masport engine driven systems owner/operator manual. pressure/vacuum gauge..... f. swing check...

PRICE: $5.00 90353

MASPORT INCORPORATED

Toll Free 1(800) 228-4510www.masportpump.com

© Masport Incorporated All Rights Reserved

Phone (402) 466-8428Fax (402) 466-8355

6140 McCormick DriveLincoln, NE 68507

Masport Engine Driven SystemsOwner/Operator Manual

For Belt Driven System Models:12519, 12513, 12549, 12544, 12581, 12583,12609, 12611, 12616, 12815, 12187, 12158

For Direct Drive System Models:12515, 12517, 12548, 12547, 12565, 12567

I. LIMITED WARRANTY.......................................................................... II. SYSTEM PLUMBING AND INSTALLATION....................................... A. SYSTEM INSTALLATION............................................................... B. PLUMBING CONNECTIONS.......................................................... C. VALVE OPTIONS...........................................................................

III. START-UP AND OPERATION INSTRUCTIONS................................ A. ENGINE START-UP INSTRUCTIONS............................................ B. LUBRICANT.................................................................................... C. FUEL.............................................................................................. D. THROTTLE SPEED........................................................................

IV. MASPORT VACUUM / PRESSURE PUMP........................................ A. LUBRICANT.................................................................................... B. LUBRICANT ADJUSTMENTS AND SETTINGS............................. C. OIL FLOW RATE SETTINGS FOR H1V AND H1F SYSTEMS...... D. OIL FLOW RATE SETTING IN THE FIELD.................................... E. BELT DRIVE MAINTENANCE........................................................

V. OPERATING TIPS...................................................................................... A. SUMMER - 32 DEGREES AND HIGHER...................................... B. WINTER - 32 DEGREES AND LOWER.........................................

VI. SYSTEM INSTALLATION.................................................................. A. SYSTEM WITH INTEGRAL VALVE (V-SERIES)............................ B. SYSTEM WITH REMOTE 4-WAY VALVE (F-SERIES)...................

VII. PUMP PROTECTION COMPONENTS............................................. A. PRIMARY AND SECONDARY........................................................ B. INLET FILTER................................................................................. C. VACUUM RELIEF VALVE............................................................... D. PRESSURE RELIEF VALVE........................................................... E. PRESSURE/VACUUM GAUGE...................................................... F. SWING CHECK VALVE.................................................................. G. HIGH EFFICIENCY OIL SEPARATOR........................................... H. COMPONENT CHECKLIST............................................................

TABLE OF CONTENTS pg. 1

pg. 2

223

pg. 33333

pg. 444555

556

pg. 666

pg. 667777888

I. Table of contents continued next page

VIII. PUMP MAINTENANCE.......................................................................... A. FLUSHING KIT..................................................................................... B. PUMP STORAGE............................................................................... C. PUMP REPAIR KIT INSTALLATION...................................................

IX. PUMP DISASSEMBLY........................................................................... A. ENDCOVER REMOVAL..................................................................... B. ROTOR REMOVAL............................................................................. C. BEARING REMOVAL......................................................................... D. BEARING REPLACEMENT................................................................ E. OIL SEAL REMOVAL AND REPLACEMENT......................................

X. PUMP ASSEMBLY.................................................................................

XI. TECHNICAL OVERVIEW...................................................................... A. AIR COOLED DIRECT DRIVE SYSTEMS.......................................... B. AIR COOLED BELT DRIVE SYSTEMS..............................................

XII. DIMENSIONAL DATA..........................................................................

INSTALLATION DIAGRAM 90417............................................................ INSTALLATION DIAGRAM 90414............................................................

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.....................................................................

TABLE OF CONTENTS (continued)

II.

pg. 99

1010

pg. 101011111112

pg. 12

pg. 141414

pg. 15

1819

20212223242526272829

Do Not attempt to install, operate, or service this pump without reading and understanding the corresponding section in this manual.

Table of contents continued next page

PURCHASER - KEEP FOR RECORD TERMS OF LIMITED WARRANTY: 12 MONTHS DATE PURCHASED: SERIAL NUMBER:

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I. LIMITED WARRANTYManufacturer warrants defects in workmanship, materials or parts for a period of twelvemonths 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.

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 68507-3296.

3. 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.

Masport Engine Driven SystemOwner/ Operator Manual

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 thepump should be smaller than the recommended plumbing size below.

Pump Model: Recommended Plumbing Size:

H1V, H1F 1 1/4” I.D.HXL2V, HXL2F 1 1/2” I.D.HXL3V, HXL3V 1 1/2” I.D.HXL4V, HXL4F 1 1/2” I.D.HXL75V 2 1/2” I.D.HXL15V 3” I.D.

Hose between the Pump, Accessories, and Tank should be no smaller than the pumpporting. 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 preventleaks. “LOCTITE” Pipe Sealer with Teflon has proven to be the easiest and most effectiveproduct Masport has tested. Teflon tape should not be used as pieces of the tape can bedrawn 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

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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 90417 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 90414 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.

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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 andHXL3V, HXL4V, HXL4F, HXL75V, and HXL15V.This system utilizes a direct gear-driven oil pump which is preset to deliver the requiredamount of lubricating oil to the vacuum pump. The oil pump is maintenance free andrequires 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”!

IV. MASPORT VACUUM / PRESSURE PUMP

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.

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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.

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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 mountedin such a way as to permit easy access to the integral valve handle to control the modethe pump is functioning in. This situation also lends itself well to the use of the integrallubrication and XL-Lubrication systems as outlined in the Lubrication Section. Installationdiagram 90417 details the correct location of the components. Components not in theproper 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 underthe frame of the truck. Installation diagram 90414 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

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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 filterextends your system’s life and performance. Each Masport Inlet Filter is equipped withdurable iron wing nuts which allow the lid to be removed quickly and easily. The uniquedesign features a 300 micron washable stainless steel element. An inlet filter is a must inany 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.

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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 -C.F.M. @ 0”Hg 20-40 40-80 80-180 180-300 300-400

Primary Shut-Off Trap 16311 16311 16311 16321 16331

Super Scrubber-Moisture Trap 16410 16410 16410 16420 16430

Vacuum Relief Valve 25054 25056 25056 25056 25056

Vacuum/ Pressure Gauge - 2 1/2” Face 21051 21051 21051 21051 21051

Vacuum/ Pressure Gauge - 3” Face 21052 21052 21052 21052 21052

Adjustable Pressure Relief Valve 25038 25038 25038 25039 25039

* Remote 4-Way Valve 968106 968106 968106 968106 25173

* Swing Check Valve 25128 25128 25128 25130 25131

Horizontal Scrubber 16137 16137 16137 16139 16139

Inlet Filter 15115 15115 15115 15116 15118

Oil Separator 15461 15461 15461 (*15462-5) 15463 15464-3

* For remote mount applications only.

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VIII. PUMP MAINTENANCEIf 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.

NOTE: If for any reason the pump begins to hammeror clatter, it should be stopped immediately and theproblem corrected to prevent permanent damage.this type of problem is most commonly caused by

foreign material entering the pump. If this is the casethe flushing instructions should be followed.

Pump clattering can also be caused by overheatingdue to operation beyond the recommended limits. Ifthis is the case the pump should be allowed to cool

and the problem corrected.

MASPORT FLUSHING KIT

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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 3/8” 968217HXL2V, HXL2F 4 1/16” x 1 7/8” 1 5/8” 975536HXL3V, HXL3F 6” x 1 7/8” 1 5/8” 968236HXL4V, HXL4F 11” x 2 9/16” 2 1/4” 975393HXL75V 8 9/16” x 2 5/8” 2 1/4” 975539HXL15V 12 7/8” x 2 9/16” 2 1/4” 968218

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 DISASSEMBLYRefer 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

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 thenipple 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.

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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

Rotor Between Bearing Spacers

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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 ASSEMBLYBefore 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.

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Phone (402) 466-8428Fax (402) 466-8355


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:

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SYSTEM NUMBER 12515 12517 12548 12547 12565 12567Pump Model H1F H1V HXL2F HXL2V HXL3F HXL3VPump RPM 1750 1750 1750 1750 1750 1750Pump Max C.F.M. @ 0”Hg 36 36 76 76 106 106Lubrication (P/V - XL) P/V P/V XL XL XL XLRecommended Tank Size 100/

600100/600

500/1300

500/1300

800/1800

800/1800

VacuumContinuous 20

272027

2027

2027

2027

2027Intermittent

PressureContinuous 10

151015

1015

1015

1015

1015Intermittent

Oil Reservoir(integral / remote) Int. Int. remote remote remote remote

ENGINE FEATURESEngine Horsepower 5.5 5.5 9.0 9.0 9.0 9.0Clutch (yes / no) yes yes yes yes yes yesBattery Included(yes / no) no no no no no no

SYSTEM NUMBER 12519 12513 12549 12544 12581 12583 12609 12611 12616 12185 12187 12158Pump Model H1F H1V HXL2F HXL2V HXL3F HXL3V HXL4F HXL4V HXL4V HXL

75VHXL 75V HXL15V

Pump RPM 1750 1750 1750 1750 1750 1750 1250 1250 1250 1250 1250 1200Pump Max C.F.M. @ 0”Hg 36 36 76 76 106 106 165 165 165 230 230 350Lubrication (P/V - XL) P/V P/V XL XL XL XL XL XL XL XL XL XLRecommended Tank Size 100/

600100/600

500/1300

500/1300

800/1800

800/1800

1000/2200

1000/2200

1000/2200

1800/3800

1800/3800

2200/4500

VacuumContinuous 20

272027

2027

2027

2027

2027

2027

2027

2027

2027

2027

2027Intermittent

PressureContinuous 10

151015

1015

1015

1015

1015

57

57

1517

1015

1520

1015Intermittent

Oil Reservoir(integral / remote) Int. Int. remote remote remote remote remote remote remote remote remote remote

ENGINE FEATURESEngine Horsepower 5.5 5.5 9.0 9.0 9.0 9.0 9.0 9.0 11.0 20.0 24.0 24.0Clutch (yes / no) no no no no no no no no no no no noBattery Included (yes/no) no no yes yes yes yes yes yes yes no no no

XI. TECHNICAL OVERVIEW

A. AIR COOLED DIRECT DRIVE SYSTEMS

B. AIR COOLED BELT DRIVE SYSTEMS

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XII. DIMENSIONAL DATA

Sys. A B C D E F G H J K L M12519 1” 16 7/8” 17 1/8” 23” 13 7/8” 11” 3/8” 6 3/8” 3 1/8” 6 15/16” 5 11/16” 9 3/16”

12513 1” 16 7/8” 17 1/8” 23” 13 7/8” 11” 3/8” 6 3/8” 3 1/8” 6 15/16” 5 11/16” 9 3/16”

Sys. A B C D E F G H J K L M12549 1 1/2” 20 7/8” 19 1/4” 29 5/8” 13 3/8” 9 7/8” 3/8” 18 7/8” 16 1/8” ------ 5 7/8” ------

12544 1 1/2” 20 7/8” 19 1/4” 29 5/8” 13 3/8” 9 7/8” 3/8” 18 7/8” 6 1/8” ------ 5 7/8” ------

12581 1 1/2” 20 7/8” 19 1/4” 29 5/8” 13 3/8” 9 7/8” 3/8” 18 7/8” 6 1/8” ------ 5 7/8” ------

12583 1 1/2” 20 7/8” 19 1/4” 29 5/8” 13 3/8” 9 7/8” 3/8” 18 7/8” 6 1/8” ------ 5 7/8” ------

16

XII. DIMENSIONAL DATA (continued)

Sys. A B C D E F G H J K L M

12609 1 1/2” 32 15/16” 20 3/8” 24 3/8” 14 1/8” 9 9/16” 3/8” 24 1/16” 17 1/2” 11 3/16” 7 1/8” ------

12611 1 1/2” 32 15/16” 20 3/8” 24 3/8” 14 1/8” 9 9/16” 3/8” 24 1/16” 17 1/2” 11 3/16” 7 1/8” ------

12616 1 1/2” 32 15/16” 20 3/8” 24 3/8” 14 1/8” 9 9/16” 3/8” 24 1/16” 17 1/2” 11 3/16” 7 1/8” ------

Sys. A B C D E F G H J K L M

12185 2 1/2” 36” 25 3/16” 25 1/8” 18” 9/16” 3/8” 33” 17 13/16” ------ ------ 18

15/16”

12187 2 1/2” 36” 25 3/16” 25 1/8” 18” 9/16” 3/8” 33” 17 13/16” ------ ------ 18

15/16”

12158 3” 36” 25 3/16” 25 1/8” 18” 9/16” 3/8” 33” 17 13/16” ------ ------ 18

15/16”

17

XII. DIMENSIONAL DATA (continued)

Sys. A B C D E F G H J K L M12515 ----- 1” 8” 19 3/4” 25” 26 1/4” 3/8” 13 3/4” 17” ------ 16 1/4” ------

12517 1” 1” 8” 19 3/4” 25” 26 1/4” 3/8” 13 3/4” 17” 11” 16 1/4” ------

12548 ----- 1 1/2” 10 1/4” 19 3/4” 27 1/4” 31 1/2” 3/8” 13 3/4” 20” 12 23/32” 19 1/2” ------

12547 1 1/2” ------ 10 1/4” 19 3/4” 27 1/4” 31 1/2” 3/8” 13 3/4” 20” 13 3/4” 19 1/2” ------

12565 ------- 1 1/2” 27 1/8” 19 5/8” 27 1/8” 35 3/4” 3/8” 13 3/4” 20” ------ 19 1/2” ------

12567 1 1/2 ------ 27 1/8” 19 5/8” 27 1/8” 35 3/4” 3/8” 13 3/4” 20” 13 3/4” 19 1/2” ------

90417 © MASPORT INCORPORATED All Rights Reserved

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.

NEW ZEALAND

INSTALLATION DIAGRAM 90417Integral Valve

18


PUMP SYSTEM INSTALLATION RECOMMENDATIONS






NEW ZEALAND

INSTALLATION DIAGRAM 90417Integral Valve


PUMP WITH REMOTE 4-WAY VALVE INSTALLATION RECOMMENDATIONS



3. Pump intake or exhaust may be connected to either side of the 4-way valve.




INSTALLATION DIAGRAM 90414Remote 4-way valve

19

90042 © MASPORT INCORPORATED All Rights Reserved Effective 4-1-2007

PARTSLISTH1V

H1V AIR COOLED VACUUM / PRESSURE PUMP PARTS LIST (968120)

* QUANTITY VARIES. # NOT SHOWN

Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt 501848 12 12 Gasket 568098 1 2 Nut 220221 6 13 Washer 568096 2 3 Set Screw 503225 6 14 Cap 968103 1 4 Endcover 968109 2 15 Cap Screw 568064 4 # Endcover Plug 975132 1 16 Washer 503196 5 (Single End) 17 Bolt 501702 1 5 Endcover Shim Gasket 18 Handle 968099 1 .001” Thickness 575023 * 19 Oil Seal 504282 1 .002” Thickness 575024 * 20 Spool 968102 1 6 Oil Seal 501573 2 21 Cap Screw 568186 4 7 Bearing 501574 2 22 Plug 143901 1 8 Bearing Spacer 975109 2 23 Valve Body 968101 1 9 Rotor Assembly 968154 1 24 Gasket 568188 2 (Includes 7, 8) 25 Plug 501679 2 # Rotor Assembly 968192 1 26 Dowel Pin 575111 4 (Single End) 27 Vane Pack (4) 968217 1 10 Cylinder 968111 1 28 Integral Valve Assembly 968191 1 11 NRV Poppet Assembly 968189 1 (Incl. 11,12,13,14,15,16, 17,18,19, 20, 22, 23)

20


PARTSLISTH1F

H1F AIR COOLED VACUUM / PRESSURE PUMP PARTS LIST (968110)

* QUANTITY VARIES. # NOT SHOWN.

Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt 501848 12 7 Bearing 501574 2 2 Nut 220221 6 8 Bearing Spacer 975109 2 3 Set Screw 503225 6 9 Rotor Assembly 968154 1 4 Endcover 968109 2 (Includes 7, 8) # Endcover Plug 975132 1 # Rotor Assembly 968192 1 (Sinlgle End) (Single End) 5 Endcover Shim Gasket 10 Cylinder 968111 1 .001” Thickness 575023 * 11 Dowel Pin 575111 4 .002” Thickness 575024 * 12 Plug 501679 2 6 Oil Seal 501573 2 13 Vane Pack (4) 968217 1

21

HXL2V/HXL3V , AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST

PARTSLISTHXL2V/HXL3V


Ref Description Part No. Part No. Qty. Ref Description Part No. Part No. Qty. 1 Bolt 501569 501569 16 22 Cap Screw 2 Nut 220221 220221 6 (Serial # < 98420) 568065 568065 4 3 Set Screw 503225 503225 3 (Serial # > 98419) 568241 568241 4 4 Endcover 968242 968242 1 23 Plug 143901 143901 1 5 Endcover Shim Gasket 24 Valve Body 968081 968081 1 .002” Thickness 575006 575006 * * * 25 Gasket 568066 568066 2 .003” Thickness 575007 575007 * * * 26 Bearing 501575 501575 1 6 Swivel Elbow * 568086 568086 1 27 Gear 568071 568071 1 7 Oil Seal 501578 501578 3 28 Endcover 968243 968243 1 8 Bearing 501577 501577 1 29 Swivel Elbow * 568085 568085 1 9 Bearing Spacer 575131 575131 2 30 Bolt 503227 503227 3 10 Rotor Assembly 968126 968246 1 31 Set Screw 503226 503226 3 (Includes 8, 9, 25) 32 Shaft Guard 975264 975264 1 11 Plug ——— ——— 2 33 Drive Shaft Assembly 968045 968045 1 12 Cylinder 975541 975551 1 34 Oil Pump 575366 575366 1 13 NRV Poppet Assembly 968068 968068 1 35 Cap Screw 504262 504262 1 14 Gasket 568063 568063 1 36 Cap Screw 504261 504261 1 15 Washer 568056 568056 2 37 Dowel Pin 575111 575111 4 16 Cap 968053 968053 1 38 Set Screw 504264 504264 1 17 Cap Screw 568064 568064 4 39 Blank Flange 975487 975487 2 18 Washer 503196 503196 1 40 Gasket 568009 568009 2 19 Bolt 501702 501702 1 41 Vane Pack (4) 975536 968236 1 20 Handle 968055 968055 1 42 Integral Valve Assembly 968070 968070 1 21 Spool 968052 968052 1 (Incl. 7,13,14,15,16,17, 18, 19, 20, 21, 23, 24) 43 Oil Line (ft.) * * 600293 600293 * * *

* * NOT SHOWN. * * * QUANTITY VARIES. 22

HXL2F, HXL3F AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968140, 968235)


* * NOT SHOWN. * * * QUANTITY VARIES.

Ref.

1.2.3.4.5.

6.7.8.9.

10.

11.12.13.14.

PARTSLISTHXL2F,HXL3F

Qty.HXL3F

Part No.Ref. DescriptionHXL2F

Part No.

15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.31.

BearingGearEndcoverSwivel Elbow *BoltSet ScrewShaft GuardDrive Shaft AssyOil PumpCap ScrewCap ScrewDowel PinSet ScrewBoltFlangeVane Pack (4)Oil Line (ft.) * *

501575568071968243568085503227503226975264968045575366504262504261575111504264501878968204975536600293

501575568071968243568085503227503226975264968045575366504262504261575111504264501878968204968236600293

1111331111141421

* * *

BoltNutSet ScrewEndcoverEndcover Shim Gasket .002” Thickness .003” ThicknessSwivel Elbow *Oil SealBearingBearing SpacerRotor Assembly(Includes 8, 9, 15)PlugCylinderGasketBlank Flange

DescriptionHXL2F

Part No. Qty.HXL3F

Part No.

501569220221503225968242

575006575007568086501578501577575131968126

------975541568009975487

501569220221503225968242

575006575007568086501578501577575131975254

503416975551568009975487

16631

* * ** * *

12121

2142

23

HXL4V AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968440)


PARTSLISTHXL4V

* * NOT SHOWN * * * QUANTITY VARIES

Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt 501569 10 21 Spool 968052 1 2 Nut 501682 6 23 Plug 143901 1 3 Set Screw 504274 3 24 Valve Body 968081 1 4 Endcover 975479 1 25 Gasket 568066 2 5 O-Ring 501004 2 26 Gear 568069 1 6 Swivel Elbow * 568086 3 27 Endcover 975468 1 7 Oil Seal 501676 2 28 Swivel Elbow * 568085 1 8 Bearing 500082 2 29 Bolt 501571 3 9 Bearing Spacer 975496 2 30 Set Screw 504275 3 10 Rotor Assembly 975469 1 31 Shaft Guard 961412 1 (Includes 8, 9) 32 Drive Shaft Assembly 975482 1 11 Cylinder 975471 1 33 Oil Pump 575437 1 12 NRV Poppet Assembly 968068 1 34 Cap Screw 504262 1 13 Gasket 568063 1 35 Cap Screw 504261 1 14 Washer 568056 2 36 Dowel Pin 575111 4 15 Cap 968053 1 37 Set Screw 504264 1 16 Cap Screw 568064 4 38 Blank Flange 975487 2 17 Washer 503196 1 39 Gasket 568009 2 18 Bolt 501702 1 40 Vane Pack (4) 975393 1 19 Handle 968055 1 41 Integral Valve Assembly 968070 1 20 Oil Seal 501578 1 (Incl. 12, 13, 14, 15, 16, 22 Cap Screw (Serial # < 98420) 568065 4 17,18,19,20,21,23,24) (Serial # > 98419) 568241 4 42 Oil Line (ft.) * * 600293 * * *

24


PARTSLISTHXL4F

HXL4F AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968435)

* NOT SHOWN. * * QUANTITY VARIES.

Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt 501569 10 15 Endcover 975468 1 2 Nut 501682 6 16 Swivel Elbow 568085 1 3 Set Screw 504274 3 17 Bolt 501571 3 4 Endcover 975479 1 18 Set Screw 504275 3 5 O-Ring 501004 2 19 Shaft Guard 961412 1 6 Swivel Elbow 568086 3 20 Drive Shaft Assembly 975482 1 7 Oil Seal 501676 2 21 Oil Pump 575437 1 8 Bearing 500082 2 22 Cap Screw 504262 1 9 Bearing Spacer 975496 2 23 Cap Screw 504261 1 10 Rotor Assembly 975469 1 24 Dowel Pin 575111 4 (Includes 8, 9) 25 Set Screw 504264 1 11 Cylinder 975471 1 26 Bolt 501878 4 12 Gasket 568009 4 27 Flange 968159 2 13 Blank Flange 975487 2 28 Vane Pack (4) 975393 1 14 Gear 568069 1 29 Oil Line (ft.) * 600293 * *

25

HXL75V SERIES II AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968675)

PARTSLISTHXL75V II

* * NOT SHOWN. * * * QUANTITY VARIES.


Ref Description Part No. Qty. Ref Description Part No. Qty.

1 Bolt 501569 16 24 Gasket 568044 1 2 Nut 504278 6 25 Gear 568158 1 3 Set Screw 504276 3 26 Endcover 968854 1 4 Endcover 968843 1 27 Swivel Elbow 568085 1 5 Swivel Elbow * 568086 3 28 Bolt 501571 3 6 O-Ring 501677 2 29 Set Screw 504277 3 7 Oil Seal 501015 3 30 Shaft Guard 568622 1 8 Bearing 503098 2 31 Drive Shaft Assembly 968045 1 9 Bearing Spacer 968611 2 32 Oil Pump 575437 1 10 Rotor Assembly (Incl. 8, 9) 968614 1 33 Cap Screw 504262 1 11 Cylinder 968401 1 34 Cap Screw 504261 1 12 Flap Assembly 968026 1 35 Dowel Pin 503258 4 13 Gasket 568610 1 36 Set Screw 504264 1 14 Valve Body 968010 1 37 Plug 27300 1 15 Washer 500203 4 38 Vane Pack (4) 975539 1 16 Bolt 501666 4 39 Integral Valve Assembly 968003 1 17 Cap 968035 1 (Incl. 7, 14, 17, 18, 19, 18 Washer 501610 4 20, 21, 22, 23, 24) 19 Bolt 501617 5 40 Endcover Shim Gasket * * 20 Washer 501550 1 .002” Thickness 542011 * * * 21 Handle 968037 1 .003” Thickness 542012 * * * 22 Spring 568038 1 41 Oil Line (ft.) * * 600293 * * * 23 Spool 968094 1

26

PARTSLISTHXL15V II

HXL15V SERIES II AIR COOLED PRESSURE / VACUUM PUMP PARTS LIST (968880)


* NOT SHOWN. * * QUANTITY VARIES.

Ref Description Part No. Qty. Ref Description Part No. Qty. 1 Bolt 501569 16 24 Spring 568038 1 2 Nut 504278 6 25 Spool 968804 1 3 Set Screw 504276 3 26 Gasket 568044 1 4 Endcover 968843 1 27 Gear 568158 1 5 Swivel Elbow 568086 3 28 Endcover 968854 1 6 O-Ring 501677 2 29 Swivel Elbow 568085 1 7 Oil Seal 501015 2 30 Bolt 501571 3 8 Bearing 503098 2 31 Set Screw 504277 3 9 Bearing Spacer 968611 2 32 Shaft Guard 568622 1 10 Rotor Assembly (Incl. 8, 9) 968848 1 33 Drive Shaft Assembly 968045 1 11 Cylinder 968881 1 34 Oil Pump 568437 1 12 Flap Assembly 968026 2 35 Cap Screw 504262 1 13 Gasket 568884 1 36 Cap Screw 504261 1 14 Vacuum Relief Valve 25056 1 37 Dowel Pin 503258 4 15 Valve Body 968883 1 38 Set Screw 504264 1 16 Washer 500203 7 39 Vane Pack (4) 968218 1 17 Bolt 501666 7 40 Integral Valve Assembly 968887 1 18 Cap 968035 1 (Incl. 15,18,19,20,21, 19 Washer 501610 4 22, 23, 24, 25, 26) 20 Bolt 501617 5 41 Endcover Shim Gasket * 21 Washer 501550 1 .002” Thickness 542011 * * 22 Handle 968037 1 .003” Thickness 542012 * * 23 Oil Seal 501674 1 42 Oil Line (ft.) * 600293 * *

27


OIL RESERVOIR KIT (13023)

Reference: Description Part Number Qty1 8 ft. Hose 1/4” 24299 12 Lubricator Tank 4 Qt. 36001 13 Clamps MXL #4 24310 2

PARTS LISTOIL RESERVOIR KIT

28

90503 © 2008 Masport Incorporated All Rights Reserved

MASPORT VACUUM PUMP OIL IS THE ONLYRECOMMENDED OIL FOR MASPORT PUMPS.

SUBSTITUTE OILS RECOMMENDED FOR TEMPORARY USE IN MASPORT VACUUM / PRESSURE PUMPS

MASPORT VACUUM PUMP OILMasport Incorporated - Lincoln, NE 800-228-4510

One Gallon Case of 6 GallonsSummer BlendWinter Blend 13998

1399713999

13996

OILS OR FLUIDS THAT SHOULD NOT BE USED IN MASPORT VACUUM PUMPS

TRANSMISSION FLUIDUSED OIL

HYDRAULIC FLUID

AUTOMOTIVE MOTOR OILVEGETABLE OIL

GEAR OIL

POWER STEERING FLUIDBRAKE FLUIDSCENTED OIL

SHELL TURBO T OIL 32, 68, 100Shell Oil Company - Houston, TX 800-231-6950

MONOLEC COMPRESSOR OIL*Lubrication Engineers - Fort Worth, TX 817-834-6321

MOBIL SHC 525 (Synthesized Hydrocarbon)Mobil Oil Company - Fairfax, VA 800-662-4525

ANDEROL 497Anderol Inc - East Hanover, NJ 888-263-3765

CHEVRON GST 32, 68ChevronTexaco Corporation - San Ramon, CA 800-822-5823

PENNZBELL TO OIL 32, 46, 68Pennzoil Oil Company - Houston, TX 800-332-6457

REGAL OIL R & O 32, 68ChevronTexaco Corporation - San Ramon, CA 800-822-5823

For more information call:MASPORT INCORPORATED

6140 McCormick Drive • Lincoln, Nebraska 68507Phone: 402-466-8428 • FAX: 402-466-8355 • Toll Free 800-228-4510

* 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.

29

masport engine driven systems owner/operator manual. pressure/vacuum gauge..... f. swing check...

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