Masport Engine Driven Systems Owner/Operator Manual

Transcription

1 Masport Engine Driven Systems Owner/Operator Manual For Belt Driven System Models: 12519, 12513, 12549, 12544, 12581, 12583, 12609, 12611, 12616, 12815, 12187, For Direct Drive System Models: 12515, 12517, 12548, 12547, 12565, MASPORT INCORPORATED 6140 McCormick Drive Lincoln, NE Phone (402) Fax (402) Toll Free 1(800) PRICE: $5.00 Masport Incorporated All Rights Reserved 90353

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3 TABLE OF CONTENTS I. LIMITED WARRANTY... pg. 1 II. SYSTEM PLUMBING AND INSTALLATION... pg. 2 A. SYSTEM INSTALLATION... 2 B. PLUMBING CONNECTIONS... 2 C. VALVE OPTIONS... 3 III. START-UP AND OPERATION INSTRUCTIONS... pg. 3 A. ENGINE START-UP INSTRUCTIONS... 3 B. LUBRICANT... 3 C. FUEL... 3 D. THROTTLE SPEED... 3 IV. MASPORT VACUUM / PRESSURE PUMP... pg. 4 A. LUBRICANT... 4 B. LUBRICANT ADJUSTMENTS AND SETTINGS... 4 C. OIL FLOW RATE SETTINGS FOR H1V AND H1F SYSTEMS... 5 D. OIL FLOW RATE SETTING IN THE FIELD... 5 E. BELT DRIVE MAINTENANCE... 5 V. OPERATING TIPS... 5 A. SUMMER - 32 DEGREES AND HIGHER... 5 B. WINTER - 32 DEGREES AND LOWER... 6 VI. SYSTEM INSTALLATION... pg. 6 A. SYSTEM WITH INTEGRAL VALVE (V-SERIES)... 6 B. SYSTEM WITH REMOTE 4-WAY VALVE (F-SERIES)... 6 VII. PUMP PROTECTION COMPONENTS... pg. 6 A. PRIMARY AND SECONDARY... 6 B. INLET FILTER... 7 C. VACUUM RELIEF VALVE... 7 D. PRESSURE RELIEF VALVE... 7 E. PRESSURE/VACUUM GAUGE... 7 F. SWING CHECK VALVE... 8 G. HIGH EFFICIENCY OIL SEPARATOR... 8 H. COMPONENT CHECKLIST... 8 I. Table of contents continued next page

4 TABLE OF CONTENTS (continued) VIII. PUMP MAINTENANCE... pg. 9 A. FLUSHING KIT... 9 B. PUMP STORAGE C. PUMP REPAIR KIT INSTALLATION IX. PUMP DISASSEMBLY... pg. 10 A. ENDCOVER REMOVAL B. ROTOR REMOVAL C. BEARING REMOVAL D. BEARING REPLACEMENT E. OIL SEAL REMOVAL AND REPLACEMENT X. PUMP ASSEMBLY... pg. 12 XI. TECHNICAL OVERVIEW... pg. 14 A. AIR COOLED DIRECT DRIVE SYSTEMS B. AIR COOLED BELT DRIVE SYSTEMS XII. DIMENSIONAL DATA... pg. 15 INSTALLATION DIAGRAM INSTALLATION DIAGRAM H1V PARTS LIST H1F PARTS LIST HXL2V / HXL3V PARTS LIST HXL2F / HXL3F PARTS LIST HXL4V PARTS LIST HXL4F PARTS LIST HXL75V PARTS LIST HXL15V PARTS LIST OIL RESERVOIR KIT PARTS LIST RECOMMENDED OIL LIST Do Not attempt to install, operate, or service this pump without reading and understanding the corresponding section in this manual. II. Table of contents continued next page

5 Masport Engine Driven System Owner/ Operator Manual I. LIMITED WARRANTY Manufacturer warrants defects in workmanship, materials or parts for a period of twelve months from date of sale. The limited warranty is restricted to repair or replacement of parts or pumps at Masport Incorporated s discretion. Masport Incorporated neither assumes, nor authorizes any person to assume any other obligation or liability in connection with Masport Incorporated s products, parts or services sold or delivered. Masport Incorporated shall not be liable for injury or damage to property other than the products or parts themselves, nor for incidental, consequential or special damages. PURCHASER - KEEP FOR RECORD TERMS OF LIMITED WARRANTY: 12 MONTHS DATE PURCHASED: SERIAL NUMBER: 1. The product must be returned to Masport Incorporated. The limited warranty does not cover the cost of collection or delivery. 2. Any claim under this limited warranty must be made in writing and received within twelve months from date of sale. Claims should be addressed to Masport Incorporated. Masport Vacuum/Pressure Pump Warranty Claims Department, 6140 McCormick Drive, Lincoln, NE This limited warranty will not apply to any malfunction, defect, or damage of any product resulting from repair or alteration other than by Masport Incorporated. 4. This limited warranty excludes the following: damage during shipment, damage from other than normal or intended use, normal wear, any defects arising from installation or operation of the products other than in accordance with the operating instructions provided, or any product which has been subject to misuse, neglect, or accident. 5. This limited warranty is not transferable and shall extend only to the original purchaser. 1

6 II. SYSTEM PLUMBING AND INSTALLATION A. SYSTEM INSTALLATION The vacuum pump system should be installed on a level and secure base, on or near the tank or truck. The system should also be accessible for maintenance. If installed in a toolbox or other enclosed area make sure there is adequate ventilation. B. PLUMBING CONNECTIONS Due to the high volumes of air handled by the pump, none of the plumbing attached to the pump should be smaller than the recommended plumbing size below. Pump Model: H1V, H1F HXL2V, HXL2F HXL3V, HXL3V HXL4V, HXL4F HXL75V HXL15V Recommended Plumbing Size: 1 1/4 I.D. 1 1/2 I.D. 1 1/2 I.D. 1 1/2 I.D. 2 1/2 I.D. 3 I.D. Hose between the Pump, Accessories, and Tank should be no smaller than the pump porting. Using smaller than the recommend hose size will restrict the airflow of the vacuum pump which may cause overheating and damage. The type of hose used is very important to the performance of the system. The hose must be rated for full vacuum in all cases. When pressure off-loading, the hose should be rated for 20 P.S.I. minimum. The interconnecting hose is also subjected to high temperatures (300 F +) and oil, which may cause damage to the liner of some hoses. Masport recommends the use of Hot Tar and Asphalt Hose for plumbing connections between the pump, components and tank. It is also recommended that two hose clamps be used to secure each hose connection. Some type of pipe sealer should be used on the threads of all pipe fittings to prevent leaks. LOCTITE Pipe Sealer with Teflon has proven to be the easiest and most effective product Masport has tested. Teflon tape should not be used as pieces of the tape can be drawn into the pump and cause vanes to stick. NOTE: Make certain that all fittings used in the installation of the pumping system are free from metal chips sometimes left in the fitting when it is produced. These chips can cause considerable damage to the pump on initial start up if allowed to remain in the system. 2

7 C. VALVE OPTIONS The HV and HXLV-Series Pumps are equipped with an integrally mounted pressure change over valve and a built in anti-backspin check valve. The integral change over valve allows switching from vacuum operation to pressure operation by turning the control lever. The built in check valve prevents the pump from spinning backwards when the drive system is shifted into neutral with either pressure or vacuum in the tank. A V-Series pump is desirable when the system can be located in an area on the truck that allows easy access to the valve control lever. An example of an installation using an HV-Series pump is shown in the INSTALLATION DIAGRAM on page 18. The HF and HXLF-Series Pumps are equipped with a threaded porting plate and can be used with vacuum only or pressure only operation or with a remote 4-way valve to allow both pressure and vacuum operation. An example of an installation using a Masport Four Way Remote Valve is shown in the INSTALLATION DIAGRAM on page 19. III. START-UP AND OPERATION INSTRUCTIONS A. ENGINE START-UP INSTRUCTIONS Read the owner / operator manual supplied with the engine before starting the system. B. LUBRICANT The engine lubricant should be checked to make sure that no lubricant is lost in shipping and that the engine is at the proper level. (See Engine Manual). C. FUEL Any automotive gasoline with an octane rating of 86 or higher, or a research octane number or 91 or higher may be used. Unleaded fuel should be used, Gasohol use is restricted. (See Engine Manual). D. THROTTLE SPEED The throttle speed is set from factory and should provide the correct speed for the pump when operating at full throttle. 3

8 IV. MASPORT VACUUM / PRESSURE PUMP A. LUBRICANT The lubricator reservoir on H1V and H1F systems is filled at Masport with 20 wt. Masport Vacuum Pump Lubricant. The continued use of this product is recommended and will extend the life of the vacuum pump. Automotive oils should never be used because the additives will break down, due to the high temperatures inside the pump. A quality rotary turbine or rotary compressor oil should be used in all Masport Pump models. Masport provides approved Rotary Pump Oil through the local Masport Sales Representatives. Masport Rotary Pump Oil is available by the US gallon or a case of four gallons. For a list of suitable oil that can be in a Masport vacuum pump, refer to the recommended oils sheet on page 29. B. LUBRICATOR ADJUSTMENTS AND SETTINGS The lubricator supplied with the Masport H1V or H1F vacuum pump is an adjustable flow rate vacuum / pressure actuated type. The system has two adjustable sight-feed valves mounted directly on the pump at the bearings that are set from the factory. The system is actuated by vacuum/pressure, so once the sight-feed system is properly set, it will tend to automatically compensate for changes in system demands. Automatic mechanical oil pump type for pump models HXL2F, HXL2V, HXL3F and HXL3V, HXL4V, HXL4F, HXL75V, and HXL15V. This system utilizes a direct gear-driven oil pump which is preset to deliver the required amount of lubricating oil to the vacuum pump. The oil pump is maintenance free and requires no operator adjustment. IMPORTANT: The oil reservoir must be mounted higher than the oil feed connection on the oil pump. The oil pump must be primed before initial start-up. The oil pump must be bled prior to initial operation and anytime afterwards when the oil pump is operated without oil for any period of time. See Diagram below. It is best to top off the oil reservoir everyday. Lubricating oil for the pump is depleted when the level in the reservoir reaches approximately 1. Do not operate the pump if the oil level has descended to 1! The XL-Lubricator automatic oil pump for HXL-Series Vacuum pumps. The oil pump must be bled prior to initial operation. To bleed oil pump, loosen the bleed nut. 4

9 C. OIL FLOW RATE SETTINGS FOR H1V AND H1F SYSTEMS The sight-feeds on the vacuum pump are factory set to deliver 15 to 30 drops per minute per sight-feed with the vacuum pump operating at 15 Hg of vacuum. The lubricator sight-feeds need to be periodically checked to ensure that the correct oil flow rate is being maintained during operation. System need to operate at a minimum of four to five inches of vacuum or two to three pounds of pressure to function. D. OIL FLOW RATE SETTING IN THE FIELD 1.) With the valves on the vacuum tank closed, set the vacuum relief valve to maintain the vacuum in the tank at 15 Hg. 2.) Loosen the packing nut on the oil sight-feed valve. 3.) Set the flow rate to 15 to 30 drops per minute. 4.) Tighten the packing nut. 5.) Check the flow rate to ensure it did not change when the packing nuts were tightened. NOTE: System must be completely installed before the oil flow rate can be checked or set. E. BELT DRIVE MAINTENANCE Belt drives are set at the correct tension when shipped complete with the engine from Masport. Tightening of the drive is usually not necessary through the life of the belt; although, a periodic check of the belt tension and condition is recommened. V. OPERATING TIPS A. SUMMER - 32 DEGREES AND HIGHER Once the installation of the system is complete, according to the recommendations made in this manual, the normal operation of the equipment is quite simple. The main operational tips are as follows: 1.) Make frequent checks of the oil levels in the engine, the vacuum pump oil reservoir and the oil sight-feed rate. 2.) Set the vacuum relief valve to a maximum level of 20 Hg when pumping for exteneded periods of time. 3.) When using pressure to unload, a pressure relief valve must be installed in the system to avoid over-pressurizing the system. 4.) Maintain your trap system as previously instructed to ensure it is always in proper working condition. These protect the pump and could be the difference between profits and problems. 5

10 B. WINTER - 32 DEGRESS AND LOWER Once the installation of the system is complete, according to the recommendations made in this manual, the normal operation of the equipment is quite simple. The main operational tips are as follows: 1.) Before leaving the last job site of the day, draw a vacuum on the system sufficient to cause the lubrication system to function. Then open the sight-feed valves far enough to allow a full stream of oil to flow into the vacuum pump for three to five seconds. This will, in most cases, allow enough oil to remain in the pump overnight to prevent freezing of any condensation and prevent the pump damage on start-up. 2.) Always be sure to drain the Secondary Moisture Trap / Scrubber after each job and at the end of each working day to prevent the float mechanism from freezing and causing the trap to frail. VI. SYSTEM INSTALLATION A. SYSTEM WITH INTEGRAL VALVE (V-SERIES) The Masport V-Series pump is applicable on systems where the pump can be mounted in such a way as to permit easy access to the integral valve handle to control the mode the pump is functioning in. This situation also lends itself well to the use of the integral lubrication and XL-Lubrication systems as outlined in the Lubrication Section. Installation diagram details the correct location of the components. Components not in the proper location can result in damage to the equipment. B. SYSTEM WITH REMOTE 4-WAY VALVE (F-SERIES) The Masport F-Series pump is particularly useful when the pump is to be mounted under the frame of the truck. Installation diagram details the layout of a system used for pressure and vacuum operation with the installation of a Masport four way remote valve. This diagram shows the components necessary for a properly operating system in the correct relationships. Deviation from this layout can cause failure of the system to function properly and possible damage to the system. VII. PUMP PROTECTION COMPONENTS A. PRIMARY AND SECONDARY TRAPS In order to perform properly, the pump must be protected at all times from liquid and foreign materials entering the pump. Due to the high airflow rates and rapid loading capability of the system, both a primary and secondary trap are necessary. Masport 6

11 offers a primary and a separate secondary moisture trap scrubber that matches the need of the vacuum/pressure pump system. These traps are available through your local Masport Sales Representative or Masport Incorporated. B. INLET FILTER By capturing particles that could damage the vacuum/pressure pump, the inlet filter extends your system s life and performance. Each Masport Inlet Filter is equipped with durable iron wing nuts which allow the lid to be removed quickly and easily. The unique design features a 300 micron washable stainless steel element. An inlet filter is a must in any system to prevent contamination of the vacuum pump from foreign particles. C. VACUUM RELIEF VALVE A vacuum relief valve must be installed on any vacuum system. This valve acts to limit the maximum vacuum level. Without a vacuum relief valve in the system the vacuum pump can overheat from operating at a vacuum level that is too high. The relief valve should be mounted between the pump and the secondary moisture trap/scrubber. In the event the trap system is activated, closing the vacuum line, the pump will still be protected by the valve. The vacuum relief valve should be set at 20 Hg against a good liquid filled gauge. Vacuum relief valves are available from your local Masport Sales Representative or Masport Incorporated. D. PRESSURE RELIEF VALVE When using the system for vacuum loading and pressure unloading, a pressure relief valve is absolutely necessary. Failure to prevent over-pressuring the pump, tank, or other system components with a properly sized pressure relief valve could result in system damage or personal injury. The pressure relief valve should not exceed 15 P.S.I.G. ASME code pressure relief valves are available from your local Masport Representative or Masport Incorporated. E. PRESSURE/VACUUM GAUGE Installation of a pressure/vacuum gauge is necessary to properly monitor the performance of the vacuum/pressure pumping system. Without a gauge, it is impossible to accurately adjust the relief valve and prevent the pump from overheating. The vacuum/pressure gauge should be installed between the pump and the secondary moisture trap/scrubber, to prevent the gauge from coming in contact with the products being pumped. Vacuum/Pressure Gauges are available from the local Masport Sales Representative or Masport Incorporated. 7

12 F. SWING CHECK VALVE A swing check valve should be installed in the pumping system to prevent pump backspin when the pump is disengaged with vacuum or pressure in the tank. Failure to install a check valve can have a number of undesirable effects. 1.) The speed at which the pump can spin backwards, under some conditions, can be great enough to overheat and damage the bearings. 2.) When the pump is spinning backwards and taking air in from the atmosphere, dirt or foreign material may be drawn up the exhaust hose damaging the pump. NOTE: The swing check valve must be mounted in a horizontal position. G. HIGH EFFICIENCY OIL SEPARATOR Masport high efficiency oil separators are designed to catch 85-90% of the oil exhausted, eliminating job-site mess and clean-up. When the vacuum pump operates in the pressure mode, the oil separator functions as an oil bath cleaner to prevent dust and foreign material from entering the pump. Oil Separators are available from the local Masport Sales Representative or Masport Incorporated. H. COMPONENT CHECKLIST Below is a checklist of the components need to complete a Vacuum Only (V) or Vacuum/ Pressure (V/P) system. Only one pressure relief valve is necessary on a Vacuum/ Pressure system. For Masport Vacuum/ Pressure Pump Model H1V, H1F HXL2V, HXL2F HXL3V, HXL3F, HXL4V*, HXL4F* HXL75V, HXL15V SIZE BY PUMP AIRFLOW - 0 Hg Primary Shut-Off Trap Super Scrubber-Moisture Trap Vacuum Relief Valve Vacuum/ Pressure Gauge - 2 1/2 Face Vacuum/ Pressure Gauge - 3 Face Adjustable Pressure Relief Valve * Remote 4-Way Valve * Swing Check Valve Horizontal Scrubber Inlet Filter Oil Separator (* ) * For remote mount applications only. 8

13 VIII. PUMP MAINTENANCE If the pump begins to clatter, or hammer, it should be stopped immediately to prevent permanent damage. This problem is most commonly caused by foreign material being drawn into the pump. If so, the pump should be cleaned by following the directions on flushing the pump. Pump clatter can also be caused by overheating. If so, the pump should be stopped and allowed to cool. Care should be taken so the pump is operated within the vacuum and pressure ranges recommended. Always operate the vacuum pump at the R.P.M. set at the factory. Operating the pump at too low of R.P.M. will cause overheating and vane clatter which will damage the pump. A. FLUSHING THE VACUUM PUMP To eliminate build-up of foreign material on inner working surfaces of the pump and assure smoother operation and maximum pump life, it is recommended that the pump be flushed daily. Flushing the pump is also required when any foreign material enters the pump. To flush the pump, pour four ounces of Masport Flushing Oil over approximately a minute into the suction inlet of the pump while it is at operating speed. Allow the pump to run for an additional minute or two to allow the flushing fluid to be completely purged from the pump. The Masport Flushing Kit that makes this process simple, safe and effective. Contact your local Masport Distributor or Masport for purchase of the Flushing Kit. Flushing Procedure: 1.) Start vacuum pump and bring vacuum to 15 Hg. 2.) Open ball valve to begin flushing fluid flow. 3.) Continue to run pump until fluid level drops 1 graduation (Approx. 7 fluid ounces). 4.) Close ball valve. 5.) Continue to operate the pump 1 additional minute to ensure all fluid is purged from pump. 6.) Stop vacuum pump. 7.) Drain Oil Catch Muffler or Oil Separator and dispose used fluid at approved recycling site. MASPORT FLUSHING KIT NOTE: If for any reason the pump begins to hammer or clatter, it should be stopped immediately and the problem corrected to prevent permanent damage. this type of problem is most commonly caused by foreign material entering the pump. If this is the case the flushing instructions should be followed. Pump clattering can also be caused by overheating due to operation beyond the recommended limits. If this is the case the pump should be allowed to cool and the problem corrected. 9

14 B. PUMP STORAGE If the pump is to remain idle for two weeks or more, it is advisable to pour one ounce of oil into the intake of the pump and the bearing lubrication inlets. Then rotate the pump slowly, preferably by hand, to thoroughly lubricate the inner surfaces. C. PUMP REPAIR KIT INSTALLATION The following repair techniques are given for use on pumps that don t have damage to the end covers or cylinder. This procedure is not a complete rebuild and is only intended to ensure the pump has good vanes, bearings, and oil seals. Installations requiring machining of any pump part should only be done by a Masport authorized rebuild center. Contact Masport Inc. for information regarding the rebuild center in your area. The pump should be inspected once a year to check the progress of vane wear. If the vane wear is not monitored, the vanes can become too short, be forced out of their slots during operation and cause major structural damage to the pump. Inspection for vane wear is accomplished by removing the non-drive end cover and removing one of the vanes for measurement. See the chart below for the suggested minimum vane widths. Masport Pump Model: Original Vane Dimensions (L x W): Minimum Vane Width: Replacement Vane Part Number (Pack of 4): H1V, H1F 3 1/8 x 1 5/8 1 3/ HXL2V, HXL2F 4 1/16 x 1 7/8 1 5/ HXL3V, HXL3F 6 x 1 7/8 1 5/ HXL4V, HXL4F 11 x 2 9/16 2 1/ HXL75V 8 9/16 x 2 5/8 2 1/ HXL15V 12 7/8 x 2 9/16 2 1/ Upon inspection if the vanes are shorter than the suggested minimum width, they should be replaced along with oil seals, bearings, bearing spacers and gaskets where applicable. IX. PUMP DISASSEMBLY Refer to the parts list at the back of this manual for exploded diagrams of the Masport Pump. A. ENDCOVER REMOVAL With the drive pump removed from the system, mark the drive side endcover and the corresponding side of the cylinder, using a center punch. Marking these will avoid the possibility of assembling the pump with the endcovers on the wrong ends. Now turn the 10

15 vacuum pump upside down. This will prevent the rotor from falling and hitting the bore of the cylinder. First, remove the endcover bolts. Drive the endcover off the dowel pins with a flat ended punch. Place the punch on the cover removal boss that is cast into the cover alongsided the dowel pin holes. CAUTION: In order to maintain factory set clearances, avoid damaging the dowels pins during endcover removal. To properly remove the endcover, work evenly from each side of the cover. Avoid misaligning the endcover and bending the dowel pins. Never pry on the endcover. B. ROTOR REMOVAL With one cover removed, the rotor can be pulled out of the cylinder. The bearings are a slip fit into the endcovers, but due to the tight clearance, the bearing may bind in the endcover if it is not pulled out straight. If it does not pull free on the first try, put it all the way back in, using a rubber mallet, and start over again. Putting all the way back in will realign the bearing with the housing and will allow it to pull free from the cover. C. BEARING REMOVAL Bearings should only be removed using the proper tools. A bearing puller is the only tool that will work properly. The bearing spacers behind the bearings are not reuseable. Even the best bearing puller will damage them and make them unfit to use again. D. BEARING REPLACEMENT Place the new spacer on the shaft, taking care to place the side with the largest inside diameter toward the rotor (See Figure 1). Next, the new bearing can be pressed on the shaft. If there is a bearing press available, use it. If not, freeze the rotor to shrink it, and then use 6 long pipe nipple and cap to drive the bearing onto the shaft. Do this by placing the pipe over the shaft and against the bearing inner race and striking the pipe cap with a large hammer. If this method is used, be sure any dirt or pipe scale is removed from the nipple before use to prevent contaminating the bearing. Drive the bearing onto the rotor shaft using the inner race only. Striking the outer race will damage the bearing and cause failure. Rotor Between Bearing Spacers 11

16 E. OIL SEAL REMOVAL AND REPLACEMENT To remove the oil seal, place the endcover on a flat surface, with the inside face down. Use a flat faced punch to drive the seal out, working a bit at a time from side to side, until it comes free. To install the new seal, turn the cover over and place the new seal into the housing, with the spiral-loaded side of the seal facing up (See Figure 2). The seal can now be driven in to the endcover using light taps, and drive the seal onto its seat, working evenly around the diameter to prevent damaging the seal. X. PUMP ASSEMBLY Before going any further, make certain the pump parts and work area are clean. Attempting to reassemble the pump with oil or dirt on the parts will make clearance adjustments impossible. 1.) Clean the rotor surfaces and the non-drive end cover surfaces. 2.) Replace any end cover gaskets that were on the pump with the same quantity and color. Place the non-drive end cover on the cylinder and tap the end cover on the dowel pins evenly with a rubber mallet (be sure the center punch marks made during disassembly are lined up). Replace the end cover retaining bolts and torque to 15 ft. lbs. 3.) Insert the rotor into the cylinder. Be sure to line the bearing bore and bearing up so the rotor slides into the cylinder easily. The rotor may need to be tapped into the cylinder with a rubber mallet. 4.) Insert the vanes into the slots, taking care that the beveled edge of the vanes is inserted towards the inside of the rotor. 12

17 5.) Place the drive side end cover over the shaft. Taking care not to damage the oil seal. Once again driving the cover onto the dowel pins with the rubber mallet. Replace the end cover retaining bolts and torque 15 ft. lbs. 6.) Turn the pump by hand, making certain the pump turns freely and is not binding. If it will not go all the way around, take one of the end covers off and make sure the vanes are free and set squarely in their slots. Reassemble and check again. 7.) When everything turns freely, the pump can be installed back on the system. CAUTION: Make certain to lubricate the pump before initial start-up to prevent damage in the first few seconds of operation. For additional information or assistance, contact your Masport Sales Representative in your area or contact: MASPORT INCORPORATED 6140 McCormick Drive Lincoln, NE Phone (402) Fax (402) Toll Free 1(800)

18 XI. TECHNICAL OVERVIEW A. AIR COOLED DIRECT DRIVE SYSTEMS SYSTEM NUMBER Pump Model H1F H1V HXL2F HXL2V HXL3F HXL3V Pump RPM Pump Max 0 Hg Lubrication (P/V - XL) P/V P/V XL XL XL XL Recommended Tank Size 100/ / / / / / 1800 Vacuum Continuous Intermittent Pressure Continuous Intermittent Oil Reservoir (integral / remote) Int. Int. remote remote remote remote ENGINE FEATURES Engine Horsepower Clutch (yes / no) yes yes yes yes yes yes Battery Included (yes / no) no no no no no no B. AIR COOLED BELT DRIVE SYSTEMS SYSTEM NUMBER Pump Model H1F H1V HXL2F HXL2V HXL3F HXL3V HXL4F HXL4V HXL4V Pump RPM Pump Max 0 Hg Lubrication (P/V - XL) P/V P/V XL XL XL XL XL XL XL XL XL XL Recommended Tank Size 100/ / / / / / / / / 2200 HXL 75V 1800/ 3800 HXL 75V 1800/ 3800 HXL15V Vacuum Continuous Intermittent Pressure Continuous Intermittent Oil Reservoir (integral / remote) Int. Int. remote remote remote remote remote remote remote remote remote remote ENGINE FEATURES Engine Horsepower Clutch (yes / no) no no no no no no no no no no no no Battery Included (yes/no) no no yes yes yes yes yes yes yes no no no 2200/

19 XII. DIMENSIONAL DATA Sys. A B C D E F G H J K L M /8 17 1/ /8 11 3/8 6 3/8 3 1/8 6 15/ /16 9 3/ /8 17 1/ /8 11 3/8 6 3/8 3 1/8 6 15/ /16 9 3/16 Sys. A B C D E F G H J K L M /2 20 7/8 19 1/4 29 5/8 13 3/8 9 7/8 3/8 18 7/8 16 1/ / /2 20 7/8 19 1/4 29 5/8 13 3/8 9 7/8 3/8 18 7/8 6 1/ / /2 20 7/8 19 1/4 29 5/8 13 3/8 9 7/8 3/8 18 7/8 6 1/ / /2 20 7/8 19 1/4 29 5/8 13 3/8 9 7/8 3/8 18 7/8 6 1/ /

20 XII. DIMENSIONAL DATA (continued) Sys. A B C D E F G H J K L M / / / / / / /8 24 3/8 14 1/8 9 9/16 3/8 24 1/ /2 11 3/16 7 1/ /8 24 3/8 14 1/8 9 9/16 3/8 24 1/ /2 11 3/16 7 1/ /8 24 3/8 14 1/8 9 9/16 3/8 24 1/ /2 11 3/16 7 1/ Sys. A B C D E F G H J K L M / / /8 18 9/16 3/ / / /8 18 9/16 3/ / /8 18 9/16 3/ / / / / / /16 16

21 XII. DIMENSIONAL DATA (continued) Sys. A B C D E F G H J K L M / /4 3/8 13 3/ / / /4 3/8 13 3/ / /2 10 1/4 19 3/4 27 1/4 31 1/2 3/8 13 3/ / / / /4 19 3/4 27 1/4 31 1/2 3/8 13 3/ /4 19 1/ /2 27 1/8 19 5/8 27 1/8 35 3/4 3/8 13 3/ / / /8 19 5/8 27 1/8 35 3/4 3/8 13 3/ /4 19 1/

22 NEW ZEALAND INSTALLATION DIAGRAM Integral Valve PUMP SYSTEM INSTALLATION RECOMMENDATIONS 1. Follow Owner/Operator Instructions on pump operating limits covering vacuum/pressure, speeds, and in the case of the liquid cooled pumps, the temperature recommendations. Please also note lubrication, maintenance and sevice data. 2. A primary shut-off trap and moisture trap/scrubber must be used on all vacuum/pressure pump installations to stop liquid or solids from entering the pump. The primary shut-off should be installed down in the tank rather than in the dome lid area, as the tank will continue to fi ll after the fl oat shuts off the vacuum if the vacuum tank is in the higher ranges. 3. Iron pipe size should not be reduced from pump inlet or exhaust port size, or restricted in any way. (Do not use street elbows.) 4. A fl exible hose section should be used between pump and trap and between trap and tank. Inside diameters of the hose connector and the hose should not be smaller than the iron pipe I.D. 5. Install vacuum relief valve, pressure relief valve and gauge between pump and moisture trap/scrubber MASPORT INCORPORATED All Rights Reserved

23 INSTALLATION DIAGRAM Remote 4-way valve PUMP WITH REMOTE 4-WAY VALVE INSTALLATION RECOMMENDATIONS 1. Follow Owner/Operator Instructions on pump operating limits covering vacuum/pressure, speeds, and in the case of the liquid cooled pumps, the temperature recommendations. Please also note lubrication, maintenance and sevice data. 2. A primary shut-off trap and moisture trap/scrubber must be used on all vacuum/pressure pump installations to stop liquid or solids from entering the pump. The primary shut-off should be installed down in the tank rather than in the dome lid area, as the tank will continue to fi ll after the fl oat shuts off the vacuum if the vacuum tank is in the higher ranges. 3. Pump intake or exhaust may be connected to either side of the 4-way valve. 4. Iron pipe size should not be reduced from pump inlet or exhaust port size, or restricted in any way. (Do not use street elbows.) 5. A fl exible hose section should be used between pump and trap and between trap and tank. Inside diameters of the hose connector and the hose should not be smaller than the iron pipe I.D. 6. Install vacuum relief valve, pressure relief valve and gauge between pump and moisture trap/scrubber MASPORT INCORPORATED All Rights Reserved

24 PARTS LIST H1V H1V AIR COOLED VACUUM / PRESSURE PUMP PARTS LIST (968120) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Gasket Nut Washer Set Screw Cap Endcover Cap Screw # Endcover Plug Washer (Single End) 17 Bolt Endcover Shim Gasket 18 Handle Thickness * 19 Oil Seal Thickness * 20 Spool Oil Seal Cap Screw Bearing Plug Bearing Spacer Valve Body Rotor Assembly Gasket (Includes 7, 8) 25 Plug # Rotor Assembly Dowel Pin (Single End) 27 Vane Pack (4) Cylinder Integral Valve Assembly NRV Poppet Assembly (Incl. 11,12,13,14,15,16, 17,18,19, 20, 22, 23) * QUANTITY VARIES. # NOT SHOWN MASPORT INCORPORATED All Rights Reserved Effective

25 PARTS LIST H1F H1F AIR COOLED VACUUM / PRESSURE PUMP PARTS LIST (968110) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Bearing Nut Bearing Spacer Set Screw Rotor Assembly Endcover (Includes 7, 8) # Endcover Plug # Rotor Assembly (Sinlgle End) (Single End) 5 Endcover Shim Gasket 10 Cylinder Thickness * 11 Dowel Pin Thickness * 12 Plug Oil Seal Vane Pack (4) * QUANTITY VARIES. # NOT SHOWN MASPORT INCORPORATED All Rights Reserved Effective

26 PARTS LIST HXL2V/ HXL3V HXL2V/HXL3V, AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST Ref Description Part No. Part No. Qty. Ref Description Part No. Part No. Qty. 1 Bolt Cap Screw 2 Nut (Serial # < 98420) Set Screw (Serial # > 98419) Endcover Plug Endcover Shim Gasket 24 Valve Body Thickness * * * 25 Gasket Thickness * * * 26 Bearing Swivel Elbow * Gear Oil Seal Endcover Bearing Swivel Elbow * Bearing Spacer Bolt Rotor Assembly Set Screw (Includes 8, 9, 25) 32 Shaft Guard Plug 2 33 Drive Shaft Assembly Cylinder Oil Pump NRV Poppet Assembly Cap Screw Gasket Cap Screw Washer Dowel Pin Cap Set Screw Cap Screw Blank Flange Washer Gasket Bolt Vane Pack (4) Handle Integral Valve Assembly Spool (Incl. 7,13,14,15,16,17, 18, 19, 20, 21, 23, 24) 43 Oil Line (ft.) * * * * * * * NOT SHOWN. * * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

27 PARTS LIST HXL2F, HXL3F HXL2F, HXL3F AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968140, ) Ref. Description HXL2F Part No. HXL3F Part No. Qty. Ref. Description HXL2F Part No. HXL3F Part No. Qty Bolt Nut Set Screw Endcover Endcover Shim Gasket.002 Thickness.003 Thickness Swivel Elbow * Oil Seal Bearing Bearing Spacer Rotor Assembly (Includes 8, 9, 15) Plug Cylinder Gasket Blank Flange * * * * * * Bearing Gear Endcover Swivel Elbow * Bolt Set Screw Shaft Guard Drive Shaft Assy Oil Pump Cap Screw Cap Screw Dowel Pin Set Screw Bolt Flange Vane Pack (4) Oil Line (ft.) * * * * * * * NOT SHOWN. * * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

28 PARTS LIST HXL4V HXL4V AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968440) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Spool Nut Plug Set Screw Valve Body Endcover Gasket O-Ring Gear Swivel Elbow * Endcover Oil Seal Swivel Elbow * Bearing Bolt Bearing Spacer Set Screw Rotor Assembly Shaft Guard (Includes 8, 9) 32 Drive Shaft Assembly Cylinder Oil Pump NRV Poppet Assembly Cap Screw Gasket Cap Screw Washer Dowel Pin Cap Set Screw Cap Screw Blank Flange Washer Gasket Bolt Vane Pack (4) Handle Integral Valve Assembly Oil Seal (Incl. 12, 13, 14, 15, 16, 22 Cap Screw (Serial # < 98420) ,18,19,20,21,23,24) (Serial # > 98419) Oil Line (ft.) * * * * * * * NOT SHOWN * * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

29 PARTS LIST HXL4F HXL4F AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968435) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Endcover Nut Swivel Elbow Set Screw Bolt Endcover Set Screw O-Ring Shaft Guard Swivel Elbow Drive Shaft Assembly Oil Seal Oil Pump Bearing Cap Screw Bearing Spacer Cap Screw Rotor Assembly Dowel Pin (Includes 8, 9) 25 Set Screw Cylinder Bolt Gasket Flange Blank Flange Vane Pack (4) Gear Oil Line (ft.) * * * * NOT SHOWN. * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

30 PARTS LIST HXL75V II HXL75V SERIES II AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968675) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Gasket Nut Gear Set Screw Endcover Endcover Swivel Elbow Swivel Elbow * Bolt O-Ring Set Screw Oil Seal Shaft Guard Bearing Drive Shaft Assembly Bearing Spacer Oil Pump Rotor Assembly (Incl. 8, 9) Cap Screw Cylinder Cap Screw Flap Assembly Dowel Pin Gasket Set Screw Valve Body Plug Washer Vane Pack (4) Bolt Integral Valve Assembly Cap (Incl. 7, 14, 17, 18, 19, 18 Washer , 21, 22, 23, 24) 19 Bolt Endcover Shim Gasket * * 20 Washer Thickness * * * 21 Handle Thickness * * * 22 Spring Oil Line (ft.) * * * * * 23 Spool * * NOT SHOWN. * * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

31 PARTS LIST HXL15V II HXL15V SERIES II AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968880) Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt Spring Nut Spool Set Screw Gasket Endcover Gear Swivel Elbow Endcover O-Ring Swivel Elbow Oil Seal Bolt Bearing Set Screw Bearing Spacer Shaft Guard Rotor Assembly (Incl. 8, 9) Drive Shaft Assembly Cylinder Oil Pump Flap Assembly Cap Screw Gasket Cap Screw Vacuum Relief Valve Dowel Pin Valve Body Set Screw Washer Vane Pack (4) Bolt Integral Valve Assembly Cap (Incl. 15,18,19,20,21, 19 Washer , 23, 24, 25, 26) 20 Bolt Endcover Shim Gasket * 21 Washer Thickness * * 22 Handle Thickness * * 23 Oil Seal Oil Line (ft.) * * * * NOT SHOWN. * * QUANTITY VARIES MASPORT INCORPORATED All Rights Reserved Effective

32 PARTS LIST OIL RESERVOIR KIT OIL RESERVOIR KIT (13023) Reference: Description Part Number Qty 1 8 ft. Hose 1/ Lubricator Tank 4 Qt Clamps MXL # MASPORT INCORPORATED All Rights Reserved

33 MASPORT VACUUM PUMP OIL IS THE ONLY RECOMMENDED OIL FOR MASPORT PUMPS. MASPORT VACUUM PUMP OIL Masport Incorporated - Lincoln, NE One Gallon Summer Blend Winter Blend Case of 6 Gallons OILS OR FLUIDS THAT SHOULD NOT BE USED IN MASPORT VACUUM PUMPS TRANSMISSION FLUID USED OIL HYDRAULIC FLUID AUTOMOTIVE MOTOR OIL VEGETABLE OIL GEAR OIL POWER STEERING FLUID BRAKE FLUID SCENTED OIL SUBSTITUTE OILS RECOMMENDED FOR TEMPORARY USE IN MASPORT VACUUM / PRESSURE PUMPS SHELL TURBO T OIL 32, 68, 100 Shell Oil Company - Houston, TX MONOLEC COMPRESSOR OIL* Lubrication Engineers - Fort Worth, TX MOBIL SHC 525 (Synthesized Hydrocarbon) Mobil Oil Company - Fairfax, VA ANDEROL 497 Anderol Inc - East Hanover, NJ CHEVRON GST 32, 68 ChevronTexaco Corporation - San Ramon, CA PENNZBELL TO OIL 32, 46, 68 Pennzoil Oil Company - Houston, TX REGAL OIL R & O 32, 68 ChevronTexaco Corporation - San Ramon, CA * Monolec Compressor Oil is colored red and should not be confused with transmission fl uid. These oils have been approved for use in Masport Vacuum/Pressure Pumps. Use of these oils will extend the life of the vacuum pump and ensure proper performance and lubrication. NOTE: Oils numbered 32 & 46 are for winter use**. Oils numbered 68 & 100 are for summer use. **Check pour point to determine minimum temperature. For more information call: MASPORT INCORPORATED 6140 McCormick Drive Lincoln, Nebraska Phone: FAX: Toll Free Masport Incorporated All Rights Reserved 29

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35 MASPORT INCORPORATED 6140 McCormick Drive Lincoln, NE Phone (402) Fax (402) Toll Free 1(800) Masport Incorporated All Rights Reserved 90353