, marks, or scratches.
below pertaining to your plunger size and valve
The seat should retain a smooth edge where the
type.
ball contacts for proper sealing. If the seat edge
is worn or damaged, or has any pits, marks, or BE SURE TO FOLLOW
scratches, it should be replaced. If the ball and/ INSTRUCTIONS CAREFULLY
or seat is excessively damaged, the replacement AND REFER TO THE APPROPRIATE FIGURE WHEN
REASSEMBLING CHECK VALVES. IF CHECK VALVE
schedule should be shortened accordingly. CARTRIDGES ARE INSTALLED INCORRECTLY, ONE OF THE
If the ball and seat are both in good condition, the FOLLOWING WILL OCCUR: (A) IMMEDIATE SEVERE DAMAGE
replacement schedule can be lengthened. TO PUMP MECHANISM, (B) NO PUMPING, (C) REVERSE
PUMPING ACTION (FROM DISCHARGE LINE INTO SUCTION
BEFORE CARRYING OUT ANY LINE).
SERVICING OPERATION ON THE
METERING UNIT OR PIPES, DISCONNECT ELECTRICAL
POWER FROM THE PUMP, AND TAKE THE NECESSARY STEPS
TO ENSURE THAT THE HARMFUL LIQUID THEY CONTAIN
CANNOT ESCAPE OR COME INTO CONTACT WITH
PERSONNEL. SUITABLE PROTECTIVE EQUIPMENT MUST BE
PROVIDED. CHECK THAT THERE IS NO SYSTEM FLUID
PRESSURE BEFORE PROCEEDING WITH DISMANTLING OF
LIQUID END COMPONENTS.
16 Instruction Manual
SECTION 4 - MAINTENANCE
1-1/4” Plunger;Plastic Single Ball Check 1-1/4” Plunger; Metallic Double Ball Check
Valves: see Figure 12 Valves: see Figure 13
1. Unscrew the valve body (445). The metallic check valves used on the 1-1/4”
2. Remove the cartridge assembly (425): includes plunger size pumps are precision assembled at
cartridge (ball, seat, ball guide), O-ring, and the factory. Do not attempt to disassemble these
washer. cartridges. If they become inoperative, flush them
with solvent, wash them with warm detergent and
3. Clean the valve housing and mating port in the
blow them out with compressed air to remove any
liquid end.
foreign matter. If this treatment does not eliminate
4. Press a new clear plastic washer into valve
the trouble, the cartridge assembly should be
body.
replaced.
5. Install new cartridge valve assembly in
orientation shown in figure 12. A. Disassembly (refer to figure 13)
1. The check valve cartridge assemblies use
• Make sure that seat end of cartridge (white)
an SAE straight thread with an O-ring seal to
is always facing down.
facilitate port alignment with the connecting
• On discharge side, drop cartridge assembly pipes. To remove the cartridge from the liquid
into threaded port in head. The O-ring should end, first loosen the lock nut (435) one or two
be stretched around outside of cartridge on threads, then unscrew the cartridge (444,
same end as ball seat. Screw valve body into 445).
discharge side of diaphragm head until valve 2. Remove and discard the O-ring (441) and split
is hand tight. Do not overtighten. ring (439).
• On suction side, drop cartridge assembly 3. Carefully clean any parts to be reused. If any
into check valve body. The O-ring should chemicals are used in the cleaning process,
be stretched around outside of cartridge on ensure that they are compatible with the process
opposite end of ball seat. Screw suction valve liquid.
housing with cartridge valve into suction side
of head. Do not overtighten.
Instruction Manual 17
SECTION 4 - MAINTENANCE
B. Reassembly (refer to figure 13) 1-3/4, 2-1/2, and 3”Plungers: Plastic Single- Ball
1. To install the cartridge, position the lock nut Check Valves: see Figure 11
(435) toward the shoulder of the cartridge so A. Disassembly
that the recess on the face of the lock nut is 1. Unscrew the union nut (435). The union end
adjacent to the O-ring (441). (445) is held in place by the union nut and will
2. Make certain the split ring (439) is coiled in now separate easily from check valve ball guide
a counterclockwise helix(this is opposite the (424).
direction normally employed by suppliers of 2. Unscrew the ball guide (424) from the liquid
these rings). Fit this split ring in the lock nut end.
recess. Push it firmly down in the recess as 3. Screw the union nut partially (one or two turns)
completely as possible. onto the end of the ball guide containing the
3. Install a new O-ring (435) against the split seat. Be sure the union nut is loosely installed
ring. to allow for a gap for the seat (420) to drop into
Note: as it is removed from the ball guide.
To assure a tight, leak free seal, new O-rings 4. Sit the ball guide/union nut onto a flat surface
and split rings should be used each time the with the union nut down. Looking into the top
check valves are disassembled.
of the ball guide, you will see four large holes
4. Screw the cartridge assembly (444, 445) into the surrounding one small hole. Insert a thin, blunt
liquid end until the O-ring band is approximately instrument such as a hex head screwdriver into
level with the top of the spot face in the liquid the small center hole until it rests on the top of
end, then screw it one (1) additional turn plus a the ball (422).
partial turn as required to align the pipe thread 5. Tap screwdriver gently with a hammer until ball
port with connecting pipe. and seat are released from the ball guide.
SUCTION AND DISCHARGE IF YOU ARE DISASSEMBLING
CHECK VALVE CARTRIDGES UNIT FOR INSPECTION ONLY,
ARE NOT IDENTICAL. BE SURE THAT THE CORRECT BE SURE TO USE A BLUNT INSTRUMENT AND TAP GENTLY TO
CARTRIDGE IS BEING SCREWED INTO THE PROPER PORT. AVOID DAMAGING THE BALL. IF THE BALL AND/OR SEAT ARE
(DISCHARGE CARTRIDGES HAVE HEXAGONAL CAP ON THE DAMAGED DURING DISASSEMBLY, THEY WILL NEED TO BE
TOP; SUCTION CARTRIDGES DO NOT.) IF CHECK VALVE REPLACED. TO AVOID DAMAGE, IF AVAILABLE, IT IS
CARTRIDGES ARE INSTALLED INTO THE WRONG PORT, ONE ADVISABLE TO USE GENTLE AIR PRESSURE (APPLIED AT
OF THE FOLLOWING WILL OCCUR: (A) IMMEDIATE SEVERE END OPPOSITE THE SEAT-420) FOR BALL AND SEAT
DAMAGE TO PUMP MECHANISM, (B) NO PUMPING, (C) REMOVAL.
REVERSE PUMPING ACTION (FRONT DISCHARGE LINE INTO
6. Carefully remove the two O-rings (419) from the
SUCTION LINE).
ball guide and seat.
5. After completing pipe connection, tighten lock
nut securely against spot face so that O-ring is
trapped in chamfer of liquid end thread. Make
sure that the split ring is completely contained in
its recess and not extending to the outside.
18 Instruction Manual
SECTION 4 - MAINTENANCE
7. Inspect the balls carefully. If they are smooth, 4. Position the union end (445) onto the correct
round and free of deposits or pits, they are end of the ball guide. Refer to Figure 11 as the
suitable for continued use. Examine the check correct end is determined by whether the valve
valve seats. The area of the seat in contact is intended for the suction or discharge port of
with the ball (the un-chamfered side) must be the liquid end. Slip the union nut (435) over the
in near perfect condition for continued use. union end and screw tightly (hand tight only)
Any visible imperfection on the seating surface onto the ball guide.
(pits, erosion, cracks) necessitates replacement
THE ORDER OF ASSEMBLY OF
of the seat. If both the balls and the seats are in THE SUCTION AND DISCHARGE
good condition, then the length of time between CHECK VALVES IS DIFFERENT. REFER TO FIGURE 11 FOR
parts replacement may be increased. If the PROPER ASSEMBLY ORDER. IF CHECK VALVE CARTRIDGES
ARE INSTALLED INCORRECTLY, ONE OF THE FOLLOWING
balls and seats are severely damaged, then
WILL OCCUR: (A) IMMEDIATE SEVERE DAMAGE TO PUMP
the length of time between parts replacement MECHANISM, (B) NO PUMPING, (C) REVERSE PUMPING
should be shortened. Carefully clean any ACTION (FROM DISCHARGE LINE INTO SUCTION LINE).
parts to be reused. If any chemicals are used 5. Screw the valve assembly into the liquid
in the cleaning process, ensure that they are end body(hand tight only). DO NOT
compatible with the process liquid. OVERTIGHTEN!
B. Reassembly 1-1/4” Plunger, Plastic Double Ball Check
1. Drop the ball into the curved inner chamber end Valves 1-3/4”, 2-1/2”, 3” Plungers, Plastic &
of the ball guide. Metallic Double Ball Check Valves
2. Sit the ball guide on a flat surface so that the side A. Disassembly (Refer to Figure 10).
with the ball faces upwards. Position seat on the
Double ball check valves differ from the plastic
ball guide, trapping the ball inside. When the
single ball check in that the ball seat is now
seat is pressed into the ball guide, the beveled
integral to the ball guide. The seats cannot easily
edge of the seat must be facing outward.
be inspected for damage or wear. If you suspect
The bevel should not face the inside of the check
that the check valve may be damaged or worn,
valve (refer to Figure 11). Use a flat surface such
replace the entire check valve assembly as per
as a board to press the seat into the ball guide
instructions below.
with firm, even pressure.
1. If metallic valve, unscrew the coupling (445)
IF THE SEAT IS IMPROPERLY
POSITIONED (WITH BALL from the ball guide (424). If plastic, unscrew the
AGAINST BEVELED SURFACE), THE BALL WILL NOT CREATE union nut (435, figure 11) and remove union end
A TIGHT SEAL AND POOR PUMPING PERFORMANCE WILL (445, figure 11) from the ball guide (424).
RESULT.
2. Unscrew the ball guide (424) from the liquid
3. Fit new O-rings into grooves in the ball guide end.
and seat.
3. Remove and discard the O-rings (419).
Note: 4. Remove ball stop (420) and balls (421, 422).
To assure a tight, leak free seal, new O-rings
should be used each time the check valves are
disassembled.
Instruction Manual 19
SECTION 4 - MAINTENANCE
Inspect the balls carefully. If they are smooth, (445) onto the check valve assembly, trapping
round and free of deposits or pits, they are a new O-ring (419) between the coupling and
suitable for continued use. Examine the ball the check valve assembly. If plastic check
seat areas in the valve body (424). A magnifying valve, position the union end (445) onto the
glass is recommended for this inspection. correct end of the ball guide. Slip the union
The seat must be in near perfect condition for nut (435) over the union end and screw tightly
continued use. Any visible imperfection on the (hand tight only) onto the ball guide. DO NOT
seating surface (pits, erosion, cracks) renders OVERTIGHTEN!
the seat unusable thereby requiring replacement
4.3.5 Oil Strainer Replacement
of the valve body (424). If both the balls and the Refer to Figure 8.
seats are in good condition, then the length Over time, the oil strainer (670) which screws into
of time between parts replacement may be the refill valve body (660) can become fouled or
increased. If the balls and seats are severely clogged. It should therefore be replaced yearly
damaged, then the length of time between parts and is included with the check valve parts in the
replacement should be shortened. Carefully RPM Kit. If the strainer becomes clogged more
clean any parts to be reused. If any chemicals frequently than once a year (which is extremely
are used in the cleaning process, ensure that unlikely), it can be ordered separately.
they are compatible with the process liquid.
Since the oil must first be drained from the pump
B. Reassembly (Refer to Figure 10): casing, it is a good idea to schedule strainer
1. Drop the balls (422, 421) into the valve body replacement with oil replacement.
(424). Drop ball stop (420) into place making 1. Drain oil as described in the above “Oil
sure that side with O-ring groove is facing up. Replacement” section of this manual.
Install new O-rings (419) on both ends of valve 2. Unscrew the strainer (670) from the refill valve
body. body (660).
Note: 3. Clean any debris from the strainer cavity in the
To assure a tight, leak free seal, new O-rings valve body.
should be used each time the check valves are
disassembled. 4. Screw a new strainer into the refill valve body.
5. Refill pump casing with recommended oil as
2. Screw the correct end of the check valve
described in the “Oil Replacement” section.
assembly into the liquid end (hand tight only)
trapping a new O-ring between the liquid
end and the check valve assembly. DO NOT
OVERTIGHTEN!
THE END OF THE CHECK VALVE
THAT IS SCREWED INTO THE
PUMP HEAD IS DIFFERENT FOR THE SUCTION AND
DISCHARGE CHECK VALVES. REFER TO FIGURE 10 FOR
PROPER ASSEMBLY ORDER. IF CHECK VALVE CARTRIDGES
ARE INSTALLED INCORRECTLY, ONE OF THE FOLLOWING
WILL OCCUR: (A) IMMEDIATE SEVERE DAMAGE TO PUMP
MECHANISM, (B) NO PUMPING, (C) REVERSE PUMPING
ACTION (FROM DISCHARGE LINE INTO SUCTION LINE).
20 Instruction Manual
SECTION 4 - MAINTENANCE
4.4 CORRECTIVE MAINTENANCE 4. Slide OFF activation button (780) and spring
(800).
4.4.1 3- Function Hydraulic Valve
5. Remove large retaining ring (810) using the
The 3- function hydraulic valve assembly
appropriate retaining ring pliers (Waldes Truarc
(see Figure 8) operates in filtered hydraulic oil
Internal Type, Waldes Truarc part# 0300).
and should require maintenance only if unusual
circumstances occur, such as if corrosive media 6. Reinstall small retaining ring (820) in groove in
contaminates the fluid. valve stem (770).
Assembly and disassembly is straightforward. 7. To avoid damage to valve stem, grip retaining
Follow instructions in the “Start- Up of Pump ring with pliers and pull remaining valve
Containing No Oil in Casing and Displacement assembly out of displacement chamber.
Chamber” section of the manual. Field servicing 8. Discard O-rings (830,840) and retaining rings
should be limited to inspection and cleaning only. (810, 820).
Repairs of this critical component should only be
NOTE:
carried out by an authorized Milton Roy repair When reinstalling, make certain that new
facility. O-rings and retaining rings are installed on
MARS assembly.
4.4.2 “MARS” Valve Assembly
The Mechanically Activated Refill System (MARS) B. Reassembly
valve assembly (see Figures 8 & 9) requires no 1. Install new O-rings (830, 840) on valve body
periodic maintenance. Clean hydraulic oil is critical (750) and apply a light layer of O-ring grease
for proper operation. Field servicing should be to O-rings.
limited to inspection and cleaning only. Repairs of 2. Push assembly into place until it reaches stop
this critical component should only be carried out in displacement chamber.
by an authorized Milton Roy repair facility.
3. Reinstall large bowed retaining ring (810).
The valve is designed to be easily removed through Using a hammer and flat tipped screwdriver,
the front of the pump without having to remove gently tap the ring to insure that it is securely
the displacement chamber. The following steps seated in the retaining groove machined into
describe the procedure for removal of the valve the displacement chamber.
from the displacement chamber (refer to Figure 9):
4. Reinstall spring (800) and activation button
A. Disassembly (780).
1. Remove liquid end according to instructions 5. While pressing button (780), reinstall small
in the “Removing the Liquid End” portion of retaining ring (820). Gently tap on the ring to
the “Diaphragm Replacement” section of the insure that it is securely seated in the retaining
manual. ring groove machined into the valve stem
2. Insert a small tip screw driver into one of the two (770).
small holes in the valve button (780) and gently 6. Press plastic cap piece (790) into activation
pry out plastic cap (790). button (780).
3. While pressing down on button (780), remove 7. Valve is now ready for service.
the retaining ring (820) using the appropriate
retaining ring pliers (Waldes Truarc External
Type, Waldes Truarc part# M-1520).
Instruction Manual 21
SECTION 4 - MAINTENANCE
4.4.3 Refill Valve Assembly (see Figure 8). 4.4.4 Diaphragm Replacement
The only required periodic maintenance for the MILROYAL ® G liquid ends are designed to
refill valve assembly is the suggested annual provide reliable service under normal operating
replacement of the oil strainer (see above “Oil circumstances and should not require replacement
Strainer Replacement” section). Clean hydraulic of the diaphragm. However, in the unlikely event
oil is critical for proper operation. Field servicing of a failure, the diaphragm can be replaced by the
of the valve assembly is limited to inspection and following the procedure:
cleaning only. Repairs of this critical component
A. Removal of Diaphragm (Figures 7 & 8):
should only be carried out by an authorized
Milton Roy repair facility. BEFORE BEGINNING DISASSEMBLY
PROCEDURES, RELIEVE ALL
The valve is designed to be easily removed through PRESSURE FROM SYSTEM, ISOLATE THE LIQUID END FROM ALL
the bottom of the pump without having to remove SOURCES OF PROCESS LIQUID WITH APPROPRIATE VALVING, AND
the displacement chamber. The following steps PURGE LIQUID END OF ALL PROCESS LIQUID.
describe the procedure for removal of the valve 1. Disconnect both the suction inlet and discharge
from the displacement chamber (Figure 8): outlet from the piping system.
A. Disassembly 2. Locate drain pan under diaphragm head to
1. Drain oil from the pump housing as described collect oil. Approximately 1 pint of oil will drain
in the above “Oil Replacement” section. from the displacement chamber after removal
of the diaphragm.
2. Unscrew the valve body (660) from the
displacement chamber (600). 3. Remove the diaphragm head bolts (1025) which
hold the head to the displacement chamber and
3. Clean any debris from the valve cavity in the
remove diaphragm head (1020). Oil will begin to
displacement chamber.
leak out. In most cases, the white teflon-faced
4. Discard O-rings (720, 730).
diaphragm will remain in the displacement
Note: chamber.
When reinstalling the valve assembly, be sure 4. Remove the diaphragm. Oil will now drain out
to install new O-rings (720, 730).
of the front of the displacement chamber.
B. Reassembly
1. Install new O-rings (720, 730) and coat rings
with O-ring grease.
2. Screw valve assembly back into displacement
chamber until it reaches mechanical stop.
3. Make sure the strainer (670) is installed and
strainer plug (650) is tight. Valve is now ready for
service. Refill pump casing with recommended
oil as described in the “Oil Replacement”
section.
22 Instruction Manual
SECTION 4 - MAINTENANCE
B. Installation of New Diaphragm A. Disassembly:
(Figures 7 & 8): 1. Disconnect both the suction inlet and discharge
1. Make sure the contoured diaphragm support outlet from the piping system.
surface and O-ring groove machined into
2. Drain oil as described in the above “Oil
displacement chamber are clean. To prevent
Replacement” section of this manual.
leakage from occurring, be careful not to scratch
the O-ring groove when cleaning. 3. Remove 3- Function Valve assembly as
described in the “Start- Up of Pump Containing
2. Install the diaphragm into the displacement
No Oil in Casing and Displacement Chamber”.
chamber with the black rubber side against
the contoured surface of the displacement 4. Remove six displacement chamber bolts (570)
chamber. Make sure the diaphragm sealing and lock washers (560) which secure liquid end
bead fits securely in the diaphragm groove of the to pump drive housing.
displacement chamber. The white teflon-face of 5. Locate a container under liquid end to catch
the diaphragm should be facing outward and approximately 1 pint of oil that will escape during
visible. next step.
3. Align the two holes in the diaphragm head with the 6. Gently pull liquid end OFF drive housing
locating pins (610) in the displacement chamber being careful to avoid damage to plunger
and reinstall diaphragm head (1020). (520, figure 5) during removal. Drain oil into
4. Reinstall head bolts (1025), flat washer (1040), waste container.
lock washers (1035), and nuts (1030). 7. Discard displacement chamber gasket (590).
5. Tighten bolts firmly in a crisscross pattern. 8. Place the liquid end, diaphragm head up, on
a bench or other clean, flat, convenient work
4.4.5 Removal of Pump Liquid End area.
(Figures 7 & 8)
MILROYAL ® G liquid ends are designed to B. Reassembly:
provide reliable service under normal operating 1. Make sure gasket surface on pump housing
circumstances and should not require removal and displacement chamber are clean and free
of the liquid end. However, if the need arises, the of markings which could serve as leak paths.
following describes the procedure. 2. Install new displacement chamber gasket (590)
BEFORE BEGINNING DISASSEMBLY in correct orientation on liquid end.
PROCEDURES, RELIEVE ALL
PRESSURE FROM SYSTEM, ISOLATE THE LIQUID END FROM ALL
3. With vent cap (620) at 12 O’clock, gently slide
SOURCES OF PROCESS LIQUID WITH APPROPRIATE VALVING, AND liquid end over plunger.
PURGE LIQUID END OF ALL PROCESS LIQUID.
4. Reinstall six displacement chamber bolts (570)
and lock washers (560) and tighten securely.
5. Follow procedure for filling pump housing
and liquid end with oil described in “Start- Up
of Pump Containing No Oil in Casing and
Displacement Chamber”.
Instruction Manual 23
SECTION 5 - TROUBLESHOOTING
24 Instruction Manual
SECTION 5 - TROUBLESHOOTING
Instruction Manual 25
SECTION 6 - PART NUMBERS
26 Instruction Manual
SECTION 6 - PART NUMBERS
Note 1: Worm Assembly (343) includes worm, coupling (346), spring (360), and bearing cone (340).
Note 2: For part numbers not listed, consult local Milton Roy representative or Milton Roy Aftermarket
Department (215-441-0800).
Instruction Manual 27
SECTION 6 - PART NUMBERS
Note 1: Include items 750, 760, 770, 810, 820, 830, 840.
Note 2: Not sold separately. Must purchase item 775 (MARS Valve Assembly).
28 Instruction Manual
SECTION 6 - PART NUMBERS
6.2.3 3- FUNCTION VALVE (see Figure 8)
Qty.
Item No. Description
Req.
850 Valve Cap 1
860 Purge Button 1
870 Pin 1
880 Purge Button Spring 1
890 Relief Valve Adjustment Screw 1
900 Relief Valve Locking Nut 1
910 Relief Valve Adjustment Nut 1
920 O-Ring 2
930 Purge Stem 1
935 Washer 1
940 O-Ring 1
950 Relief Valve Spring (1-1/4, 1-3/4” plungers)
PVC Liquid End (purple) 1
Metallic Liquid End (orange) 1
950 Relief Valve Spring (2-1/2, 3” plungers),purple 1
1015(note 1) Poppet Assembly 1
960(note 2) Air Bleed Valve Body 1
970(note 2) Ball 1
980(note 2) O-Ring 1
990(note 2) Air Bleed Ball Seat 1
1000(note 2) Spring 1
1005(note 2) Air Bleed Body Seat 1
Instruction Manual 29
SECTION 6 - PART NUMBERS
6.2.5 PVC Liquid End (see Figures 10-13)
1-1/4” plunger: Single Ball Check Valve
(see Figure 12)
Item No. Description Qty. Req.
71 Check Valve Assembly Tubing Conn: includes 2
425 Cartridge Valve Assembly 2
435 Tubing Connector 2
445 Valve Body-Tube 2
71 Check Valve Assembly NPT Conn. includes 2
425 Cartridge Valve Assembly 2
445 Valve Body- NPT 2
30 Instruction Manual
SECTION 6 - PART NUMBERS
1-3/4, 2-1/2, 3” plungers: Single Ball Check
Valves, (Figure 11).
Item No. Description Qty. Req.
Check Valve Assembly Assemblies include two seals (419), seat (420), ball
425 1
(422), ball guide (424)
419 Seal, PTFE Encapsulated Rubber 2
420 Seat, PVDF 1
422 Ball; 5/8” Ceramic 1
423 Seat, Seal, Ball-Replacement Kit 1
424 Ball Guide/Body, PVDF 1
435 Union Nut, PVC 1
445 Union End, PVC, ½” NPT Female 1
Instruction Manual 31
SECTION 6 - PART NUMBERS
Alloy 20 Liquid End, 1-3/4, 2-1/2, 3” plungers:
Double Ball Check Valves (Figure 10)
Item No. Description Qty. Req.
425 Check Valve Assembly 1
Check Valve assemblies include two seals (419), seat (420), balls (421, 422), ball guide (424)
419 O-Ring, viton 2
420 Ball Stop 1
421 Ball, 14mm 1
422 Ball, 22mm 1
424 Ball Guide/Body 1
445 Coupling, ½” BSP Female 1
445 Coupling, ½” NPT Female 1
32 Instruction Manual
SECTION 6 - PART NUMBERS
Instruction Manual 33
Model No. MGH281
Product Code
10CDM2SE11NN22
9”
S/N1234567891 (228.6 mm)
Flow Rate
X.X GPH @ XX PSI
Motor
XXX PSI MA WP CL
Tag No. 12345678 41/2”
Pressure
Relief
Valve
Suction
Accumulator
Dampener
34 Instruction Manual
182TC MOTOR
EC80
MOTOR
56C MOTOR
390
400
376
376 370
400
410
377
60
346
360 520
417
343
525
340
40 460
470
465
450
Instruction Manual 35
330 335
160
171
175
200
310
140
570
320
205
190
110
130
10
50
19
30 100 120
20
36 Instruction Manual
1020
PLASTIC ONLY
1050 PLATE IS USED ON 1-1/4” PLUNGER ONLY.
LARGER PLUNGER SIZES USE WASHERS
TORQUE TO
1025 40 IN-LB FOR METALIC
20 IN-LB FOR PLASTIC
630 610
560 570
Instruction Manual 37
870
530
540 510
550 1020
TORQUE TO
125 IN-LB
MARS VALVE
SEE FIGURE
NEXT SHEET
600
590
580
730
740
710 700 660 670
720
690
680
38 Instruction Manual
MARS VALVE
Mechanically Activated Refill System (MARS) Valve assembly.
Except for O-rings, the valve may only be purchased as an assembly.
760
790
775 770 800 780
The MARS Valve is located between the plunger and the diaphragm.
Instruction Manual 39
445
419 420
422
420
419
422 424
421
424
419
419 445
DISCHARGE SUCTION
PVC and Metallic Double Ball Check Valve Parts- 1-1/4” thru 2-1/2” Plunger Sizes
419 420
422 424
421
Figure 10.
445
419
435
419
424 422
424
419
422
435
DISCHARGE SUCTION
Figure 11.
40 Instruction Manual
425
435
071
445
445
425
435
DISCHARGE SUCTION
445
425
071
425
445
DISCHARGE SUCTION
Instruction Manual 41
METALLIC CHECK VALVES
437
419
445
426
435
424
421
439
420
421
441
424
441 421
420 425
439
421
435
444
42 Instruction Manual
PVC LIQUID END FOUR FUNCTION BLEED VALVE 1.25” PLUNGER
447 SPACER(0.040”)
448 SPACER(0.020”)
Instruction Manual 43
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and technologically advanced flow control systems and
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®