Pioneer PT Series Manual

Revision0039/21/2018
Pioneer Self Priming Series
PT Series
Operation & Maintenance Manual
Manual #2501
Corporate Office
310 South Sequoia Parkway
Canby, OR 97013
Phone [phone]
Fax [phone]

Table of Contents
Introduction…………………………………………………………………………...…..Page 4
Inspection……………………………………………………………………………….....Page 4
Pre-installation Inspection
Recording Model and Serial Numbers…………….…………………………………….Page 5
Warranty
Safety Information……………………………………….………………………………..Page 6
Installation…………………………………………………………………………………Page 7
Foundation /Base plate/ Skid
Leveling
Grout
Trailer Mounted Units
Installation…………………………………………………………………………………Page8
Installing Pump
Suction Piping
Discharge Piping
Suction and Discharge Flanges
Installation…………………………………………………………………………………Page 9
Screening
Sump Design
Lifting
Alignment of Pump and Motor
Rotation
Operation………………………………………………………………………………….Page 10
Pre-Start Checklist
Priming
Operation…………………………………………………………………………………..Page 11
Operation of Engine Driven Unit
Starting
Rotation/Operation
Operation…………………………………………………………………………………..Page 12
Liquid Temperature
Overheating
Pump Vacuum Check
Stopping
Cold Weather Preservation
Bearing Temperature Check
Maintenance…………………………………………………………………………....…Page 12
Maintenance………………………………………………………………………………Page 13
Disassembly
Maintenance………………………………………………………………………………Page 14
Disassembly cont’d
Suction Cover and Wear Plate
Rotating Assembly
Suction Check Valve
Impeller
2

Maintenance………………………………………………………………………………Page 15
Disassembly cont’d
Pump case removal
Mechanical seal removal
Shaft and Bearings
Reassembly of components
Shaft and Bearings
Maintenance………………………………………………………………………………Page 16
Reassembly cont’d
Seal Installation
Maintenance………………………………………………………………………………Page 17
Reassembly cont’d
Seal installation cont’d
Maintenance………………………………………………………………………………Page 18
Reassembly cont’d
Seal installation cont’d
Impeller
Suction Cover and Wear Plate
Lubrication
Parts……………………………………………………………………………………….Page 19
Parts order
Spares
Storage
Trouble Shooting…………………………………………………………………………Page 20
Conditions and Terms of Sale...…………………………………………………………Page 21
Parts illustration…………………………………………………………………………A2801A
3

INTRODUCTION
Thank you for purchasing a Pioneer Self-Priming centrifugal pump, complete with integral suction
check valve. The pump is designed for handling non-volatile, non-flammable, mild industrial
corrosives, residues and slurries containing large entrained solids. The standard pump is constructed
of ASTM A536 ductile iron casing with ductile iron impeller and 17-4 PH stainless steel shaft and
steel and iron wear parts.
WARNING!!!
This manual provides installation, operation and maintenance instructions for your Pioneer Self-
Prime Pump and is intended to make your personnel aware of any procedure that requires special
attention because of potential hazards to personnel or equipment. Read all instructions carefully and
remember, pump installations are seldom identical. Therefore, this manual cannot possibly provide
detailed instructions and precautions for each specific application. Thus, it is the owner/installer’s
responsibility to ensure that applications not addressed in this manual are performed only after
establishing that neither operator safety nor pump integrity are compromised by the installation.
WARNING!!!
Centrifugal Pumps are designed for specific service and may or may not be suited for any other
service without loss of performance or potential damage to equipment/personnel. If there is ever any
doubt about suitability for a specific purpose; contact your Pioneer Pump, Inc. representative or the
factory for assistance.
Remember: Pump performance may be affected by changes in pumpage such as, specific gravity,
viscosity, temperature, operating speed and NPSHA (net positive suction head available).
INSPECTION
PRE-INSTALLATION INSPECTION
The pump assembly was inspected and tested before shipment from the factory. Before installation,
inspect the pump for damage that may have occurred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage.
b. Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying,
check for loose hardware at mating surfaces.
c. Carefully read all warnings and cautions contained in this manual or affixed to the pump, and
perform all duties indicated. Note the direction of rotation indicated on the pump and check
that the pump shaft rotates counter-clockwise when standing on the suction side of the pump
and facing the impeller.
4

CAUTION!!!
If equipment is stored more than twelve (12) months, some of the components or lubricants may
have exceeded their maximum shelf life. These must be inspected and replaced as necessary prior to
pump operation to ensure proper pump performance.
RECORDING MODEL & SERIAL NUMBERS
Please record the model and serial number for your Pioneer Pump in the spaces provided below.
The factory will need this information when you require parts or service.
Pump Model: _____________________________________________
Pump Serial Number: ______________________________________
Engine/Motor Serial #: _____________________________________
Engine/Motor Mgf: __________________________________
WARRANTY INFORMATION
Pioneer Pump’s current terms and conditions, including limited warranty policy, can be found on our
website http://www.pioneerpump.com from the homepage by selecting More > Resources > Terms
and Conditions or by following this link:
http://pioneerpump.com/media/232391/M5132_Pioneer_Standard_Terms_and_Conditions-1-.pdf
5

SAFETY INFORMATION
These warnings apply to PT Series basic pumps. In many cases, Pioneer Pump, inc. has no control
over or particular knowledge of the power source that will be used. Therefore, refer to the manual
accompanying the power source before attempting to begin operation.
WARNING!!!
Before attempting to open or service the pump:
1. Familiarize yourself with this manual.
2. Disconnect or lock out the power source to ensure that the pump will remain inoperative.
3. Allow the pump to cool if overheated.
4. Check the temperature before opening any covers, plates or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cautiously.
7. Drain the Pump.
WARNING!!!
This pump is designed to handle mild industrial corrosives, residues and slurries containing large
entrained solids. Do not attempt to pump volatile, corrosive, or flammable materials that may
damage the pump or endanger personnel as a result of pump failure.
WARNING!!!
After the pump has been positioned, make certain that the pump and all piping connections are tight,
properly supported and secure before operation. (Refer to Installation section)
DANGER!!!
Do not operate the pump without the guards in place over the rotating parts. Exposed rotating parts
can catch clothing, fingers, or tools, causing severe injury to personnel.
WARNING!!!
Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor
pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the
pump to cool before servicing.
WARNING!!!
Do not operate the pump against a closed discharge valve for long periods of time. If operated
against a closed discharge valve, pump components will deteriorate, and the liquid could come to a
boil, build pressure, and cause the pump casing to rupture or explode.
WARNING!!!
Remove suction and discharge piping from pump prior to moving. Use lifting and moving
equipment with adequate capacity and in good repair.
6

INSTALLATION
WARNING!!!
Review safety information in safety information section. This section is intended to outline general
recommendations and practices required to position and arrange the pump and piping in static lift
situations. If installing the unit in flooded suction applications some of the information will need to
be tailored to the specific application. Never exceed the maximum permissible operating pressure
of the pump as shown on the pump performance curve.
FOUNDATION/BASE PLATE/SKID
If using a concrete foundation it should be rigid enough to inhibit vibration. Pour the foundation
well in advance of installation of pump equipment to allow time for drying and curing.
If the pump is to be mounted on a steel frame, or similar structure, it should be set directly over the
supporting beams. These beams and the structure must be rigid enough to prevent distortion and
potential misalignment due to movement within the structure or base.
The location of this structure should be as close as possible to the pumpage source. Provide
adequate space for operation, maintenance and inspection of the pump and equipment.
The concrete foundation should be provided with anchor bolts for attachment to the base plate. If
required, provide adequate drainage to keep pump and motor dry and clean. Also, provide either
leveling nuts or leveling wedges for mounting the base plate to the foundation.
LEVELING
When mounting the base plate to the foundation use the leveling nuts or wedges to provide a level,
flat base plate. Use a machinist's level on the mounting pads and make adjustments as necessary as
the anchor bolts are tightened. This will provide the true alignment between the pump and motor.
GROUT
If this base plate is to be grouted, ensure that you have the mounting surface flat and level for correct
alignment of pump and motor. Build a dam around the base plate perimeter that is to be watertight.
Use standard grouting practice and be sure to protect (cover) the leveling wedges with caulk or
plastic tape if they are to be removed later. After the grout has thoroughly hardened, remove forms.
If the wedges are removed, fill holes with grout. Seal grout by covering with a quality paint or
sealer.
TRAILER MOUNTED UNITS
See “OPERATION” section.
7

INSTALLING PUMP
Ensure that all foreign material has been removed from the pump before mounting. Be sure to
remove all shipping protection prior to operation.
NOTE: Many of the bare pumps are shipped with protective guards and coatings.
SUCTION PIPING
For best performance the suction piping should be at least as large as the pump flange, never smaller.
Use an eccentric reducer at the suction flange with the straight side up. The use of flow-retarding
fittings is to be avoided and if necessary should never be placed closer to the pump suction than four
(4) times the pipe diameter. The pump should be at the highest point of the piping. Slope the piping
up to the pump to prevent air pockets and avoid changing pipe
size with the exception of the eccentric reducer mentioned above. All suction piping and fittings are
to be checked for any foreign material (rocks, bolts, wire, etc.) and also any sharp burrs that could
disrupt the flow.
CAUTION!!!
The suction and discharge pipe/hose material should be compatible with the liquid being pumped.
CAUTION!!!
If hose is used on the suction line it should be of the reinforced type to prevent collapse under
suction lift.
DANGER!!!
If a manual shut-off valve is installed in the discharge line, it must not be left closed during
operation, a closed manual shut off valve will cause overheating and possible explosive rupture of
the pump casing. Personnel could be severely injured!
DISCHARGE PIPING
Use a concentric taper on the discharge side to increase discharge pipe diameters. All valving and
additional fittings should be the same size as the discharge main-line. The discharge size should be
adequate to maintain reasonable velocities and reduce friction losses.
SUCTION & DISCHARGE PIPE FLANGES
All piping is to be supported, braced and lined up square before connection to the pump flanges. A
flexible fitting is recommended on both suction and discharge, to eliminate misalignment loads or
stresses being transmitted to the pump.
NOTE: Flexible pipe couplings must be restrained so as not to transmit any strain to the pump
flanges when expanding or contracting under pressure. Unrestrained expansion fittings can transmit
enormous forces to the pump flanges.
8

SCREENING
Make provisions for the installation of a suction screen or strainer to prevent any debris from
clogging the impeller. The open area of the strainer should be equal to at least four (4) times the
area of the pipe. The screen should be rigid enough to prevent collapse when flow is reduced due to
clogging.
SUMP DESIGN
The submergence of the suction pipe into the liquid should be at least four (4) to five (5) times the
pipe diameter. If this is not possible then provide a baffle or a floating board. This is to prevent any
vortex action allowing air into the pipe. For best performance a bell mouth fitting is recommended.
Refer to the Hydraulic Institute Handbooks or other Hydraulic Data books for detailed sump design
information.
LIFTING
Any lifting equipment is to be rated for at least five (5) times the weight of the item being lifted.
Use only established methods when lifting or moving any heavy components.
ALIGNMENT OF PUMP AND MOTOR
Precise alignment is mandatory to achieve correct performance of the system. Every time a
component is moved this alignment will have to be checked. The alignment can be checked with a
straight edge and an outside caliper, taper thickness gauge, dial indicators, or for best results, use a
laser alignment tool. Use the straight edge across the outside diameters of the coupling to ensure
that the two halves are concentric and parallel. The outside calipers or the taper thickness gauge is
to correct for any angular misalignment and to verify the correct gap between the coupling flanges.
Use a laser alignment tool or dial indicators to adjust for concentric and angular displacement. With
dial indicators, rotate shafts together and take readings every ninety (90) degrees. Make adjustments
by placing shims under the driver, and be sure that the mounting bolts are properly tightened while
taking readings and after final adjustment then install coupling guard.
ROTATION
CAUTION!!
When connecting a pump to an electric motor, it is common practice to “bump” the motor starter to
check for correct rotation. It is imperative that the PT pump inspection cover be removed prior
to this rotation check! The PT series pumps use threaded shafts and impellers; if the motor is
“bumped” and rotation is backward, the impeller will unscrew and be forced against the wear plate.
This will often apply enough force to the wear plate / inspection cover assembly to break the
inspection cover clamp.
If, after removing the inspection cover and “bumping” the starter, it is found that the rotation is
backward, then shut down and lock out the power to the pump and correct the wiring connection
(reverse two leads for a three phase motor). Before reconnecting the power to the motor, retighten
the impeller per instructions under the SEAL INSTALLATION section.
9

10
OPERATION
Review all safety information in the safety information section.
PRE-START
1) Verify that rotation is correct and that the shaft rotates freely. CAUTION see “Rotation”
section above.
2) Check all piping connections for tightness.
3) Inspect all accessories and make sure they are appropriate for your installation.
4) Verify that the driver and coupling are aligned correctly and that all guards are in place.
5) Ensure that all bearings and grease seals are lubricated.
6) Oil levels should be checked and also, maintained during pump operation.
7) Follow the instruction on all tags, labels and decals attached to the equipment.
8) Review the operations manual furnished with the power source. (Equipment driver)
WARNING!!!
This pump is designed to handle most non-volatile, non-flammable liquids containing specified
entrained solids and corrosives. Do not attempt to pump volatile, corrosive, or flammable
liquids that may damage the pump or endanger personnel as a result of pump failure.
CAUTION!!!
Pump speed and operating condition points must be within the continuous performance range
shown on the Performance Curve in the separate Part List Manual for your specific pump
model.
PRIMING
This pump is self-priming, but the pump should never be operated unless there is liquid in the
pump casing.
CAUTION!!!
The pump will not prime when dry. Extended operation of a dry pump will destroy the seal
assembly.
Add liquid to the pump casing when:
1. The liquid in the pump casing is low.
2. The pump has not been used to an extended period of time.
3. The pump is being put into service for the first time.
Once the pump casing has been filled, the pump will prime and reprime as necessary.
WARNING!!!
Do not attempt to operate the pump unless all connecting piping, fill plug and other fittings are
securely installed, failure to do so, could cause liquid pumped to be forced out under pressure
causing injury to personnel.

WARNING!!!
Never run the pump with the discharge valve closed for extended periods of time. Never use
the suction valve to throttle the flow. Check all suction and discharge piping for leaks.
If a suction strainer is installed, check the pressure drop across the strainer. If the differential in
pressure exceeds five (5) PSI have the strainer cleaned.
OPERATION OF ENGINE DRIVEN UNITS
Review pre-start instructions in the beginning of the Operation section.
Before Starting
Check the fuel level and oil levels in the engine.
CAUTION!!!
Make sure the pump is level. Lower jack stands and chock the wheels. Use caution when
positioning the skid-mounted unit to prevent damage to the fuel tank. Consult the engine
operations manual before attempting to start the unit.
WARNING!!!
Do not operate the pump without guards in place over the rotating parts. Exposed rotating parts
can catch clothing, fingers or tools, causing severe injury to personnel.
STARTING
Consult the operations manual furnished with the power source.
Rotation
CAUTION see “rotation section” on preceding pages
The correct direction of pump rotation is counter-clockwise when standing on the suction side
of the pump and facing the impeller. The pump could be damaged and performance adversely
affected by incorrect rotation. If pump performance is not within the specified limits, verify
rotation. If necessary, check the connection to the power source, and interchange two leads
(three phase power) in order to change rotation.
If an electric motor is used to drive the pump, remove V-belts, couplings, or otherwise
disconnect the pump from the motor before checking motor rotation. Operate the motor
independently while observing the direction of the motor shaft, or cooling fan.
If rotation is incorrect consult the power source operation manual.
Operation
Open all valves in the discharge line and start the power source. Priming is indicated by a
positive reading on the discharge pressure gauge or by a quieter operation. The pump may not
prime immediately because the suction line must first fill with liquid. If the pump fails to
prime within five minutes, stop it and check the suction line for leaks.
11

Liquid Temperature and Overheating
The maximum liquid temperature for this pump is 160º F (71º C). Do not apply it at a higher
operating temperature.
Overheating can occur if operated with the valves in the suction and/or discharge lines closed.
Operating against closed valves could bring the liquid to a boil, build pressure, and cause the
pump to rupture or explode. If overheating occurs, stop the pump and allow it to cool before
servicing it. Refill the pump casing with cool liquid.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge in the system. Block the suction line and
start the pump. At operating speed, the pump should pull a vacuum of 20 inches of mercury
(508.0 mm) or more. If it does not, check for air leaks at the suction piping gaskets.
STOPPING
Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly,
damaging shock waves can be transmitted to the pump and piping system. Close all connecting
valves slowly.
On engine driven pumps, reduce the throttle speed slowly and allow the engine to idle briefly
before stopping.
Cold Weather Protection
If the pump is to remain idle during below freezing conditions, drain the pump to prevent
damage from freezing. Also, clean out any solids by flushing with a hose.
Bearing Temperature Check
Bearings normally run at higher than ambient temperatures because of heat generated by
friction. Temperatures up to 160º F (71º C) are considered normal for bearings, and they can
operate safely to at least 180º F (82º C).
Measure bearing temperature with a contact type thermometer.
MAINTENANCE
WARNING!!!
Before attempting to service this pump, read this manual carefully. Operators and maintenance
personnel should have a good understanding of all aspects of this pump and the pumping
conditions. Failure of operating personnel to be familiar with all aspects of pump operation
outlined in this manual could contribute to equipment damage, bodily injury or possible death.
WARNING!!!
Before any servicing:
1) Read this manual carefully.
2) Shut down driver and lock out incoming power to ensure that the pump will remain
inoperative.
3) If the pump or components are hot, allow adequate cooling prior to servicing the unit.
4) Close the suction and discharge valves.
5) Vent the pump slowly and drain completely.
12

WARNING!!!
If this pump is used to handle any hazardous materials that can cause illness, either directly or
indirectly, take precautions by wearing approved protective clothing and use appropriate safety
equipment.
WARNING!!!
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries
to personnel or damage to equipment. When lifting the pump with chains or cable wrapped
around the pump, make certain that they are positioned so as not to damage the pump, and so
that the load will be balanced. The bail on trailer or skid mounted units is intended for use in
lifting the pump assembly only. Suction and discharge hoses and piping must be removed from
the pump before lifting.
CAUTION!!!
When servicing this pump, use only components provided by Pioneer Pump, Inc. Any use of
non-authorized parts could result in sub-standard performance, damage to equipment and
possible injury to personnel. Non-authorized parts will also void the warranty.
When using this manual any reference to part names will is directed to the cross-section
drawing. These parts will also be called out in the bill of materials for full description.
Drain volute case of pumpage when pumping unit is idle to avoid freezing and possible thermal
cracking of pump case.
This manual also provides a troubleshooting section to diagnose many operational or
performance problems. The equipment covered in this section is limited to the pump and drive
components only. Refer to the applicable vendor's manual for motors, engines and other
accessory equipment. Use the troubleshooting section to help determine the cause of any
problems, and only disassemble the pump components required to remedy the problem
condition.
WARNING!!!
Select a clean suitable location for any required maintenance, and note that all work must be
performed by qualified personnel.
An ongoing record of performance will assist in any troubleshooting and/or analysis of
problems. A pressure gauge can be installed on the suction and discharge side of the pump to
monitor any changes in differential pressure. Differential pressure is useful in monitoring and
diagnosing any possible degradation in pump performance.
DISASSEMBLY
Verify the following:
1. Driver is shut down and power is locked out.
2. If pump components are hot, allow to adequately cool.
3. Suction and discharge valves are shut.
4. Drain pump after it has adequately cooled.
5. For power source maintenance refer to power source O & M manual
13

DISASSEMBLY CONT’D
Review all safety information and follow the instructions in this manual, as well as, all tags,
labels and decals attached to the pump or related equipment.
Under normal conditions this pump is designed to run maintenance free, because of its rugged
construction, for extended periods of time. However, all centrifugal pumps contain wear parts
that will gradually deteriorate, affecting pump performance. This pump does contain wear
parts and these parts should be replaced as required to maintain optimum performance.
General maintenance can be performed without removing the pump from the driver. The
following instructions assume a complete disassembly of the pump is required.
SUCTION COVER AND WEAR PLATE
Before attempting to service the pump allow unit to cool and then remove the casing drain
plug, and drain the pump. Once drained, clean the plug and reinstall in suction cover. Turn the
T-handle screw on the cover clamp bar to loosen the cover clamp bar, and remove the cover
clamp bar. The inspection cover / wear plate assembly can now be removed from the
suction–side of the pump case. Inspect the wear plate and replace if badly worn or scored. To
remove the wear plate, loosen and remove the two nuts and washers from the wear plate studs.
Inspect the suction cover o-ring and replace if necessary.
ROTATING ASSEMBLY
The power source must be removed prior to removing the rotating assembly. Drain the oil in
the seal plate cavity and seal oil reservoir by removing the seal plate drain plug. Clean and
replace the drain plug after draining seal cavity of oil.
Remove the inspection cover and wear plate from the suction side of the pump. Immobilize the
impeller by wedging a block of wood between the impeller vanes and the pump casing. Attach
a strap wrench to the drive-end of the shaft or to the shaft-end coupling half With the impeller
rotation still blocked pry in a counter-clockwise direction (when facing drive end of shaft) until
the impeller becomes loose. Remove the wrench and the four (4) bolts on the drive end of the
bearing housing.
SUCTION CHECK VALVE
To service the suction flapper valve assembly, remove the suction flapper pin (model PT2.0).
Remove the four capscrews and washers or four nuts (depending on model), and pull the
suction piece off the pump case. The suction flapper valve and suction flapper retainer can
now be disassembled (PT2.0). For the PT1.5 the suction flapper valve is integral with the
suction piece gasket and does not require further disassembly for replacement. If the suction
flapper valve is damaged in any way, it should be replaced. Replacement is simply the reverse
of disassembly.
IMPELLER
After loosening impeller per previous instructions, it can be unscrewed by hand and removed
from the pump case.
14

PUMP CASE REMOVAL
Use a wrench on the hex section under the seal oil reservoir to remove the reservoir and oil
reservoir nipple. Remove the four nuts that secure the pump case and seal plate to the
bearing housing. The pump case can now be removed from the seal plate register.
CAUTION! At this point the seal plate will no longer be bolted to the bearing housing
register and should be supported so that it does not fall against the shaft. A bolt can be
placed through the bearing housing flange and seal plate flange and secured with a nut
until the seal plate is to be removed.
MECHANICAL SEAL REMOVAL
The pump shaft, mechanical seal rotating element and shaft sleeve will now be accessible.
It should be possible to pull the shaft sleeve and mechanical seal rotating element off the shaft
as an assembly. Now the seal plate can be pulled straight off. Take care to support the seal
plate while sliding it off of the shaft so that the mechanical seal stationary seat does not make
contact with the shaft. The stationary seat is very brittle and could break if bumped against the
shaft. If the mechanical seal is to be replaced, then this is not a concern.
Insert a screwdriver (blade-type) through the backside of the seal plate and against the backside
of the stationary seat retainer (if used) or the mechanical seal stationary seat. Tap the end
of the screwdriver handle with the heal of the hand to push it out. If the stationary seat is to be
reused, a towel or cushion of some type should be placed under the seal plate for the stationary
seat to fall onto.
Press the seal plate lip seal out from the impeller-side of the seal plate.
SHAFT AND BEARINGS
Remove the bearing housing drain plug and drain the oil. Clean plug and reinstall in housing.
Remove fasteners, and slide the bearing cover and bearing cover lip seal off the shaft. Press
the lip seal from the bearing cover. Remove the deflector from the pump-end of the shaft.
Place a block of wood against the impeller end of the shaft and gently tap the shaft and bearings
out of the housing. Alternately, a press can be used to remove the shaft and bearing assembly.
Clean the housing and components with appropriate cleaning solvent and use compressed air to
dry components. If bearings need replacement, use appropriate bearing puller to remove
bearings from shaft, or a press can be used to push the shaft out of the bearing.
RE-ASSEMBLY OF COMPONENTS
SHAFT AND BEARINGS
Clean all components with appropriate solvent. Inspect shaft and replace if distorted, nicked or
scratched beyond repair.
15

REASSEMBLY CONT’D
If bearings are to be replaced:
The bearings may be heated to 250º F for ease of installation. An induction heater, electric
oven or hot plate may be used to heat the bearings. A direct flame should never be used. After
heating the bearings slide the bearings on the appropriate shaft end. If the bearings are shielded
on one side, the inboard bearing should be installed with the shielded side toward the
impeller, and the outboard bearing should be installed with the shield facing the bearing
cover. After installation of bearing, ensure that bearings are tight against shaft shoulders.
When installing the bearings onto the shaft press against the inner bearing race only.
Press a new bearing housing pump-end lip seal into the bearing housing. Make sure that the
open side of the lip seal case faces the bearing. Press the lip seal in until the closed side of the
case is flush with the pump-end face of the bearing housing. Use your finger to apply a coat of
grease to the seal lip. Apply a coat of grease to the shoulder of the shaft where the shaft sleeve
abuts. This will help the shaft pass through the lip seal during shaft installation.
Slide the shaft and assembled bearings into the bearing housing until pump-end bearing rests
against the bottom of the bearing housing. Take care not to cut or fold the bearing housing
pump-end lip seal when installing the shaft.
Press a new bearing cover lip seal into the bearing cover from the open side. Make sure that
the open side of the lip seal case is facing the bearing. Press the lip seal in until it bottoms in
the bearing cover. Apply a coat of grease to the lip of the seal. Slide the bearing cover over the
shaft, taking care not to cut the lip seal on the shaft keyway. Install bearing cover capscrews
and tighten.
SEAL INSTALLATION
Press a new seal plate lip seal into the seal plate with the open side of the lip seal case toward
the seal plate. Press the lip seal in until it bottoms in the bore. This pump may be equipped
with a “rubber bellows” type mechanical seal or a “pusher” type seal. Installation methods are
slightly different for each. The rubber bellows seal can be identified by the elastomer on the
inside diameter of the seal and by the separate, single spring. The pusher-type seal will have no
visible spring and only an o-ring on the inside diameter.
For the rubber bellows seal
Remove the old mechanical seal stationary seat from the stationary seat retainer. Clean
the stationary seat retainer, then lubricate the inside diameter with 30 wt motor oil or similar
(do not use silicone based lubricants or grease). Lubricate the stationary seat o-ring, and press
the seat into the retainer using your thumbs. Clean the seat bore in the seal plate and lubricate
with 30 wt. motor oil. Lubricate the o-ring of the seat retainer, and press the retainer into the
seal plate bore. Make certain that the seat retainer is seated squarely against the bottom of the
seal plate bore and that the stationary seat is seated squarely against the bottom of the seat
retainer. Using a clean rag, wipe the face of the stationary seat. Apply a few drops of 30 wt.
motor oil to the stationary seat face.
16

SEAL INSTALLATION CONT’D
Very carefully slide the seal plate over the shaft and up against the bearing housing register.
This requires caution to prevent bumping the mechanical seal stationary seat against the shaft.
The silicon carbide stationary seat is very brittle and will chip easily. Once the seal plate is
positioned against the bearing housing register it should be secured with a bolt and nut or a c-
clamp until you’re ready to install the case. Alternately the reassembly can be performed with
the pump positioned vertically – pump-end of the shaft pointing upward.
Now lubricate the entire service of the shaft sleeve with liberal amounts of 30 wt motor oil or a
very thin film of STP® or heavy gear oil. Likewise, lubricate the inside diameter of the
mechanical seal bellows. Place the mechanical seal spring guide over the sleeve and up
against the flange at end of the sleeve. Make sure that the open side of the spring guide facing
the non-flanged end of the sleeve. Place the mechanical seal spring over the sleeve and up
against the spring guide. Push the mechanical seal onto the sleeve with the polished face away
from the spring. Push the seal up the sleeve until the spring rests against the back of the
mechanical seal. The remainder of the seal and impeller installation must occur right away so
that the mechanical seal does not “set-up” in the wrong position on the sleeve.
Place the shaft sleeve o-ring over the end of the shaft and up against the shaft shoulder (where
the sleeve abuts). Apply a little grease or oil to the o-ring. Slide the mechanical seal / sleeve
assembly over the shaft with the flanged end of the sleeve toward the end of the shaft. Slide the
assembly as far as the seal spring will allow.
Apply a small amount of Loctite 262® (red) or equivalent to the shaft threads, and install the
impeller. As with impeller removal, attach a strap wrench or bearing nut spanner to the drive-
end of the pump shaft. Have an assistant hold this wrench to immobilize the shaft. Tighten the
impeller as much as possible by hand by rotating it clockwise.
A new seal assembly should be installed anytime the old seal is removed. The wear pattern on
the old seal can cause premature failure if reused.
For pusher-type seal
Clean the seat bore in the seal plate and lubricate with 30 wt. motor oil. Lubricate the o-ring of
the stationary seat, and press the seat into the seal plate bore using your fingers (tools may
break the seat). Make certain that the seat is seated squarely against the bottom of the seal plate
bore. Using a clean rag, wipe the face of the stationary seat. Apply a few drops of 30 wt motor
oil to the stationary seat face.
Very carefully slide the seal plate over the shaft and up against the bearing housing register.
This requires caution to prevent bumping the mechanical seal stationary seat against the shaft.
The silicon carbide stationary seat is very brittle and will chip easily. Once the seal plate is
positioned against the bearing housing register it should be secured with a bolt and nut or a c-
clamp until you’re ready to install the case. Alternately the reassembly can be performed with
the pump positioned vertically – pump-end of the shaft pointing upward.
Now lubricate the entire service of the shaft sleeve with 30 wt motor oil or a very thin film of
STP® or heavy gear oil. Likewise, lubricate the inside diameter of the mechanical seal o-ring.
Push the mechanical seal onto the sleeve with the polished face away from the spring. Push the
seal up the sleeve until the seal spring rests against the sleeve flange.
17

SEAL INSTALLATION CONT’D
Place the shaft sleeve o-ring over the end of the shaft and up against the shaft shoulder (where
the sleeve abuts). Apply a little grease or oil to the o-ring. Slide the mechanical seal / sleeve
assembly over the shaft with the flanged end of the sleeve toward the end of the shaft. Slide the
assembly as far as the seal spring will allow.
IMPELLER
Apply a small amount of Loctite 262® (red) or equivalent to the shaft threads, and install the
impeller. As with impeller removal, attach a strap wrench or bearing nut spanner to the drive-
end of the pump shaft. Have an assistant hold this wrench to immobilize the shaft. Tighten the
impeller as much as possible by hand by rotating it clockwise.
The shaft and impeller threads must be completely clean before re-installing the impeller. Do
not use anti-seize compounds on the shaft threads! Screw the impeller onto the shaft until
tight.
SUCTION COVER AND WEAR PLATE
The impeller should be adjusted to within .010 to .020 of wear plate. With the pump resting
horizontally on its feet push the pump so that the drive-end of the shaft is against a stop (back
of the workbench). This will ensure that the shaft and impeller are as far toward the wear plate
as possible. Now loosen the inspection cover clamp T-handle. Back each of the inspection
cover adjustment set screws until the wear plate makes contact with the impeller. Now
tighten each adjustment set screw ¼ turn at a time, and slightly tighten the T-handle screw. If
the impeller and wear plate are still rubbing, repeat the procedure until the wear plate no longer
rubs against the impeller.
LUBRICATION
Seal Assembly
Prior to starting the pump, fill the transparent seal oil reservoir. Use an ISO viscosity grade 32
Turbine oil.
Bearings
The bearing housing was lubricated at the factory and the oil level should be maintained at the
middle of the sight gauge. Use an ISO viscosity grade 32 Turbine oil, and fill through the air
vent hole.
CAUTION!!!
Over-filling of oil can result in premature failure of bearings. Under normal use drain and refill
bearing housing at least once every 12 months.
18

PARTS ORDER
When ordering parts from Pioneer Pump, Inc. please provide the following information:
1) Pump serial number
2) Pump model
3) Cross section drawing number
4) Part number from cross section drawing (or part name if no number is noted)
5) Description of part
6) Quantity required
7) Package VIN (Vehicle Identification Number for skid or trailer mounted units)
SPARE PARTS
Spare parts should be kept on hand to reduce downtime. At a minimum the following parts
should be stocked.
Wear Plate
All O-rings
Set of bearings
Mechanical seal
Set of grease seals
If you have unusual pumping conditions, consult Pioneer Pump, Inc. for additional
recommended spare parts.
STORAGE
Pumps are adequately prepared for outside storage prior to shipment, but use the following list
of additional suggestions for extended storage.
1) Store the unit off the ground so no water will accumulate around the equipment.
2) Protect unit from blowing sand and dirt.
3) Stack no other items on top of pump/equipment.
4) Protect unit from the entry of any animals.
5) Periodically rotate shaft to lubricate bearings and protect bearings from brinelling.
6) Protect unit with approved drying agents.
7) Ensure all bare metal areas are coated with rust preventative.
8) Inspect unit every four (4) weeks and replace drying agents (Silica Gel) as required or a
minimum of ever six (6) months.
9) Keep an inspection record showing dates of inspection with any maintenance preformed
and condition of drying agents.
10) Before installation ensure that all rust protection has been removed. Also, remove any
foreign material that may have accumulated during storage.
11) Before installation remove all drying agents (Silica Gel).
19

TROUBLE SHOOTING
Symptom Possible Causes Symptom Possible Causes
No Discharge
Reduced Capacity
Reduced Pressure
Loss of Prime
Power consumption
excessive, driver runs
hot
Pump Fails Prime
1,2,3,4,5,7,8,9,10,17,18,19,20,
37,49
2,3,4,5,7,8,9,10,11,17,19,20,21,383
9,40,47,49
5,7,8,11,13,18,19,38,39,40,47,49
2,3,4,7,10,11,20,21,22,23,49
6,12,13,17,18,19,24,33,34,35,3637,
38,41,42,43,44
1,4,5,10,20,21,49,50,51
Vibration and noise
Seal: excessive leakage,
short life, seal housing
overheating
Bearings: over heating,
short life, noise
Pump overheating, seizes
Corrosion, erosion,
pitting, oxidation or other
loss of material
2,4,9,10,14,15,17,26,27,28,29
30,31,32,33,34,35,36,39,40,
41,42,43,44,48,49
22,23,25,33,34,35,36,41,44,
45,46
26,27,28,29,30,31,32,33,34,
35,36,41,42,43,44
1,8,9,14,33,34,35,36,41,42,43,
44
7,8,11,14,15,16
1. Pump not primed 19. Low speed 39. Impeller damage
2. Suction line not filled 20. Air leak into suction line. 40. Improper balance (after repair)
3. Air pocket in suction line 21. Air leak through mechanical seal 41. Bent shaft
4. Suction inlet or foot valve 22. Seal fluid contaminated, hot or 42. Excessive thrust
obstructed, insufficiently insufficient
submerged, or too small 43. Rotational element dragging
23. Seal fluid system not vented
5. System head higher than pump 44. Worn or incorrectly installed
design head 24. High speed bearings
6. System head lower than pump 25. Mechanical seal insufficient 45. Mechanical seal not properly set,
design head O-rings damaged or hardened
26. Bearing housing excessively
7. Insufficient NPSH cooled 46. Shaft scored at seal
8. Parallel pump application is 27. Low oil pressure 47. Volute O-ring
incorrect (oil lube bearings)
48. Foundation not rigid or settle
9. Suction pressure to vapor pressure 28. Improper or poor lubrication
Below minimum. 49. Suction line collapsed
29. Lubrication defective
10. Suction lift too high 50. Not enough liquid in casing
30. Dirt in lubrication/bearings
11. Excess vapor in pumpage 51. Suction check valve
31. Moisture in lubricant/bearing contaminated or damaged
12. Specific gravity of pumpage housing
different than design
32. Lubricant excess
13. Viscosity of pumpage different
than design 33. Pipe strain
14. Operation at below rated capacity 34. Temperature growth
15. Cavitation 35. Misalignment
16. Electrolysis 36. Coupling improperly installed
17. Impeller obstructed 37. Impeller installed backwards
18. Wrong-Rotation direction 38. Wear rings-worn
20