Document: 3 inch Vane Pump System-in-a-Box Assembly Instructions SPS100370

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1 1.0 What is a System-in-a-Box? System-in-a-Box for 3 inch vane pumps (SPSZRS-V3N VANE SYS KIT) contains all of the castings, mounting plates and hardware that make up the base system, with the exception of the pump, for a patented Safety Pumping System from Heavy Duty Innovations (HDI). System-in-a-Box is ideal for customers that already have a pump and need the safety features of an SPS pump system. These assembly instructions define the process for assembling and testing an SPS, 3 inch vane pump system, SPSZRS-V3N VANE SYS KIT (system-in-a-box) using a distributor or customer provided pump. SPSZRS-V3N VANE SYS KIT works with 3 inch Blackmer vane pump models, either single or dual shafts with left hand rotation, see model numbers below. Manufacturer Blackmer (single shaft) Blackmer (double shaft) Manufacturers Part Number TXD3E-4-1L-A TXD3E-4-40-A Note: If a dual shaft pump is used, it will be necessary to cut off the non-driving shaft only if an inside bottom crossover is to be installed, see pictures below. 2.0 Warranty Disclaimer for SPSZRS-V3N systems HDI warrants that all components supplied as part of the SPSZRS-V3N VANE SYS KIT are free of manufacturing defects for a period of one year, reference HDI Warranty, which is downloadable on HDI recommends that any used pumps be rebuilt in accordance with the manufacturers recommendations prior to being assembled into an SPS pump system. The system will be only as good as the pump. THE HDI WARRANTY DOES NOT EXTEND TO ASSEMBLY ERRORS OR DEFECTS, REFERENCE HDI WARRANTY CARD. ALL SYSTEM-LEVEL DEFECTS ARE THE RESPONSIBILITY OF THE ENTITY ASSEMBLING THE SYSTEM. 1 of 22 Rev. 04

2 3.0 Required Supplies and Equipment 3.1 Air compressor with air hose and appropriate fittings 3.2 Air-driven impact socket wrench with a minimum of 50 lbs torque 3.3 ½ inch, ¾ inch and 9/16 inch wobble impact sockets 3.4 ½ inch, inch, ¾ inch and 9/16 inch wrenches, preferably with ratchet head 3.5 Adjustable wrench 3.6 Bench-mounted vise EA, 3 inch standard Blackmer square gaskets (typically provided with pump) 3.8 Grease 3.9 Locktite 3.10 Pipe joint compound, fuel proof Permatex or equivalent 3.11 Channel locks 3.12 Wire cutters 3.13 Crimping tool or vise grips 3.14 Pressure plates and gauge, capable of measuring up to 40 psi Liquid dishwashing soap and spray bottle 4.0 Assembly of SPSZRS-V3N VANE SYS KIT, system-in-a-box base pump system with customer or distributor-provided pump. 4.1 Insure that all parts and tools are available, see system-in-a-box contents list below: HDI P/N Description Qty Per SPS ASSY,STRAINER,FILTER,3 IN, 1/8 IN MESH 1 SPS ASSY,VALVE,4 WAY,ALUM, 3 IN 1 SPS CLAMP,VICTAULIC,VITON,ALUM,3 IN 1 SPS FAB,GUARD,DRV LINE,STEEL,BLK 1 SPS FAB,PLATE,MOUNTING,BLK,VANE 1 SPS FAB,PLATE,MOUNTING,SPACER,VANE 1 SPS FIT,BUSHING,1/2 X 1/4,S/S SPS FIT,ELBOW,1/4 IN,S/S SPS FIT,NIPL,THRD,1/4 IN,2 IN,S/S SPS FIT,NIPL,THRD,1/4 IN,14.5 IN,S/S SPS FIT,STRT ELBOW,1/2 IN,S/S SPS HDW,BOLT,USS GRADE 5,1/2-13 X 1 1/2 6 SPS HDW,BOLT,USS GRADE 5,1/2-13 X 1 1/4 12 SPS HDW,BOLT,USS GRADE 5,1/2-13 X 3 3/4 4 SPS HDW,NUT,NYLOCK,USS GRADE 5,1/ SPS HDW,WASHER,FLAT,SAE,1/2 20 SPS MACH,ELBOW,120GRV,ALUM,VANE 1 SPS MACH,STRAINER,BODY,ALUM,3 IN 1 SPS MACH,STRAINER,CAP,ALUM,3 IN 1 SPS NUT,FLUTED,2,IN,POLY,BLK 2 SPS ORING,VALVE,BODY FLNG,VITON 1 SPS TUBE,3 BEND,ALM,STEEL,BLK,3 IN 1 SPS VALVE,DEADMAN,BRASS,1/2 IN 1 SPS VALVE,DRAIN,W/CORD,BRASS 1 2 of 22 Rev. 04

3 4.2 If installing a new pump, remove protective masking tape from the two ports of the pump and drain out any fluid from the pump cavity (not applicable for used or rebuilt pumps). 4.3 Once you have confirmed that you have the correct pump configuration, position the pump so that the foot of the pump is vertical and the relief valve is pointing upwards. Use a piece of wood or other object to tilt the shaft of the pump slightly upwards, see pictures below. 4.4 Position pump spacer bracket, P/N SPS100024, in front of the foot of the pump. Position the pump mounting bracket, P/N SPS in front of the spacer bracket so that the holes align with the spacer bracket and the holes in the foot of the pump, see pictures below. 3 of 22 Rev. 04

4 4.5 Locate four (4) ½ X 3 ¾ inch bolts, P/N SPS100239, four (4) ½ inch washers, P/N SPS100092, and four (4) ½ inch Nylock nuts, P/N SPS100091, see picture below. 4.6 Place a flat washer on each bolt and insert the bolts through the holes in the mounting bracket, the spacer bracket and the foot of the pump. Secure with four (4) ½ inch nylock nuts, P/N SPS100091, see pictures below. IMPORTANT: Hand thread, but do not tighten these bolts and nuts at this time. 4 of 22 Rev. 04

5 4.7 Locate one of the two three (3) inch square gaskets (not included in kit) and your grease, see pictures below. Note: These gaskets typically are included with the Blackmer pump when the pump is purchased with flanges, otherwise they must be ordered separately from Blackmer. 4.8 Apply grease evenly to one side of the gasket and place it on the top (inlet) port of the pump so that the holes align with the holes in the pump flange, see pictures below. 5 of 22 Rev. 04

6 4.9 Apply a thin layer of grease to the other side of the gasket, see picture below Locate the cast aluminum elbow with a Victaulic groove, P/N , four (4) 1/2 X 1 1/4 inch bolts, P/N SPS100088, four (4) 1/2 inch flat washers, P/N SPS Position the cast aluminum elbow on the inlet port of the pump so that the holes line up with the holes in the flange and gasket. The opening of the elbow should face towards the shaft of the pump, see pictures below. 6 of 22 Rev. 04

7 4.11 Install one flat washer on each bolt and insert into each of the four (4) holes in the flange of the cast aluminum elbow. Thread each of the four bolts into the threaded holes in the pump and snug, but do not tighten the nuts at this time. Locate the SPS Victaulic clamp, P/N SPS100172, and disassemble, see pictures below. IMPORTANT: Hand thread, but do not tighten these bolts and nuts at this time Apply a thin layer of grease to the outside surfaces of the Victaulic clamp s gasket, see pictures below. The grease prevents the gasket from being damaged when the clamp housings are tightened. 7 of 22 Rev. 04

8 4.13 Slip the greased Victaulic clamp gasket over the end of the cast aluminum elbow so that it is flush with the end of the fitting, see pictures below Locate the cast aluminum strainer body, P/N SPS100045, and position it on the pump system mounting bracket. Temporarily hold the strainer body in place using a ½ inch bolt and nut through a hole in the valve flange of the bracket, finger tightened only. Align the Victaulic grooves of the strainer body and the elbow and slide the Victaulic gasket so that it is equally spaced across two fittings, see pictures below. 8 of 22 Rev. 04

9 4.15 Carefully position the two Victaulic clamp housings over the Victaulic gasket and thread the two nuts onto the studs. Rotate the clamp so that the bolts are parallel to the bench at the 12 o clock and 6 o clock positions. Tighten the nuts until the two housings touch, see pictures below Locate four (4) ½ in X 1 ¼ bolts, P/N SPS100088, four (4) ½ in X 1 ½ bolts, P/N SPS and eight (8) ½ inch flat washers, P/N SPS Position the aluminum 4-way valve with the handle pointing upwards. The longer 1 ½ inch bolts are used where the bolt passes through the pump system mounting bracket before threading into 4-way valve. Use one flat washer per bolt and carefully thread the bolts into the threads in the 4-way valve. Pay close attention not to cross-thread the bolts, see pictures below. IMPORTANT: Hand thread, but do not tighten these bolts and nuts at this time. 9 of 22 Rev. 04

10 4.17 Locate the tri-bend tube, P/N SPS and position it so that one square flange aligns with the left side of the 4-way valve and the other square flange aligns with the outlet port at the rear of the pump. Use the ½ inch X 1 ½ inch and ½ inch X 1 ¼ inch bolts, each with a flat washer, see pictures below. IMPORTANT: Hand thread, but do not tighten these bolts and nuts at this time Locate four (4) ½ inch X 1 ¼ inch bolts, P/N SPS and four (4) 1/2 inch flat washers, P/N SPS Apply grease to both sides of the second 3 inch paper gasket, see pictures below. 10 of 22 Rev. 04

11 4.19 Position the gasket between the rear flange of the pump and the square flange of the tri-bend tube, P/N SPS Place a flat washer on each bolt and insert into the holes in the tube flange, see pictures below Bolt Tightening Sequence. It is very important to tighten the bolts in the sequence described below Firmly tighten all four bolts of the tri-bend tube at the flange and the rear port of the pump. Next firmly tighten the four bolts holding the aluminum elbow to the top flange of the pump, see pictures below. 11 of 22 Rev. 04

12 Firmly tighten the front four bolts attaching the components to the 4-way valve. Be careful not to over-tighten these bolts or you can strip the threads in the aluminum 4-way valve. Do not tighten the rear four bolts yet. They are the last bolts to be tightened. Next tighten the four bolts between the pump mounting bracket and the foot of the pump, see pictures below Tightening all of the bolts as described above aligns the valve so that you can then tighten the last four bolts, the bolts between the mounting bracket valve flanges and the back bolts of the 4-way valve, see pictures below. 12 of 22 Rev. 04

13 4.21 Locate the last two ½ inch X 1 ½ inch bolts and the Locktite. Apply a thin bead of Locktite on the shoulder of the two bolts and thread them into the threads in the strainer cap flange of the strainer body from behind, see pictures below Locate the aluminum strainer cap, P/N SPS100049, and the strainer cap O-Ring, P/N SPS Apply four (4) drops of Locktite spaced equally around the O-Ring groove. Seat the O-Ring into the O-Ring groove and wipe off any excess Locktite, see pictures below. 13 of 22 Rev. 04

14 4.23 Locate the strainer element, P/N SPS and insert it into the strainer body so that it is fully seated, see pictures below Locate the two (2) plastic fluted nuts, P/N SPS Position the strainer cap over the threads that extend outward from the strainer body so that the SPS logo is facing upwards. Thread the two fluted nuts onto the threads and firmly finger-tighten both nuts, see pictures below. 14 of 22 Rev. 04

15 4.25 Locate the following Zero Retain components: ¼ inch 14 ½ inch stainless steel nipple, P/N SPS100060, ¼ inch X 2 inch stainless steel nipple, P/N SPS100062, ¼ inch stainless steel elbow, P/N SPS100063, ½ x ¼ inch stainless steel bushing, P/N SPS100083, ½ inch stainless steel street elbow, P/N SPS and the ½ inch brass spring-close valve, P/N SPS Remove the ¼ inch plug from the pump and discard, see pictures below Apply pipe joint compound to the threads of the ¼ inch X 2 inch nipple and thread it into the ¼ inch stainless steel elbow. Apply pipe joint compound to the other end of the nipple and thread it into the tapped ¼ inch hole in the pump body, tightening both components with a channel lock so that the threaded opening of the elbow faces towards the front of the system, see pictures below. 15 of 22 Rev. 04

16 4.27 Apply pipe joint compound to the threads of the ¼ X 14 ½ inch stainless steel nipple and then thread the ½ X ¼ inch stainless steel bushing onto the nipple, see pictures below Insert the other end of the stainless steel nipple through the hole in the pump mounting bracket. Apply pipe joint compound to the threads of the nipple and then, thread it into the ¼ inch elbow. Note: some adjustment of the 2 inch nipple and ¼ inch elbow may be necessary to properly align the threads with the threads of the longer nipple. Use channel locks to make these adjustments if needed. Tighten all of the threads in the stainless steel components using an adjustable wrench on the bushing, see pictures below. 16 of 22 Rev. 04

17 4.29 Apply pipe joint compound to the ½ inch threads of the stainless steel bushing. Locate the brass spring close valve and thread it onto the bushing. Note: make sure that the handle pulls away from the pump mounting bracket when opened. Tighten the valve with a wrench engaged on the body of the spring close valve, see pictures below Apply pipe joint compound to the male threads of the stainless steel street elbow and thread it into the spring close valve. Use an adjustable wrench and channel locks to tighten all of the fittings so that the handle on the valve is vertical and the street elbow faces downwards, see pictures below. 17 of 22 Rev. 04

18 4.31 Locate the drive line guard, P/N SPS and the drive line guard Caution sticker, P/N SPS Peel off the back of the sticker and apply it carefully to the drive line guard. Remove bolts that hold the pump end plate in position and rotate the so that the grease fitting is at the 3 o clock position. This is so that it will be accessible after the drive line guard is installed, see pictures below Rethread three (3) of the bolts and then align the drive line guard over the three (3) remaining holes and rethread the remaining three (3) bolts. Tighten all six bolts with a socket wrench, see pictures below. 18 of 22 Rev. 04

19 4.33 Locate the fuel proof pipe joint compound and the brass spring valve with cable, P/N SPS Apply pipe joint compound to the threads of the valve and thread it into the tapped ¼ inch hole in the bottom of the strainer body. Tighten with an adjustable wrench. Do not over-tighten as you may strip the aluminum threads, see pictures below Loop the cable around the strainer body just behind the strainer cap and slide the ferrule so that the cable is tight around the strainer body, but has slack between the spring close valve and the ferrule. Important: leaving slack in the cable is important. If the cable is too tight, the valve will be held in the open position. Crimp the ferrule so that it holds tightly to the cable and cut off any excess cable using a pair of wire cutters. 19 of 22 Rev. 04

20 5.0 The adjustment of all SPS 4-way valves, P/N SPS100002, should be checked prior to installing the system. Position the valve handle in the vertical position and insert a.001 inch feeler gauge while moving the valve handle to the LOAD OFF position. If the valve is adjusted properly, the feeler gauge will be pinched so that it cannot move freely. If it moves freely, the valve is out of adjustment and must be adjusted before installation. If this is the case, follow W102 4-Way Valve Adjustment procedure, which is available as a download from see picture below. IMPORTANT: IF THE 4-WAY VALVE IS NOT ADJUSTED CORRECTLY, THE SYSTEM WILL NOT PERFORM PROPERLY AND WILL NOT CLEAR HOSES OF PRODUCT. 6.0 Pressure testing (method 27) of the assembled system. IMPORTANT: ALL SYSTEMS MUST BE PRESSURE TESTED (METHOD 27 TEST) PRIOR TO INSTALLATION AND USE. 6.1 Install the pressure testing plates with pressure gauge on the top port of the 4-way valve using a gasket and four (4) ½ inch X 3 ½ inch bolts. Install pressure testing plate on the bottom port of the 4-way using a gasket and four (4) ½ inch X 3 ½ inch bolts, see pictures below. 20 of 22 Rev. 04

21 6.2 Attach air hose to the air fitting on the pressure test fitting and pressurize the system to 40 lbs/sq inch, see picture below. 21 of 22 Rev. 04

22 6.3 While system is pressurized at 40 lbs per square inch, lightly spray a soapy water solution on all welds, gasket connections, the spring close valve and fittings. Look for any evidence of air leakage, see picture below. 6.4 Any evidence of bubbling or fizzing indicates a leak. Leaks can be caused by bolts or nuts not tightened properly, damaged or pinched gaskets or O-rings or defective components. IMPORTANT: ALL LEAKS MUST BE CORRECTED BEFORE INSTALLATION. 6.5 Remove the parts where the leak is observed and examine for potential causes. Correct the problem or replace the defective part and then retest the entire system to confirm that the leak has been corrected and that no other leaks are present. 6.6 Once the system has passed the pressure test, remove the pressure test plates from the top and bottom ports of the 4-way valve. 6.7 Wipe off all soapy water. Clean and dry the top and bottom surfaces of the top and bottom ports of the 4-way valve, all tubes and brackets. 6.8 The system is now ready to be installed. Please refer to the Pump System Installation Procedure, available on the Downloads page of 22 of 22 Rev. 04

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