Miltonroy339-0049-000 APR 08 Color

MacRoy “G” Pump
Instruction Manual
INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL
Please record the following data for file reference

Tag Number(s): ________________________________
Model Number: ________________________________
Serial Number: ________________________________
Installation Date: ______________________________ 339-0049-000
Installation Location: ___________________________ ISSUED 04/2008
THIS PAGE INTENTIONALLY BLANK
TABLE OF CONTENTS
SECTION 1 - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 LEAK DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 3 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 SHIPPING PUMPS FOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4.1 Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4.1.1 Plastic Check Valves (PVC, PVDF, POLY, & H2SO4) . . . . . . . . . . . . . . . . . 15
4.4.1.2 Models G6 & G7 Liquid End - Stainless Steel Check Valves (PVC, PVDF,
POLY, & H2SO4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.1.3 Model G5 Liquid End - Stainless Steel Check Valves (PVC, PVDF, POLY, &
H2SO4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.1.4 Model G5 Liquid End - Slurry Check Valves . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.1.5 Models G6 & G7 Liquid End - Slurry Check Valves . . . . . . . . . . . . . . . . . . 18
4.4.1.6 Models G5, G6 & G7 Liquid End - Polymer Check Valves . . . . . . . . . . . . . 18
4.4.2 Diaphragm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.2.1 Diaphragm Removal (All types; Refer to Figures 6-12 ) . . . . . . . . . . . . . . . 19
i
TABLE OF CONTENTS (CONT.)
4.4.2.2 Disassembly (Only Those Units With a “Hex Head“
Diaphragm Cap Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.2.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.2.4 Reinstallation of Assembly (Refer to Figure 6 Through 12) . . . . . . . . . . . 19
4.4.3 Replacing Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 - TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 6 - PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 ILLUSTRATED PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 DRIVE, SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 DRIVE, TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 G5 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.6 G5 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8 G6 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.10 G7 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.11 CHECK VALVE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.12 LEAK DETECTION PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ii
SECTION 1
DESCRIPTION
1.1 GENERAL INFORMATION sure, cavitation will occur, negatively impacting

the performance of the pump. If you suspect
The MacRoy G is a reciprocating, chemical dosing the possibility of cavitation, contact your Milton
pump capable of producing controlled flows up to Roy Representative for assistance.
310 gallons per hour (1175 L/H) at pressures up to
150 psi (10 BAR) (depending on the model). These As the diaphragm starts forward on the discharge
pumps feature a mechanically actuated diaphragm stroke the pressure immediately rises inside the
liquid end, which eliminates the need for flow- liquid end. When the liquid end pressure rises
restricting contour plates, and a stroke adjustment above the discharge line pressure, the discharge
mechanism based on the variable eccentric princi- ball check is “pushed” upward and the process fluid
ple instead of the traditional lost-motion design. in the liquid end flows into the discharge line. When
This design substantially reduces pressure and the discharge stroke ends, the diaphragm momen-
flow pulsations contributing to an increase in the tarily stops again. The pressure in the liquid end
life of system components and more continuous equalizes with the discharge line pressure and the
chemical injection. It is designed for industrial ser- discharge ball check reset. The cycle then starts
vice and offers an accuracy of ±2% of 100% rated again.
flow between 10% and 100% of its flow range.
1.3 GENERAL SPECIFICATIONS
1.2 PRINCIPLES OF OPERATION
FLOW RATE:
The pump consists of two major assemblies; the
drive and the liquid end. Pump delivery is a func- Up to 310 GPH (1175 L/H)
tion of the drive’s stroke rate, liquid end size and
PRESSURE:
stroke length. Stroke length can be adjusted while
the pump is running or stopped by turning the Up to 150 PSIG (10 BAR)
stroke adjusting knob.
DESIGN:
The drive motor transmits rotary motion to a worm
gear speed reduction unit which in turn drives the Mechanically Actuated Diaphragm
variable eccentric crank. The adjustable crank
DRIVE:
imparts reciprocating motion to the diaphragm
through an interposing connecting rod. The stroke Variable Eccentric
length is adjusted by changing the position of the
variable eccentric crank in the connecting rod ACCURACY:
assembly.
±2% of 100% rated flow between 10% and 100%
of rated flow
As the diaphragm starts back on the suction stroke,
the pressure immediately drops inside the liquid ADJUSTMENT:
end. When the liquid end pressure drops below the
suction line pressure, the suction ball check is Lockable micrometer is adjustable from 0% to
“pushed” upward and the process fluid in the suc- 100% while pump is running or stopped
tion line flows into the liquid end chamber. When
LUBRICATION:
the suction stroke ends, the diaphragm movement
momentarily stops. The pressure in the liquid end Oil bath Over 50ºF (10ºC), Zurn EP 95, 3 1/2
equalizes with the pressure in the suction line and qt.(3.3 liter). Below 50ºF (10ºC), Zurn EP 35
the suction ball check seats.
WEIGHT:
NOTE: It is important that the pressure in the
90 lb (40.8kg) Without EEC
liquid end remain above the vapor pressure of 109 lb (49.4 kg) With EEC
the process fluid during the suction stroke. If
the fluid pressure drops below the vapor pres-
1
Figure 1. Model/Product Code.
2
ROUTINE MAINTENANCE KITS (RPM)
MACROY G Liquid Liquid End Material Kit
End Number
Liquid Liquid End Kit
End Material Number PP / PVC / ACRYLIC RPM045
PVDF RPM046
POLYPRO RPM019 316SS RPM047
GB40 PVC RPM022 H2SO4 NPT CONN. RPM175
5
PVDF RPM025 POLYMER RPM126
316SS RPM028 SLURRY RPM044
POLYPRO RPM020 PP / PVC ACRYLIC RPM048
GB60 PVC RPM023 PVDF RPM049
PVDF RPM026 316SS RPM050
316SS RPM029 6
H2SO4 NPT CONN. RPM194
POLYPRO RPM021 POLYMER RPM176
GB80 PVC RPM024 SLURRY RPM219
PVDF RPM027 PP / PVC / ACRYLIC RPM051
316SS RPM030 PVDF RPM052
316SS RPM053
7
H2SO4 NPT CONN. RPM203
POLYMER RPM221
SLURRY RPM220
1.3 GENERAL SPECIFICATIONS (CONT.) breakdown shown in Figure 1. A sample name-

plate is shown in Figure 2.
TEMPERATURE
Ambient and Liquid:
122 ºF (50 ºC) Maximum

14 ºF (-10 ºC) Minimum
SUCTION LIFT
8.2 ft. (2.5 meters) of water column maximum. 11

psia minimum internal pressure (4 psi maximum
vacuum).
PAINT
Powder Coating
1.4 PRODUCT CODE
MacRoy G pumps are available in a variety of dif-

ferent configurations. 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
Figure 2. Sample Nameplate
3
4
SECTION 2
INSTALLATION
2.1 UNPACKING
Pumps are shipped f.o.b. factory or representative

warehouse and the title passes to the customer
ANY SERVICING OF THIS EQUIPMENT
when the carrier signs for receipt of the pump. In
MUST BE CARRIED OUT WHEN THE
the event that damages occur during shipment, it is
UNIT IS STOPPED AND ALL PRES-
the responsibility of the customer to notify the car-
SURE HAS BEEN BLED FROM THE LIQ-
rier immediately and to file a damage claim.
UID END. SHUT-OFF VALVES IN
SUCTION AND DISCHARGE SIDES OF
Carefully examine the shipping crate upon receipt
THE LIQUID END SHOULD BE CLOSED
from the carrier to be sure there is no obvious dam-
WHILE THE UNIT IS BEING SERVICED.
age to the contents. Open the crate carefully so
ACTIONS SHOULD BE TAKEN TO ELIM-
accessory items fastened to the inside of the crate
INATE THE POSSIBILITY OF ACCIDEN-
will not be damaged or lost. Examine all material
TAL START-UP WHILE SERVICING IS
inside the crate and check against packing list to
TAKING PLACE. A NOTICE SHOULD BE
be sure that all items are accounted for and intact.
POSTED BY THE POWER SWITCH TO
WARN THAT SERVICING IS BEING
2.2 SAFETY PRECAUTIONS
CARRIED OUT ON THE EQUIPMENT.
SWITCH OFF THE POWER SUPPLY AS
WARNING SOON AS ANY FAULT IS DETECTED
DURING OPERATION (EXAMPLES:
ABNORMALLY HIGH DRIVE TEMPERA-
WHEN INSTALLING, OPERATING, AND
TURE, UNUSUAL NOISE, DIAPHRAGM
MAINTAINING THE MACROY G PUMP,
FAILURE).
KEEP SAFETY CONSIDERATIONS
FOREMOST. USE PROPER TOOLS,
2.3 STORAGE
PROTECTIVE CLOTHING, AND EYE
PROTECTION WHEN WORKING ON Short Term Storage (Less than 6 Months)
THE EQUIPMENT AND INSTALL THE
EQUIPMENT WITH A VIEW TOWARD It is preferable to store the material under a shelter
ENSURING SAFE OPERATION. FOL- in its original package to protect it from adverse
LOW THE INSTRUCTIONS IN THIS weather conditions. In condensing atmospheres,
MANUAL AND TAKE ADDITIONAL follow the long term storage procedure.
SAFETY MEASURES APPROPRIATE
TO THE LIQUID BEING PUMPED. BE Long Term Storage (Longer than 6 Months)
EXTREMELY CAREFUL IN THE PRES-
ENCE OF HAZARDOUS SUBSTANCES The primary consideration in storage of pump
(E.G., CORROSIVES, TOXINS, SOL- equipment is to prevent corrosion of external and
VENTS, ACIDS, CAUSTICS, FLAM- internal components. This corrosion is caused by
MABLES, ETC.). natural circulation of air as temperature of the sur-
roundings change from day to night, day to day,
and from season to season. It is not practical to
prevent this circulation which carries water vapor
and other corrosive gasses, so it is necessary to
THE PERSONNEL RESPONSIBLE FOR protect internal and external surfaces from their
INSTALLATION, OPERATION AND effects to the extent possible.
MAINTENANCE OF THIS EQUIPMENT
MUST BECOME FULLY ACQUAINTED When the instructions given in this section are
WITH THE CONTENTS OF THIS MAN- completed, the equipment is to be stored shel-
UAL. tered; protected from direct exposure to weather.
5
The prepared equipment should be covered with a Support the pump firmly in a level position on a
plastic sheet or a tarpaulin, but in a manner which solid, vibration-free foundation, preferably with the
will allow air circulation and prevent capture of base above floor level to protect the pump from
moisture. Equipment should be stored 12 inches or wash downs and to provide easier access for ser-
more above the ground. vice. Be sure to allow enough space around the
pump for easy access during maintenance opera-
If equipment is to be shipped directly from Milton tions, pump adjustments, and/or oil filling or drain-
Roy into long term storage, contact Milton Roy to ing procedures.
arrange for factory preparation.
MacRoy G pumps are provided with mounting
Pump Drive holes to accommodate anchor bolts. Refer to Fig-
ure 3 for mounting hole dimensions.
1. Flood the gearbox compartment with a high
grade lubricating oil/rust preventative such as Some MacRoy G pumps are shipped with motors
Mobile Oil Corporation product “Mobilarma 524.” dismounted. After anchoring pump in position,
Fill the compartment completely to minimize air install motor, referring to Figure 6, Sheet 1.
space and water vapor condensation. After stor-
age, drain this material and refill the equipment Make sure spring (360) provided with pump is
with the recommended lubricant for equipment installed in worm shaft prior to motor installation.
commissioning.
Pumps installed outdoors should be protected by a
2. Remove drive motor and liquid end, and brush shelter.
all unpainted metal surfaces with multipurpose
grease (NLGI grade 2 or 3). Store these unat- 2.5 PIPING
tached.
NPSH Considerations
Electrical Equipment
Size piping to accommodate peak instantaneous
1. Motors should be prepared in the manner pre- flow. Because of the reciprocating motion of the
scribed by their manufacturer. If information is not pump diaphragm, pump delivery follows an approx-
available, dismount and store motors as indicated imate sine curve with a peak instantaneous flow pi
in step 3 below. (3.14) times the average flow. Therefore, piping
must be designed for a flow 3.14 times the pump
2. Dismount electrical equipment (including capacity; this means that a pump rated for 88 gal-
motors) from the pump. lons per hour (333.1 L/hr.) requires piping sufficient
for 3.14 x 88 gph, or 276 gph (1044.7 L/hr.).
3. For all electrical equipment, place packets of
Vapor Phase Corrosion Inhibitor (VPCI) inside of
the enclosure, then place the entire enclosure, with
additional packets, inside a plastic bag. Seal the
bag tightly closed. Contact Milton Roy Service
Department for recommended VPCI materials.
2.4 MOUNTING
TO AVOID POSSIBLE DAMAGE TO

EITHER PUMP OR PERSONNEL, BOLT Figure 3. Mounting Hole Dimensions
PUMP DOWN AS SOON AS IT IS IN
POSITION.
6
To minimize viscous flow losses when handling vis- • Use piping heavy enough to withstand
cous liquids, it may be necessary to use suction maximum pressures.
piping up to four times larger than the size of the
suction connection on the pump. If in doubt, con- • Remove burrs, sharp edges, and debris
tact your nearest Milton Roy representative to from inside piping. Blow out all pipe lines
determine the necessary pipe size. before making final connections to pump.
General Piping Considerations • Because vapor in the liquid end will cause
inaccurate pump delivery, piping should be
• Use extreme care in piping to plastic liquid sloped to prevent vapor pockets
end pumps with rigid pipe such as PVC. If
excessive stresses or vibration is unavoid- • When pumping suspended solids (such as
able, flexible connections are recom- slurries), install plugged crosses at all 90°
mended. line turns to permit line cleaning without
dismantling piping.
• Use piping materials that will resist corro-
sion by the liquid being pumped. Use care • See Figure 4 for a typical recommended
in selecting materials to avoid galvanic cor- pump installation scheme.
rosion at pump liquid end connections.
Figure 4. Typical Recommended Pump Installation Scheme
7
Suction Piping Considerations • If possible use metal or plastic tubing for
the suction line because tubing has a
• It is preferable to have the suction of the smooth inner surface and can be formed
pump flooded by locating the liquid end into long, sweeping bends to minimize fric-
below the lowest level of the liquid in the tional flow losses.
supply tank. Installing the supply vessel on
the suction line close to the pump can help • A strainer should be used in the suction
ensure a flooded suction line. (Consult Mil- line to prevent foreign particles from enter-
ton Roy for assistance in such applica- ing the liquid end. This and any other mea-
tions.) sures which prevent debris from entering
and fouling the ball-checks will give
• Avoid negative suction pressure conditions increased maintenance-free service.
(suction lift), as such conditions adversely Check strainer frequently to prevent block-
affect metering accuracy. A lift of 8.2 feet age which could lead to cavitation.
(2.5 meters) of water column is the maxi-
mum suction lift permissible. • Keep suction piping as short and straight
as possible.
• MacRoy G pumps are designed to operate
with process liquid supplied at or above • Piping size should be larger than the liquid
atmospheric pressure. Although these end suction fitting to prevent pump starva-
pumps can move liquids supplied at less tion.
than atmospheric pressure, in these nega-
tive pressure applications it is important • If long suction lines are unavoidable, install
that all connections be absolutely drip free a stand pipe near the pump in the suction
and vacuum tight, and that a foot valve be line.
installed at the bottom of the suction line
(see Figure 5). • Suction piping must be absolutely airtight
to ensure accurate pumping. After installa-
• When pumping a liquid near its boiling tion, test suction piping for leaks with air
point, provide enough suction head to pre- and soap solution.
vent the liquid from “flashing” into vapor
when it enters the pump liquid end on the Discharge Piping Considerations
suction stroke.
• Install pipe large enough to prevent exces-
sive pressure losses on the discharge
stroke of the pump. Maximum pressure at
the discharge fitting on the liquid end must
be kept at or below the rated pressure
(Max. allowable working pressure shown
on the pump nameplate).
• The pump will not deliver a controlled flow

unless the discharge line pressure is 10 psi
greater than the suction line pressure.
There are a number of ways to create an
artificial pressure, such as by installing a
back pressure valve. (Please contact Mil-
ton Roy for recommendations to increase
back pressure in slurry applications.)
• When pumping water-treatment chemicals

directly into boiler drums, use one liquid
end assembly for each boiler drum. Dis-
Figure 5. Suction Lift Installation charging into a manifold having the slight-
8
est pressure difference between its several (This will prevent pump damage from accidental
discharge connections can diminish meter- valve closure.) Pipe the safety valve outlet back to
ing accuracy as the outlet with the lowest the suction tank or to drain, but in either case
pressure will receive more liquid than the ensure that the pipe end is continuously visible so
other outlets. safety valve leakage may be detected. Milton Roy
safety valves must be installed at top of supply tank
Back Pressure Valves in order to function properly (see Figure 4).
A Milton Roy Back Pressure Valve should be Check Valves

installed in the discharge line near the pump to
ensure sufficient discharge head pressure for A check valve should be installed at the point
proper pump metering action. Normally, the valve where the discharge line enters a boiler or other
should be located near the pump; however, back high-pressure vessel. This will prevent back flow
pressure valves for large pumps with long and through the discharge piping and will isolate the
extremely small discharge lines may have to be pump discharge from system pressures (a safety
installed near the point of discharge into the pro- consideration).
cess (to minimize siphoning tendencies).
Shut-off Valves
Pulsation Dampeners
Provide shut-off valves in both suction and dis-
An accumulator, surge chamber, surge suppressor, charge lines next to the pump. Locate discharge
or pulsation dampener should be used with the line shut-off valve downstream from the inlet con-
back pressure valve in the discharge line to absorb nection of the safety valve. Figure 4 shows recom-
the flow peaks between the pump and the back mended valve locations.
pressure valve. Without the pulsation dampener
the valve mechanism will snap open and closed 2.6 LEAK DETECTION
with the surge from each pump stroke. The pulsa-
tion dampener will allow the back pressure valve to Without double diaphragm option:
oscillate about a partly-closed position, thus mini-
mizing wear on the valve. Discharge line pulsation MacRoy G pumps are equipped with a leak detec-
dampeners offer the further advantage of limiting tion port. For ease of installation, each pump has a
the flow and pressure variations characteristic of plastic tubing connector installed in the leak detec-
this kind of pump. Installing a properly sized pulsation port (see item 448 in Figure 6, Sheet 2). In the
tion dampener will improve pump performance and event of a failure of the oil seal (70 in Figure 6,
may reduce system costs dramatically by permit- Sheet 1) or PTFE diaphragm assembly (260 in Fig-
ting the substitution of smaller piping. Please con- ures 7 through 12), pump drive oil or process fluid
tact Milton Roy Company for further information on will escape from this leakage port. During pump
pulsation dampeners. installation, actions should be taken to insure that
this leakage is safely collected by installing tubing
Safety Valves between the leak detection port and an appropriate
containment vessel.
Motor-driven positive displacement pumps can
develop excessive discharge pressures long With double diaphragm option:
before thermal overload devices interrupt the motor
electrical circuit. To prevent a blocked discharge The Macroy also is available with a double dia-
line from causing damage to the pump, piping, or phragm option that includes tubing to a pressure
process equipment, install a Milton Roy Safety gauge and switch as shown in Figure 14. In the
Valve in the pump discharge line. This valve is event of a diaphragm leak the process fluid is
designed and sized to handle system flow rates trapped inside the system and the pressure switch
and pressures safely while resisting corrosion by (760, Figure 14) is tripped to set an alarm or shut-
the process liquid. down.
Install the safety valve in the discharge line This leak detection system is not filled with any
between the pump and the nearest shut-off valve. fluid and will only be pressurized in the event of a
9
seal failure. A drain (790, Figure 14) is provided for Before operating the pump, check the direction of
pressure relief prior to system disassembly. rotation of the motor to be sure it matches the
direction of the arrow stamped on the motor (rota-
2.7 ELECTRICAL CONNECTIONS tion should be clockwise when viewed from the top
of the motor). If motor rotation is incorrect, refer to
Ensure that the electrical supply matches the pump the motor data plate or motor manufacturer’s
motor nameplate characteristics. instructions for reversing.
OPERATION WITH THE WRONG DO NOT FORGET TO CONNECT THE

MOTOR ROTATION WILL DAMAGE THE PUMP TO AN EARTH GROUND!
PUMP AND MOTOR AND VOID THE
WARRANTY. Electric protection of the motor (fuses, overload
meters or relays) should correspond to the rated
current indicated on the motor data plate.
10
SECTION 3
OPERATION
3.1 INITIAL START-UP Exxon .....................Spartan E.P. 68

Mobil ......................Mobilgear 626
Texaco ...................Meropa 68
WARNING Shell .......................Omaha 68
FAILURE TO CHECK TORQUE ON NON-

METALLIC HEAD BOLTS PRIOR TO
STARTUP AND AFTER ONE WEEK OF
OPERATION MAY EXPOSE
BEFORE SWITCHING ON POWER TO
OPERATING PERSONNEL TO
THE PUMP, TURN THE CAPACITY
HAZARDOUS LIQUIDS.
ADJUSTMENT KNOB TO ZERO. CHECK
THAT ALL SHUT-OFF VALVES IN THE
Check the torque on all non-metallic head bolts
SUCTION AND DISCHARGE LINES ARE
prior to startup. Recheck torque on all non-metallic
OPEN BEFORE INCREASING THE
head bolts after pump has been operating for one
CAPACITY ADJUSTMENT FROM ZERO.
week. Torque the head assembly screws in a
crosswise pattern as follows:
Manual Capacity Control
(1) Liquid End Size G5 and G6 non-metallic
To adjust pump capacity, loosen the stroke locking
head bolts to 90 inch pounds.
knob (320, Figure 6, Sheet 2) located in the pump-
side cover. Pump capacity is adjusted by turning
(2) Liquid End Size G7 non-metallic head bolts
the micrometer type stroke adjustment knob (330)
to 125 inch pounds.
clockwise to decrease capacity or counterclock-
wise to increase capacity as required. The adjust-
Check that all mounting bolts are tight, piping is
ment scale is marked in percent (%) of full stroke,
installed properly, and the discharge line is open.
with calibration lines on the knob at 1% intervals.
After adjusting the knob to the desired capacity set-
Check oil drain plug for tightness. Remove the oil
ting, hand tighten the stroke locking screw to main-
fill cap and fill the pump casing until level is
tain the capacity setting.
between the markings on the oil fill cap dipstick,
(approximately 3 quarts (2.8 Liters)).
Filling Pumping System
NOTE: The oil furnished with the pump is
It is especially important that pump suction and dis-
grade AGMA No. 5 EP with a viscosity of 1000
charge lines be free of entrained air. To ensure this
SSU at 100°F (218.4 cSt at 40°C). For opera-
condition, operate the pump without any discharge
tion in ambient temperatures below 50°F
pressure and fill the entire pumping system with liq-
(10°C), substitute AGMA No. 2 EP with a vis-
uid before starting pressure tests. A simple method
cosity of 400 SSU at 100°F (86.4 cSt at 40°C).
to assure priming of the pump is to install a tee and
Manufacturers' equivalent oils are shown
a shut-off valve at the discharge connection of the
below.NOTE:
pump.
ABOVE 50°F
If the pump is idle for long periods, temperature
Chevron ................. N.L. Gear Compound 220
changes in the process liquid may produce air in
Exxon .................... Spartan E.P. 220
the system. To discharge the air, install a valve in
Mobil ...................... Mobilgear 630
the discharge line which will allow the process liq-
Texaco ................... Meropa 220
uid to be pumped to exhaust when starting the
Shell ...................... Omaha 220
pump.
BELOW 50°F
Chevron ................. N.L. Gear Compound 68
11
Capacity Calibration
After the first 12 hours of operation, the pump may

be tested and calibrated to find the exact pump THE FOLLOWING METHOD IS NOT
capacity under specific operating conditions. GENERALLY RECOMMENDED AS IT
MAY EXPOSE OPERATING PERSON-
Usually, calibrating the pump at only 100, 50, and NEL TO HAZARDOUS LIQUIDS. FUTH-
10 percent capacity settings is enough to indicate ERMORE, THE PUMP MAY OVER PUMP
pump performance throughout the adjustment DRAMATICALLY AND THE POSITION
range. OF THE CAPACITY ADJUSTMENT
KNOB MAY HAVE LITTLE EFEECT ON
The pump can be calibrated by measuring the MEASURING FLOW RATE.
decrease in liquid level pumped from a calibrated
vessel. This method is recommended for hazard- The pump can also be calibrated by collecting and
ous liquids because it eliminates operator contact measuring pumped liquid at the pump discharge
with the liquid. Milton Roy test-tube Calibration Col- port. It may be necessary to create discharge head
umns are available for convenient and accurate at the liquid takeoff point so that the pump will
calibration of any pump. operate properly. (See Section 2 for recommended
ways to do this.)
12
SECTION 4
MAINTENANCE
4.1 SPARE PARTS All Other Liquid Ends
To avoid excessive downtime in the event of a (1) Diaphragm (260)

parts malfunction, the spare parts shown below
should be stocked for each pump to prevent seri- (2) Oil Seal (70)
ous delays in repairs. Refer to Figures 7–13 and
the accompanying parts lists. For your conve- (3) Seat, O-Ring, Ball Set (423)
nience, these parts can be purchased either sepa-
rately or packaged in the form of Routine (See parts list)
Preventive Maintenance (RPM) Kits. RPM kit
numbers are listed in Section 1. Parts orders must include the following:
RPM kit numbers RPM019 through RPM030 con- 1. Quantity required

tain pre-assembled diaphragms, oil seal and check
valve parts. Cap piece (240), set screw (250), dia- 2. Part number
phragm (260), and support nut (270) is pre-assem-
bled in kits RPM019 through RPM030. A spanner 3. Part description
wrench, which may not always be available in the
field, is required to disassemble the diaphragm 4. Pump serial number (found on nameplate)
assembly.
5. Pump model number (found on nameplate)
RPM Kits RPM045 through RPM053 and RPM126,
through RPM220 contain a diaphragm, oil seal, 6. Pump product code (found on nameplate)
and check valve parts. Macroy G pumps built with
the latest design do not need a spanner wrench to Always include the serial number, model number,
disassemble the diaphragm assembly. The dia- and product code in all correspondence regarding
phragm assembly can be disassembled with a the unit.
30mm socket (Section 4, paragraph 4.4.2). The
diaphragm can then be replaced. Drive Worms and Gears
Either type of kit can be used for your pump. The Worms (Fig 6, Item 342) and gears (50) must be
user must decide which type is better for them. sold in sets to assure proper operation.
When ordering RPM Kits RPM045 through
RPM053 for an old style pump, where a spanner 4.2 SHIPPING PUMPS FOR REPAIR
wrench is required to disassemble the diaphragm
assembly, order a new hex head support nut (270) Pumps can not be accepted for repair without a
with the RPM kit. Future maintenance on the Mac- Return Material Authorization. Pumps should be
roy pump will not require a spanner wrench. clearly labeled to indicate the liquid being pumped.
Process liquid should be flushed from the pump liq-
G5, Metallic Liquid End uid end and oil should be drained from the pump
housing before the pump is shipped.
(1) Diaphragm (260)
NOTE: Federal law prohibits handling of
(2) Oil Seal (70) equipment that is not accompanied by an
OSHA Material Safety Data Sheet (MSDS). A
(3) Check Valve Assemblies (425) completed MSDS must be packed in the ship-
ping crate with any pump shipped for repair.
(See parts list) These safety precautions will aid the trouble-
shooting and repair procedure and preclude
serious injury to repair personnel from hazard-
13
ous residue in pump liquid end. A Materials Inspect the ball check and seat for chemical or
Safety Data Sheet must accompany all returns. physical damage. The ball should be perfectly
round and free of pits, mars, or scratches. The seat
All inquiries or parts orders should be addressed to should retain a sharp edge where the ball contacts
your local Milton Roy representative or distributor. for proper sealing. If the seat edge is worn or dam-
aged, or has any pits, mars, or scratches, it should
4.3 PREVENTIVE MAINTENANCE be replaced. If the ball and/or seat is excessively
damaged, the replacement schedule should be
Milton Roy pumps are carefully designed, manu- shortened accordingly. If the ball and seat are both
factured, assembled, and quality tested to give reli- in good condition, the replacement schedule can
able service with minimal maintenance. However, a be lengthened.
weekly maintenance check is recommended to
visually confirm proper operation of the pump. Complete instructions for replacing worn check
valve parts are given in the “Corrective Mainte-
Drive nance” section.
Initially, change gear drive oil after the first 250 4.4 CORRECTIVE MAINTENANCE
hours of operation. Then change drive oil after
every 4000 hours of operation or every six months,
whichever comes first. Refer to “Initial Start-up” in
Section 3, Operation, for information on recom-
mended oil and oil capacity. BEFORE CARRYING OUT ANY SERVIC-
ING OPERATION ON THE METERING
NOTE: When adding oil, pour in a thin, slow UNIT OR PIPES, DISCONNECT ELEC-
stream to avoid overflow. TRICAL POWER FROM THE PUMP,
AND TAKE THE NECESSARY STEPS
Diaphragm Assembly TO ENSURE THAT THE HARMFUL LIQ-
UID THEY CONTAIN CANNOT ESCAPE
The MacRoy G diaphragm assembly should be OR COME INTO CONTACT WITH PER-
replaced every 4000 hours of operation to avoid SONNEL. SUITABLE PROTECTIVE
the possibility of failure. Refer to the instructions in EQUIPMENT MUST BE PROVIDED.
the “Corrective Maintenance” section. CHECK THAT ALL PRESSURE HAS
BEEN BLED FROM THE PUMP DRIVE
Oil Seal AND PUMP LIQUID END BEFORE PRO-
CEEDING WITH DISMANTLING.
The MacRoy G oil seal should be replaced every
4000 hours of operation to avoid the possibility of Cleaning Fouled Check Valves
failure. Oil seal replacement requires the removal
of the diaphragm assembly, so it is recommended Check valve assemblies are designed to be self
that the oil seal and diaphragm be replaced at the cleaning and should seldom need servicing.
same time. Refer to the instructions in the “Correc- Fouled check valves can usually be cleaned by
tive Maintenance” section. pumping a solution of mild detergent and warm
water (if compatible with liquid being pumped) for
Check Valves 15 minutes, followed by flushing with water.
Milton Roy company recommends that check valve 4.4.1 Check Valve Replacement
balls, seats, gaskets, and o-rings be replaced on a
annual basis. If highly corrosive material (acids, General
slurries, etc.) is being pumped, some applications
may require more frequent replacement. Before beginning work on the valve assemblies,
make sure the shut-off valves are closed and that
To determine if check valves need maintenance, pressure has been bled from the system. When
disassemble the check valves following the instruc- replacing the valves, take care to systematically
tions in the “Corrective Maintenance” section. change their O-rings and/or gaskets. Take care to
14
properly assemble the valve assemblies; the ball
must be placed on the sharp edge of the seats.
Check valves are supplied in four different configu- IF YOU ARE DISASSEMBLING UNIT
rations: plastic, stainless steel, slurry, and polymer. FOR INSPECTION ONLY, BE SURE TO
Be sure to refer to the appropriate instructional set USE A BLUNT INSTRUMENT AND TAP
below. GENTLY TO AVOID DAMAGING THE
BALL. IF THE BALL AND/OR SEAT ARE
DAMAGED DURING DISASSEMBLY,
THEY WILL HAVE TO BE REPLACED. IF
AVAILABLE, TO AVOID DAMAGE, IT IS
BE SURE TO FOLLOW INSTRUCTIONS ADVISABLE TO USE GENTLE AIR
CAREFULLY AND REFER TO THE PRESSURE (APPLIED AT END OPPO-
APPROPRIATE FIGURE WHEN REAS- SITE THE SEAT - 420) FOR BALL AND
SEMBLING CHECK VALVES. IF CHECK SEAT REMOVAL.
VALVE CARTRIDGES ARE INSTALLED
INCORRECTLY, ONE OF THE FOLLOW- 5. Tap screwdriver gently with a hammer until the
ING WILL OCCUR: (A) IMMEDIATE ball and seat are released from the ball guide.
SEVERE DAMAGE TO PUMP MECHA-
NISM, (B) NO PUMPING, (C) REVERSE 6. Carefully remove the two or three o-rings (de-
PUMPING ACTION (FROM DISCHARGE pending on model number) from the ball guide and
LINE INTO SUCTION LINE). seat.
4.4.1.1 Plastic Check Valves (PVC, PVDF, Poly, 7. Carefully clean any parts to be reused. If any
H2SO4, Fig 13A or 13C): chemicals are used in the cleaning process,
ensure that they are compatible with the process
Disassembly liquid.
Check pump data plate for model number. Reassembly
1. Unscrew the union nut (435). The union end 1. Fit new o-rings into position on the ball guide
(445) is held in place by the union nut and will sep- and seat.
arate easily from the other liquid end parts.
NOTE: To assure a tight, leak free seal, new
2. Unscrew the ball guide (424) from the liquid o-rings should be used each time the check
end. valves are disassembled.
3. Screw the union nut part way (one or two 2. Drop the ball into the curved inner chamber
turns) onto the end of the ball guide that has the end of the ball guide.
seat in it. Be sure the union nut is on loosely. This
will allow a gap for the seat (420) to fall into as it is
removed from the ball guide.
4. Set the ball guide/union nut onto a flat surface IF THE SEAT IS IMPROPERLY POSI-
with the union nut down. Looking into the top of TIONED, THE BALL WILL NOT CREATE
the ball guide, you will see four large holes sur- A TIGHT SEAL AND POOR PUMPING
rounding one small hole. Insert a thin, blunt instru- PERFORMANCE WILL RESULT.
ment such as a hex head screwdriver into the small
center hole until it rests on the top of the ball (422). 3. Set the ball guide on a flat surface so that the
side with the ball faces upwards. Position seat on
the ball guide, trapping the ball inside. When the
seat is pressed into the ball guide, the beveled
edge of the seat must be facing outward. The
15
bevel should not face the inside of the check valve 5. Carefully clean any parts to be reused. If any
(refer to Figure 13A or 13C). Use a flat surface chemicals are used in the cleaning process,
such as a board to press the seat into the ball ensure that they are compatible with the process
guide with firm, even pressure. liquid.
Reassembly
1. Drop the ball into the curved inner chamber

THE ORDER OF ASSEMBLY AND ORI- end of the ball guide.
ENTATION OF THE SUCTION AND DIS-
CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 7, 9,
11, 13A, AND 13C FOR PROPER
ASSEMBLY ORDER AND ORIENTA- DO NOT REUSE OLD GASKETS (419).
TION. IF CHECK VALVE CARTRIDGES EVEN IF BALL AND SEAT ARE NOT
ARE INSTALLED INCORRECTLY, ONE WORN AND DO NOT NEED REPLAC-
OF THE FOLLOWING WILL OCCUR: (A) ING, NEW GASKETS MUST BE USED
IMMEDIATE SEVERE DAMAGE TO ANY TIME THE CHECK VALVES ARE
PUMP MECHANISM, (B) NO PUMPING, DISASSEMBLED.
(C) REVERSE PUMPING ACTION
(FROM DISCHARGE LINE INTO SUC- 2. Place a new gasket on the rim of the ball guide
TION LINE). (424), and sit the seat on top of the ball guide, trap-
ping the ball and gasket between the seat and ball
4. Position the union end (445) onto the correct guide.
end of the ball guide. Refer to Figure 13A or 13C,
as the correct end is determined by whether the
valve is intended for the suction or discharge port
of the liquid end. Slip the union nut (435) over the
union end and screw tightly (hand tight only) onto THE ORDER OF ASSEMBLY AND ORI-
the ball guide. ENTATION OF THE SUCTION AND DIS-
5. Screw the valve assembly into the liquid end DIFFERENT. REFER TO FIGURE 10, 12,
body (hand tight only). DO NOT OVER AND 13D FOR PROPER ASSEMBLY
TIGHTEN. ORDER AND ORIENTATION. IF CHECK
VALVE CARTRIDGES ARE INSTALLED
4.4.1.2 Models G6 & G7 Liquid Ends - Stain- INCORRECTLY, ONE OF THE FOLLOW-
less Steel Check Valves (PVC, PVDF, Poly, ING WILL OCCUR: (A) IMMEDIATE
H2SO4, Figure 13D): SEVERE DAMAGE TO PUMP MECHA-
NISM, (B) NO PUMPING, (C) REVERSE
Disassembly PUMPING ACTION (FROM DISCHARGE
LINE INTO SUCTION LINE).
1. Unscrew the three screws (441 & 442) and
remove them and their three washers (439). 3. Position the connection (435) onto the correct
end of the ball guide with a gasket trapped
2. Remove the valve clamp (437). between the two metal surfaces. Refer to Figure
13D, as the correct end is determined by whether
3. The connection (435), seat (420), ball (422) the valve is intended for the suction or discharge
and ball guide (424) should all now slip apart eas- port of the liquid end.
ily.
4. Position the check valve assembly onto the liq-
4. Remove and discard the three gaskets (419). uid end, trapping a gasket between the two metal
surfaces (Seat and pump head).
16
5. Slide the valve clamp (437) over the connec- 1. Screw the correct end of the check valve
tion (435) and screw into the liquid end using the assembly into the liquid end (refer to Figure 13B),
three screws (441,442) and their split washers trapping a new o-ring between the liquid end and
(439). Since one screw (441) is shorter than the the check valve assembly.
others, be sure that it is screwed into the appropri-
ate hole. NOTE: To assure a tight, leak free seal, new
o-rings should be used each time the check
4.4.1.3 Model G5 Liquid End - Stainless Steel valves are disassembled.
Check Valve (PVC, PVDF, POLY, H2SO4, Fig
13B): 2. Screw the coupling (445) onto the check valve
assembly, trapping a new o-ring (419, 423)
Disassembly between the coupling and the check valve assem-
bly.
G5 & GC stainless steel check valves differ from
the plastic versions in that the ball seat is integral 4.4.1.4 Model G5 Liquid End - Slurry Check
to the ball guide. The seats cannot easily be Valves:
inspected for damage or wear. If you suspect that
the check valve may be damaged or worn, replace Replacement
the entire check valve assembly as per the instruc-
tions below.
1. Unscrew the coupling (445).

THE ORDER OF ASSEMBLY AND ORI-
2. Unscrew the ball guide (424) from the liquid ENTATION OF THE SUCTION AND DIS-
end. CHARGE CHECK VALVES IS
DIFFERENT. REFER TO FIGURE 7 AND
3. Remove and discard the o-rings (419). 13E FOR PROPER ASSEMBLY ORDER
AND ORIENTATION. IF CHECK VALVE
4. Carefully clean any parts to be reused. If any CARTRIDGES ARE INSTALLED INCOR-
chemicals are used in the cleaning process, RECTLY, ONE OF THE FOLLOWING
ensure that they are compatible with the process WILL OCCUR: (A) IMMEDIATE SEVERE
liquid. DAMAGE TO PUMP MECHANISM, (B)
NO PUMPING, (C) REVERSE PUMPING
Reassembly ACTION (FROM DISCHARGE LINE INTO
SUCTION LINE).
1. Unscrew the coupling (445).
THE ORDER OF ASSEMBLY AND ORI- 2. Unscrew the valve body (424) from the pump
ENTATION OF THE SUCTION AND DIS- head (280).
DIFFERENT. REFER TO FIGURE 8 AND 3. Remove and discard the valve assembly:
13B FOR PROPER ASSEMBLY ORDER assembly includes two O-rings (419), slurry seal
AND ORIENTATION. IF CHECK VALVE ring (420), ball (422), check valve body (424), and
CARTRIDGES ARE INSTALLED INCOR- dowel pin.
RECTLY, ONE OF THE FOLLOWING
WILL OCCUR: (A) IMMEDIATE SEVERE 4. Clean the new valve assembly and threaded
DAMAGE TO PUMP MECHANISM, (B) port in the head (280).
ACTION (FROM DISCHARGE LINE INTO NOTE: To assure a tight, leak free seal, new
SUCTION LINE). o-rings should be used each time the check
valves are disassembled.
17
5. Screw the correct end of the check valve 7. Screw the correct end of the check valve
assembly into the liquid end (refer to Figure 13E), assembly into the liquid end (refer to Figure 13G),
trapping a new o-ring (419) between the liquid end trapping a new o-ring (419) between the liquid end
and the check valve assembly. and the check valve assembly.
6. Screw the coupling (445) onto the check valve 8. Screw the coupling (445) onto the check valve
assembly, trapping a new o-ring (419) between the assembly, trapping a new o-ring (419) between the
coupling and the check valve assembly. coupling and the check valve assembly.
4.4.1.5 Models G6 & G7 Liquid End - Slurry 4.4.1.6 Models G5, G6 & G7 Liquid End - Poly-
Check Valves (Figure 13G): mer Check Valves (Figure 13F): Replacement
Replacement Suction
Follow the instruction for replacement of ball, seat,

& seal: liquid end G6 and G7 - plastic check valves
paragraph 4.4.1.1. The procedures are the same.
THE ORDER OF ASSEMBLY AND ORI-
ENTATION OF THE SUCTION AND DIS- Discharge
1. Unscrew the valve body (425) from the pump
DIFFERENT. REFER TO FIGURE 13G
head (280).
FOR PROPER ASSEMBLY ORDER AND
ORIENTATION. IF CHECK VALVE CAR-
2. Remove the valve assembly: assembly
TRIDGES ARE INSTALLED INCOR-
includes two O-rings (419), seat (420), ball (422),
RECTLY, ONE OF THE FOLLOWING
poppet (426), spring (423) and check valve body
WILL OCCUR: (A) IMMEDIATE SEVERE
(425).
DAMAGE TO PUMP MECHANISM, (B)
3. Replace O-rings (419), seat (420), ball (422),
ACTION (FROM DISCHARGE LINE INTO
poppet (426), and spring (423).
SUCTION LINE).
4. Clean the valve body (425) and threaded port in
1. Unscrew the valve body (424) from the pump
the head (280).
head (280).
5. Install new check valve assembly in orientation
2. Remove the valve assembly: assembly
shown.
includes ball (421), seat (420), valve body (424),
and three O-rings (419).
On discharge side, drop cartridge assembly into
threaded port in head. Screw valve body into dis-
3. Remove and discard the o-rings (419), seat
charge side of diaphragm head until valve is hand
(420) and ball (421).
tight. DO NOT OVERTIGHTEN.
4. Clean the valve body (424) and threaded port
4.4.2 Diaphragm Replacement
in the head (280).
5. Place a new O-ring (419) around seat (420).

Place new seat (420) and new ball (422) inside
valve body (424).
BEFORE BEGINNING DIAPHRAGM
6. Add O-ring (419) and install new check valve REPLACEMENT, MAKE SURE THAT
assembly in orientation shown. ALL SHUT-OFF VALVES ARE CLOSED
AND ALL PRESSURE IS BLED FROM
NOTE: To assure a tight, leak free seal, new THE LIQUID END. MAKE SURE POWER
o-rings should be used each time the check TO PUMP IS TURNED OFF AND CAN-
valves are disassembled. NOT BE ACTIVATED.
18
It is recommended that the oil seal and diaphragm 4. DO NOT OVERTIGHTEN the support nut.
be replaced at the same time. The instructions Use a 30mm hex socket and torque wrench to
given under “Replacing the Oil Seal” are complete tighten the support nut. The torque depends on
instructions for replacing both the oil seal and dia- pump model number.
phragm. If you plan to replace both, refer to the
“Replacing the Oil Seal” instructions, and disregard • For model numbers G5 & G6: Torque is 20
the instructions below. These instructions are foot pounds.
intended for use only if the diaphragm is being
replaced independent of the oil seal. • For model number G7: Torque is 25 foot
pounds.
4.4.2.1 Diaphragm Removal (All types; Refer to
Figures 6-12) 4.4.2.4 Reinstallation of Assembly (Refer to
Figure 6 Through 12)
1. Set the stroke adjusting knob to 100%.
1. With the stroke adjusting knob at 100% and
2. Disconnect the suction and discharge piping. the diaphragm fully forward as in steps 1 and 5 of
paragraph 4.4.2.1, screw the diaphragm assembly
3. Unscrew the six diaphragm head bolts (290). into the connecting rod until it reaches its natural
mechanical stop.
4. Remove the pump head (280) from the pump
body. 2. Turn the motor fan by hand until the diaphragm
rests properly on the diaphragm support (230).
5. Turn the motor fan by hand (remove the motor Reinstall the motor shroud if previously removed.
shroud if necessary) until the end of the diaphragm
(240) is fully forward, and unscrew the diaphragm 3. Fit the diaphragm head back into place on the
assembly from the connecting rod (60). pump body.
4.4.2.2 Disassembly (Only Those Units With a 4. Torque the six diaphragm head bolts to the fol-
“Hex Head “ Diaphragm Cap Design) lowing inch pounds in a crisscross pattern:
1. Secure the hex cap (240) in a vise, and loosen (1) Liquid End Size G5 and G6 metallic and
the support nut (270) using a 30mm hex socket. non-metallic head bolts to 90 inch pounds.
2. After complete disassembly inspect the sup- (2) Liquid End Size G7 non-metallic head bolts
port nut (270). It should be free of corrosion and to 125 inch pounds.
clean. The angled surface must be smooth to pro-
tect the diaphragm from damage. If the support (3) Liquid End Size G7 metallic head bolts to
nut does not meet these requirements, replace it. 250 inch pounds.
4.4.2.3 Reassembly 4.4.3 Replacing Oil Seal
1. Mount the hex cap (240) in a vise (do not over-

tighten), and with surfaces cleaned place a new
diaphragm (260) onto the cap as shown Figure 7
through Figure 12 (convolution pointing toward the BEFORE BEGINNING OIL SEAL
support nut). REPLACEMENT, MAKE SURE THAT
ALL SHUT-OFF VALVES ARE CLOSED
2. The set screw (250) hand tight in the cap (240) AND ALL PRESSURE IS BLED FROM
with the hex socket end visible. THE LIQUID END. MAKE SURE POWER
TO PUMP IS TURNED OFF AND CAN-
3. Screw the support nut (270) onto the set screw NOT BE ACTIVATED.
until hand tight
19
When replacing the oil seal, the diaphragm assem- retaining ring (220). A drive socket large enough to
bly must be removed first. For ease of service, it is fit over the end of the connecting rod should be
recommended that the oil seal be replaced in con- used to push the retaining ring until it snaps into
junction with the diaphragm assembly. Therefore, place in the retaining ring groove in the connecting
the instructions below include the “Diaphragm rod.
Replacement” instructions, and can be used for
both oil seal replacement and diaphragm replace- 3. Secure the large oil seal clamp (80) over the oil
ment. seal with the four slotted screws (90).
Disassembly (Refer to Figure 6 through 12). 4. Place the diaphragm support ring (230) into
position making sure beveled side (for diaphragm
1. Drain oil from the pump by unscrewing drain support) is facing up (refer to Figure 6 through 12).
plug and O-ring, located underneath capacity For G7 liquid ends, the support ring (230) has
adjustment knob (330). stepped diameters. Make sure that the larger
diameter is installed into the metal adapter ring
2. Set the capacity adjusting knob (330) to 100%. (225 Figure 11 and 12).
3. Disconnect the suction and discharge piping. 5. With the stroke adjusting knob at 100% and
the diaphragm fully forward as in steps 2 and 6 of
4. Unscrew the six diaphragm head bolts. disassembly instructions, screw the diaphragm
assembly into the connecting rod until it reaches its
5. Remove the diaphragm head assembly from natural mechanical stop.
the pump body.
6. Turn the motor fan by hand until the diaphragm
6. Turn the motor fan by hand (remove the rests properly on the diaphragm support ring (230).
shroud if necessary) until the end of the diaphragm Reinstall the motor shroud if previously removed.
assembly (240) is fully forward, and unscrew the With the stroke adjusting knob at 100% and the
diaphragm from the connecting rod (60), using a diaphragm fully forward as in steps 2 and 6 of dis-
30mm hex socket on diaphragm cap (240). assembly instructions, screw the diaphragm
assembly into the connecting rod until it reaches its
7. Remove the diaphragm support ring (230). natural mechanical stop.
8. Remove the retaining ring (220) from the con- 7. Fit the diaphragm head back into place on the
necting rod. pump body.
9. Slide the small oil seal clamp (210) off the 8. Torque the six diaphragm head bolts to the fol-
connecting rod. lowing inch pounds in a crisscross pattern:
10. Remove the large oil seal clamp (80) by (1) Liquid End Size G5 and G6 metallic and
unscrewing the four slotted screws (90). non-metallic head bolts to 90 inch pounds.
11. Pull the oil seal (70) off of the connecting rod. (2) Liquid End Size G7 non-metallic head bolts
to 125 inch pounds.
Reassembly (Refer to Figure 6 through 12).
(3) Liquid End Size G7 metallic head bolts to
1. Install a new oil seal (70) onto the connecting 250 inch pounds.
rod.
4. Add oil to pump, following directions given in
2. Slide small oil seal clamp (210) onto the end of “Initial Start-up” in Section 3.
the connecting rod and secure in place with the
20
SECTION 5
TROUBLESHOOTING GUIDE
SYMPTOMS REMEDIES
Pump will not operate • Low process liquid level in the tank. Add liquid
• Worn or dirty check valves. Clean or replace.
• Blocked discharge line. Clear line.
• Frozen liquid. Thaw liquid throughout pumping system.
• Blown fuse. Replace fuse.
• Open thermal overload device in motor starter. Reset
device
• Broken wire. Locate and repair.
• Low voltage. Investigate and correct (wiring may be too
light).
• Pump not primed. Allow suction line and pump head to fill
with liquid before pumping against pressure. Refer to
“Filling Pumping System” in Section 3.
• Capacity adjustment set at zero. Readjust capacity.
Insufficient delivery • Incorrect capacity adjustment. Readjust capacity setting.
• Incorrect pump seed. Match live voltage and frequency to
pump motor data plate.
• Starved suction. Increase piping size or suction head.
• Leaky suction piping. Repair piping.
• High suction lift. Rearrange equipment to decrease lift.
• Liquid near boiling. Cool liquid or increase suction head.
• Leaky safety valve in discharge line. Repair or replace
safety valve.
• High liquid viscosity. Reduce viscosity (e.g., heat or dilute
liquid).
• Worn or dirty check valve seats. Clean or replace.
Erratic delivery • Leaky suction piping. Repair piping.
• Leaky safety valve. Repair or replace safety valve.
• Insufficient suction head. Raise suction tank level or pres-
surize tank.
• Liquid near boiling. Cool liquid or increase suction head.
• Worn or dirty check valves. Clean or replace.
• Clogged or dirty line strainer. Clean strainer.
Motor and pump body hot • Normal operating temperature of both motor and pump
body is frequently uncomfortable to the touch. However,
neither should exceed 200°F (93°C).
• Power supply does not match electrical requirement of
motor. Insure proper matching of power supply and
motor.
• Pump is being operated at greater than rated perfor-
mance. Reduce pressure or stroke speed. If this is not
practical, contact service facility.
• Pump improperly lubricated. Drain oil and refill with
proper amount of recommended lubricant.
21
SYMPTOMS REMEDIES
Pump still pumps even at zero capac- • Improperly adjust micrometer knob. Readjust capacity
ity setting setting.
• Insufficient discharge pressure. Correct condition (e.g.,
install a back pressure valve).
Gear noise • Excessive backlash. Consult service facility.
• Worn bearings. Consult service facility.
• Wrong or insufficient lubricant. Replace or replenish lubri-
cant.
Loud knock with each stroke • Excessive gear set wear. Consult service facility.
• Worn bearings. Consult service facility.
Noisy operation in liquid end • Nosie in check valves. Ball checks move up and down
with some force. A distinct “clicking” noise is normal,
especially in metal piping systems.
22
SECTION 6
PARTS
6.1 GENERAL
This section gives information regarding replace-

able components.
6.2 ILLUSTRATED PARTS LIST
1. Figure and Item Number Column
a) The item numbers shown in the detailed

parts list correspond to the item numbers
appearing on the exploded view illustra-
tion. To find an unknown part number,
locate the part on the illustration and note
the item number. Look for the item number
on the detailed parts list. The part number
is on the same line. A dash (-) precedes
non-illustrated item numbers.
2. Description Column
a) The name of the item is in the description

column.
3. Part Number Column
a) The supplier’s part number is listed in the

part number column.
4. Quantity Column
a) The numbers appearing in the quantity col-

umn are the total quantity of the listed part
required in its immediate assembly.
5. Reference Code Column
a) This column is used to denote assembly

and detail part variations among similar
components (models) covered by this pub-
lication. When the symbol “A1”, “B1”, “C1”,
etc. is entered in this column, the part is
used only in the model (liquid end and
material codes, see Figure 1 and pump
data plate) at which the symbol appears. If
the column is blank, the part is used in all
models.
23
Figure 6 (Sheet 1 of 2). MacRoy G Drive Parts - Side View
24
6.3 DRIVE, SIDE VIEW
FIGURE ITEM DESCRIPTION PART QTY REFERENCE

NUMBER NUMBER NUMBER CODE
6 40 Bearing Cup (Timken) 4090116050 1
60 Connecting Rod S60654 1
70 Oil Seal, Buna N 60048 1
80 Oil Seal Clamp, Aluminum 60034 1
90 Slotted Pan Head Screw, M3x10, 60294 4
304 SS
340 Bearing Cone (Timken) (See Note 1) 4090116040 1
342 Worm, 8:1 (See Note 1) S60198 1
342 Worm, 10:1 (See Note 1) S60195 1
342 Worm, 14:1 (See Note 1) S60828 1
342 Worm, 20:1 (See Note 1) S60196 1
342 Worm, 40:1 (See Note 1) S60197 1
- Worm Assembly (43 SPM, 56C, 40:1), 60397 1
Gear S60011 (See Note 1)
- Worm Assembly (36 SPM, IEC 80 60224 1
Frame, 40:1), Gear S60011 (See Note
1)
1)
1)
Frame, 8:1), Gear S60050 (See Note 1)
344 Spring Pin, 0.187 x 1-1/8 STL (See 4010005101 1
Note 1)
346 Worm Shaft Coupling, 56C (See Note 60261 1
1)
346 Worm Shaft Coupling, IEC 71 (See 60260 1
Note 1)
- Items not shown
25
6 346 Worm Shaft Coupling, IEC 80 (See 60194 1
Note 1)
360 Spring (56C) (See Note 2) 60264 1
360 Spring (IEC 80) (See Note 2) 60225 1
370 Vent with Dip Stick 70067 1
376 IEC 80 Motor Adapter Ring 60199 1
377 Hex Head Screw, M10 x 25MM Steel 4350001732 4
(IEC 80 motor)
390 Motor (1 hp, 1 ph, 1800 rpm, 115/230, 4112008010 1
60 hz, 56C)
390 Motor (1 hp, 3 ph, 1500 rpm, 220/380, 4112008315 1
50 hz, 56C)
390 Motor ( 1hp, 3 ph, 1800 rpm, 230/460, 4112008310 1
60 hz, 56C)
390 Motor (1 hp, 1750 rpm, 90 VDC, PM- 4112008610 1
TEFC-56C)
390 Motor (1 hp, W/VAR SPD AC Drive) 60297 1
400 Hex Head Screw (3/8-16 x 1) (56C 4050018119 4
motor)
400 Hex Head Screw (M10 x 25 mm) (IEC 4350001732 4
80 motor)
410 Flat Washer (3/8) (56C motor) 4040009012 4
410 Flat Washer (M10) (IEC 80 motor) 4340005152 4
417 Caution, Motor Decal G 60148 1
450 Base 61266 1
460 Hex Head Screw (M8 x 35 mm) 4350035542 4
465 Spring Lock Washer (8 mm) 4340009002 4
470 Hex Nut (M8) 4350000042 4
- Items not shown
Note 1: Worm-Gear-Shaft Assembly includes gear (50) worm (342), spring pin (344), spring (360),
worm shaft coupling (346), and bearing cone (340). Gear (50) and worm (342) sold only as assembly
(343)
Note 2: Part number for 56C motor spring (60264) applies to two-piece worm assembly: worm and
motor coupling piece joined together by a spring pin (344). If worm is previous one-piece design (no
spring pin), the correct 56C motor spring part number is 60059.
26
Figure 6 (Sheet 2 of 2). MacRoy G Basic Parts - Top View
27
6.4 DRIVE, TOP VIEW

6 10 Drive Housing Assembly (Includes 60001 1
Items 30, 40, and 448))
10 Housing, Stroke Counting (Includes 60877 1
Items 30, 40, and 448)
30 Thrust Bearing, Bronze 60014 1
50 Gear (36/43 SPM), 50 Hz/60 Hz (See S60011 1
Note 1)
Note 1)
Note 1)
Note 1)
50 Gear (180 SPM), 50 Hz (See Note 1) S60050 1
100 Sliding Crank 60002 1
101 Spring Pin, 0.125 x 1/2 4010003031 1
110 Eccentric, Steel 60003 1
110 Eccentric, Stroke Counting 60875 1
120 Shoe 60052 1
140 Single Row Bearing 4099994000 1
150 Truarc Retaining Ring 4040107231 1
160 Parker O-ring, Buna N 4080095171 1
170 Stroke Adjustment Screw Assembly 60950 1
171 Stroke Screw, Part of Item 170 H60768 1
172 Bearing Retainer, Part of Item 170 H60757 1
174 Socket Head Screw M4 x 8MM, part of 41663 4
item 170
175 Stroke Scale 2530046062 1
185 Dowel Pin 1/8 x 1-3/8, Part of Item 170 4010021143 1
190 Parker O-ring (2-246), Buna N 4080095371 1
200 Cover H60767 1
205 Hex Head Screw (M8 x 16 mm) 4350001622 4
210 Oil Seal Clamp, Aluminum 60043 1
220 Truarc Retaining Ring 4040133060 1
- Items not shown.
28
6 - M12 Lockwasher, 18-8 SS 4340009095 6
- M12 Hex Nut, 304 SS 4350000085 6
310 Ball 5/16, Nylon 60152 1
320 Stroke Locking Knob 60398 1
322 O-Ring, 2-012 Bunan N 4080109091 1
330 Stroke Adjustment Knob 70066 1
331 Flat Washer 1/4”, 18.8 SS 4040005012 1
332 Pan Head Screw #8 x 1-1/2”, 18.8 SS 40722 1
335 Logo Decal (Stroke Knob) 70022 1
448 Tubing Connector (1/4” OD x 1/4” ID) 4020479028 1
- Gear Oil (AGMA 5 EP, ZURN EP95) - 1 4070152010 3
Quart Can
- Items not shown.
Note 1: Worm-Gear-Shaft Assembly includes gear (50) worm (342), spring pin (344), spring (360),
worm shaft coupling (346), and bearing cone (340). Gear (50) and worm (342) sold only as assembly
(343)
Note 2: Part number for 56C motor spring (60264) applies to two-piece worm assembly: worm and
motor coupling piece joined together by a spring pin (344). If worm is previous one-piece design (no
spring pin), the correct 56C motor spring part number is 60059.
29
Figure 7. G5 Plastic Liquid End
30
6.5 G5 PLASTIC LIQUID END
Model: Model:
Liquid End: Material: ReferenceCode: Liquid End: Material: ReferenceCode:
G5_ _ _ _ _ _ 8_ _ _ _ _ _ A (PVC) G5_ _ _ _ _ _ P_ _ _ _ _ E (POLYMER)
G5_ _ _ _ _ _ 4_ _ _ _ _ _ B (BLACK POLY) G5_ _ _ _ _ _ L_ _ _ _ _ F (SLURRY)
G5_ _ _ _ _ _ 2_ _ _ _ _ _ C (PVDF) G5_ _ _ _ _ _ N_ _ _ _ _G (H2SO4)
G5_ _ _ _ _ _ A_ _ _ _ _ _ D (ACRYLIC)
(Consult Factory)

7 230 Diaphragm Support Ring 60035 1
240 Diaphragm Cap, Part of Item 261 60628 1 A, E, F, G
240 Diaphragm Cap, Part of Item 261 60629 1 B
240 Diaphragm Cap, Part of Item 261 60630 1 C
250 Set Screw, Dog Pt., M10 x 45 mm, Sin- 4350071284 1 A, B, C, E
gle Diaphragm, Part of Item 261
250 Set Screw, Dog Pt., M10 x 70 mm, Dou- 4350071334 1 A, B, C
ble Diaphragm, Part of Item 261A
260 Diaphragm, Part of Item 261 60618 1
Diaphragm, Part of Item 261A 60618 2
261 Diaphragm Assy, (Replaceable Design, 60150 1 A, E, F, G
Consists of Items 240, 250, 260, and
270), See Note 1
261 Diaphragm Assembly, (Replaceable 3050976110 1 B
Design, Consists of Items 240, 250,
260, and 270), See Note 1
261 Diaphragm Assy, (Replaceable Design, 3050976130 1 C
270), See Note 1
261A Double Diaphragm Assy, (Replaceable 60274 1 A, E, F, G
Design, Consists of Items 260(2X),
261, 262, 263, and 266), See Note 2
261A Double Diaphragm Assy, (Replaceable 60275 1 B
261, 262, 263, and 266), See Note 2
261A Double Diaphragm Assly, (Replace- 60276 1 C
able Design, Consists of Items 260(2X),
261, 262, 263, and 266), See Note 2
262 Double Diaphragm Spacer, PVC, Part 980367071 1 A, B, C
of Item 261A
263 Double Diaphragm Intermediate Ring 980366071 1 A, B, C
(Included in double diaphragm assem-
bly Item 261A)
31
7 266 Hex Nipple 1/4 NPT connection, 316 60208 1
SS (Included in double diaphragm
assembly, Item 261A)
270 Diaphragm Support Nut, Part of Item 60632 1
261
280 Diaphragm Head, PVC 60033 1 A, E, F, G
280 Diaphragm Head, White PP 60032 1 B
280 Diaphragm Head, Black PP 60882 1 B
280 Diaphragm Head, PVDF 60031 1 C
290 Hex Head Screw, M8 x 90, Single Dia- 4350035655 6 A, B, C
phragm
290 Hex Head Screw, M8 x 110, Double 4350001655 6 A, B, C
Diaphragm
300 Flat Washer (M8) 4340005085 6
300 Back-up Plate G5/G6 60754 1 B
Note 1: Diaphragm Assembly (261) can be purchased assembled or items 240, 250, 260, and 270
can be purchased separately.
Note 2: Double Diaphragm Assembly (261A) can be purchased assembled or items 260, 261, 262,
263, and 266 can be purchased separately.
32
Figure 8. G5 Metallic Liquid End
33
6.6 G5 METALLIC LIQUID END - STAINLESS STEEL- NPT
Model:
Liquid End: Material:
G5_ _ _ _ _ _ 7_ _ _ _ _ _

240 Diaphragm Cap, Part of Item 261 60631 1
250 Set Screw, Dog Pt., M10 x 45 mm, Sin- 4350071284 1
250 Set Screw, Dog Pt., M10 x 70 mm, Dou- 4350071334 1
261 Diaphragm Assy, (Replaceable Design, 3050976120 1
270), See Note 1
261A Double Diaphragm Assy, (Replaceable 60273 1
262, 263, and 266), See Note 2
262 Double Diaphragm Spacer, PVC, Part 980367071 1
of Item 261A
263 Double Diaphragm Intermediate Ring 980366071 1
bly Item 261A)
266 Hex Nipple 1/4 NPT connection, 316 60208 1
261
280 Diaphragm Head 210760016 1
290 Hex Head Screw, M8 x 90, Single Dia- 4350035655 6
phragm
290 Hex Head Screw, M8 x 110, Double 4350001655 6
Diaphragm
300 Flat Washer (M8) 4340005085 6
34
35
Model: Model:
G6_ _ _ _ _ _ 2_ _ _ _ _ _ C (PVDF) G6_ _ _ _ _ _ N_ _ _ _ _G (H2SO4)
G6_ _ _ _ _ _ A_ _ _ _ _ _ D (ACRYLIC)
(Consult Factory)

ble Diaphragm Only, P/O 261A
261 Diaphragm Assy, (Replaceable Design, 60151 1 A, E, F, G
270), See Note 1
270), See Note 1
261A Double Diaphragm Assy, (Replaceable 60278 1 A, E, F, G
261, 262, 263, and 266), See Note 2
261, 262, 263, and 266), See Note 2
261A Double Diaphragm Assy, (Replaceable 60280 1 C
261, 262, 263, and 266), See Note 2
of Item 261A
36
9 263 Double Diaphragm Intermediate Ring 980368071 1
bly only, Item 261A)
261
280 Diaphragm Head, PVC 60130 1 A, E, F, G
280 Diaphragm Head, Black PP 60883 1 B
280 Diaphragm Head, PVDF 60068 1 C
phragm
Diaphragm
300 Flat Washer (M8) 4340005085 6
300 Back-up Plate G5/G6 60754 1 B
37
38
6.8 G6 METALLIC LIQUID END - STAINLESS STEEL - NPT
Model:
G6_ _ _ _ _ _ 7_ _ _ _ _ _

270), See Note 1
262, 263, and 266), See Note 2
of Item 261A
bly Item 261A)
261
phragm
Diaphragm
300 Flat Washer (M8) 4340005085 6
39
40
Model: Model:
G7_ _ _ _ _ _ 2_ _ _ _ _ _ C (PVDF) G7_ _ _ _ _ _ N_ _ _ _ _G (H2SO4)
G7_ _ _ _ _ _ A_ _ _ _ _ _ D (ACRYLIC)
(Consult Factory)

11 225 Adapter Ring, Aluminum 60165 1
227 Socket Head Screw (M8 x 25 mm), Zinc 4350003473 6
PLT
230 Diaphragm Support Ring 60159 1
250 Set Screw, Dog Pt., M10 x 70 mm, Sin- 4350071334 1 A, B, C, F
250 Set Screw, Dog Pt., M10 x 90 mm, Dou- 4350071374 1 A, B, C
261 Diaphragm Assy, (Replaceable Design, 60226 1 A, F, G
270), See Note 1
270), See Note 1
261A Double Diaphragm Assy, (Replaceable 60270 1 A, F, G
262, 263, and 266), See Note 2
262, 263, and 266), See Note 2
261A Double Diaphragm Assy, (Replaceable 60272 1 C
262, 263, and 266), See Note 2
41
11 262 Double Diaphragm Spacer, PVC, Part 60232 1 A, B, C
of Item 261A
263 Double Diaphragm Intermediate Ring 60233 1 A, B, C
bly Item 261A)
261
280 Diaphragm Head 60171 1 A, E, F, G
280 Diaphragm Head 60174 1 B, C
290 Hex Head Screw, M8 x 90, Single Dia- 4350036035 6 A, B, C
phragm
290 Hex Head Screw, M12 x 160, Double 4350036065 6 A, B, C
Diaphragm
300 Flat Washer (M8) 4340055073 6
42
43
6.10 G7 METALLIC LIQUID END - STAINLESS STEEL - NPT
Model:
G7_ _ _ _ _ _ 7_ _ _ _ _ _

12 225 Adapter Ring, Aluminum 60165 1
227 Socket Head Screw (M8 x 25 mm), Zinc 4350003473 6
PLT
230 Diaphragm Support Ring 60159 1
270), See Note 1
262, 263, and 266), See Note 2
of Item 261A
bly Item 261A)
261
290 Hex Head Screw, M12 x 130, Single 4350036035 6
Diaphragm
Diaphragm
300 Flat Washer (M12) 4340055073 6
44
FIGURE 13. CHECK VALVE PARTS
Figure 13A. Model G5 Plastic Check Valve Figure 13C. Model G6 & G7 Plastic Check Valve
Parts (Item Number 425) Parts (Item Number 425)
Figure 13D. Model G6 & G7 Metallic Check

Figure 13B. Model G5 Metallic Check Valve
Valve Parts (Item Number 425)
Parts (Item Number 425)
45
FIGURE 13. CHECK VALVE PARTS (CONT.)
DISCHARGE SHOWN
Figure 13G. Model G6 & G7 Slurry Check Valve

Figure 13E. Model G5 Slurry Check Valve Parts Parts (Item Number 425)
(Item Number 425)
Figure 13F. Model G5, G6, and G7 Polymer

Check Valve Parts (Item Number 425)
46
6.11 CHECK VALVE PARTS
Model: Model:
Liquid End: Material: ReferenceCode: Liquid End Material ReferenceCode:
5_ _ _ _ _ _ 7 (316SS) A1 6_ _ _ _ _ _ A (ACRYLIC) B5(Consult Factory)
5_ _ _ _ _ _ 8 (PVC) A2 6_ _ _ _ _ _ P (POLYMER) B6
5_ _ _ _ _ _ 4 (BLK POLY) A3 6_ _ _ _ _ _ L (SLURRY) B7
5_ _ _ _ _ _ 2 (PVDF) A4 6_ _ _ _ _ _ N (H2SO4) B8
5_ _ _ _ _ _ A (ACRYLIC) A5(Consult Factory)
5_ _ _ _ _ _ P (POLYMER) A6 7_ _ _ _ _ _ 7 (316SS) C1
5_ _ _ _ _ _ L (SLURRY) A7 7_ _ _ _ _ _ 8 (PVC) C2
5_ _ _ _ _ _ N (H2SO4) A8 7_ _ _ _ _ _ 4 (BLK POLY) C3
7_ _ _ _ _ _ 2 (PVDF) C4
6_ _ _ _ _ _ 7 (316SS) B1 7_ _ _ _ _ _ A (ACRYLIC) C5(Consult Factory)
6_ _ _ _ _ _ 8 (PVC) B2 7_ _ _ _ _ _ P (POLYMER) C6
6_ _ _ _ _ _ 4 (BLK POLY) B3 7_ _ _ _ _ _ L (SLURRY) C7
6_ _ _ _ _ _ 2 (PVDF) B4 7_ _ _ _ _ _ N (H2SO4) C8

13 419 O-ring, 2-117, Viton A 4080068075 4 A1, A2, A3,
A6, A7, A8
419 O-ring, 2-117, Teflex Parker 40348 4 A4
419 Gasket, Teflon, 1 inch Ball, 2250075275 6 B1, C1
(See Note 3)
419 O-ring, 2-123, Viton A 4080068135 6 B2, B3, B6, B7
C2, C3, C6,
C7, B8, C8
419 O-ring, Teflex-V-123 60765 6 B4, C4
420 Seat, (See Note 2) 920064016 2 A1
420 Seat, 5/8 PVDF 2240173078 2 A2, A3, A4
420 Seat, 5/8 UHMWPE 2240173073 2 A3
420 Seat, PVC, Double Ball 920064071 2 A2
420 Seat, 5/8 316SS 2240173016 2 A6
420 Seat, 166mm 316SS 2240089016 2 B1, C1
420 Seat, 1 inch Polyethylene 60240137073 2 B2, B3, C2, C3
- Items not shown.
47
13 420 Seat, PVDF 60240137078 2 B4, C4
420 Seat, 1 inch 316SS 240137016 2 B6, B7, C6, C7
420 Seal, Ring 316SS 60819 2 A7
420 Seat, 1 inch CA20 61216 2 B8, C8
420 Seat, 5/8 CA20 60855 2 A8
421 Ball, 14mm 316SS, (See Note 60709 2 A1, A7
1 and 4)
421 Ball, 14mm Ceramic, Double 4370000140 2 A2
Ball
422 Ball, 22mm 316SS, ( See Note 60710 2 A1
2)
422 Ball, 5/8 Ceramic 4070015171 2 A2, A3, A4
422 Ball, 5/8 PVC 4070170173 2 A2
422 Ball, 7/8 Ceramic, Double Ball 4070015211 2 A2
422 Ball, 5/8 CA20 4070014173 2 A2, A8
422 Ball, 5/8 316SS 4070014172 2 A2, A6
422 Ball, 1 inch 316SS 4070014232 2 B1, B6, B7,
C1, C6, C7
422 Ball, 1 inch Ceramic 4070015231 2 B2, B3, B4,
C2, C3, C4
422 Ball, 1 inch CA20 4070014233 2 B8, C8
423 Seat, Seal, and Ball Set (See Note 2) 2 A1
423 Seat, Seal, and Ball Set 3050436322 2 B1, C1
423 Seat, Seal, and Ball Set 3050879500 2 A2, A3
423 Seat, Seal, and Ball Set 3050879700 2 A4
423 Seat, Seal, and Ball Set 3050629500 2 B2, B3, C2, C3
423 Seat, Seal, and Ball Set 3050629700 2 B4, C4
423A Spring Hastelloy, Polymer (Dis- 800123026 1 A6
charge)
423A Spring Hastelloy, Polymer (Dis- 60800083026 1 B6, C6
charge)
424 Ball Guide, 316SS, (See Note 210696016 2 A1
2)
424 Ball Guide, 316SS 2920052016 2 B1, C1
424 Ball Guide, PVDF 60024 2 A2, A3, A4, A8
424 Ball Guide, PVC 60030106071 2 B2, C2, C8
- Items not shown.
48
13 424 Ball Guide, PP 030106070 2 B3, C3
424 Ball Guide, PVDF 60030106078 2 B4, C4, B8
424 Ball Guide, PVDF, Polymer 60024 1 A6
(Suction)
424 Ball Guide, PVC, Spring 030156071 1 A6
Loaded, Polymer (Discharge)
424 Ball Guide, PVC (Polymer Suc- 60030106071 1 B6, C6, C8
tion)
424 Ball Guide, PVC Spring 60030134071 1 B6, C6
Loaded, Polymer (Discharge)
424 Ball Guide, Slurry, 316SS, 60818 2 A7
(See Note 1 and 4)
424 Ball Guide, Slurry, 316SS, 61118 2 B7, C7
(See Note 1 and 4)
424 Double Ball Guide, PVC 210696071 2 A2
425 Check Valve Assembly 3050876602 2 A1
(See Note 1 and 2)
425 Check Valve Assembly 3050583022 2 B1, C1
(See Note 1)
(See Note 1)
(See Note 1)
(See Note 1)
(See Note 1)
(See Note 1)
(See Note 1)
425 Check Valve Assembly(Dis- 61645 1 B6, C6
charge)
425 Check Valve Assembly(Suc- 61646 1 B6, C6
tion)
425 Check Valve Assembly (See 60827 2 A7
Note 1 and 4)
- Items not shown.
49
13 425 Check Valve Assembly 61277 2 B7, C7
425 Ball Guide PVC For Spring 60030134071 1 B6, C6
(Discharge)
426 Poppet, PVDF 440090078 1 A6
426 Dowel Pin, 316SS (See Note 60820 2 A7
4)
426 Spring Seat, PVC 60440045071 1 B6, C6
435 Union Nut, 1/2 PVC 4320236038 2 A2, A3, A4,
A6, A7, A8
435 Union Nut, PVC (1”) 4320236058 2 B2, B3, B4,
B6, B7, B8,
C2, C3, C4,
C6, C7, C8
435 Connection (1” NPT Male) 450128116 2 B1, C1
435 Connection (1” BSP Male) 450128016 2 B1, C1
437 Valve Clamp, Steel 040215010 2 B1, B2, B3,
B4, C1, C2,
C3, C4
439 Split Washer (M10) 304 SS 4340009015 6 B1, B2, B3,
B4, C1, C2,
C3, C4
441 Hex Head Screw (M10 x 65 4350035765 2 B1, B2, B3,
mm) 304 SS B4, C1, C2,
C3, C4
442 Hex Head Screw (M10 x 75 4350035785 4 B1, B2, B3,
mm) 304 SS B4, C1, C2,
C3, C4
445 Union End, PVC (1/2” NPT 60117 2 A2, A3, A6, A7
Female)
445 Union End (1” NPT) 60132 2 B2, B3, B6, B7
C2, C3, C6,
C7, C8
445 Union End (Metric Socket 15 x 4320350028 2 A2, A3
20)
445 Union End (Metric Socket 25 x 4320350008 2 B2, B3, C2, C3
32), PVC w/Solvent Weld
445 Union End (1/2” NPT) 60119 2 A4
445 Union End (1/2” BSP) 60146 2 A4
445 Union End (1” NPT) 60133 2 B4, C4
- Items not shown.
50
445 Union End (1” BSP) 60147 2 B4, C4
445 Coupling, 316SS (1” BSP x 1/ 60135 2 A1
2” NPT)
445 Coupling (1” BSP x 1/2” BSP) 450420016 2 A1
447 Elbow, PVC w/1” Tube 61395 2 B2, B4
- Items not shown.
Note 1: Item 425 (Check Valve Assembly) consists of items 424 (Ball Guide), 420 (Seat), 422 (Ball),
419 (Seal), and 421(Ball, Metallic Liquid End Codes 5 & C, 316SS and Slurry only).
Note 2: G5 stainless check valves does not contain a removable ball seat (seat is integral to ball
guide). Ball guide, ball and seal are not sold seperately. Replacement requires purchase of the com-
plete check valve assembly (part # 305-0876-602).
Note 3: Seal is a PTFE gasket for the G6, GD, G7, and GF stainless steel check valves. For all others
the seal is an O-ring.
Note 4: Check Valve Assembly (425, P/N 60827) does not contain a removable ball seat. Replace-
ment of ball (421, P/N 60709), ball guide (424, P/N 60818) and dowel pin (426, P/N 60820) requires
purchase of the complete check valve assembly.
51
LEAK DETECTION PARTS (SWITCH AND GAUGE)
Figure 14. Leak Detection, Switch and Gauge (Optional)
52
6.12 LEAK DETECTION PARTS
Old Model: Model: Code:

G5, GC, 40 5 A
G6, GD, 60 6 B
G7, GF, 80 7 C
FIGURE ITEM DESCRIPTION PART QTY. REFERENCE

14 250 Set Screw, Dog Pt. M10X70mm -Steel 4350071334 1 A, B
250 Set Screw. Dog Pt. M10X90mm - Steel 4350071374 1 C
260 Diaphragm - Gylon 60618 1 A
260 Diaphragm - Gylon 60624 1 B
260 Diaphragm - Gylon 60162 1 C
262 Leak Detector Spacer - PVC 980367071 1 A
262 Leak Detector Spacer - PVC 980369071 1 B
262 Leak Detector Spacer - PVC 60232 1 C
263 Leak Detector Intermed. Ring - PVC 980366071 1 A
263 Leak Detector Intermed. Ring - PVC 980368071 1 B
263 Leak Detector Intermed. Ring - PVC 60233 1 C
266 Male Elbow 1/8t X 1/4 NPT - 316 SS 4020553042 1
290 Hex Head Screw M8X110mm - 304 SS 4350001655 6 A
290 Hex Head Screw M8X130mm - 304 SS 60206 6 B
290 Hex Head Screw M12X160mm - 304 4350036065 6 C
SS
750 Bracket 2040199006 1
760 Nema 4 Pres. Switch 5-30 PSI 4060388001 1
760 Nema 7 Pres. Switch, 5-30 PSI 4060389001 1
770 Reducing Hex Nipple 1/2X1/8 NPT - 40064 1
316 SS
780 Tee 1/8 NPT Female - 316 SS 40062 2
790 Bleed Valve 1/8 NPT - 316 SS 40063 1
800 Tubing Connector 1/8T X 1/8 NPT - 40061 3
316 SS
810 Tubing, Gauge to Nema 4 Switch 2490136016 1
810 Tubing, Gauge to Nema 7 Switch 60983 1
820 Reducing Adapter 1/4F X 1/8M NPT - 40067 1
316 SS
- Items not shown.
53
FIGURE ITEM DESCRIPTION PART QTY. REFERENCE
14 830 Pres. Gauge 0-400 PSI (Dual Face) 40066 1
Flange Mt.
838 Tubing, Check Valve to Pump 60984 1 A, B
838 Tubing, Check Valve to Pump 60987 1 C
840 Check Valve 1/8 Tube (1/3 PSI) - 316 40065 1
SS
850 Tubing, Gauge to Check Valve - 316 60983 1
SS
860 Hex Head Screw 1/4-20X3/4 - 18-8SS 4050016095 2
870 Spring Lock Washer 1/4” - 18-8 SS 4040039022 2
880 Hex Nut 1/4-20NC - 18-8 SS 4050064012 2
- Items not shown.
54
55
Milton Roy Company
201 Ivyland Road • Ivyland, PA 18974 • (215) 441-0800 • Fax: (215) 441-8620 • www.miltonroy,com

Miltonroy339-0049-000 APR 08 Color

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MacRoy “G” Pump

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1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.6 LEAK DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.7 ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 SHIPPING PUMPS FOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.1 Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.1.1 Plastic Check Valves (PVC, PVDF, POLY, & H2SO4) . . . . . . . . . . . . . . . . . 15

POLY, & H2SO4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.1.4 Model G5 Liquid End - Slurry Check Valves . . . . . . . . . . . . . . . . . . . . . . . . 17

4.4.1.5 Models G6 & G7 Liquid End - Slurry Check Valves . . . . . . . . . . . . . . . . . . 18

4.4.1.6 Models G5, G6 & G7 Liquid End - Polymer Check Valves . . . . . . . . . . . . . 18

4.4.2 Diaphragm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4.2.1 Diaphragm Removal (All types; Refer to Figures 6-12 ) . . . . . . . . . . . . . . . 19

4.4.2.4 Reinstallation of Assembly (Refer to Figure 6 Through 12) . . . . . . . . . . . 19

4.4.3 Replacing Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 5 - TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.2 ILLUSTRATED PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.3 DRIVE, SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.4 DRIVE, TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.5 G5 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.6 G5 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.7 G6 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8 G6 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.9 G7 PLASTIC LIQUID END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.10 G7 METALLIC LIQUID END - STAINLESS STEEL - NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.11 CHECK VALVE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.12 LEAK DETECTION PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.1 GENERAL INFORMATION sure, cavitation will occur, negatively impacting

1.3 GENERAL SPECIFICATIONS (CONT.) breakdown shown in Figure 1. A sample name-

Ambient and Liquid:

122 ºF (50 ºC) Maximum

8.2 ft. (2.5 meters) of water column maximum. 11

1.4 PRODUCT CODE

MacRoy G pumps are available in a variety of dif-

Pumps are shipped f.o.b. factory or representative

TO AVOID POSSIBLE DAMAGE TO

Figure 4. Typical Recommended Pump Installation Scheme

• The pump will not deliver a controlled flow

• When pumping water-treatment chemicals

A Milton Roy Back Pressure Valve should be Check Valves

OPERATION WITH THE WRONG DO NOT FORGET TO CONNECT THE

3.1 INITIAL START-UP Exxon .....................Spartan E.P. 68

FAILURE TO CHECK TORQUE ON NON-

After the first 12 hours of operation, the pump may

4.1 SPARE PARTS All Other Liquid Ends

To avoid excessive downtime in the event of a (1) Diaphragm (260)

RPM kit numbers RPM019 through RPM030 con- 1. Quantity required

Check pump data plate for model number. Reassembly

1. Drop the ball into the curved inner chamber

1. Unscrew the coupling (445).