QED LEP-150-P Operating instructions

Maintenance and Troubleshooting
Guide V1.5
LEP-150-P, LEP-225-P Pump
QED Environmental Systems
www.QEDENV.com

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ATZ PUMP MAINTENANCE & TROUBLESHOOTING GUIDE
Thank you for purchasing aQED pump. We stand by our motto that we make all of our products
Trusted, Proven and Reliable, and trust that you will be very pleased with your purchase. It is our hope
that this guide will prove useful for any maintenance and troubleshooting issues that may arise in the
field. If, however, any questions remain or are not answered in this guide, please do not hesitate to
contact us directly at [e-mail].
This guide has three sections:
Section I:Pump Components and Required Tools
Section II: Maintenance Tasks
Section III: Troubleshooting

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SECTION I: PUMP COMPONENTS AND REQUIRED TOOLS
PUMP COMPONENTS
Exploded view drawings and part lists for the below components are available in the appendices to this
guide.
DRAWING DESCRIPTION
DRAWING NO.
APPENDIX
PAGE
Reciprocating Pump Component Options
LP-ASSBLY OPTIONS
1
Complete Pneumatic Leachate Pump Assembly
LP-PNEUMATIC
2-4
Pump Head Assembly
LP-PH-ASSBLY
5-7
Drop Assembly
LP-DA-ASSBLY
8
Lower Pump Assembly
LP-LP150F/150/225-ASSBLY
9-17
Typical Well Cap Assembly
TYP CONFIG_WCA
18
TOOLS REQUIRED
Maintenance and troubleshooting tasks may require the use of the following tools:
1) Channel lock pliers
2) Vise Grips or 2 pipe wrenches
3) Set of imperial combination wrenches
4) Set of imperial Allen keys
5) 2mm Allen Key
6) Short blade screwdriver
7) WD-40, Jig-a-loo or equivalent
8) Loctite 242 or equivalent thread sealant
9) All required Personal Protective Equipment including Gas Monitors
SECTION II: MAINTENANCE
The maintenance requirements for our pumps fall under three main areas: seals and bearings, motor
components and lower assembly components.
SEALS
Seals are found both in the pump head and piston assembly. The length of time between seal
replacement can vary greatly with amount of use and the nature of the leachate being pumped.
Most clients begin maintenance on the seals within three to four months of continuous 24/7 pumping.
These signs will help you know when seals need to be replaced:

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Piston seals: when output drops appreciably
Pump head seals: when significant amounts of leachate leaks from the indicator hole on the
pump head
PISTON SEALS
The piston assembly includes two U-cup straight
seals. When pumping particulate filled leachate,
the average life expectancy for these two piston
seals is 3-4 months, whereas when pumping
clean water one can expect at least 12-18
months before any changes need to be made.
Piston seal wear is indicated by an appreciable
decrease in pumping output when other causes
are ruled out. Even if the piston seals wear, the
pump should continue to operate and continue
to pump liquid.
In order to replace the U-cup seals on the piston, the lower pump assembly must be pulled from the
well. Once disconnected from the drop assembly, the piston can then be pulled out the top end of the
pump. Upon removal of the old seals, the new piston U-cup seals MUST be installed with the open end
of “U” facing UPWARD. The piston assembly can be re-inserted into the cylinder body from the TOP end
and plunged downward into position. Do not forget the ¾” SS ball before re-screwing the cylinder seat
into place.
PUMP HEAD SEALS
The pump head assembly includes our seal body
as well as the seal body pin.
When pumping particulate filled leachate, the
average life expectancy for these seals is 3-4
months. When pumping cleaner water expect 12-
18 months before any seal replacements need to
be made.
The seal body can be replaced as a complete
assembly or replacement seal kits are also
available. Many customers keep spare complete
seal body assemblies on hand to be easily
exchanged in the field, with additional seal kits to replace worn seals once the seal bodies are removed
from the field.

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If seals are to be installed on site, a blunted hook tool may aid the
process. Take care not to puncture seals during installation.
The pump head and seal body incorporate a tell-tale seal wear indicator port which alerts technicians to
the failure of the lower set of seals inside the seal body. This same port also accommodates the
expansion of pumped liquid under freezing conditions, thereby preventing failure or destruction of the
pump head assembly.
In order to replace the seals in the seal body, it must be removed from the pump head and unscrewed
(in half). For proper function of the seal body, upon removal of the old seals the new seals MUST be
installed following the diagram above.
BEARINGS
Bearings are found both in the backplate and linkage assembly. The length of time between bearing
replacement can vary greatly with amount of use and the nature of the leachate being pumped. Most
clients only perform maintenance on the bearings upon indication of a problem, and usually only the
bottom linear bearing and exterior dog bone bearing will ever require replacement. These signs will help
you know if bearings need to be replaced:
Backplate linear bearings: if there is significant wear within the housing, as evidenced by
significant lateral movement of the insert within the mounting pillow block.
Linkage assembly bearings: if they show significant wear, as evidenced by significant lateral or
sloppiness within the bearing assembly.

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PNEUMATIC BACKPLATE ASSEMBLY
The operational lifespan of the pneumatic
backplate assembly depends greatly on the
dryness and cleanliness of the air supply. Drain
water from the filter/regulator housing
regularly by loosening then retightening the
blue vent screw circled at right.
In the event of difficulty with the pneumatic
assembly function, refer to the troubleshooting
steps in Section III.
LOWER PUMP ASSEMBLY
The lower pump assembly includes the PVC Piston and 2 x 316 series
stainless steel balls, which may experience wear over time, especially with
highly abrasive content in the leachate. The PVC piston and one ball are
shown at left.
One of the best methods to reduce wear on the lower pump assembly
and seals is through the use of our optional Intake Screen Filter, shown
below. This simple slotted PVC pipe extends from the lower seat of the
pump and provides an initial filtration of larger particles so as to reduce
the abrasive elements entering the pump.
Should there be high temperatures (>130 degrees F), or a high percentage
of abrasive content in the leachate, such as sand or silica, we recommend
the use of our upgraded high temperature version of our piston,
Part # LP-150-11.
Portion of Intake Screen Filter, typically 24 inches in length

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SECTION III –TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSES
SOLUTION
PUMP NOT OPERATING
No pneumatic power
Check that pneumatic power exists
and that all connections are sound.
Insufficient regulator
pressure for pump load
Check regulator setting and adjust
if needed.
Limit switches or may be out
of position
Verify correct limit switch position
(refer to installation manual).
Ensure that lower limit switch is
raised at least 1/8inch above its
lowest position.
Exhaust regulator settings
may be too restricted
Unscrew the adjustment screw in
both the lifting and return exhaust
regulator to check for improved
operation.
PUMP WILL NOT OPERATE
AT FULL SPEED, OR STALLS
AFTER A FEW MINUTES OF
OPERATION
Blockage in discharge line
Remove discharge line and confirm
pump operation with no line
attached. To remedy locate
blockage in discharge line and
remove.
Discharge line is frozen
Heat tracing and insulation is
recommended in colder climates,
as well as keeping the pump
operational 24/7 to keep lines from
freezing.
Exhaust regulator settings
may be too restricted
Unscrew the adjustment screw in
both the lifting and return exhaust
regulator to check for improved
operation.
Insufficient regulator
pressure for pump load
Check regulator setting and adjust
if needed.
PUMP IS OPERATING, BUT
OUTPUT IS MINIMAL
PVC piston seals have worn
Pull pump, replace piston seals.
Crack or leak in drop
assembly, either fiberglass
drop shafts or PVC
Pull pump. Inspect drop assembly
for disconnections, cracks, over-
tightening.
Intake filter or lower pump
assembly clogged
Pull pump. Remove build up/clog.
Replace intake filter if necessary.

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SYMPTOM
POSSIBLE CAUSES
SOLUTION
PUMP IS OPERATING, BUT
NOT PUMPING FLUID
Air bubble in intake cylinder
(especially if right after
install/re-install)
Turn the pump off, manually move
the push rod through a full stroke,
and restart the pump.
Piston has disconnected from
piston rod
Pull pump, dry piston and piston
rod threads, apply crazy glue, and
reassemble.
Stainless steel ball is stuck on
piston seat
Pull pump, clean and inspect the
piston.
PUMP OPERATING BUT NOT
PUMPING FLUID,
DISCHARGE LINE HAS
VACUUM AND IS SUCKING
AIR IN
Well is dry or pump depth is
above liquid level
Lower pump depth setting. Turn
the pump off, remove the well cap
and drive components, install a 5
or 10 foot length of drop assembly
to lower pump depth setting.
Crack or disconnection in
drop assembly, either
fiberglass drop shafts or PVC
Pull pump. Inspect drop assembly
for disconnections, cracks
Piston has disconnected from
piston rod
Pull pump, dry piston and piston
rod threads, apply crazy glue, and
reassemble.
Intake filter or lower pump
assembly clogged
Pull pump. Remove build up/clog.
Replace intake filter if necessary.
ABNORMALLY RAPID SEAL
FAILURE OR WEAR ON
BEARINGS
Alignment is not linear. Drop
assembly may be
crooked/cross-threaded at
couplings.
Pull pump, inspect drop assembly
for cross-threading.
Backplate or push rod may
be bent
Inspect backplate and push rod for
warping/bending.
Push rod may be worn
through at contact point with
linear bearing
Replace push rod, linear bearing,
and seals in pump head.
LEACHATE IS LEAKING FROM
SEAL WEAR INDICATOR
HOLE ON PUMP HEAD
ASSEMBLY
Shafting may be too tall,
causing push rod to exit seals
Verify push rod protrusion per
install manual p. 9 and adjust stack
height if necessary.
Seals inside the seal body
need to be replaced
Remove seal body assembly from
pump head and inspect. If worn,
install new seals. Replacement seal
kits and seal body assemblies are
available through QED.

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SYMPTOM
POSSIBLE CAUSES
SOLUTION
PVC DROP PIPE CRACKS OR
BREAKS AT FIRST COUPLING
OR AT PUMP HEAD
ASSEMBLY
Blockage in discharge line
Locate blockage in discharge line
and remove. Lower the overload
status adjustment for the motor.
Pump has bottomed out
Pull pump and inspect. Upon re-
installation ensure to raise the
push rod up approximately 1 inch
from the lowest point ensuring the
PVC piston does not bottom out
during operation.
Intake filter or lower pump
assembly clogged
Pull pump. Remove build up/clog.
Replace intake filter if necessary.
Lower the overload status
adjustment for the motor.
DROP ASSEMBLY
DIFFICULT/IMPOSSIBLE TO
REMOVE FROM WELL
Well may be pinched or
crooked, drop assembly may
be caught on in well debris
Move drop assembly back and
forth to dislodge. If not successful,
remove as much of the drop
assembly as possible, and pull
upwards with force on fiberglass
drop shaft to eventually disconnect
piston from lower pump assembly.
Fish lower assembly out if possible,
if not, it may be left in the well and
another pump installed at a higher
depth setting.