Installation, Operation & Maintenance Manual
Contents
1. PZ7 No Part Number Description Qty 1 7001 037NC225A Hex head bolt 4 2 7206 037A Lock washer 0 375 4 3 5457 AOV adjustment stem cap 1 4 5471 X AOV adjustment stem retainer ring 1 5 5471 X Hex nut 3 6 5471 X Air operated valve adjustment stem 1 7 5459 AOV low flow adjustment bushing 1 8 5471 X O ring 1 9 5470 Air operated valve housing 1 10 2854 Threaded pipe plug 1 11 5471 X Lock washer 0 3125 1 12 5471 X Air operated valve disc 2 18 5471 X Air operated valve diaphragm 2 14 5464 Air operated valve intermediate plate 1 15 5465 Air operated valve diaphragm cover 1 16 5471 X Diaphragm valve disc 1 17 5460 10 24 x 1 flat head cap screw 2 18 5472 Air operated valve gasket 1 Available with the 5471 X AOV diaphragm assembly or sold separately 20 Not sold separately Only available with the 5471 X Air Operated Valve AOV diaphragm assembly Available with the 5471 X AOV diaphragm assembly or sold separately Appendix E Part Details for the PZ10 Air Operated Valve AOV 5462 X Air Operated Valve AOV Assembly for a PZ10 e No Part Number Description Qty 1 7001 037NC275A Hex head bolt 4 2 7206 037A Lock washer 0 375 4 3 5457 AOV adjustment stem cap 1 4 5466 X AOV adjustment stem retainer ring 1 5 5466 X Hex nut 3 6 5466 X Air operated valve ad2. E F 10 30 10 01 a O 7 95 ORKEN ANI Ac IA mI i KET AME 422 2 03 NS J 2 03 L NND m 5 20 o T o 65 Is WV mad bur NE Inches centimeters 17 Appendix E Part Details for the PZ7 with Standard Bypass Valve Shaft cover may be installed on either side of the pump 18 Available with all 4431 X seal assemblies or sold separately See item number 6 in table below PartNo Description 1 5368 Pump case 1 Y e 2 1166 1X6R Rotor shaft assembly 1 3 5372 Vane 6 4 4262 X Vane driver 3 5 3932 Sideplate 2 4431 XA1 Seal assbly Buna N O ring stainless stl seat 2 O ring Code 4431 XA2 Seal assembly Buna N O rings cast iron seat 2 A Buna N 6 4431 XA3 Seal assembly Buna N O rings Ni Resist seat 2 D Viton 4431 XD1 Seal assembly Viton O rings S S seat 2 4431 XD2 Seal assembly Viton O rings cast iron seat 2 4431 XD3 Seal assembly Viton O rings Ni Resist seat 2 No
3. DURING THE BLEED DOWN PROCESS TO AVOID DANGER TO PERSONNEL AND PROPERTY IN THE AREA Take your time in bleeding your system and make proper provisions to vent or capture the product in accordance with local regulations ONLY A PROPERLY TRAINED INDIVIDUAL SHOULD BE ALLOWED TO BLEED A PUMPING SYSTEM Disassembly and Assembly Instructions for the PZ Series Pump Disassembly Instructions 1 Truck engine must be turned off and PTO disengaged 2 Bleed all product from the system as described above NOTE There is a 1 4 NPT connection in the bottom of the pump case that allows you to easily drain the pump 3 Remove the PTO shaft or hydraulic drive motor adapter and coupling 4 Remove the eight 7 16 head bolts from one head 5 Slide head assembly off pump shaft ensuring the pump rotor shaft remains in the pump 6 Inspect the mechanical seal carbon face for scoring or pitting and discard if damaged Ensure the rotor shaft remains inside pump NOTE If rotor is pulled with head it will disengage the seal assembly on the opposite side 7 If the mechanical seal requires replacement slide a screwdriver through the head assembly from the bearing cap and tap the stationary seal face out 8 10 11 12 13 14 15 16 17 Remove the four 3 8 bolts from the bearing cap to gain access to the thrust bearing Retain the bearing cap shims independently for each side of the pump Inspect the thrust washers and n
4. 50 75 100 125 Differential Pressure psi Pump Speed Differential Pressure Nominal Flowrate Brake HP Required Torque Required RPM psi bar gpm L min bhp kW inelbs Nem 800 90 6 2 98 371 6 8 5 0 536 60 5 800 50 3 4 105 397 3 8 2 2 299 33 8 640 90 6 2 78 295 5 5 4 1 542 61 2 640 50 3 4 84 318 3 1 2 3 305 34 5 575 90 6 2 70 273 4 9 3 7 537 60 7 575 50 3 4 75 284 2 7 2 0 296 33 4 420 90 6 2 51 182 3 6 2 7 540 61 0 420 50 3 4 55 197 2 0 1 5 300 33 9 These curves depict performance of the PUMP ONLY Performance will vary in applications due to system design and variables Approximate capacities and horsepowers are based on 38 SSU 3 cP fluid 13 Appendix C Performance Curves PZ10 Truck Pump 180 170 160 800 RPM 150 140 S 640 RPM 2 130 a T O 110 575 RPM 420 RPM 0 7 Differential Pressure psi 0 25 5 Pump Speed Differential Pressure Nominal Flowrate Brake HP Required Torque Required RPM psi bar gpm L min bhp kW inelbs Nem 800 90 6 2 152 575 10 3 7 7 811 91 7 800 50 3 4 161 609 5 7 4 3 449 50 7 640 90 6 2 121 458 8 2 6 1 808 91 2 640 50 3 4 128 485 4 6 3 4 453 51 2 575 90 6 2 109 413 7 3 5 4 800 90 4 575 50 3 4 115 435 4 1 3 1 449 50 8 420 90 6 2 80 303 5 4 4 0 810 91 6 420 50 3 4 85 321 3 0 2 2 450 50 9 These
5. curves depict performance of the PUMP ONLY Performance will vary in applications due to system design and variables Approximate capacities and horsepowers are based on 38 SSU 3 cP fluid 14 Appendix D Outline Dimensions for the PZ7 PZ7 with Standard Bypass Valve 5 60 14 22 1 4 Keyway All et i i i 1 120 2 844 i 1 118 2 839 4 50 146 11 40 1 45 3 68 3 71 Y Inches centimeters PZ7 with Standard Bypass Valve PZ7 with Air Operated Valve AOV 6 06 e 1 76 8 54 sa no 176 15 40 4 47 21 69 4 47 T I i H aw le 4 56 1422 KH i 091 p 44 1 12 Holes Inches centimeters 15 Appendix D Outline Dimensions for the PZ10 PZ10 with Standard Bypass Valve 1118 2 839 1 120 2 844 Eu i JO OL TE cm BIB d H 5 60 Q O 14 22 1 4 Keyway m L e x OQ 5363 2 RV B To id m i eon A IAN ps 1 db M oe Cy T 9 4 50 ion H ss 2 H 1t
6. or O rings failed Inspect seal assembly and replace if necessary Keep new seal very clean when replacing seal Recommend a light oil film on O rings Has pump been run dry If so check for damage to vanes amp rotor shaft assembly 23 Appendix G Flush and Storage Instructions for the PZ Series Pump If the PZ Series pump is to be removed from service for some time the pump must be protected Piping and tanks not in service should also be protected as the rust particles can destroy the pump s seals almost immediately after start up 1 Fill or thoroughly flush the pump with a light rust inhibiting oil If the pump is flushed with oil place some desiccant packets inside the pump for added protection 2 Plug all pump openings 3 Store in a dry location 4 Before placing the pump back into service drain the oil and remove any desiccant packets 5 Refer to the Operation of the PZ Series Truck Pump on page 5 of this Installation Operation amp Maintenance IOM manual Solutions beyond products CORKEN Corken Inc A Unit of IDEX Corporation P O Box 12338 Oklahoma City OK 73157 U S A Phone 405 946 5576 or 1 800 631 4929 Fax 405 948 7343 Visit our website at http www corken com E mail us at info corken idexcorp com Printed in the U S A December 2005
7. 002 8 4439 1 Bearing cap shim 0 010 2 4439 1 Bearing cap shim 0 010 2 4439 2 Bearing cap shim 0 020 2 4439 2 Bearing cap shim 0 020 2 4441 Grease seal 2 4441 Grease seal 2 5372 Vane 6 5372 Vane 6 PZ10 Repair Kit 5498 X1A Buna N PZ10 Repair Kit 5498 X1D Viton Part Number Description Qty Part Number Description Qty 1480 Gasket 1 1480 Gasket 1 2 234A O ring Buna N 3 2 234D O ring Viton 3 2270 Shaft key 1 2270 Shaft key 1 2754 X Roller bearing 2 2754 X Roller bearing 2 4262 X Vane driver 5 4262 X Vane driver 5 4431 XA2 Seal assembly Buna N 2 4431 XD2 Seal assembly Viton amp 2 4432 Thrust bearing 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim 0 002 8 4439 Bearing cap shim 0 002 8 4439 1 Bearing cap shim 0 010 2 4439 1 Bearing cap shim 0 010 2 4439 2 Bearing cap shim 0 020 2 4439 2 Bearing cap shim 0 020 2 4441 Grease seal 2 4441 Grease seal 2 5365 Vane 6 5365 Vane 6 Viton is a registered trademark of the Dupont company 10 Appendix A Model Number and Identification Code for PZ Series Model Number Base XX XXX XX Base Model T Basic pump Model PZ7 or PZ10 Standard PZ7 Specification Fields No strain
8. 41 11 43 8 58 SSS 3 58 f r81B 1 50 l2 e zl 1 50 3 81 3 81 2 50 wl 2 50 6 35 6 35 8 62 8 62 zl 21 89 21 89 PZ10 with Standard Bypass Valve Inches centimeters H zm 1 91 44 1 12 4 Holes PZ10 with Air Operated Valve AOV d 75 1 91 el 44 1 12 4 Holes Inches centimeters 16 Appendix D Outline Dimensions for Air Operated Valve and Strainer 5470 X Air Operated Valve AOV for PZ7 Pump CS 3 25 8 26 i pes IT IT 4 25 T 10 79 feo r a lt 3 25 FE 8 26 p te OO M 3 25 8 26 Inches centimeters 5462 X Air Operated Valve AOV for the PZ10 Pump a 3 75 9 52 4 48 O O LL 11 30 3 75 E a No P 9 52 NT E Inches centimeters 5422 X Strainer Assemly for the PZ7 and PZ10 Pump 4 4 64 3 94 11 79
9. EN INC 3805 N W 36 Street Oklahoma City Oklahoma 73112 Parts subject to wear or abuse such as mechanical seals vanes piston rings packing and other parts showing signs of abuse are not covered by this limited warranty Also equipment parts and accessories not manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser must look to the original manufacturer s warranty if any This limited warranty is void if the Corken product has been altered or repaired without the consent of Corken All implied warranties including any implied warranty of merchantability or fitness for a particular purpose are expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warranty period Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken products Transfer of toxic dangerous flammable or explosive substances using Corken products is at the user s risk Such substances should be handled by experienced trained personnel in compliance with governmental and industrial safety standards Contacting the Factory Before you contact the factory note the model number and serial number of your pump The serial number directs us to a file containing all information on material specifications and test data applying to your specific pump When ordering parts the Corken service manual or IOM Installati
10. ID107D Installation Operation amp Maintenance Manual PZ Series Coro VanesPetroleum Pump For Refined Petroleum Products and Industrial Solvents PZ7 Model with Standard Bypass Valve Warning 1 Periodic inspection and maintenance of Corken products is essential 2 Inspection maintenance and installation of Corken products must be made only by experienced trained and qualified personnel 3 Maintenance use and installation of Corken products must comply with Corken instructions applicable laws and safety standards such as NFPA Pamphlet 58 for LP Gas and ANSI K61 1 1972 for Anhydrous Ammonia 4 Transfer of toxic dangerous flammable or explosive substances using Corken products is at user s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards Solutions beyond products CORKEN Warning Install use and maintain this equipment according to Corken s instructions and all applicable federal state local laws and codes Periodic inspection and maintenance is essential Corken One Year Limited Warranty Corken Inc warrants that its products will be free from defects in material and workmanship for a period of 12 months following date of purchase from Corken Corken products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced at Corken s option when returned freight prepaid to CORK
11. Number Air T Valve P77 5470 X l PZ10 5462 X Appendix B Technical Specifications for PZ7 and PZ10 Operating Specifications Standard connections 2 or 2 1 2 NPT Optional connections 2 or 2 1 2 Slip on weld BSPT Maximum differential pressure 125 psid 8 6 bar Operating temperature range Up to 300 F 149 C Maximum working pressure 200 psi 13 8 bar Maximum speed 800 RPM Fluids For refined petroleum products and industrial solvents Material Specifications Part Model Material Case All Ductile iron ASTM A536 Head All Ductile iron ASTM A536 Flanges All Ductile iron ASTM A536 Rotor All Ductile iron ASTM A536 Bearing cap All Ductile iron ASTM A536 Sideplates All Cast iron Class 30 Vanes amp vane drivers All Advanced polymer By pass valve All 17 4 PH Stainless steel By pass spring All Steel Seal seat All Cast iron standard Stainless steel and Ni Resist optional Seal metal parts All Steel Shaft All 8620 steel Thrust bearing All Steel O rings All Viton standard Buna N optional Viton is a registered trademark of the Dupont Company 12 Appendix C Performance Curves PZ7 Truck Pump 120 110 100 800 RPM E 90 S 640 RPM 80 o z S 70 575 RPM 60 420 RPM 50 40 0 25
12. Part Number Description Qly 7 4416 Head 2 25 2 234 O ring 2 a aE 2 26 7001 050NC150A Hex head bolt 8 9 2754 X Roller bearing 2 27 3442 Pipe plug 1 4 NPT 5 10 2760 244 Retainer ring 2 28 7001 043NC125A Hex head bolt 16 11 4435 Thrust bearing mounting ring 2 29 2397 1 Name plate 1 SRL Tuki bedna ASSEN 2 30 7012 006SF019E Pan head Phillip 6 32 x 3 16 6 13 4439 2 Bearing cap shim 0 020 2 31 1359 Lubrication plate 2 14 4439 1 Bearing cap shim 0 010 2 32 4985 Shaft cover 1 15 4439 Bearing cap shim 0 002 8 33 7012 010SFO50E Pan head Phillip 10 24 x 1 2 2 16 4417 Bearing cap 2 34 2270 Shaft key 1 17 4441 Grease seal 2 35 5454 Bypass valve 1 18 2158 Grease zerk 2 5477 Bypass valve spring 50 75 psi 1 19 1943 Grease relief fitting 4 36 5407 Bypass valve spring 75 100 psi 1 20 2159 Lubricap 2 5480 Bypass valve spring 100 125 psi 1 21 7206 037A Lock washer 3 8 8 37 5447 Bypass valve spring guide 1 22 7001 037Nc150A Hex head bolt 8 38 5446 Bypass valve cap 1 23 EDI O ring 39 5505 Adjustment set screw 1 5363 2 Flange 2 NPT 2 40 1480 Gasket 1 3363 25 Flange 2 1 2 NPT 2 41 2458 Adjustment set screw cap 1 p4 2367 2 __ Flange 2 BSPT 2 42 7001 037NC075A Hex head bolt 4 5367 2 5 Flange 2 1 2 BSPT 2 43 2 142 O ring 1 5363 28 Flange 2 Weld 2 Registered trademark of the DuPont company 5363 2 5S Flange 2 1 2 Weld 2 Availab
13. ad bolt 16 13 4439 2 Bearing cap shim 0 020 2 29 2397 1 Name plate 1 14 4439 1 Bearing cap shim 0 010 2 30 7012 006SFO19E Pan head Phillip 6 32 x 3 16 6 15 4439 Bearing cap shim 0 002 8 31 1359 Lubrication plate 2 16 4417 Bearing cap 2 32 4985 Shaft cover 1 17 4441 Grease seal 2 33 7012 010SFO50E Pan head Phillip 10 24 x 1 2 2 18 2158 Grease zerk 2 34 2270 Shaft key 1 19 1343 Grease relief fitting 4 35 5373 Bypass valve 1 20 2159 Lubricap 2 5481 Bypass valve spring 50 75 psi 1 21 7206 037A Lock washer 3 8 8 36 5360 Bypass valve spring 75 100 psi 1 ee ca Hex head bolt 8 5 Spes valve spring 1 00 1 25 psi 1 ypass valve spring guide 1 23 2201 O ring 2 38 5409 Bypass valve cap 1 9363 2 Flange 2 NPT 2 39 5504 Adjustment set screw 1 5363 2 5 Flange 2 1 2 NPT 2 40 1480 Gasket 1 24 5367 2 Flange 2 BSPT 2 41 2458 Adjustment set screw cap 1 5367 2 5 Flange 2 1 2 BSPT 2 42 7001 037NC125A Hex head bolt 4 5363 28 Flange 2 Weld 2 1 Registered trademark of the DuPont company 5363 2 5S Flange 2 1 2 Weld 2 Available with all 4431 X__ seal assemblies or sold separately 3 denotes O ring code listed above Appendix E Part Details for the PZ7 Air Operated Valve AOV 5470 X Air Operated Valve AOV Assembly for a Not sold separately Only available with the 5471 X Air Operated Valve AOV diaphragm assembly
14. and lubricate with light oil Carefully slide the first head assembly over the rotor shaft ensuring the rotor shaft remains within the pump case Install the eight 5 8 hex head bolts and torque in a crossing pattern to 45 ftelb Repeat for remaining head assembly Install thrust bearing assemblies onto each mounting ring and place over each end of the rotor shaft Ensure the needle roller assemblies are sandwiched between the thrust washers and their orientation is facing outward from the pump Press each outer grease seal into each bearing cap 14 15 16 17 18 19 20 Place one bearing cap over the end of the rotor shaft and bolt in place finger tight Grasp the rotor shaft and ensure it does not turn by hand Measure the gap between the head and bearing cap Remove the bearing cap and install the measured amount of shims plus 006 yellow shims are 020 brown shims are 010 and red shims are 002 Round up if necessary Install bearing cap with four 3 8 x 1 1 2 bolts and lock washers and torque to 25 ftelb Place the remaining bearing cap over the other end and again tighten the four bolts finger tight Again measure the gap between the head and the bearing cap and remove the bearing cap Install the measured amount of shims plus 002 and install bearing cap as described above Ensure the pump rotates smoothly without binding If binding occurs repeat steps 14 and 15 If you have a standar
15. cts the additional use of a throttle control which is optional All adjustments must be made at normal operating speeds 5 1 Set the low pressure adjustment first by slowly closing the nozzle to relieve the air pressure in the AOV assembly Remove the adjustment stem cap and O ring see parts details on pages 20 and 21 Truck Air Check Valve Supply 5 2 Truck Tank n Filter Shut Off Valve Carburetor or dese Pump Air Cylinder Engine Speed Control Use either a direct Push throttle rod or connected Pull with cable Flow Sensing Valve i Pump with Air Operated Valve AOV Figure 2 Typical truck delivery system using an AOV 5 3 Turn the low pressure adjustment bushing counter clockwise to decrease the bypass pressure and vice versa to increase the pressure see parts details on pages 20 and 21 5 4 Rerinstall the O ring and adjustment stem cap and tighten securely 5 5 Open and close the nozzle several times to ensure proper setting and repeatablility Slowly close the delivery nozzle again to relieve the air pressure in the AOV assembly 5 6 5 7 5 8 Remove the adjustment stem cap and O ring Adjust the locknuts clockwise to decrease delivery flow rate and or pre
16. d bypass valve install the O ring into the O ring groove in the bypass valve cap and lubricate using light oil Install the valve spring guide and cap on the pump with the four 3 8 bolts and torque to 15 ftelbs If you have an Air Operated Valve AOV assembly install the vent plate between the two diaphragms ensuring proper orientation with the screw holes in the housing Slide the diaphragm assembly into the housing and install the diaphragm cover plate and recessed head machine screws and tighten securely Install this assembly with the valve spring and gasket to the pump using the four 3 8 bolts and lock washers and torque to 15 ftelbs Install both locknuts all the way down the adjustment stem and replace the retainer ring Install the new O ring and outer adjustment stem cap Refer to Operation of the PZ Series Truck Pump on page 5 for adjustment procedure Grease bearings per the instructions listed on page 6 under Pump Maintenance Schedule Install the pump according to the installation guidelines mentioned previously on page 4 Mechanical Seal and Vane Replacement Instructions Cleanliness and Workmanship Even the smallest amount of dirt on your new seal can cause early failure Keep all parts tools and your hands clean while installing the seal Never touch the smooth lapped faces of the carbon rotor or seal seat Lastly your Corken pump is a precision piece of equipment with very close clearances Treat it as suc
17. ective meter Service meter Pump will not turn Foreign matter in pump Clean out the pump check strainer in suction line Internal bypass valve set too low or stuck open Ocke up Vanes broken Clean out pump carefully and replace vanes Has pump been operated dry Then check for damage to cam and rotor shaft assembly Bearing seized Replace pump bearings Grease monthly Use ball bearing grease manufactured for intended service Moisture frozen in pump Let thaw and break loose carefully Will not build Poor suction conditions Clean inlet strainer Increase pipe size pressure Check valve or set valve for higher pressure see instructions Worn vanes and or sideplates Disassemble inspect and repair as necessary Has pump been run dry If so check for damage to vanes amp rotor shaft assembly Pump is noisy Cavitation from poor suction conditions Clean inlet strainer Increase pipe size Vanes sticking Remove vanes and clean out foreign material check strainer Replace vanes if swollen Bearings worn Replace if necessary grease monthly Very high differential pressure Check for restriction in discharge line Delivery hose too small and too long Slow down pump Check vapor release float assembly on meter air eliminator and meter differential valve PTO shaft vibration Inspect and repair driveline component Pump leaks around shaft Seal
18. eedle roller assembly for scoring or pitting Discard if damage found Retain mounting ring for future use Remove the spiral snap ring in the pump head to facilitate removal of the main bearing Inspect the bearing rollers and inner race for scoring or pitting Replace if damage is found Retain the snap ring for future use The main bearing can be easily removed by inserting a screwdriver through the head from the mechanical seal side and lightly tapping Work the screwdriver around the inside perimeter of the bearing as the bearing is lightly pressed into the head Inspect inner grease seal and head O ring for cuts or abrasions and remove and change if necessary Inspect the outer grease seal in the bearing cap for cuts or abrasions and remove if necessary Repeat steps 3 through 10 for remaining head assembly Using a bearing cap or flange bolt 3 8 slide the sideplate off of the rotor shaft while holding other end of rotor shaft in place Once removed the rotor shaft can be pulled slightly toward the remaining sideplate and allowed to rest within the pump case Inspect the sideplates for wear If sideplates are worn on both sides discard for replacement Carefully remove the rotor shaft assembly with the vanes and drivers by cupping the lower vanes in place Inspect vanes and drivers for wear or abrasions Replace if damage is found Inspect the rotor O D and cam inner surface for scoring or pitting Should the condition a
19. er Standard N Strainer Strainer Optional S Internal bypass Standard valve Standard S valve Air Operated Valve Optional A Low 50 75 psi Optional Bypass valve spring Std 75 100 psi Standard 2 High 100 125 psi Optional 3 Seal O ring Viton Standard D material Buna N Optional A Stainless steel Optional Seal seat material Cast iron Standard 2 Ni Resist Optional 3 Strainer is attached to the pump when specified by suffix S in the configurated string When the strainer is required separate from the pump order using the Part Number found in the Strainer Assembly table on page 12 Viton is a registered trademark of the Dupont company Inlet Flange Options 2 NPT 2 1 2 NPT 2 BSPT 2 1 2 BSPT 2 Weld 2 1 2 Weld Standard Optional A n Zz c ym Outlet Flange Options 2 NPT 2 1 2 NPT 2 BSPT 2 1 2 BSPT 2 Weld 2 1 2 Weld Standard Optional A m zicim 11 Appendix A Model Number and Identification Code for Strainer and Air Operated Valve AOV Strainer Assembly Seal Material Strainer Assy Part Number Strainer assembly Viton standard 5422 XD Buna N optional 5422 XA Strainer Assembly ordered by Part Number when not assembled to the pump VitonO is a registered trademark of the Dupont company Air Operated Valve Assembly AOV For Pump Models AOV Part
20. gs per instructions listed on page 6 under Pump Maintenance Schedule and the instructions listed below Lubrication Regrease the bearing after thoroughly cleaning the grease opening and fittings If dirt is forced into the bearings early failure will result Special relief fittings have been provided to help prevent over greasing the bearings Excessive grease may drip out after lubrication Over greasing can damage the pump bearings and cause seal leaks Use only recommended ball bearing grease If you use a hand grease gun put the grease in slowly and stop as soon as the relief fitting opens Grease the U joints and the spline of the drive shaft when greasing the pump Repair Kits for the PZ Series PZ7 Repair Kit 5497 X1A Buna N PZ7 Repair Kit 5497 X1D Viton Part Number Description Qty Part Number Description Qty 1480 Gasket 1 1480 Gasket 1 2 142A O ring Buna N 1 2 142D O ring Viton 1 2 234A O ring Buna N 2 2 234D O ring Viton 2 2270 Shaft key 1 2270 Shaft key 1 2754 X Roller bearing 2 2754 X Roller bearing 2 4262 X Vane driver 3 4262 X Vane driver 3 4431 XA2 Seal assembly Buna N 2 4431 XD2 Seal assembly Viton amp 2 4432 Thrust bearing 2 4432 Thrust bearing 2 4435 Thrust bearing mounting ring 2 4435 Thrust bearing mounting ring 2 4439 Bearing cap shim 0 002 8 4439 Bearing cap shim 0
21. h Never use force during assembly or disassembly 1 CAUTION Bleed all pressure and product from the pump and piping before installing your new seal assembly 2 Remove the PTO shaft or hydraulic drive motor adapter and coupling Remove the eight 5 8 hex head bolts from one head Slide one head assembly off the pump shaft ensuring the pump rotor shaft remains in the pump Remove the mechanical seal carbon face assembly while pressing against the sideplate ensuring the rotor shaft remains within the pump case Remove the inner grease seal and stationary face by inserting a screwdriver through the head assembly from the bearing cap and tapping the grease seal and stationary face out 7 Using the old seal stationary face press a new inner grease seal in place ensuring the seal cup faces toward the mechanical seal This can be accomplished with a hammer and drift 8 Apply a light oil to the new stationary seal face O ring and press in with your fingers ensuring the grooved side faces the main bearing 9 Repeat steps 3 through 8 for the remaining head assembly If vane replacement is necessary follow steps 10 through 16 If not proceed to step 17 10 Using a bearing cap or flange bolt 3 8 slide one sideplate off of the rotor shaft while holding other end of rotor shaft in place Once removed the rotor shaft can be pulled slightly toward the remaining sideplate and allowed to rest within the pu
22. ie 8 teln terii ola Mec 9 Repair Kits fof the PZ Series niieoee ta a Aa pausa Deu Deu e peat Eaa A east sieantenti A EEES ENERE 10 Appendix A Model Number and Indentification Code sss enne nennen nennen nennen 11 Appendix B Technical Specifications siisii ean esses senten nennen enhn adaa aiaa sans aaa aai 12 Appendix C Performance Curves sssisssssssssesssesseenee einn nannten sss thtne tenni sentes es sn asset nisi sanete siis nn nennen assent 13 Appendix D Outline Dimensions for the PZ7 viidi sinandang inaa anaana senten nenne a i Sanaa a aE sain aiea enn 15 Appendix D Outline Dimensions for the PZ10 2 nti reiecta dade E Te cod deve 16 Appendix D Outline Dimensions for the Air Operated Valve AOV and Strainer sssssseese 17 Appendix E Parts Details for the PZ7 with the Standard Bypass Valve sse 18 Appendix E Parts Details for the PZ10 with the Standard Bypass Valve sssssssseeens 19 Appendix E Parts Details for the PZ7 Air Operated Valve AOV ssssssssssssseeeeeeeeeen enne nnns 20 Appendix E Parts Details for the PZ10 Air Operated Valve AOV eene 21 Appendix E Parts Details for the Strainer sssssssssssssssssssseessee ener nennen nnns nnne nennen nnns 22 Appendix F Trouble Shooting Guide for the PZ Series Pump sese 23 Appendix G Flush and Storage Instruction
23. ing Clean Inlet Strainer Check for leaks Inspect hose and fittings Bearing Lubrication There are two lubrication points in which to grease the pump bearings one zerk per bearing cap located at opposite ends of the pump Four grease relief and seal ventilation fittings have been provided two at each end of the pump to help prevent over greasing the bearings Over greasing can cause seal failure if grease passageways are blocked in some way Remove relief fittings or confirm free movement of relief prior to greasing bearings Clean each fitting before lubricating the bearings This practice helps to prevent foreign material contamination of the bearings and accidental over pressurization of the mechanical seals Use only Ball Bearing Grease MIL G 10924C with a temperature rating of 70 F Normal wear parts are the mechanical shaft seals bearings vanes vane drivers and sideplates All of these parts plus O rings and grease seals are offered in the repair kit Use only genuine Corken replacement parts when repairing your PZ Series pump Follow the instructions provided with the parts When it becomes necessary to repair your pump or remove it from the system you must be absolutely certain that all product being pumped is bled from the pump and connected piping Once all the product has safely been bled from the pump and connected piping make certain no pressure is left in the system SPECIAL CARE MUST BE TAKEN
24. ing code listed above 2 234A for Buna N or 2 234D for Viton Registered trademark of the DuPont company 1 2 22 Appendix F Trouble Shooting Guide for the PZ Series Pump In diagnosing pump and system troubles record the following data during product transfers 1 Pressure at pump suction 2 Pressure at pump discharge 3 Pipe size and length of suction and discharge lines 4 Pump speed if practical Problem Cause Solution Low capacity Pump speed too slow Check engine speed and PTO ratio Consult pump performance curve Use tachometer on pump if speed is questionable High differential pressure Restriction in discharge piping or hose too small Pump speed too high Clogged strainer Clean strainer Suction pipe too small or restricted Indicated by pump inlet pressure dropping several pounds when pump is started Remove restriction or modify piping Worn vanes Replace Worn sideplates Reverse or replace sideplates Check universal drive assembly to make sure angularity is within limits yokes are parallel and slip joint is greased Check bearings Vanes sticking Remove vanes and clean out foreign material check strainer Replace vanes if swollen Pump runs but no flow Valve closed Check valves Make sure tank valve is open Refer to manufacturer s instructions Broken shaft Disassemble and inspect pump Repair if necessary Def
25. justment stem 1 Not sold separately 7 5459 AOV low flow adjustment bushing 1 Only available with the 5466 X Air Operated Valve 8 5466 X O ring 1 AOV diaphragm assembly 9 5462 Air operated valve housing 1 10 2854 Threaded pipe plug 1 11 5466 X Lock washer 0 3125 1 12 5466 X Air operated valve disc 2 ae 18 5466 X Air operated valve diaphragm 2 14 5461 Air operated valve intermediate plate 1 15 5463 Air operated valve diaphragm cover 1 16 5460 10 24 x 1 flat head cap screw 2 17 5466 X Diaphragm valve disc 1 18 54672 Air operated valve gasket 1 1 Not sold separately Only available with the 5466 X Air Operated Valve AOV diaphragm assembly Available with the 5466 X AOV diaphragm assembly or sold separately Available with the 5466 X AOV diaphragm assembly or sold separately 21 Appendix E Part Details for Strainer 5422 X_ Strainer Assembly for a PZ7 and PZ10 1 1 o S e D gt E gt c Ss 77 o ci o 9 o a a a c pan x g o o c o o c amp E o gt x lt c eo o P 1 P P e 3E op O 92 op lt e e s Oo o 2 Z S iB a z e a eo e eo N c e e eI e5 e st lt t oa N to e ie ie o Zz N co E LO O ring Code A Buna N D Viton denotes O ring code listed above 5422 XA for Buna N or 5422 XD for Viton denotes O r
26. k Pump The following steps should be performed for the initial pumping operation 1 Close the shutoff valve on the end of the delivery hose 2 Start the pump and cycle the nozzle open and closed to clear all air from the system 3 Check the discharge pressure on the outlet of the pump This pressure is typically set at 80 to 95 psi 4 Standard Bypass Valve For a standard bypass valve locate the adjustment set screw under the adjustment set screw cap see parts details on pages 18 and 19 Turn adjustment screw clockwise to increase pressure and flow Turn counter clockwise to decrease pressure and flow Close nozzle and check bypass pressure If too high turn adjustment screw counter clockwise until desired pressure is reached With the hose nozzle open adjust the pump bypass valve setting to the desired flow rate Close the nozzle slowly and check the system pressure CAUTION DO NOT EXCEED ACLOSED NOZZLE PRESSURE OF 125 PSI Replace adjustment set screw cap with seal washer and tighten 5 Air Operated Valve AOV assembly For pumps equipped with an Air Operated Valve AOV assembly air must be supplied from the truck air system via a flow sensing valve Approximately 70 psi 4 8 bar minimum air pressure is required to properly operate the air operated valve THE AIR PRESSURE MUST NOT EXCEED 125 psi 8 6 bar The sensing valve should be installed in accordance with the diagram shown in Figure 2 This system depi
27. laced SIDEPLATES may be reversed for extended service life The sideplates are easily replaced should the need arise THE MECHANICAL SEAL is designed for longer life under greater loads and may be inspected or replaced without disturbing the piping of the pump No special tools are needed BEARINGS are heavy duty roller type for long bearing life THRUST BEARINGS are heavy duty needle roller type rated for 4 000 Ibs NONMETALLIC VANE DRIVERS do not penetrate the vanes like the conventional steel vane drivers Available with adjustable internal BYPASS VALVE or optional AIR OPERATED VALVE AOV for high and low flow control Installation of the PZ Series Pump The mechanical installation of the PZ Series pump is a simple matter A rotation arrow is located on the side of the pump so check the PTO to determine its direction of rotation The PZ Series pump will match either PTO rotation Connect the drive shaft to the pump shaft that turns the pump in the direction of the arrow The PTO SELECTION is important The pump requires a PTO with an average output speed of 500 to 700 RPM for maximum performance when the truck engine is operating at the proper speed to maintain oil pressure and water circulation THE DRIVESHAFT connecting the pump to the PTO should be of the splined or slip type This type driveshaft permits the shaft to adjust for PTO movement and twisting of the truck frame A fixed driveshaft transfers the forces directl
28. le with all 4431 X__ seal assemblies or sold separately 3 denotes O ring code listed above Appendix E Part Details for the PZ10 with Standard Bypass Valve Shaft cover may be installed on either side of the pump Available with all 4431 X__ seal assemblies or sold separately See item number 6 in table below 19 Part No Description Qty 1 5361 Pump case 1 2 3983 X6R Rotor shaft assembly 1 3 5365 Vane 6 4 4262 X Vane driver 5 5 3932 Sideplate 2 4431 XA1 Seal assbly Buna N O ring stainless stl seat 2 4431 XA2 Seal assembly Buna N O rings cast iron seat 2 g 4431 XA3_ Seal assembly Buna N O rings Ni Resist seat 2 O ring Code 4431 XD1 Seal assembly Viton amp O rings S S seat 2 A Buna N 4431 XD2 Seal assembly Viton O rings cast iron seat 2 D VitonG 4431 XD3 Seal assembly Viton O rings Ni Resist seat 2 7 4416 Head 2 8 4438 Grease seal oil seat 2 No Part Number Description Qty 9 2754 X Roller bearing 2 25 2 234 3 O ring 3 10 2760 244 Retainer ring 2 26 7001 050NC150A Hex head bolt 8 11 4435 Thrust bearing mounting ring 2 27 3442 Pipe plug 1 4 NPT 5 12 4432 Thurst bearing assembly 2 28 7001 043NC125A Hex he
29. mp case Inspect the sideplates for wear If sideplates are worn on both sides discard for replacement 11 Remove the rotor shaft assembly from the pump case by cupping the bottom three vanes with your hand This will not allow the vanes and drivers to fall from the rotor shaft slots 12 Place three vanes into the upper three rotor shaft slots Ensure the curved tip of each vane faces radially outward 13 While cupping these vanes in place rotate the rotor shaft over 180 and install the vane drivers 14 Place rotor shaft and blade assembly into pump case with the three vanes on the bottom Ensure the ribs in the vanes face into the direction of rotation of the pump 15 Place the remaining three vanes into the upper rotor shaft slots facing the same direction as the first three vanes 16 Install both sideplates into the pump simultaneously to keep the rotor shaft level and centered in the pump case Rotate each sideplate until the square notch is in the twelve o clock position Rotate the rotor shaft to expose the seal drive pins 17 Install the mechanical seal assemblies onto each end of the rotor shaft Ensure the seal drive pin properly engages the mechanical seal retainer detent Lightly oil each carbon seal face 19 Install each head by supporting the back end of the rotor shaft and working the head into place over the rotor shaft 20 Install the head bolts and torque to 45 ftelb 2 Grease bearin
30. on Operations and Maintenance manual should be consulted for the proper part numbers ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS The model and serial numbers are shown on the nameplate of the unit Record this information for future reference Model no Serial no Date purchased Date installed Purchased from Installed by Table of Contents Principles Of the PZ SeneS PUMP ccce eerie Eee oie ER decide iu le wt asina up co ts heey Del dase deua PE pared Re tendra eR nra 4 Exclusive Features of PZ Series PUMP iiiaae hint ein vit ede oa Do ada dr Ede eer aa de ees 4 Installation of the PZ Series Pump wissiena pienu arasina aaeei a Aaa aiaa aaia sans aiaa aeiaai 4 Operation of the PZ Series Truck Pump sssssssssssssssssss nadidiin iea ddenai asna nai aeaaeai nnde d aiaa 5 Maintenance of Your PUMP SyStelri ecce ete peperere teer en reme a ege ge a Eea Ea ES a ANa EGE NOSE 6 Pump Maintenance Schedule 22 3D eee 6 Disassembly and Assembly Instructions for the PZ Series Pump ssssssssssssssseeeeeee eee nnne 6 Disassembly Instructions essisssssssssessesseeeee a a nnn e nni reset nsi iss eaa eA aaa tensis sanas NEREA 6 ASSO mO STUGUNS ERR TT 7 Mechanical Seal and Vane Replacement Instructions sess eene nnns nnne 8 Cleanliness and Workmanship sssssssssssssseseeeseee enne enn oa ENa sin EAEE AAE aa
31. one another within plus or minus one degree Improper alignment will cause jerking and back and forth whip to the pump shaft thereby imparting a surging pulsation to the liquid flow which results in noise vibration and abnormal wear Second the angle of the floating shaft should be within the limits for the particular equipment being used usually a maximum of 15 at pump speeds up to 800 RPM To ensure that shaft expansion or contraction does not distort the drive system a splined slip joint should be placed between the two universal joints The drive shaft should be of the splined or slip type to permit the shaft to adjust for PTO movement and twisting of the truck frame A fixed drive shaft transmits the forces directly to the pump and PTO which will shorten the life of both considerably Third the yokes of the drive shaft universal joints must be in a parallel position Figure 1 on page 5 illustrates the proper arrangement of the yokes Improper installation of the U joints will soon destroy them along with the bearings in the pump and PTO Properly mounted the second universal gives uniform motion to the drive shaft by compensating for the rotational error introduced by the first U joint An even number of universal joints 2 4 6 etc should always be used An odd number of U joints will cause unbalanced pump shaft rotation This problem becomes greater with increased angularity Other points to consider include the p
32. rise the pump should be completely replaced if severe scoring of the cam inner surface is discovered If you have the standard bypass valve remove the bypass valve adjustment screw cap and turn the adjustment screw counterclockwise to relieve the spring tension Remove the four 3 8 bolts from the bypass valve cap Use caution as a small amount of spring tension will remain on the bypass valve spring before complete bolt removal Inspect bypass valve spring and bypass valve cap O ring for wear abrasions etc Replace if damage is found If you have an Air Operated Valve AOV ensure the air supply pressure has been relieved and the supply line disconnected from the valve housing Remove the outer cap and discard the O ring from underneath Remove the retainer ring and locknuts from the adjustment stem Remove the four 3 8 bolts and lock washers from the bypass valve housing Use caution as a small amount of spring tension may remain on the bypass valve spring Carefully remove the AOV assembly from the pump along with the spring and valve Remove and discard the gasket and clean the gasket areas Remove the two recessed head machine screws and the diaphragm cover plate Slide the diaphragm assembly out from the housing Remove the vent plate from between the two diaphragms Inspect the diaphragms spring and valve for abrasions and replace if necessary Assembly Instructions 1 10 12 13 Place three vanes into the
33. roper sizing of the shaft components with a maximum horsepower load to be expected good alignment of hanger bearings and proper pump coupling alignment Improper PTO systems account for a high percentage of truck pump failures Always remember to disengage the clutch before shifting the PTO into gear Shifting the PTO into gear without disengaging the clutch imparts an enormous shock on the PTO drive shaft pump and meter and will soon damage one or all of them For proper installation of pump drives follow the rules listed below 1 Driver shaft and pump shaft must be parallel plus or minus one degree Operating angle of the floating shaft must be 15 maximum Universal yokes must be in line and parallel Splined slip joints must be used where needed Use an even number of universal joints oo RK C I Always use the least practical number of shafts The shafts must be parallel Floating shaft with splined joint take off U joints yokes must be in line and parallel Figure 1 Shaft alignment PTO selection and drive system design is extremely important The PTO should have an average output speed up to 800 RPM to maximize the performance of the PZ Series pump when the truck engine is operating at the recommended speed The designer of the drive system must select a PTO drive shaft capable of meeting the torque requirements of the pumping system Operation of the PZ Series Pump Truc
34. s for the PZ Series Pump sss 24 Principles of the PZ Series Pump The PZ Series pump is a special type of rotary positive displacement pump known as a sliding vane pump The sliding vane pump has many of the positive displacement advantages of the gear pump plus the ability to compensate for wear and operate at a lower noise level The sliding vane pump consists of a rotor turning in a cam machined eccentrically in relation to the rotor thereby displacing the liquid trapped between the rotor cam and vanes The PZ Series pumps are made with vanes produced from advanced polymers which exhibit extremely low coefficients of friction The vanes are self adjusting for wear which gives the pump long life Exclusive Features of the PZ Series Pump The pumping of volatile liquids is one of the most difficult of all pumping jobs and pumping from a delivery truck makes it even more difficult so more attention must be given to the design and manufacturing of the pump and to its installation and operation In addition to being especially suited for handling volatile liquids your PZ Series pump has a number of features to help make it more easily operated and maintained The CASE and HEADS are made of Ductile Iron not Cast Iron for extra strength and toughness The VANES are manufactured of advanced polymers to provide excellent life and quiet operation After long service the vanes are simply and inexpensively rep
35. ssure and vice versa to increase the flow rate NOTE Make sure the locknuts are securely locked against each other before re installing the adjustment stem cap and O ring Slowly open the delivery nozzle and note delivery flow rate and or pressure 5 9 5 10 Repeat steps 5 7 through 5 9 until desired flow rate and or pressure are achieved 6 You may increase the speed of the pump as long as it increases the flow through the delivery nozzle It is recommended to turn the pump at approximately 575 RPM for optimum performance However the pump can be safely turned to 800 RPM if system conditions permit NOTE IF PUMP SPEED IS INCREASED BE CERTAIN THE METER AND PIPING SYSTEM WILL HANDLE THE INCREASED FLOW AND PRESSURE Maintenance of Your Pump System Your PZ Series pump requires regular maintenance and care like all mechanical equipment A neglected or improperly repaired pump will result in premature failure and cause unsafe conditions To promote product longevity and safety maintenance must be performed by properly trained technicians Make sure all safety systems are in place and the system pressure has been relieved before attempting ANY maintenance Pump Maintenance Schedule Make sure the transfer hoses are not kinked A kinked hose can cause excessive pump discharge pressure Always make sure your hoses are not out of date Daily Monthly 3 Months Lubricate bearings Inspect drive coupl
36. upper three rotor shaft slots Ensure the curved tip of each blade faces radially outward and all in the same direction of rotation While cupping these vanes in place rotate the rotor shaft over 180 and install the three blade drivers Place rotor shaft and blade assembly into pump case with the three vanes on the bottom Ensure the ribs in the vanes face into the direction of rotation of the pump see parts details on pages 18 and 19 Place the remaining three vanes into the upper rotor shaft slots facing the same direction as the first three vanes Install both sideplates into the pump simultaneously to keep the rotor shaft level and centered in the pump case Rotate each sideplate until the square notch is in the twelve o clock position Rotate the rotor shaft to expose the seal drive pins Install the mechanical seal assemblies onto each end of the rotor shaft Ensure the seal drive pin properly engages the mechanical seal retainer detent Lightly oil each carbon seal face Press the inner grease seals into each head with the cup opening toward the mechanical seal Press the main bearings into each head and install the Spiral retainer ring Install the stationary seal face by applying a light oil DO NOT use WATER based penetrants and pressing into place with the protective cardboard disc and your fingers Apply another coat of light oil to the face to remove any debris from installation Install the head O ring
37. y into the pump and PTO and will shorten the life of both considerably The yokes of the driveshaft universal joints must be positioned as shown on page 5 Figure 1 Improper positioning will soon wear them out and potentially destroy the bearings in the pump and PTO INLET PIPING should be as short as possible and at least the minimum diameter specified for the model with minimum restrictions so that the pressure drop is limited The outlet piping should include the following 1 Apressure gauge should be installed in the pump outlet or near it A pressure gauge is necessary to determine the efficiency of your pumping system 2 If a meter with an air eliminator is installed never pipe the eliminator directly into the pump inlet piping or into the liquid part of the system at any point refer to the meter installation manual 3 The discharge piping should be at least the same size as the meter piping Power Take Off Drive Systems Proper pump operation and long life is directly dependent upon a good drive system Many truck pumps utilize a power train consisting of shafts and universal joints from a power take off shaft on the truck engine to the pump There are several basic principles that should be followed in laying out a PTO drive These principles should not be violated to produce a workable power train that results in long pump life and reduced drive wear First the driver shaft and the driven shaft must be parallel to
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